A multi-channel, multi-media corrosion testing device and control system

Abstract

This invention provides a multi-channel, multi-media corrosion testing device and control system, belonging to the field of testing equipment technology. The device includes a main platform, a control host, a reaction chamber, a clamping system, an observation system, guide rails, pipes, gas cylinders, a platform, and a vacuum pump. The main components of the multi-channel, multi-media corrosion testing device are placed on the main platform and controlled by the control host. The material to be tested is placed on the platform, and the clamping system clamps and places the experimental material, achieving automatic control of the material experiment. This replaces manual experimental procedures, improves experimental safety, and avoids the negative impacts of manual operation. It greatly improves the automation level of the metal material testing process. The reaction chamber and gas cylinder are connected by pipes. The gas cylinder contains corrosive gas, and the host controls the entry of the corrosive gas into the reaction chamber, enabling corrosion testing of metal materials under various corrosive media environments at room temperature or high temperature.

Description

Technical Field

[0001] This invention relates to the field of testing equipment technology, specifically to a multi-channel, multi-medium corrosion testing device and control system. Background Technology

[0002] In aerospace, petrochemical, marine engineering, and metallurgical materials fields, materials are subjected to complex conditions of high temperature and multi-media corrosion for extended periods. Their corrosion resistance directly determines the operational safety, reliability, and service life of equipment. Therefore, conducting precise corrosion tests to simulate the corrosion behavior of materials under real-world conditions, analyzing corrosion mechanisms, and verifying the corrosion resistance of materials are core aspects of materials research and development, product selection, and engineering applications. These methods are of great significance for enhancing the core competitiveness of equipment and reducing safety risks.

[0003] With the rapid development of industrial technology, the performance requirements for corrosion testing equipment are becoming increasingly stringent. These equipment must not only be adaptable to various types of corrosive media, cover wide temperature ranges, and simulate complex operating conditions, but also meet the needs of batch testing, automated operation, and multi-dimensional data linkage analysis. However, existing corrosion testing equipment still faces many technical bottlenecks in practical applications, making it difficult to balance testing efficiency, accuracy, and the realism of operating condition simulation.

[0004] Existing corrosion testing equipment lacks effective isolation structures, making it prone to cross-contamination of media. This prevents parallel testing of different media and operating conditions, resulting in low testing efficiency and failing to meet the needs of rapid evaluation of batch materials. Furthermore, most equipment has limited media compatibility, only capable of testing single types of corrosive media (such as salt spray or single gases), and cannot simulate the high-temperature airflow of aero-engines or the H2S, CO2, and Cl- content in marine environments. - In complex corrosion scenarios involving multiple media, the test results deviate significantly from actual working conditions, limiting their reference value.

[0005] The lack of automation and data correlation are prominent shortcomings of existing equipment. Most equipment still relies on manual labor for sample loading, replacement, and data recording. Manual transport of high-temperature samples poses safety hazards, and manual operation is prone to introducing errors, resulting in poor test repeatability. At the same time, the existing equipment's functions such as quality monitoring, morphology analysis, and media parameter monitoring are mostly independent, lacking a unified control and communication platform. This makes it impossible to achieve synchronous acquisition, linkage analysis, and full life cycle traceability of multi-dimensional test data, and it is difficult to establish the correlation between "media parameters-corrosion rate-surface morphology," thus failing to provide complete data support for in-depth research on corrosion mechanisms.

[0006] In addition, existing equipment's cyclic corrosion systems often suffer from uneven media mixing and insufficient temperature control accuracy, failing to ensure sufficient and uniform contact between the corrosion medium and the sample surface, resulting in poor consistency in sample corrosion effects. Furthermore, the communication interface is limited, and the data acquisition frequency and reliability are limited, making it difficult to meet the needs of efficient transmission and management of industrial-grade test data. Summary of the Invention

[0007] Technical problems to be solved

[0008] To address the shortcomings of existing technologies, this invention provides a multi-channel, multi-medium corrosion testing device and control system, which solves the problems of existing technologies.

[0009] Technical solution

[0010] To achieve the above objectives, the present invention provides the following technical solution: a room temperature and high temperature multi-channel multi-media corrosion testing device, comprising a main platform, a control host, a reaction chamber, a clamping system, an observation system, guide rails, pipes, gas cylinders, a platform, and a vacuum pump; the main platform includes a platform panel and a platform base; the control host, reaction chamber, clamping system, observation system, guide rails, and platform are mounted on the platform panel; the pipes pass through the platform panel; and the gas cylinders and vacuum pump are located below the platform panel.

[0011] Preferably, the reaction chambers are configured as eight, arranged in two columns; the guide rails are configured as three columns, with the three columns of guide rails alternating with the two columns of reaction chambers; clamping systems are installed on the two side guide rails respectively, and an observation system is installed on the middle guide rail; the platform is located at one end of the guide rails.

[0012] Preferably, each reaction chamber is connected to five pipes, one of which is a vacuum pipe and four are corrosive gas input pipes; the four corrosive gas input pipes are connected to gas cylinders respectively, and the vacuum pipe is connected to a vacuum pump.

[0013] Preferably, the control host is connected to the clamping system, the observation system, the valve control terminal of the reaction chamber, and the vacuum pump, respectively; the control host outputs the clamping system's gripping control command and movement control command, the observation system's movement control command, the reaction chamber's valve opening command and valve closing command, and the vacuum pump's start command and stop command.

[0014] Preferably, a control system for a room temperature and high temperature multi-channel multi-media corrosion testing device is provided. The control system is housed within a control host and includes a task scheduling module, a chamber status management module, a media dosage calculation module, a motion scheduling module, a vacuum control module, an image analysis module, and a parameter correction module. The task scheduling module stores the correspondence between sample number, reaction chamber number, media number, reaction time, and image number. The chamber status management module stores the status code of each reaction chamber. The media dosage calculation module stores the media introduction time parameters of each reaction chamber. The motion scheduling module outputs the action sequence of the clamping system and the observation system. The vacuum control module outputs the running time of the vacuum pump. The image analysis module receives image data acquired by the observation system. The parameter correction module receives the image analysis results and updates the media introduction time parameters, reaction time parameters, and vacuum time parameters.

[0015] Preferably, the chamber status management module divides the operating status of each reaction chamber into the following states: ready to load sample, loaded sample, introduced sample, reacting sample, evacuated sample, observed sample, and sampled sample. The control host switches the status code of the corresponding reaction chamber in the order of ready to load sample, loaded sample, introduced sample, reacting sample, evacuated sample, observed sample, and sampled sample. At the same time, different reaction chambers correspond to different status codes.

[0016] Preferably, the medium dosage calculation module calls the corresponding import time parameters according to the reaction chamber number. The import time parameters include pre-evacuation time, pre-charge time, main charge time, homogenization time, and stabilization time. The control host first outputs the start command of the vacuum pump and continues the pre-evacuation time, then outputs the valve opening command of the corresponding reaction chamber and continues the pre-charge time, then outputs the valve opening command of the corresponding reaction chamber and continues the main charge time, then outputs the valve closing command of the corresponding reaction chamber and continues the homogenization time, and finally outputs the valve closing command of the corresponding reaction chamber and continues the stabilization time.

[0017] Preferably, the motion scheduling module stores the target reaction box number of the gripping system, the target reaction box number of the observation system, the start time of the gripping system's action, the start time of the observation system's action, the duration of the gripping system's action, and the duration of the observation system's action. When the target reaction box number of the gripping system is the same as the target reaction box number of the observation system, or when the start time of the gripping system's action coincides with the start time of the observation system's action, the control host modifies the start time of the observation system's action to after the end time of the gripping system's action.

[0018] Preferably, the evacuation control module stores the medium number, total import time, total reaction time, and evacuation time of each reaction chamber; after the reaction state ends, the control host reads the medium number, total import time, and total reaction time of the corresponding reaction chamber, calls the corresponding evacuation time according to these three data, outputs the start command of the vacuum pump, and continues the evacuation for the specified time; after the evacuation time ends, the control host switches the status code of the corresponding reaction chamber from evacuation state to observation state.

[0019] Preferably, the image analysis module extracts corrosion area value, edge grayscale change value, color distribution value, and spot quantity value from the image data acquired by the observation system; the parameter correction module compares the corrosion area value, edge grayscale change value, color distribution value, and spot quantity value with the target parameters of the corresponding sample number, generates import time correction value, reaction time correction value, and evacuation time correction value, and writes the import time correction value into the medium dosage solution module, and writes the reaction time correction value and evacuation time correction value into the task scheduling module.

[0020] Beneficial effects

[0021] This invention provides a multi-channel, multi-medium corrosion testing device and control system. It has the following beneficial effects:

[0022] 1. This invention, through a control architecture of "centralized management and control, distributed execution, and intelligent linkage," transforms multi-channel corrosion testing from manual, decentralized operation to unified scheduling and control. It enables the parallel and independent operation of multiple reaction chambers on a single main platform, thus simultaneously balancing multi-channel testing efficiency with single-channel control accuracy. The host control system provides unified control over the clamping system, observation system, reaction chamber valves, media release, and vacuuming process, allowing each reaction chamber to execute processes such as heating, sample loading, media introduction, corrosion reaction, vacuuming, observation, and sampling according to its set parameters. This ensures both the independence of individual channels in terms of temperature, media, and operational procedures, and the coordination between multiple channels at the scheduling level.

[0023] 2. The control host of this invention issues heating commands according to the set heating rate. After the temperature reaches the set value, it switches to the heat preservation mode and dynamically adjusts the power of each heating group through a PID algorithm. At the same time, it corrects the heating power of each zone based on the temperature uniformity monitoring results in the furnace, so as to keep the internal temperature of the reaction chamber stable. In terms of media control, the control host automatically calculates the flow parameters of each medium based on data such as furnace volume, temperature, and pressure, and sends the control quantity to the MFC and metering pump. At the same time, it uses a concentration sensor to collect media data in real time. When the detected value deviates from the set value, it compensates and corrects in time, so as to maintain the set concentration of various corrosive media during long-term continuous supply. In terms of circulating heat load corrosion control, the control host starts the circulating pump and adjusts the flow rate after the furnace temperature stabilizes, so that the medium enters the furnace through the pipeline. It dynamically adjusts the medium temperature based on the feedback signal of thermocouple or platinum resistance, and realizes closed-loop flow control through the flow sensor. Therefore, this invention can not only create a stable high-temperature corrosion environment, but also maintain the continuous stability of the medium supply and circulation state during long-term testing, reducing the problems of corrosion rate distortion, sample surface morphology deviation and poor test repeatability caused by temperature fluctuations, concentration deviations and flow instability, thereby improving the ability of test results to simulate real working conditions. Attached Figure Description

[0024] Figure 1 This is an isometric view of the present invention;

[0025] Figure 2 This is a front view of the present invention;

[0026] Figure 3 This is a top view of the present invention;

[0027] Figure 4 This is a diagram of the pipe connection structure of the present invention;

[0028] Figure 5 This is a structural diagram of the main platform of the present invention;

[0029] Figure 6 This is a structural diagram of the clamping system of the present invention;

[0030] Figure 7 This is a structural diagram of the observation system of the present invention;

[0031] Figure 8 This is a system architecture diagram of the present invention;

[0032] Figure 9 This is a system flowchart of the present invention.

[0033] The components include: 1. Main platform; 101. Platform panel; 102. Platform base; 2. Control host; 3. Reaction chamber; 4. Clamping system; 401. Equipment base; 402. Robotic arm; 403. Mechanical clamp; 5. Observation system; 501. Equipment base; 502. Camera bracket; 503. Observation camera; 6. Guide rail; 7. Pipeline; 701. Corrosive gas input pipeline; 702. Vacuuming pipeline; 8. Gas cylinder; 9. Display platform; 10. Vacuum pump. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Specific Implementation Example 1:

[0036] like Figures 1 to 7 As shown, a multi-channel, multi-media corrosion testing device and control system comprises a main platform 1, a control host 2, reaction chambers 3, a clamping system 4, an observation system 5, guide rails 6, pipes 7, gas cylinders 8, a platform 9, and a vacuum pump 10. The main platform 1, consisting of a platform panel 101 and a platform base 102, serves as the physical foundation for the entire system. The control host 2, reaction chambers 3, clamping system 4, observation system 5, guide rails 6, and platform 9 are all mounted on the platform panel 101; while the pipes 7 pass through the platform panel 101, connecting to the gas cylinders 8 and the vacuum pump 10 located below the panel. Specifically, the reaction chambers 3 are arranged in two rows on the main platform 1, totaling eight or more. Three rows of guide rails 6 are arranged alternately with the reaction chambers 3: the clamping systems 4 are installed on the outer two guide rails 6, while the observation systems 5 are installed on the middle guide rail 6. The gripping system 4 consists of a gripping base 401, a robotic arm 402, and a mechanical clamp 403, responsible for the precise gripping and displacement of samples. The observation system 5 consists of an equipment base 501, a camera bracket 502, and an observation camera 503, used for visual monitoring during the experiment. One end of each pipe 7 is connected to each reaction chamber 3, and the other end is connected to a gas cylinder 8 and a vacuum pump 10. Each reaction chamber 3 is connected to at least 5 pipes 7, one of which is dedicated to vacuuming the reaction chamber 702, and the rest are used as corrosive gas input pipes 701.

[0037] This control system solution is based on a core architecture of "centralized control, distributed execution, and intelligent linkage," adaptable to the parallel operation requirements of 8 independent furnaces. The system adopts a four-layer hierarchical architecture: the perception layer deploys a full range of sensor clusters, including S-type thermocouples, weighing sensors, medium concentration sensors, flow sensors, and displacement sensors, to collect real-time data on furnace temperature, sample mass, medium concentration, circulation flow rate, and robot position; the control layer uses a Siemens S7-1500 PLC as the core controller, paired with Siemens ET 200SP distributed I / O modules, providing independent control units for each of the 8 reaction chambers and 3 furnaces, ensuring the independence of each channel; the communication layer constructs a dual communication network of "Ethernet + RS485," with Ethernet handling high-speed interaction between the host computer and the control host, the 3D reconstruction system, and the database, and RS485 handling low-speed instruction transmission from the actuators; the application layer consists of host computer monitoring software, providing human-machine interaction and remote monitoring functions. In terms of hardware partitioning, the control host 2, data acquisition card, industrial switch, power module and other components are deployed on the left side of the platform to centrally process commands, while the 8 sets of ET 200SP modules are installed nearby next to each furnace and connected through shielded cables to shorten the transmission distance and reduce the impact of high temperature electromagnetic interference on the signal.

[0038] In terms of high-temperature furnace control, the system can achieve independent and precise temperature control of 8 furnace chambers. During the startup phase, the control host 2 issues heating commands at a set rate to drive the silicon molybdenum rods to start in zones; during the stabilization phase, the power is dynamically adjusted through a PID algorithm to maintain temperature fluctuations ≤ ±5℃ and temperature differences between zones ≤ ±3℃; during the shutdown phase, the temperature is gradually reduced to below 200℃ to prevent cracking of the furnace lining. For automatic sample changing, once the test meets the standards and the temperature drops to a safe range, the control host 2 automatically triggers the sample changing procedure, directing the clamping system 4 to transfer the old sample to the placement platform 9 using mechanical clamps 403, and then precisely place the new sample according to a preset plan. Multi-channel scheduling uses a path optimization algorithm to support parallel sample changing in 2 channels to avoid mechanical conflicts.

[0039] The corrosive media control system is compatible with various media such as H2S, O2, Cl-, and SO2, enabling arbitrary ratio control (accuracy ≤ ±1%) and dynamic concentration monitoring (accuracy ≤ 1 ppm). The control unit 2 automatically calculates parameters based on furnace data and sends them to the MFC and metering pump. Within a 1–150 hour cycle, the system monitors the gas source pressure and salt spray level. If a media leak is detected (concentration ≥ 1 ppm), the control unit 2 immediately cuts off the supply and activates the ventilation alarm. Simultaneously, the circulating heat transfer control system supports media delivery from room temperature to 1200℃, maintaining a mixing uniformity ≥ 98% through closed-loop flow regulation, and periodically operates an ultrasonic descaling module to ensure the system is free of scaling and leaks.

[0040] At the start of the experiment, the staff placed the experimental material on the platform 9 and opened the reaction chamber 3. The host computer 2 moved the clamping system 4, using mechanical clamps 403 to place the material into the reaction chamber 3. After closing the reaction chamber 3, the host computer 2 opened the valve to release corrosive gas; once the concentration reached the target, the experiment began. After the experiment, the vacuum pump 10 extracted the corrosive gas from the chamber and opened the door. At this time, the host computer 2 directed the observation system 5 to move to the top of the reaction chamber 3, using the observation camera 503 to photograph the corrosion morphology and transmit the data back to the host computer. Finally, the clamping system 4 moved the material back to the platform 9. Throughout the process, the host computer 2 simultaneously collected temperature, flow rate, mass, and morphology data, which were filtered and encrypted before being stored on a local SSD and a private cloud. The host computer software automatically generated a correlation curve of "medium parameters—corrosion rate—surface morphology," supporting retrieval and traceability analysis by channel, time, and sample number, fully meeting the high precision and efficiency requirements of corrosion testing. Specific Implementation Example 2:

[0042] like Figures 1 to 9 As shown, this equipment, based on the existing mechanical structure consisting of the main platform 1, control host 2, reaction chamber 3, clamping system 4, observation system 5, guide rail 6, pipeline 7, gas cylinder 8, placement platform 9, and vacuum pump 10, is further configured with a centralized control system that matches this structure. The control system uses the control host 2 as the unified control center, distributed execution units as the on-site action implementation units, multi-source sensor acquisition links as the status feedback units, industrial communication networks as the data exchange channels, and monitoring software and databases as the carriers for task configuration and data management, thus forming a closed-loop control process of "task issuance—parameter conversion—action execution—status feedback—deviation correction—result archiving". The control host 2 is internally divided into a task management module, equipment modeling module, temperature control module, sample change control module, media regulation module, cycle control module, data acquisition module, image analysis module, anomaly diagnosis module, and visualization management module. Each module is scheduled by a unified clock and uses channel number, sample number, and timestamp as the key to the entire process. To accommodate the parallel operation of eight reaction chambers 3, the control host 2 establishes an independent channel object for each reaction chamber 3, denoted as the... One channel is ,in Each channel object includes temperature state variables, medium state variables, action state variables, sample state variables, and alarm state variables, denoted as follows: , , , and The control host 2 uses the channel object as the basic management unit to implement parallel scheduling, independent closed-loop control, and unified coordination control of the eight channels.

[0043] The control system adopts a four-layer hierarchical architecture. The sensing layer is used to acquire field parameters, the control layer is used for real-time decision-making and execution, the communication layer is used for data transmission between different devices, and the application layer is used for human-machine interaction, process setting, process monitoring, result analysis, and historical traceability. The sensing layer is deployed in reaction chamber 3, pipeline 7, clamping system 4, observation system 5, and environmental protection area. Its data acquisition objects include temperature, medium concentration, gas flow rate, liquid flow rate, sample mass, clamp position, observation system 5 position, gas source pressure, liquid level, and chamber door status within reaction chamber 3. The control layer is centered on industrial-grade control host 2 and distributed input / output units. Control host 2 is responsible for global calculation, parameter tuning, state switching, and task scheduling. Distributed input / output units are responsible for sensor signal acquisition, actuator drive signal output, and interface connections with field valves, heating units, pumps, clamping actuators, and camera motion mechanisms. The communication layer employs a combination of Ethernet and RS485. Ethernet handles high-speed, large-volume communication between the host computer, control host 2, database, and image processing unit, while RS485 handles stable polling communication between low-speed industrial instruments and actuators. The application layer consists of monitoring software, a process database, an alarm database, and a report generation module. Operators input target values ​​for each channel, monitor operating curves, view corrosion process images and mass loss curves, and perform retrieval and analysis according to sample number, channel number, time range, and media type. To ensure a unified data organization format for the controlled objects, control host 2... Establish a state vector for each channel. in, Indicates the discrete sampling time. Indicates the first The overall temperature of the channel, This represents the zone temperature vector; if reaction chamber 3 is equipped with... Each temperature-controlled zone, then ; This represents the concentration vector of each corrosive medium within the channel. ; Represents the flow vector of each medium branch; This indicates the pressure in that channel; Indicates sample quality; This indicates that the gripping system 4 and the observation system 5 are relative to the first... Channel location information; This indicates the current task stage code for the channel. The task stage codes are defined in a fixed order as ten stages: standby, heating, isothermal control, sample loading, media introduction, stable reaction, evacuation, observation, sampling, and termination. Control host 2 calls the corresponding control program and interlock logic based on the stage code. To avoid conflicting commands from different modules to the same device, control host 2 uses a master task scheduling table to manage all action commands. Only one control program is allowed to occupy the same execution object at any given time. If concurrent requests are detected, the scheduler sorts them according to time priority, temperature safety constraints, and channel deadline before execution.

[0044] In the sensing layer, temperature detection preferably employs a composite temperature measurement method using S-type thermocouples and platinum resistance thermometers. The S-type thermocouples are used for primary measurement in the high-temperature zone, while the platinum resistance thermometers are used for calibration in the medium and low-temperature zones and for measuring the temperature of the circulating medium. Multiple temperature measurement points are arranged inside each reaction chamber 3 to obtain the zoned temperature distribution and support temperature uniformity control. Sample mass detection uses a weighing sensor; the weighing signal is bound to the sample number and channel number to calculate the corrosion rate and mass loss curve. Medium concentration detection is performed by corresponding concentration sensors. For gaseous media, electrochemical or infrared concentration detection is used; for liquid or atomized media, conductivity or ion concentration correlation detection is used. Flow rate detection uses a gas mass flow meter or liquid flow sensor, and displacement detection uses an encoder or linear displacement module to provide feedback on the position of the clamping system 4 and the observation system 5 along the guide rail 6. All sensor data are fed into a distributed I / O module after signal conditioning circuitry. The sampling period is set according to the rate of change of the physical quantity: the temperature signal sampling period is set to seconds, the flow rate and concentration signal sampling period is set to seconds, and the position and status signal sampling period is set to milliseconds. To improve sampling accuracy and reduce the impact of industrial noise on the signal, the control host 2 uses a cascaded processing method of "median filtering + Kalman filtering" for the raw data. First, it processes the data of length... Median filtering is performed on the sliding window sequence.

[0045]

[0046] in, These are the original sampled values. This is the result of median filtering. Set the window width to half its width; then... The input discrete Kalman filter, prediction and update process is as follows:

[0047]

[0048] in, To predict the state vector, The updated state vector, Let covariance matrix be the variance matrix. Here is the system state transition matrix. For the input matrix, To control the input, The process noise covariance matrix is... For the observation matrix, To measure the noise covariance matrix, For sensor measurement vectors, This represents the Kalman gain. Through the above processing, smooth, reliable state data suitable for closed-loop control can be obtained.

[0049] In the control layer, the temperature control module is responsible for the heating, temperature control, temperature uniformity adjustment, and controlled cooling of eight channels. For the first... There are 1 channel, and its target temperature is set to . , No. The measured temperature of each temperature zone is The weighted summation of the overall temperatures is defined as follows:

[0050]

[0051] in, For the first The weighting coefficients for each temperature zone satisfy the following conditions. During the heating phase, the control unit 2 operates according to the set heating rate. Generate reference trajectory:

[0052]

[0053] in, This is the starting temperature for heating. This represents the cumulative time for the current stage. Reach the target temperature Then it enters the constant temperature stage. Errors are established for each temperature zone.

[0054]

[0055] The power command is calculated using a discrete PID algorithm with a uniformity compensation term.

[0056]

[0057] in, For the first Heating power control amount for the temperature zone , , These are the proportional, integral, and differential coefficients, respectively. The sampling period is This is the uniformity compensation coefficient. (The last term...) This is used to reduce the deviation between each temperature zone and the overall temperature, so that the temperature in each zone converges towards a more uniform distribution. To prevent temperature overshoot and excessively rapid local heating, the control unit has two pairs of... Set a rate of change limit.

[0058]

[0059] in, This represents the maximum power adjustment allowed per unit sampling period. During the shutdown phase, the control unit 2 does not directly cut off heating, but instead generates a controlled cooling trajectory:

[0060]

[0061] in, To achieve the cooling rate, the furnace temperature is gradually reduced according to a predetermined curve until it falls below the safe sample replacement temperature threshold.

[0062] The sample change control module is used to automatically perform actions such as opening the box, retrieving the old sample, placing the old sample, grabbing the new sample, loading the new sample, confirming placement, and closing and locking the door after the sample has completed the corrosion reaction. To meet the scheduling requirements of eight channels running in parallel, the control host 2 defines each channel to be changed as a task node. and build a task set ,in This represents the number of channels that meet the sampling conditions at the current moment. Each task node includes a release time. Deadline Duration of the action Path length Temperature safety signs When satisfied At that time, the first The channel enters the executable sample change state, where The safe temperature threshold for allowing door opening and clamping actions is defined. Control host 2 uses a cost minimization scheduling algorithm with conflict constraints to determine the execution order, with the objective function being:

[0063]

[0064] in, Indicates the waiting time. This is the actual start time. Indicates the number of action conflicts. For weighting coefficients. Action conflict refers to the time overlap between the clamping system 4 and the observation system 5 within the adjacent section of the same guide rail 6, or the observation system 5 occupying the area above the same reaction chamber 3 when the clamping system 4 performs the door opening and sample loading action. The scheduler, when searching for the execution order, simultaneously satisfies interlocking constraints:

[0065]

[0066] or

[0067]

[0068] in, and These are the time intervals for two actions. and For the actuator position function, To ensure minimum safety distance, the gripping system 4's operation process is divided into seven sub-steps: positioning, gripping, lifting, translating, lowering, releasing, and exiting. Each step requires position feedback confirmation. The control host 2 will only proceed to the next step after the current step receives a positioning signal, thus forming a strict sequential control chain.

[0069] The corrosive medium control module is used to realize multi-medium concentration setting, ratio conversion, real-time closed-loop adjustment, supply continuity judgment, and abnormal cut-off control. Let the... The effective volume of the channel reaction chamber 3 is The total target flow rate of the medium is , No. The target volume fraction of corrosive media is The corresponding target branch flow is:

[0070]

[0071] in, If concentration is expressed in ppm, then:

[0072]

[0073] in, The target concentration value is ppm. For gaseous media, the third reaction chamber... The dynamics of component concentration can be described using a mass conservation model:

[0074]

[0075] in, This is the inlet flow rate of this component. The concentration of the inlet gas source. For export or pumping equivalent flow, This represents the equivalent consumption of the component due to reaction, adsorption, or deposition. For liquid or atomized media, the equivalent concentration versus injection volume model is used as follows:

[0076]

[0077] in, For the output flow rate of the metering pump, This is the concentration conversion factor. Here, represents the deposition and consumption coefficients. To simultaneously ensure rapid setpoint approximation and steady-state error elimination, the main control unit 2 employs a composite control method combining feedforward and feedback, with the control variable written as:

[0078]

[0079] in, For the first Control quantity of the medium actuator The feedforward quantity is calculated based on the target concentration, tank volume, total flow rate, and temperature and pressure conditions. This represents the concentration deviation. When the feed rate is converted based on an ideal gas, it is written as:

[0080]

[0081] in, The conversion factor is determined by the actuator range and the dimensions of the medium. The gas constant is... The absolute temperature. The control unit 2 continuously compares the measured concentration with the set concentration. When the concentration deviation threshold is exceeded, the control quantity is immediately recalculated, and the output of the corresponding gas source or metering pump is corrected. When the environmental leakage concentration, branch pressure, or branch flow rate is detected to exceed the safety boundary, the control host 2 writes the branch status as a fault status and executes the safety shut-off sequence of "closing the branch valve - stopping the flow actuator - starting the extraction or ventilation - recording the fault time and medium number".

[0082] The circulating hot-load corrosion control module is used to coordinate the control of the circulating pump, flow control valve, and medium temperature regulation unit, ensuring continuous circulation of the corrosive medium at a set flow rate and temperature. Let the... The channel's circulating flow rate setting is The measured value is The flow deviation is defined as follows: The control host 2 calculates the circulating pump speed command according to the PI control law:

[0083]

[0084] in, The target speed of the circulating pump, The reference speed is used. The setpoint for the circulating medium temperature is assumed to be... The measured medium temperature was Then, a PID algorithm similar to that used in furnace temperature control is employed to adjust the heating / cooling power, maintaining a specified coupling relationship between the medium temperature and the target furnace temperature. If... If the temperature difference between the furnace and the medium is indicated, then the control unit 2 will also add a temperature difference compensation item, so that... The concentration data was kept within a set range. To evaluate the uniformity of the cyclic mixing, multiple concentration data points were sampled within a single sampling window. Calculate the uniformity index:

[0085]

[0086] in, This is the average concentration. This represents the standard deviation of the concentration. When... When the flow rate decreases, it indicates a reduction in the degree of circulation mixing. Control unit 2 will then increase the circulation flow rate or adjust the branch valve position. For the tendency of scaling and blockage during long-term operation, control unit 2 will adjust the flow rate based on the flow resistance increment:

[0087]

[0088] To make a judgment, among which and These are the inlet and outlet pressures of the circulation branch, respectively. When When the value continues to increase and exceeds the threshold, the control host 2 records the maintenance event and executes the corresponding channel's cleaning or maintenance procedure.

[0089] The data acquisition module is used to perform synchronous sampling of multiple physical quantities, unified time alignment, database writing, and process curve generation. Because temperature, flow rate, concentration, mass, and image sampling frequencies differ, the control host 2 uses a unified timestamp to resample and align all data, establishing a channel-level data recording unit.

[0090]

[0091] in, Sample numbering, Channel number, For timestamps, This is an index of image features or the original image. Control host 2 correlates mass data with sample exposure time and calculates the corrosion rate using the mass loss method:

[0092]

[0093] in, For the initial mass, For a moment quality For the density of the sample material, For the corroded surface area, For exposure time, The corrosion rate is the equivalent thickness. If expressed as mass loss per unit area, it is written as:

[0094]

[0095] The control host 2 synchronously displays the corrosion rate curve along with the temperature curve, concentration curve, flow rate curve, and image feature curve, thus forming a correlated data chain of "process parameters - process status - result indicators". All data is written to an immutable log when stored locally. The log content includes at least the write time, write module, sample number, channel number, process version number, and anomaly flag to ensure the integrity of subsequent traceability.

[0096] The observation system 5 and image analysis module are used to acquire surface corrosion morphology and generate quantitative morphology indicators after the sample reaction. After the observation system 5 moves above the target reaction chamber 3, the control host 2 triggers the camera to complete image acquisition and sends the image to four steps: preprocessing, segmentation, feature extraction, and grade determination. The preprocessing step eliminates the influence of ambient light and thermal disturbance through grayscale normalization and noise reduction operations. Let the original image be... The normalized image is:

[0097]

[0098] in, and These represent the minimum and maximum gray levels in the image, respectively. The image segmentation step uses the maximum inter-class variance thresholding method to determine the threshold for the eroded region. Its objective function is

[0099]

[0100] in, and Thresholds The proportion of pixels on both sides and These represent the average gray levels of the two pixel types. After obtaining the eroded region, the eroded area percentage is calculated:

[0101]

[0102] in, The area of ​​the corroded region. This represents the total visible area of ​​the sample. Edge morphology variations can be assessed using the boundary perimeter and area to construct roughness indices.

[0103]

[0104] in, The perimeter of the corroded area is given. A larger value indicates a more irregular boundary. Color distribution values ​​are constructed using the color space mean and variance, while the number of spots is obtained by counting the number of connected components. The image analysis module combines the erosion area percentage, edge roughness, color distribution, and number of spots into a feature vector.

[0105]

[0106] in, and These represent the mean and standard deviation of the color distribution, respectively. This indicates the number of pitting or corrosion spots. This feature vector, along with the mass loss data, is written into the database for subsequent process analysis, sample grading, and control parameter correction.

[0107] The parameter self-correction and intelligent linkage module is used to automatically correct the process for subsequent similar tests based on the current test results. Let the target result vector for a certain type of sample be:

[0108]

[0109] The measured feature vector is The result deviation is defined as:

[0110]

[0111] The control host 2 performs linear or piecewise linear corrections to subsequent process parameters based on the deviation. The correction amounts for medium concentration, reaction time, and temperature are expressed as follows:

[0112]

[0113] in, , and This is the correction coefficient matrix. The corrected control objective is written as:

[0114]

[0115] If the system needs to avoid overcorrection due to a single result, a forgetting factor can be introduced. Construct a smooth correction form:

[0116]

[0117] in, This represents any process parameter to be corrected. This is the correction value calculated based on the current results. Through this mechanism, the system can feed back the experimental results to the next round of parameter settings, forming an adaptive adjustment process based on historical data.

[0118] The anomaly diagnosis module operates throughout the entire test cycle, used to identify faults such as temperature drift, excessive medium concentration, abnormal flow rate, abnormal location, communication anomalies, sensor disconnection, and image acquisition failure. Control host 2 constructs anomaly evaluation functions based on the residuals between the predicted and measured values ​​of each physical quantity. Let the... Channel at time The measurement vector is The prediction vector is Then the residual vector is:

[0119]

[0120] Further define Mahalanobis distance anomaly indicators:

[0121]

[0122] in, Let be the residual covariance matrix of this channel. When... Greater than the threshold At that time, the judgment of the first The channel is malfunctioning. For temperature anomalies, slope monitoring can also be introduced:

[0123]

[0124] When the temperature change rate exceeds the allowable range, the control host 2 records it as a temperature rise anomaly or a temperature drop anomaly. For communication anomalies, the control host 2 uses a dual judgment of heartbeat cycle and data packet verification. If a node is in... If a node fails to respond within a heartbeat cycle, or if the CRC check of the data packet fails consecutively, it will be placed in a communication failure state. After an anomaly occurs, the control host 2 will execute the following pre-defined procedures: event freezing, audible and visual alarms, shutdown of relevant actuators or switching to safe operating conditions, writing of fault codes to the database, and displaying pop-up prompts on the interface, thereby achieving fault tracking and traceable handling.

[0125] The application-layer monitoring software displays process setpoints, real-time values, status values, trend curves, and alarm information for each of the eight channels on the interface. It supports independent setting of heating curves, corrosive medium concentration curves, flow rate curves, reaction times, and sample change strategies for each channel. The system database organizes data according to the format of "Sample Master Table—Process Parameter Table—Process Data Table—Image Table—Alarm Table." The Sample Master Table records sample number, material properties, size information, and test batch. The Process Parameter Table records the target temperature, target medium concentration, target flow rate, and target duration for each test. The Process Data Table records the time-series data of continuous sampling. The Image Table records image paths, image features, and judgment results. The Alarm Table records alarm time, alarm level, alarm type, and processing results. After calling the above database, the monitoring software generates temperature-time curves, concentration-time curves, flow rate-time curves, corrosion rate-time curves, and a three-dimensional correlation diagram of "medium parameters—corrosion rate—surface morphology," enabling operators to complete parameter configuration, process monitoring, result comparison, and historical traceability all within a single interface.

[0126] The operating logic of the entire system is as follows: First, the operator inputs the target temperature, target medium composition, target flow rate, reaction time, sample number, and sample changing rules for each channel at the application layer. After the host 2 reads the parameters, it establishes the channel task and writes it into the task scheduling table. Subsequently, the temperature control module drives each reaction chamber 3 to enter the set temperature according to the heating trajectory and maintains a constant temperature. During this period, the data acquisition module collects and filters the temperature, concentration, flow rate, and position status in real time. When the sample loading conditions are reached, the sample changing control module calls the clamping system 4 to complete the sample loading. After loading, the medium control module calculates the control quantity of each branch according to the set value and imports the corresponding medium. During the stable reaction stage, the temperature, concentration, and flow rate are continuously adjusted under their respective closed-loop control loops, and the host 2 records the data of the entire process synchronously. After the reaction is completed, the vacuum pump 10 performs evacuation for the predetermined duration, the observation system 5 moves to the top of the reaction chamber 3 to collect images, the weighing module collects the sample mass change, and the data processing module calculates the corrosion rate and morphology index. Finally, the image analysis module and the parameter self-correction module correct the parameters of the next round of the same type of test based on the results of this round of test, and archive all process data and result data.

[0127] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising a reference structure" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0128] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A room temperature and high temperature multi-channel multi-media corrosion testing device, characterized in that, The system includes a main platform (1), a control host (2), a reaction chamber (3), a clamping system (4), an observation system (5), a guide rail (6), a pipe (7), a gas cylinder (8), a platform (9), and a vacuum pump (10). The main platform (1) includes a platform panel (101) and a platform base (102). The control host (2), the reaction chamber (3), the clamping system (4), the observation system (5), the guide rail (6), and the platform (9) are mounted on the platform panel (101). The pipe (7) passes through the platform panel (101). The gas cylinder (8) and the vacuum pump (10) are located below the platform panel (101).

2. The room temperature and high temperature multi-channel multi-media corrosion testing equipment according to claim 1, characterized in that, The reaction chambers (3) are set to eight, and the eight reaction chambers (3) are arranged in two columns; the guide rails (6) are set to three columns, and the three columns of guide rails (6) are arranged alternately with the two columns of reaction chambers (3); clamping systems (4) are installed on the two side guide rails (6) respectively, and observation systems (5) are installed on the middle guide rail (6); the platform (9) is set at one end of the guide rail (6).

3. The room temperature and high temperature multi-channel multi-media corrosion testing equipment according to claim 1, characterized in that, Each reaction chamber (3) is connected to five pipes (7), one of which is a vacuum pipe (702) and four are corrosive gas input pipes (701); the four corrosive gas input pipes (701) are connected to gas cylinders (8) respectively, and the vacuum pipes (702) are connected to vacuum pumps (10).

4. The room temperature and high temperature multi-channel multi-media corrosion testing equipment according to claim 1, characterized in that, The control host (2) is connected to the clamping system (4), the observation system (5), the valve control terminal of the reaction chamber (3), and the vacuum pump (10) respectively. The control host (2) outputs the gripping control command and the movement control command of the clamping system (4), the movement control command of the observation system (5), the valve opening command and the valve closing command of the reaction chamber (3), and the start command and stop command of the vacuum pump (10).

5. A control system for a room temperature, high temperature, multi-channel, multi-media corrosion testing device according to any one of claims 1-4, characterized in that, The control system is located in the control host (2). The control system includes a task scheduling module, a chamber status management module, a medium dosage solution module, a motion scheduling module, a vacuum control module, an image analysis module, and a parameter correction module. The task scheduling module stores the correspondence between the sample number, reaction chamber number, medium number, reaction time, and image number. The chamber status management module stores the status code of each reaction chamber (3). The medium dosage solution module stores the medium introduction time parameter of each reaction chamber (3). The motion scheduling module outputs the action sequence of the clamping system (4) and the observation system (5). The vacuum control module outputs the running time of the vacuum pump (10). The image analysis module receives the image data collected by the observation system (5). The parameter correction module receives the image analysis results and updates the medium introduction time parameter, reaction time parameter, and vacuum time parameter.

6. The control system of the room temperature and high temperature multi-channel multi-media corrosion testing equipment according to claim 5, characterized in that, The chamber status management module divides the operating status of each reaction chamber (3) into the state of waiting to be loaded, the state of loading completed, the state of introduction, the state of reaction, the state of evacuation, the state of observation and the state of sampling completed. The control host (2) switches the status code of the corresponding reaction chamber (3) in the order of the state of waiting to be loaded, the state of loading completed, the state of introduction, the state of reaction, the state of evacuation, the state of observation and the state of sampling completed. At the same time, different reaction chambers (3) correspond to different status codes.

7. The control system of the room temperature and high temperature multi-channel multi-media corrosion testing equipment according to claim 5, characterized in that, The medium dosage calculation module calls the corresponding import time parameters according to the reaction box number. The import time parameters include pre-evacuation time, pre-charge time, main charge time, homogenization time, and stabilization time. The control host (2) first outputs the start command of the vacuum pump (10) and continues the pre-evacuation time, then outputs the valve opening command of the corresponding reaction box (3) and continues the pre-charge time, then outputs the valve opening command of the corresponding reaction box (3) and continues the main charge time, then outputs the valve closing command of the corresponding reaction box (3) and continues the homogenization time, and finally outputs the valve closing command of the corresponding reaction box (3) and continues the stabilization time.

8. The control system of the room temperature and high temperature multi-channel multi-media corrosion testing equipment according to claim 5, characterized in that, The motion scheduling module stores the target reaction box number of the gripping system (4), the target reaction box number of the observation system (5), the start time of the action of the gripping system (4), the start time of the action of the observation system (5), the duration of the action of the gripping system (4), and the duration of the action of the observation system (5). When the target reaction box number of the gripping system (4) is the same as the target reaction box number of the observation system (5), or when the start time of the action of the gripping system (4) coincides with the start time of the action of the observation system (5), the control host (2) modifies the start time of the action of the observation system (5) to after the end time of the action of the gripping system (4).

9. The control system of the room temperature and high temperature multi-channel multi-media corrosion testing equipment according to claim 5, characterized in that, The vacuum control module stores the medium number, total import time, total reaction time and vacuum time of each reaction chamber (3); after the reaction state ends, the control host (2) reads the medium number, total import time and total reaction time of the corresponding reaction chamber (3), calls the corresponding vacuum time according to the three data, outputs the start command of the vacuum pump (10) and continues the vacuum time; after the vacuum time ends, the control host (2) switches the status code of the corresponding reaction chamber (3) from vacuum state to observation state.

10. The control system of a room temperature, high temperature, multi-channel, multi-media corrosion testing device according to claim 5, characterized in that, The image analysis module extracts corrosion area value, edge gray scale change value, color distribution value and spot number value from the image data collected by the observation system (5); the parameter correction module compares the corrosion area value, edge gray scale change value, color distribution value and spot number value with the target parameters of the corresponding sample number, generates import time correction value, reaction time correction value and evacuation time correction value, and writes the import time correction value into the medium dose solution module, and writes the reaction time correction value and evacuation time correction value into the task scheduling module.

Images