A self-control system for improving the yield of batch-manufactured atomic cluster powder

Abstract

The application discloses a self-control system for improving the yield of batch-manufactured atomic cluster powder, and belongs to the technical field of metal materials. The system comprises a data acquisition module and a data processing module. Firstly, an industrial camera is used to take a picture to identify the image in real time to determine whether the center position is deviated. Then, a secondary waveform fitting algorithm is used to accurately identify the frequency and range of the peak value for accurate control. Finally, the "center deviation determination conclusion" and the "peak value frequency range" are used as the operation basis of the motor operation mode adaptive module. The system further comprises a discharge quality detection module, a motor operation mode adaptive module, an alarm and data saving module, and a data display and interaction module. Through real-time sensing, intelligent decision-making and automatic execution under harsh working conditions, the application ensures that the manufacturing equipment can stably operate under the optimal process window, thereby providing a key guarantee for realizing the large-scale and efficient production of high-performance powder.

Description

Technical Field

[0001] This invention relates to an automated control system for improving the yield of mass-produced atomic cluster powders, belonging to the field of metal materials technology. Background Technology

[0002] In the field of preparation of atomic clusters and ultrafine metal powders, the existing mainstream technologies (such as high-frequency pulse discharge method, inert gas condensation method, electric explosion method, etc.) generally have a core contradiction: it is difficult to achieve both high-precision preparation and large-scale stable production.

[0003] Bottlenecks in high-precision fabrication: For example, the high-frequency pulsed discharge method, represented by CN119491219A, can produce atomic-level clusters, but its process control is extremely dependent on human experience. Due to the harsh working conditions such as high temperature, high pressure, strong arc light, and electromagnetic interference inside the chamber, sensors are difficult to intervene, resulting in the inability to adjust discharge parameters (such as electrode spacing) in real time and accurately. This leads to extremely low single-batch yield, poor batch consistency, and unstable yield.

[0004] The challenges of scaling up: To increase production, the industry has made various attempts, but all of them have introduced new problems. For the inert gas condensation method, although the improved technology (such as CN113069998A) has optimized the collection, it is still essentially an intermittent production. After scaling up, problems such as powder agglomeration and uneven composition are likely to occur.

[0005] For multi-electrode parallel discharge technology, early simple parallel modes (such as multi-strand twisted wire electro-explosion) can lead to process runaway due to strong electromagnetic coupling. Even with advanced solutions such as physical isolation and timing control (such as CN114905043A) to stabilize powder composition, the system complexity and cost increase significantly, and the real-time closed-loop control problem of the single-point discharge process itself is not fundamentally solved.

[0006] In summary, existing technologies share a common, yet unresolved, critical deficiency: the lack of a system capable of stable operation under the aforementioned harsh conditions, providing high-precision, automated closed-loop control over the entire "discharge-nucleation-growth" process. This directly leads to low production yield, poor stability, and high costs, becoming a fundamental obstacle restricting its transition from laboratory to large-scale industrial application. Summary of the Invention

[0007] This application aims to solve the core control problem faced by an associated manufacturing device in mass production. This associated device is based on the technical solution proposed in another patent application submitted by other applicants and currently under examination (application number 202410540155.8, hereinafter referred to as the "associated prior application", the theme of which relates to a low-melting-point and highly dispersed metal powder, its preparation equipment, and preparation method). The associated prior application provides an innovative powder material and the concept of its core production equipment.

[0008] Existing technologies (such as CN119491219A, etc.) have proven that this type of process faces the core bottleneck of being unable to achieve high-precision closed-loop control under high temperature, strong light, and electromagnetic interference, resulting in poor product consistency and difficulty in mass production. Although the aforementioned manufacturing solution proposes a new equipment concept, it is still restricted by this common problem.

[0009] Therefore, the purpose of this invention is not to propose new powders or equipment, but to overcome the above control bottleneck. This invention provides an adaptive control system that matches this manufacturing solution. By achieving real-time perception, intelligent decision-making, and automatic execution under harsh working conditions, it ensures that this manufacturing device can operate stably within the optimal process window, thus providing a key guarantee for its mass-scale and high-efficiency production of high-performance powders.

[0010] This invention specifically adopts the following technical solutions: An automatic control system for improving the yield of batch-produced atomic cluster powders, including: A data acquisition module, used to collect the voltage generated during the continuous high-frequency pulsed discharge impact of a high-frequency pulsed power supply on a target when producing atomic cluster powders; A data processing module, including: First, use an industrial camera to take pictures and identify the image in real time to determine whether the center position is offset. Then, accurately identify the frequency and range of the peak value through a quadratic waveform fitting algorithm for precise regulation. Finally, the "center offset determination conclusion" and the "peak frequency range" together serve as the operating basis for the motor operation mode adaptive module; A discharge quality detection module, for the values V p , , p , , p , p , , , , ,

[0010] , ,

[0009] and F p perform range discrimination. If the adjustment of the discharge quality is satisfied simultaneously, it is included in the total time, and finally, the ratio of the time to the total time is output as the output. V p is the average value of all data of the array P within this time period within the time window T, and F p is the effective pulse frequency monitored within consecutive time windows T; <000^004>The motor operation mode adaptive module is used to adjust the center position of the motor left and right when the image recognition algorithm detects an offset. Otherwise, a fine-tuning judgment is made based on the voltage value; The motor operation mode adaptive module is used to adjust the center position of the motor left and right when the image recognition algorithm detects an offset. Otherwise, a fine-tuning judgment is made based on the voltage value; The alarm and data storage module is used to store the voltage data, peak frequency, average data, motor running position data, and flow meter data obtained by the data processing module for easy data analysis. The data display and interaction module is used to present discharge data, real-time motor position, effective discharge rate, and alarm results to users in an intuitive chart and graph format, and provides user interaction functions.

[0011] In a preferred embodiment, the data processing module includes image recognition processing: First, image recognition algorithms are used to calculate the large-scale position of the cavity; Second, the centroid formula is used to identify the position of the discharge spot. The input is the pixel brightness I(x,y), where I(x,y) is the intensity of the discharge spot; the output is the spatial coordinates (Cx,Cy), where (Cx,Cy) is the location of the discharge spot. ; ; N represents the number of rows in the image; M represents the number of columns in the image. Finally, the deviation is determined by comparing the center of the cavity with the center of the discharge spot, and the deviation tolerance is set as D.

[0012] In a preferred embodiment, the image recognition processing employs the Hough circle algorithm to calculate the large position of the cavity: ; ; K represents the total number of detected circles. E represents the set of edge points in the image; For approximate equality judgment, satisfying: r min ≤r≤r max ; r min and r max Constrained by the actual cavity radius.

[0013] As a preferred embodiment, the parameter r is determined based on the actual value of the pixel radius occupied by the cavity. min and the parameter r max It is configured within the range of 220 to 255.

[0014] In a preferred embodiment, the offset tolerance D is set to 5-10% of the cavity radius.

[0015] In a preferred embodiment, the data processing module includes pulse peak identification: identifying all local maxima points based on the discrete voltage sampling sequence V[n], where point V[k] is determined to be a local maximum under the following condition: and ; Points (tk, Vk) that meet the above conditions are initially marked as candidate peak points.

[0016] In a preferred embodiment, the data processing module includes waveform fitting verification of valid pulses: to eliminate noise interference and confirm that it is a valid discharge pulse, m data points within a predetermined time window before and after each candidate peak point are processed. Perform a quadratic polynomial fitting, and the fitting model is as follows: : ; The coefficients a, b, and c are solved using the least squares method, with the goal of maximizing the sum of squared residuals. Minimum.

[0017] In a preferred embodiment, the data processing module includes peak array generation and pulse frequency calculation: all verified peak points (tk, Vk) are stored in array P=[p1,p2,...,pN] in chronological order of their occurrence, thus forming an "effective voltage peak array" for a production cycle; monitoring is performed within a continuous time window T, and the effective pulse frequency F is calculated. p The basic calculation formula is: F p =N / T; Where N is the length of array P within the time window T during that time period; V p This represents the mean of all data in array P within the time window T during that time period.

[0018] In a preferred embodiment, the discharge quality detection module includes: For atomic cluster powder, an RC circuit is used to calculate the ideal discharge time based on the following charging formula, and then the ideal discharge frequency F is calculated. s ; ; V0 is the initial voltage across the terminals at the instant the discharge begins (t=0), which is actually 2000V. s In practice, we take 1500V, and the RC values ​​are taken from the actual resistance and capacitance of the circuit box; after substituting into the formula to obtain the ideal discharge time t, we can then calculate the ideal discharge frequency: F s =1 / t; For V p With V s For comparison, F p With F sCompare them.

[0019] As a preferred embodiment, under ideal and normal operating conditions, the key parameters affecting the manufacturing quality of atomic cluster powder include gas flow rate, discharge voltage, and discharge frequency, and their ratio is controlled between 0.8 and 1.2.

[0020] The beneficial effects achieved by this invention are as follows: This invention addresses the core bottleneck of existing technologies, which struggle to achieve high-precision closed-loop control under high temperature, strong light, and electromagnetic interference, resulting in poor product consistency and difficulty in large-scale production. While the aforementioned manufacturing solutions propose new equipment concepts, they are still constrained by the common problem of control bottlenecks. This invention proposes an automated control system to improve the yield of mass-produced atomic cluster powders, comprising: a data acquisition module for acquiring the voltage generated when a high-frequency pulse power supply continuously discharges high-frequency pulses onto the target material during the production of atomic-level cluster powders; a data processing module, comprising: first, using an industrial camera to take pictures and identify the image in real time to determine whether the center position has shifted; then, using a quadratic waveform fitting algorithm to accurately identify the frequency and range of the peak value for precise control; finally, the "center shift determination conclusion" and "peak frequency range" together serve as the operating basis for the motor operation mode adaptive module; and a discharge quality detection module, which detects the value V obtained by the data processing module. p and F p The system performs range discrimination and, if the discharge quality adjustment is met, includes it in the total time. The final output time is the ratio of the total time to the output time. The motor operation mode adaptive module adjusts the motor's center position left or right when the image recognition algorithm detects a deviation; otherwise, it makes fine adjustments based on the voltage value. The alarm and data storage module stores voltage data, peak frequency, average data, motor operating position data, and flow meter data obtained from the data processing module for data analysis. The data display and interaction module presents discharge data, real-time motor position, effective discharge rate, and alarm results to the user in intuitive charts and graphs, and provides user interaction functions. By achieving real-time perception, intelligent decision-making, and automatic execution under harsh working conditions, it ensures that the manufacturing equipment can operate stably within the optimal process window, thus providing a key guarantee for the large-scale and efficient production of high-performance powders. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the architecture of an automated control system for improving the yield of mass-produced atomic cluster powders according to the present invention.

[0022] Figure 2 This is a schematic flowchart of an automated control system for improving the yield of mass-produced atomic cluster powders according to the present invention.

[0023] Figure 3This is an example diagram showing data shifted to the left in an embodiment of the present invention.

[0024] Figure 4 This is an example diagram showing data biased to the right in an embodiment of the present invention. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0026] Example 1: As Figure 1 As shown, this invention proposes an automated control system for improving the yield of mass-produced atomic cluster powders, comprising: The data acquisition module is used to collect the voltage generated when the high-frequency pulse power supply continuously applies high-frequency pulse discharge to the target material during the production of atomic cluster powder. The data processing module includes: first, taking pictures with an industrial camera and recognizing the images in real time to determine whether the center position is offset; then, accurately identifying the frequency and range of the peak value through a quadratic waveform fitting algorithm for precise control; and finally, the "center offset judgment conclusion" and "peak frequency range" together serve as the basis for the operation of the motor operation mode adaptive module. The discharge quality detection module, for the value V obtained by the data processing module. p and F p Range discrimination is performed, and if the discharge quality adjustment is met, the total time is included. The ratio of the final output time to the total time is used as the output. p F is the mean of all data in array P within the time window T during that time period. p The effective pulse frequency for monitoring within a continuous time window T; The motor operation mode adaptive module is used to adjust the center position of the motor left or right when the image recognition algorithm detects an offset; otherwise, it makes a fine adjustment based on the voltage value. The alarm and data storage module is used to store the voltage data, peak frequency, average data, motor running position data, and flow meter data obtained by the data processing module for easy data analysis. The data display and interaction module is used to present discharge data, real-time motor position, effective discharge rate, and alarm results to users in an intuitive chart and graph format, and provides user interaction functions.

[0027] In a preferred embodiment, the data processing module includes image recognition processing: First, the large-scale position of the cavity is calculated using the Hough circle algorithm: ; ; K represents the total number of detected circles. E represents the set of edge points in the image; For approximate equality judgment, satisfying: r min ≤r≤r max ; r min and r max Constrained by the actual cavity radius; Second, the centroid formula is used to identify the position of the discharge spot. The input is the pixel brightness I(x,y), where I(x,y) is the intensity of the discharge spot; the output is the spatial coordinates (Cx,Cy), where (Cx,Cy) is the location of the discharge spot. ; ; N represents the number of rows in the image; M represents the number of columns in the image. Finally, the deviation is determined by comparing the center of the cavity with the center of the discharge spot, and the deviation tolerance is set as D.

[0028] As a preferred embodiment, the parameter r is determined based on the actual value of the pixel radius occupied by the cavity. min and the parameter r max It is configured within the range of 220 to 255.

[0029] In a preferred embodiment, the offset tolerance D is set to 5-10% of the cavity radius.

[0030] In a preferred embodiment, the data processing module includes pulse peak identification: identifying all local maxima points based on the discrete voltage sampling sequence V[n], where point V[k] is determined to be a local maximum under the following condition: and ; Points (tk, Vk) that meet the above conditions are initially marked as candidate peak points.

[0031] In a preferred embodiment, the data processing module includes waveform fitting verification of valid pulses: to eliminate noise interference and confirm that it is a valid discharge pulse, m data points within a predetermined time window before and after each candidate peak point are processed. Perform a quadratic polynomial fitting, and the fitting model is as follows: : ; The coefficients a, b, and c are solved using the least squares method, with the goal of maximizing the sum of squared residuals. Minimum.

[0032] In a preferred embodiment, the data processing module includes peak array generation and pulse frequency calculation: all verified peak points (tk, Vk) are stored in array P=[p1,p2,...,pN] in chronological order of their occurrence, thus forming an "effective voltage peak array" for a production cycle; monitoring is performed within a continuous time window T, and the effective pulse frequency F is calculated. p The basic calculation formula is: F p =N / T; Where N is the length of array P within the time window T during that time period; V p This represents the mean of all data in array P within the time window T during that time period.

[0033] In a preferred embodiment, the discharge quality detection module includes: For atomic cluster powder, an RC circuit is used to calculate the ideal discharge time based on the following charging formula, and then the ideal discharge frequency F is calculated. s ; ; V0 is the initial voltage across the terminals at the instant the discharge begins (t=0), which is actually 2000V. s In practice, we take 1500V, and the RC values ​​are taken from the actual resistance and capacitance of the circuit box; after substituting into the formula to obtain the ideal discharge time t, we can then calculate the ideal discharge frequency: F s =1 / t; For V p With V s For comparison, F p With F s Comparison. Atomic cluster powders, including but not limited to nickel, silver, copper, tungsten, rhenium, niobium, iron, aluminum, gold, gadolinium, silicon, carbon, etc.

[0034] As a preferred embodiment, under ideal and normal operating conditions, the key parameters affecting the manufacturing quality of atomic cluster powder include gas flow rate, discharge voltage, and discharge frequency, and their ratio is controlled between 0.8 and 1.2.

[0035] like Figure 2 , Figure 3 and Figure 4 As shown, the user input voltage setting value and effective frequency The recording begins at time t0, camera data is acquired, and then processed. If the camera is tilted to the left or right, it is moved to the left or right respectively. If the camera is centered, the deviation ratio is defined by combining the measured voltage and calculating the average voltage. ,in This is the deviation value. This represents the average peak voltage. In this embodiment, under normal operating conditions... .

[0036] Using a piecewise proportional-integral (PI) control law: ; The proportional coefficient Kp is set according to the interval segmentation of the deviation ratio r: ; The integral coefficient Ki is a preset fixed value used to eliminate the steady-state error of the system. The value of Ki ranges from 0.01 to 0.1, and in this embodiment, Ki = 0.05 is selected.

[0037] Run the motor for P pulses, cyclically recording from the start time t0; where the average peak voltage is used... Then calculate the peak frequency Record the end time t1, if and The effective discharge time is Otherwise, the effective discharge time Output the total time Discharge efficiency The initial time t0 is recorded in a loop.

[0038] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0039] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1The computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to operate in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The functions specified in one or more boxes. These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable apparatus for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0040] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. An automated control system for improving the yield of mass-produced atomic cluster powders, characterized in that, include: The data acquisition module is used to collect the voltage generated when the high-frequency pulse power supply continuously applies high-frequency pulse discharge to the target material during the production of atomic cluster powder. The data processing module includes: first, using an industrial camera to capture images in real time to determine if the center position has shifted; then, using a quadratic waveform fitting algorithm to accurately identify the frequency and range of peak values ​​for precise control; finally, the resulting "center shift determination conclusion" and "peak frequency range" serve as the basis for the operation of the motor operation mode adaptive module; the data processing module includes peak array generation and pulse frequency calculation: generating all verified peak points... Store them in an array according to their occurrence time. This constitutes an "effective voltage peak array" within a production cycle; monitoring is performed within a continuous time window T, and the effective pulse frequency... The basic calculation formula is: ； Where N is the length of array P within the time window T during that time period; This represents the mean of all data in array P within a time window T during that time period. The discharge quality detection module, for the value obtained by the data processing module. and The range is determined, and if the discharge quality is adjusted, the total time is included. Finally, the ratio of the output time to the total time is used as the output. The motor operation mode adaptive module is used to adjust the center position of the motor left or right when the image recognition algorithm detects an offset; otherwise, it makes a fine adjustment based on the voltage value. The alarm and data storage module is used to store the voltage data, peak frequency, average data, motor running position data, and flow meter data obtained by the data processing module for easy data analysis. The data display and interaction module is used to present discharge data, real-time motor position, effective discharge rate, and alarm results to users in an intuitive chart and graph format, and provides user interaction functions.

2. The automated control system for improving the yield of mass-produced atomic cluster powder according to claim 1, characterized in that, The data processing module includes image recognition processing: First, image recognition algorithms are used to calculate the large-scale position of the cavity; Second, the centroid formula is used to identify the position of the discharge spot. Input: pixel brightness , Output: Spatial coordinates (indicating discharge spot intensity) , To locate the position of the discharge spot; ； ； N represents the number of rows in the image; M represents the number of columns in the image. Finally, the deviation is determined by comparing the center of the cavity with the center of the discharge spot, and the deviation tolerance is set as D.

3. The automated control system for improving the yield of mass-produced atomic cluster powders according to claim 2, characterized in that, The image recognition processing uses the Hough circle algorithm to calculate the large position of the cavity: ； K represents the total number of detected circles. E represents the set of edge points in the image; For approximate equality judgment, satisfying: ; and Constrained by the actual cavity radius.

4. The automated control system for improving the yield of mass-produced atomic cluster powders according to claim 3, characterized in that, Based on the actual value of the pixel radius occupied by the cavity, the parameters are... and the parameters It is configured within the range of 220 to 255.

5. The automated control system for improving the yield of mass-produced atomic cluster powders according to claim 2, characterized in that, The offset tolerance D is set to 5-10% of the cavity radius.

6. The automated control system for improving the yield of mass-produced atomic cluster powders according to claim 1, characterized in that, The data processing module includes pulse peak identification: based on discrete voltage sampling sequences. Identify all local maxima points, points The condition for a value to be determined as a local maximum is: ； Points that meet the above conditions They were initially marked as candidate peak points.

7. The automated control system for improving the yield of mass-produced atomic cluster powders according to claim 6, characterized in that, The data processing module includes waveform fitting verification of valid pulses: to eliminate noise interference and confirm that it is a valid discharge pulse, it performs waveform fitting verification on m data points within a predetermined time window before and after each candidate peak point. Perform a quadratic polynomial fitting, and the fitting model is as follows: : ； The coefficients a, b, and c are solved using the least squares method, with the goal of maximizing the sum of squared residuals. Minimum.

8. The automated control system for improving the yield of mass-produced atomic cluster powder according to claim 1, characterized in that, The discharge quality detection module includes: For atomic cluster powder, an RC circuit is used to calculate the ideal discharge time based on the following charging formula, and then the ideal discharge frequency is calculated. ; ； The initial voltage across the terminals at t=0, the instant the discharge begins, is actually 2000V. In practice, we take 1500V, and the RC values ​​are taken from the actual resistance and capacitance of the circuit box; after substituting into the formula to obtain the ideal discharge time t, we can then calculate the ideal discharge frequency: ； right and Comparison, and Compare them.

9. The automated control system for improving the yield of mass-produced atomic cluster powders according to claim 8, characterized in that, Under ideal and normal operating conditions, the key parameters affecting the manufacturing quality of atomic cluster powders include gas flow rate, discharge voltage, and discharge frequency, and their ratio is controlled between 0.8 and 1.2.

Images