Output self-adaptive adjustment control method, switching power supply and coating process

Abstract

The invention relates to an output adaptive adjustment control method, a switching power supply and a coating process, and aims to ensure that the process energy value output by each batch of production can reach the target process energy value under different load fluctuations by monitoring the output process energy value and the accumulated process duration in real time and dynamically adjusting the output power value. And stable product quality is ensured, and batch consistency under a non-constant load is realized. When the output power value is adaptively adjusted, it is ensured that the accumulated process duration is consistent with the target process duration, it is avoided that the accumulated process duration is prolonged due to pause of output, and it is ensured that a production plan is advanced on time and the process duration is accurate and controllable. By setting various pause conditions and corresponding pause durations and combining the adjustment coefficient to dynamically calculate the output power value, the method is suitable for industrial scenes with frequent load change, such as sputter coating and induction heating. In sputtering coating and other processes where electric arcs are prone to being generated, different types of electric arcs can be rapidly recognized and responded, and the influence of process interruption on coating quality is reduced through short-time pause and power compensation.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of power electronics, and particularly relates to a control method for adaptive adjustment of output, a switching power supply and a coating process. BACKGROUND

[0002] In the field of switching power supply, conventional control methods can be mainly divided into three types, namely constant voltage output control, constant current output control and constant power output control. The above three control methods are all based on output setting value to adjust the switching power supply, so as to make the actual output of the switching power supply equal to the setting value. Even if the input of the switching power supply fluctuates or the load changes, these control methods can adjust the output of the switching power supply to the setting value. The switching power supply shutdown time is generally determined by manual, when the manual determines that the switching power supply needs to be shut down through experience or instrument, the switching power supply is manually operated to shut down the output. Or directly set the target process time Ts in the switching power supply, and the switching power supply automatically shuts down the output after outputting Ts. The premise of the conventional control method is to simply regard the load as ideal and unchanged, or to consider that the change of the load is repeatable. Based on the above premise, as long as the setting parameters of the switching power supply are consistent in different batches of production, the result is repeatable, that is, the quality of the products is consistent, and the consistency of different batches of products can be ensured.

[0003] In the case of requiring less accuracy, the conventional control method is acceptable for the load with constant or repeatable impedance characteristics. Because the impedance characteristics of the load are constant or repeatable, the output of the switching power supply with the same parameters can be well reproduced, that is, the consistency of different batches of products can be ensured. However, with the development of society and the increase of the convenience of power application, the energy source of most applications is switched to electric energy. Therefore, the load of the switching power supply becomes more and more colorful from the original resistance and the like. At present, the characteristics of most switching power supply loads are not constant, and even change at all times. For example, in the field of sputtering coating, the load of the switching power supply is the thin working gas confined in the chamber. In the early stage of the sputtering process, the thin gas is insulating, and under the output of the switching power supply, the gas breakdown starts to conduct, generating plasma. The plasma is a combination of charged particles and neutral particles, which moves at high speed in the sputtering chamber under the action of electromagnetic force, and the load characteristics are highly free. Moreover, the type of working gas and other parameters are different for different specific sputtering processes, which further increases the diversity of load characteristics. In the field of induction heating, the load of the power supply is more diverse, although the heating coil can be the same, but the material, shape, position and temperature of the heated workpiece and other parameters will affect the load effect, resulting in changes in the load characteristics of the switching power supply. In the electrolysis field, the load of the switching power supply is affected by the electrolytic cell, electrolyte and the like, and its load characteristics are also changing. Therefore, in the application of switching power supply with non-constant load, if the conventional control method is used, even under the same setting parameters, due to the non-reproducible working conditions, the consistency of different batches of production cannot be ensured. Especially when the performance of the product is closely related to the output energy of the switching power supply, such as the film thickness and other parameters in sputtering coating. SUMMARY

[0004] The technical problem to be solved by the present application is that the existing production process control method cannot reproduce the working conditions under the same setting parameters, and cannot ensure the consistency of different batches of production. In view of the above defects of the prior art, a control method with adaptive output adjustment, a switching power supply and a coating process are provided.

[0005] To solve the above technical problems, the technical solution adopted by the present application is: A control method with adaptive output adjustment is constructed, characterized in that it comprises: During the output process, the third parameter is periodically adjusted adaptively according to the set first parameter target value and second parameter target value, and combined with the pause history generated by meeting the pre-set pause condition in the actual output process; The adaptive adjustment makes the second parameter output value reach the second parameter target value, and the first parameter cumulative value reaches the first parameter target value in the output process.

[0006] Preferably, the adaptive adjustment includes the following steps performed periodically: At the end of each adjustment period, an adjustment coefficient is calculated based on the number of times each type of pause condition occurs during that adjustment period and the pause duration corresponding to each type of pause condition. Based on the adjustment coefficient, the difference between the first parameter target value and the first parameter cumulative value, and the difference between the second parameter target value and the second parameter output value, the output power value for the next cycle is calculated and updated until the first parameter cumulative value reaches the first parameter target value, at which point the second parameter output value reaches the second parameter target value.

[0007] Preferably, the adjustment coefficient is calculated as follows: Wherein, ΔT is the preset adjustment value of the second parameter. For various pause conditions The corresponding pause output duration, Suspension conditions The adaptive adjustment cycle also includes a second parameter reset value, which is used for the working duration of the output power value in the current cycle. When the second parameter reset value reaches the second parameter adjustment value and the cumulative value of the first parameter does not reach the target value of the first parameter, the third parameter will be adjusted.

[0008] Preferably, the updated third parameter is calculated as follows: in, This is the adjustment coefficient within the current second parameter adjustment period. The target value for the first parameter. This is the cumulative value of the first parameter. The target value for the second parameter. This is the output value for the second parameter.

[0009] A switching power supply with adaptive output adjustment is constructed, comprising a power output unit and a control unit, characterized in that: Power output unit, used to provide electrical power to the load; The control unit is used to perform adaptive output adjustment; The control unit is configured to: during the output process, periodically control the output of the third parameter based on the set first parameter target value and second parameter target value, and in combination with the pause history generated by the preset pause conditions that should be met during the actual output process; The adaptive adjustment ensures that when the output value of the second parameter reaches the target value of the second parameter during the actual output process of the switching power supply, the cumulative value of the first parameter also reaches the target value of the first parameter.

[0010] Preferably, the control unit includes a parameter input interface for receiving a first parameter target value, a second parameter target value, a second parameter adjustment value, and at least one pause condition and its corresponding pause duration; The status detection module is used to monitor the third parameter and calculate the cumulative value of the first parameter and the output value of the second parameter; The power control module is used to compare the accumulated value of the first parameter with the target value of the first parameter and the output value of the second parameter with the target value of the second parameter to generate a third parameter update signal to be sent to the power output unit. The power output unit updates the third parameter and then uses the updated third parameter to provide output to the load.

[0011] Preferably, the system also includes a switch module connected in series with the power output unit. When the control unit detects that any pause condition is met, it controls the switch module to open to pause the output, and controls it to close after the corresponding pause duration to resume the output.

[0012] A coating process with adaptive output adjustment is constructed, characterized by comprising: Connect the switching power supply to the load of the coating equipment; Set the target process energy value and target process duration for the coating process; The coating process is started, and during the process, the output power value of the switching power supply is periodically adjusted according to the target process energy value and the target process duration, and in combination with the pause history triggered by the coating process due to pause conditions. The pause conditions include those triggered by an electric arc event during the coating process; The adaptive adjustment ensures that when the cumulative coating process time reaches the target process time, the total output process energy value of the switching power supply reaches the target process energy value.

[0013] Preferably, the periodic adjustment includes cyclical adjustment with the adjustment duration as the period, and performing the following steps in each adjustment period: The process energy value and cumulative process duration of the coating process are monitored, and a process reset duration is introduced. The process reset duration is configured with the output power value within the current adjustment cycle. When the process reset time reaches the adjustment time, it is determined whether the output process energy value has reached the target process energy value. If the target is not met, the output power value is updated based on the adjustment coefficient, and the process reset time used in the cycle is reset to zero to start the next adjustment cycle. If the desired result is achieved, the coating process is terminated.

[0014] Preferably, the periodic adjustment of the output power value is based on the difference between the current cumulative output process energy value and the target process energy value, the difference between the current cumulative process duration and the target process duration, and the compensation coefficient calculated based on the pause history. The output power value of the switching power supply is dynamically calculated and set. The pause conditions include conditions triggered by an arc event during the coating process. The arc event includes at least one of hard arc and micro arc. Different types of arc events correspond to different pause output durations.

[0015] The beneficial effects of this application are as follows: It achieves batch consistency under non-constant loads by dynamically adjusting the output power value through real-time monitoring of the output process energy value and cumulative process time. This ensures that the output process energy value of each batch reaches the target process energy value under different load fluctuations, guaranteeing stable product quality. The cumulative process time is precisely controllable. While adaptively adjusting the output power value, it ensures that the actual cumulative process time is consistent with the target process time, avoiding process time extensions due to output pauses and ensuring timely production progress. It has strong adaptability and wide applicability. By setting various pause conditions and corresponding pause durations, and combining them with adjustment coefficients to dynamically calculate the output power value, it is suitable for industrial scenarios with frequent load changes, such as sputtering coating, induction heating, and electrolysis. It improves process stability and repeatability. In processes prone to arc generation, such as sputtering coating, it can quickly identify and respond to different types of arcs. Through short-term pauses and power compensation, it reduces the impact of process interruptions on coating quality. The algorithm is simple, efficient, and easy to implement. Based on the energy-time relationship, the closed-loop control algorithm has low computational load, fast response, and is easy to integrate into existing switching power supply control systems without complex hardware modifications. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the present application will be further described below in conjunction with the accompanying drawings and embodiments. The drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a flowchart illustrating the control method of a preferred embodiment of this application. Figure 2 This is a schematic block diagram of a switching power supply according to a preferred embodiment of this application; Figure 3 This is a schematic diagram of the coating process according to a preferred embodiment of this application; Figure 4 This is a flowchart illustrating the adaptive adjustment process of the coating process in a preferred embodiment of this application. Figure 5Comparison diagram of the output waveforms of the switching power supply of the coating process of the preferred embodiment of the present application and the coating process of the conventional control method. Specific embodiments

[0017] In order to make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below. Apparently, the described embodiments are some, but not all, of the embodiments of the present application. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present application without creative efforts shall fall within the protection scope of the present application.

[0018] A control method for output adaptive adjustment and a switching power supply in a preferred embodiment of the present application; as Figure 1 shown, the switching power supply can be applied to various fields. For the convenience of explanation, in the present application, the constant power output control mode applied to the magnetron sputtering coating field is taken as an example, and the constant voltage or constant current mode is similar. In the magnetron sputtering coating process, under the electric field of the switching power supply, the working gas is first broken down and forms a plasma. The load characteristic changes from open circuit to conduction, and the output power of the switching power supply gradually increases until the set value and maintains this value output. However, during the output process, due to interference factors such as target contamination, arcs will occur in the sputtering chamber, resulting in the load characteristic of the switching power supply becoming a short circuit. When an arc occurs, in order to protect components such as the target, the switching power supply needs to quickly detect the arc and identify the type of the arc. For different types of arcs, corresponding operations are performed. For micro arcs, the switching power supply will temporarily stop output for as short a time as possible, so that the micro arcs are extinguished and the impact on production is reduced. For hard arcs, the switching power supply needs to stop output for an appropriate time so that the hard arcs can be extinguished but the plasma does not disappear. Considering the application situations in various fields and in order to expand the applicable range, the switching power supply in the present application has a total of n different pause conditions C1, C2... Cn, and the pause output duration corresponding to each pause condition is t C1 、t C2 ……t Cn , and the specific pause conditions can be set according to the actual application scenario. For example, in the field of magnetron sputtering power supplies, the conditions that can be set are: the pause condition C1 is that the output current I0 of "hard arc 1" > I1, and its corresponding temporary output duration t C1 = 5us; the pause condition C2 is that the output current I0 of "hard arc 2" > I2 and the output voltage Vo < V2, and its corresponding temporary output duration t C2 = 3us; the pause condition C3 is that the output voltage of "micro arc 1" has decreased by 20%, and its corresponding temporary output duration t C3 = 1us; the pause condition C4 is that the slope of the output voltage drop of "micro arc 2" > S4, and its corresponding temporary output duration t C4=1.5us, etc. The specific pause conditions and corresponding durations can be set based on actual experience.

[0019] Specifically, such as Figure 1 As shown, at the start of the process, the target process energy value Es, output power value Ps, and target process duration Ts are input to the switching power supply according to production requirements. Since the target process energy value is equal to the product of the process power value and the target process duration, only two of the three need to be input; the third parameter can be calculated based on the energy relationship formula. The target process energy value refers to the total energy output by the switching power supply in this production process being Es; the process output power value refers to the switching power supply outputting at a constant power of Ps; and the target process duration refers to the total duration of this production process being Ts. Therefore, these three values ​​mean that when the process is expected to output at a constant output power value of Ps for the target process duration Ts, the total output energy will be Es. At the beginning of the process, the process power value will be the set output power value. However, during the output process, the power supply's output power value Ps will fluctuate, and when a pause condition is met, the power supply will pause its output for a period of time before restarting. That is, when the aforementioned different pause conditions C1, C2...Cn occur, the power supply will output according to the pause duration t corresponding to each pause condition. C1 t C2 ...t CnThe corresponding time for the pause in output. Since the power output is paused, if the output is still based on the process output power value, the output will only stop when the output process energy value Et reaches the target process energy value Es. This must be greater than the cumulative process duration t of the target process duration Ts. However, if the cumulative process duration t reaches the target process duration Ts, the output process energy value Et will inevitably be less than the target process energy value Es. Therefore, in order to ensure that the cumulative process time t reaches the target process time Ts and the output process energy value Et reaches the target process energy value Es even after the power supply stops output due to a pause condition, an adjustment time ΔT and an adjustment coefficient a are introduced into the switching power supply. The output power value Ps is adaptively adjusted by the adjustment time ΔT and the adjustment coefficient a. The adjustment time ΔT determines how often a is adjusted. That is, when the process reset time Δt reaches the adjustment time ΔT, the adjustment coefficient a is adjusted, and the output power value Ps is adjusted according to the adjustment coefficient a. Then, the output is carried out with the adjusted output power value Ps until the output process energy value Et reaches the target process energy value Es, at which point the process ends. Otherwise, the output continues at the adjusted output power value Ps until the process reset time Δt reaches the adjusted time ΔT again. At this point, it is determined whether the output process energy value Et reaches the target process energy value Es, to decide whether to terminate the process or continue adjusting the adjustment coefficient a. The output power value Ps is then adjusted according to the adjustment coefficient and output again. Using the above method, a new adjustment coefficient a is calculated and the output power value Ps is updated. After each update, the switching power supply outputs the new output power value. This process continues until the output process energy value Et reaches the target process energy value Es, at which point the output is shut off. At this point, the cumulative process time t equals the target process time Ts. Under this method, it is ensured that the total output process energy value Et of each production process reaches the target process energy value Es (i.e., ensuring consistency between different batches of production), and that the cumulative process time t reaches the target process time Ts (i.e., ensuring that the production plan can proceed as scheduled).

[0020] Furthermore, the adjustment coefficient 'a' is determined by various pause conditions C1, C2...Cn and the pause output duration t corresponding to each pause condition. C1 t C2 ...t Cn It is calculated based on the adjustment duration ΔT, and the specific calculation method is shown in the following formula: The updated output power value Then by adjustment coefficient The target process energy value Es and target process duration Ts are set, and the output process energy value Et and cumulative process duration t are calculated. The specific calculation method is shown in the following formula: Furthermore, in the initial stage, no pause condition Cn has occurred, therefore t Cn Also equal to 0, adjustment coefficient Initial value when j=0 for: At the same time, the output process energy value Et and the cumulative process duration t are both 0, so the corresponding output power value... Initial value when j=0 for: Switching power supply The power setting value is output, and the pause conditions C1, C2...Cn corresponding to each pause condition within the process reset duration Δt from 0 to ΔT are recorded, along with the number of pauses that occur for each pause condition Cn. , ... The system continuously monitors the output process energy value Et. During the output process (i.e., before the process reset time Δt reaches the adjustment time ΔT), it continuously checks whether the output process energy value Et reaches the target process energy value Es. If it does, the output is turned off and the current process ends. If the target process energy value Es is not reached, the process continues... The power output value is output until the process reset duration Δt reaches the adjustment duration ΔT. At this point, the process reset duration Δt is reset to 0, and the counter j is incremented by 1, i.e., j=1 at this time. The adjustment coefficient is updated based on the number of times each pause condition Cn occurs during the power output process, combined with the pause time of each pause condition. Value: Then, combining the output process energy value Et and the cumulative process time t, and based on the adjustment coefficient... Recalculate and update output power value Updated output power value at j=1 for: The process continues in this loop until the output process energy value Et reaches the target process energy value Es, at which point the output is turned off, and the cumulative output duration t of the switching power supply is equal to the target process duration Ts.

[0021] Furthermore, the adjustment duration ΔT can be set according to the stability of the process and the requirements for real-time adjustment, typically ranging from 0.1 seconds to 10 seconds. Pause conditions and their corresponding durations (e.g., t) C1The value of t=C1=5us needs to be determined based on empirical data or experiments on specific loads (such as the type of sputtering target and working gas). Its core is to effectively extinguish abnormal arcs while minimizing interference with the process.

[0022] Furthermore, the adjustment coefficient The physical meaning is twofold: first, to compensate for the effective output time lost due to past pauses; and second, to predict the number of pauses corresponding to different pause conditions within the remaining process time (remaining process time = target process time Ts - cumulative process time t) based on the number of pauses within the most recent second parameter adjustment value, thereby compensating for the effective output time lost due to future pauses in advance. Its calculation formula is based on an idealized model: within an adjustment cycle ΔT, the actual effective output time is ΔT - To ensure that the compensated "equivalent power" can achieve the energy target within the remaining effective time (remaining process time minus the output time lost due to predicted future shutdowns), this coefficient is introduced. As the process progresses, the operating conditions become increasingly stable, and the predictions become more consistent with the actual situation, thus increasing the adjustment coefficient. It is becoming increasingly stable.

[0023] Furthermore, the control unit (such as an MCU or DSP) manages the adjustment period ΔT and the second parameter reset value Δt via an internal timer. Whenever a clock interrupt is triggered, the accumulated process duration t and the time reset value Δt increase. When Δt reaches ΔT, the calculation of the adjustment coefficient and the power update process are triggered, and Δt is reset to zero. The number of occurrences for each pause condition is also specified. The increment is performed by the corresponding interrupt service routine or status detection flag, and is called at the end of each adjustment cycle to participate in the calculation. It is then cleared to prepare for the next cycle to start counting again.

[0024] Based on the above method, by monitoring the output state of the switching power supply and the input target parameters, the output state is adaptively adjusted according to specific operating conditions to ensure that the target parameters are achieved. This guarantees the consistency of production across different batches under non-constant load conditions. Furthermore, it achieves the monitoring of past output states and adaptive adjustment of the output based on current operating conditions to ensure the target parameters are met. This implements a control method that predicts future output states based on past output states and target parameters, and adaptively adjusts future output states to ensure the consistency of products and process durations across different batches, thus facilitating on-time production planning.

[0025] Furthermore, a switching power supply consists of a power section and a control section, such as... Figure 2As shown, the power section comprises an input module, an adjustment module, an output module, a switching module, and a load module. The input module provides a 220V or 380V AC power input to the switching power supply. The adjustment module then modifies the AC power to a suitable output, which is filtered by the output module to obtain the output power for production. Finally, the switching module connects to the load. The adjustment module, under the control of the control unit, integrates the input AC power into a suitable power form, i.e., adjusting the output power value as mentioned above. The switching module, under the control unit, connects or disconnects the power output from the load, achieving the function of pausing output. The control section consists of an output current (Io) conditioning module, an output voltage (Vo) conditioning module, an ADC, a control unit module, and a human-machine interface. The human-machine interface collects setpoints and other parameters and sends them to the control unit, such as the target process energy value Es, power value Ps, and target process duration Ts, as well as different pause conditions C1, C2…Cn, with each pause condition corresponding to a pause output duration of t. C1 t C2 ...t Cn The control unit adjusts the duration ΔT and adjustment coefficient a, calculates the output power value Ps based on the actual output Io and Vo, and outputs the power value. Combined with the aforementioned control method, the adjustment module and the switching module are controlled to achieve the expected effect of the control method of this application. That is, by monitoring the output state of the switching module and the input target parameters, the output state is adaptively adjusted for the specific load so that the target parameters can be achieved, ensuring the consistency of the working time and energy generated by the load under non-constant load conditions.

[0026] A preferred embodiment of this application provides an output adaptive adjustment coating process, such as... Figures 3-4 As shown, it includes the following steps: Step S1: Receive the target value of the first parameter, the target value of the second parameter, the adjustment value of the second parameter, the pause conditions, and the pause time corresponding to each pause condition according to the process. Step S2: Initialize the cumulative value of the first parameter, the reset value of the second parameter, the counter, and the number of occurrences of each pause condition for the current process; Step S3: Calculate the initial value of the third parameter based on the target values ​​of the first and second parameters, and output the process using the initial value of the third parameter while recording the cumulative value of the first parameter; Step S4: Compare the cumulative value of the first parameter with the target value of the first parameter. If the cumulative value of the first parameter reaches the target value of the first parameter, the process ends; otherwise, proceed to step S5. Step S5: Update the third parameter according to the adjustment coefficient to obtain the updated value of the third parameter, and then proceed to step S6 after the process is carried out with the updated value of the third parameter; Step S6: If the cumulative value of the first parameter reaches the target value of the first parameter, the process ends; otherwise, the adjustment coefficient is updated and step S5 is performed.

[0027] Furthermore, such as Figure 4 As shown, taking the constant power output mode in the field of magnetron sputtering coating as an example, the following is given based on the magnetron sputtering coating production process: the target value of the first parameter, the target value of the second parameter, the adjustment value of the second parameter, the pause conditions, and the pause time corresponding to each pause condition. The target value of the first parameter is the set target process energy value Es, the target value of the second parameter is the target process duration Ts, the adjustment value of the second parameter is the adjustment duration ΔT, and each pause condition C1, C2...Cn that may occur during the coating process, and the corresponding pause output duration t for each pause condition are also given. C1 t C2 ...t Cn Then, during the output phase, the accumulated value of the first parameter, the reset value of the second parameter, the counter, and the number of occurrences of each pause condition are initialized to 0. The accumulated value of the first parameter is the output process energy value Et, and the reset value of the second parameter is the time reset value Δt. That is, when the process starts outputting, the output process energy value Et = 0, the counter j = 0, the time reset value Δt = 0, and the number of pauses for each pause condition is initialized. Then, based on the target values ​​of the first and second parameters, the initial value of the third parameter is calculated. Specifically, the initial output power value Ps is calculated using the target process energy value Es and the target process duration Ts. The coating process will proceed with the initial output power value Ps, and the calculation of the output process energy value Et will begin simultaneously. If the output process energy value Et reaches the target process energy value Es, the output will stop; otherwise, the output power value will be adjusted according to the adjustment coefficient, and the coating process will continue with the updated output power value until the output process energy value Et reaches the target process energy value Es, at which point the cumulative coating process duration t equals the target process duration Ts.

[0028] At the start of the coating process, since no pause condition Cn has yet occurred, therefore Also equal to 0, adjustment coefficient Initial value when j=0 for: At the same time, the cumulative value of the first parameter and the output value of the second parameter are both 0, so the corresponding output value of the third parameter... Initial value when j=0 for: The coating process will start with the power setting value as the output value of the third parameter, and will output according to each pause condition C1, C2...Cn corresponding to the second parameter reset value within the range of 0 to the second parameter adjustment value, as well as the number of pauses that occur for each pause condition Cn. , ... The system continuously monitors the cumulative value of the first parameter during the coating process (i.e., before the reset value of the second parameter reaches the adjustment value of the second parameter). If the target value of the first parameter is reached, the output is turned off and the coating process ends. If the target value of the first parameter is not reached, the system continues to output power as the output value of the third parameter until the reset value of the second parameter reaches the adjustment value of the second parameter. At this point, the reset value of the second parameter is reset to 0, and the counter j is incremented by 1 (j=1). The system also considers the number of times each pause condition Cn occurs during the process where the output value of the third parameter is the power output value, and the duration of each pause condition's large pause, to update the adjustment coefficient. Value: Then record the number of pauses. , ... Set all parameters to 0, combine the accumulated value of the first parameter with the output value of the second parameter, and base the result on the adjustment coefficient. Recalculate and update the third parameter output value when j=1. for: Through this cycle, the output is turned off when the accumulated value of the first parameter reaches its target value, and at this point, the output value of the second parameter of the coating process equals its target value. This achieves adaptive adjustment of the output state according to the operating conditions, ensuring that the target parameters of the coating process are met. This guarantees consistency in production across different batches and in the duration of the coating process, facilitating on-time production planning.

[0029] Furthermore, such as Figure 5 As shown, to more vividly illustrate the difference between the adaptive output power adjustment coating process control method of this application and the conventional coating process control method, the waveform diagrams of the conventional control method with constant power output and the coating process with constant power output of the switching power supply proposed in this application will be compared below. The input parameters of the conventional control method are constant power Ps=Ps0 and Ts, that is, the total output energy of this coating process is Es=Ps×Ts. Its expected ideal output waveform is as follows: Figure 5 As shown in Figure 1, the coating process outputs a constant power Ps0 ( Figure 5As shown by the solid line in .1 (corresponding to the P-axis on the left), the output process energy value Et increases at a fixed slope Ps0. Figure 5 As shown by the dashed line in .1 (corresponding to the right-hand Et axis), the target process energy value Es is reached when the target process duration Ts is reached, thus completing the production process. However, in reality, conventional control methods only control the output power value Ps and the expected process duration Ts, which cannot obtain... Figure 5 The ideal waveform shown in .1 can often only be obtained Figure 5 The actual coating process waveform described in .2. Figure 5 In section .2, the output power value of the coating process is also set to Ps0. After the coating process starts, through a soft start, the output power of the coating process gradually increases to Ps0 and maintains a constant output value. Output is paused at times T1, T3, T5, T7, T9, T11, T13, and T15 of the coating process, and resumed at times T2, T4, T6, T8, T10, T12, T14, and T16. Output is shut off when the expected process duration Ts is reached. At this time, the output energy Et waveform is as follows: Figure 5 As shown by the dashed line in section .2, the output energy Et also increases with a slope of Ps0, but during the pause in output, the output energy remains constant until the expected process duration Ts, at which point the output is shut off, and the total output energy is Es2. Clearly, the total output energy Es2 is less than the target process energy value Es. In different batches of production, it is impossible to guarantee that Es2 will be equal each time, thus compromising consistency across different batches. Another approach is as follows... Figure 5 As shown in Figure 3, stopping the output when the controlled output energy Et reaches the target process energy value Es ensures consistency across different batches. For ease of comparison, assume the output is paused in the same way as... Figure 5 .2. The same output power value Ps0, expected process duration Ts, and target process energy value Es are set. After the coating process begins, a soft start is performed, and the output power gradually increases to Ps0 and remains constant. Output is paused at times T1, T3, T5, T7, T9, T11, T13, T15, T17, T19, and T21 of the coating process. Constant power Ps0 output is resumed at times T2, T4, T6, T8, T10, T12, T14, T16, T18, T20, and T22. Output is shut off when the output energy Et reaches the target process energy value Es, completing the current process. Figure 5In section 3, in order to ensure the consistency of production between different batches of processes, the output power value Ps0 and the target process energy value Es can be controlled. However, it is obvious that under the influence of the paused output, the actual process time is T23, which is obviously greater than the expected process time Ts. In different batches of production processes, due to the different specific circumstances of the paused output, the actual process time of different batches will be different, which will make the production plan unable to be carried out on schedule, seriously affecting production scheduling and delivery.

[0030] The switching power supply using the control method of this application is used in the coating process, such as... Figure 5 As shown in Figure 4, this not only ensures that the total output energy Et during different batches of process production is the same as the target process energy value Es, but also ensures that the actual process duration t is consistent with the expected process duration Ts, thus ensuring the consistency of different batches of process production and the normal progress of the production plan. Figure 5 In section 4, for ease of comparison and analysis, we assume that the case of paused output is the same as... Figure 5 .2 and Figure 5 Consistent with section .3, the target process energy value Es and the expected process duration Ts are also the same. According to the aforementioned calculation process, the output power value Ps0 is first obtained. After soft start, the power supply maintains a constant power output of Ps0, and the total output energy Et increases at a fixed slope of Ps0, as shown below. Figure 5 The solid and dashed lines in section .4 represent the time period from 0 to T1. During the time period from T1 to T2, the power supply pauses output, the output power is 0, and the total output energy Et remains constant. At time T2, the power supply resumes output, and according to the aforementioned calculation process, a new power setting value Ps1 is obtained. The power supply outputs at the new output power Ps1, and the total output energy Et increases at a fixed slope of Ps1. As the output process becomes more stable, the adjustment coefficient a calculated above also tends to stabilize, meaning the adjusted output power also becomes more stable, as shown below. Figure 5 As shown in Figure 4, the output power fluctuations after T12 are relatively small. Finally, at the expected process duration Ts, the total output energy Et reaches the target process energy value Es, completing this process. In different batches of production, even with different pause conditions, the switching power supply applying the output adaptive adjustment control method can adaptively adjust the output based on past output conditions for specific processes, ensuring that the total output energy Et equals the target process energy value Es and the actual process duration t equals the expected process duration Ts. This guarantees the consistency of product performance across different batches and ensures that production plans are carried out on schedule.

[0031] It should be understood that this application has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this application. Furthermore, based on the teachings of this application, these features and embodiments can be modified to suit specific circumstances and materials without departing from the spirit and scope of this application. Therefore, this application is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this application.

Claims

1. A control method for adaptive output adjustment, characterized in that, include: During the output process, the third parameter is periodically adjusted adaptively based on the set target values ​​of the first and second parameters, and in combination with the pause history generated during the actual output process due to the fulfillment of preset pause conditions. The adaptive adjustment ensures that when the output value of the second parameter reaches the target value of the second parameter during the output process, the cumulative value of the first parameter also reaches the target value of the first parameter.

2. The control method according to claim 1, characterized in that: The adaptive adjustment includes the following steps performed periodically: At the end of each adjustment period, an adjustment coefficient is calculated based on the number of times each type of pause condition occurs during that adjustment period and the pause duration corresponding to each type of pause condition. Based on the adjustment coefficient, the difference between the first parameter target value and the first parameter cumulative value, and the difference between the second parameter target value and the second parameter output value, the output power value for the next cycle is calculated and updated until the first parameter cumulative value reaches the first parameter target value, at which point the second parameter output value reaches the second parameter target value.

3. The control method according to claim 2, characterized in that: The adjustment coefficient is calculated as follows: Wherein, ΔT is the preset adjustment value of the second parameter. For various pause conditions The corresponding pause output duration, Suspension conditions The adaptive adjustment cycle also includes a second parameter reset value, which is used for the working duration of the output power value in the current cycle. When the second parameter reset value reaches the second parameter adjustment value and the cumulative value of the first parameter does not reach the target value of the first parameter, the third parameter will be adjusted.

4. The control method according to claim 2, characterized in that: The updated calculation method for the third parameter is as follows: in, This is the adjustment coefficient within the current second parameter adjustment period. The target value for the first parameter. The cumulative value of the first parameter. The target value for the second parameter. This is the output value for the second parameter.

5. A switching power supply with adaptive output adjustment, comprising a power output unit and a control unit, characterized in that: Power output unit, used to provide electrical power to the load; The control unit is used to perform adaptive output adjustment; The control unit is configured to: during the output process, periodically control the output of the third parameter based on the set first parameter target value and second parameter target value, and in combination with the pause history generated by the preset pause conditions that should be met during the actual output process; The adaptive adjustment ensures that when the output value of the second parameter reaches the target value of the second parameter during the actual output process of the switching power supply, the cumulative value of the first parameter also reaches the target value of the first parameter.

6. The switching power supply according to claim 5, characterized in that: The control unit includes a parameter input interface for receiving a first parameter target value, a second parameter target value, a second parameter adjustment value, and at least one pause condition and its corresponding pause duration; The status detection module is used to monitor the third parameter and calculate the cumulative value of the first parameter and the output value of the second parameter; The power control module is used to compare the accumulated value of the first parameter with the target value of the first parameter and the output value of the second parameter with the target value of the second parameter to generate a third parameter update signal to be sent to the power output unit. The power output unit updates the third parameter and then uses the updated third parameter to provide output to the load.

7. The switching power supply according to claim 5, characterized in that: It also includes a switching module connected in series with the power output unit. When the control unit detects that any pause condition is met, it controls the switching module to open to pause the output, and controls it to close after the corresponding pause duration to resume the output.

8. A coating process with adaptive output adjustment, characterized in that, include: Connect the switching power supply to the load of the coating equipment; Set the target process energy value and target process duration for the coating process; The coating process is started, and during the process, the output power value of the switching power supply is periodically adjusted according to the target process energy value and the target process duration, and in combination with the pause history triggered by the coating process due to pause conditions. The pause conditions include those triggered by an electric arc event during the coating process; The adaptive adjustment ensures that when the cumulative coating process time reaches the target process time, the total output process energy value of the switching power supply reaches the target process energy value.

9. The coating process according to claim 8, characterized in that: The periodic adjustment includes cyclical adjustment with the adjustment duration as the period, and performing the following steps in each adjustment period: The process energy value and cumulative process duration of the coating process are monitored, and a process reset duration is introduced. The process reset duration is configured with the output power value within the current adjustment cycle. When the process reset time reaches the adjustment time, it is determined whether the output process energy value has reached the target process energy value. If the target is not met, the output power value is updated based on the adjustment coefficient, and the process reset time used within the cycle is reset to zero to start the next adjustment cycle. If the desired result is achieved, the coating process is terminated.

10. The coating process according to claim 8, characterized in that: The periodic adjustment of the output power value is based on the difference between the current cumulative output process energy value and the target process energy value, the difference between the current cumulative process duration and the target process duration, and the compensation coefficient calculated based on the pause history. The output power value of the switching power supply is dynamically calculated and set. The pause conditions include conditions triggered by an arc event during the coating process. The arc event includes at least one of hard arc and micro arc. Different types of arc events correspond to different pause output durations.

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