An intelligent management system for the production process of cylinder and lower cover bearings of an air conditioner compressor.

Abstract

This invention belongs to the field of intelligent management technology, specifically disclosing an intelligent management system for the production process of cylinders and lower cover bearings of air conditioning compressors. The system includes a proportioning determination module, a melting verification and product traceability code generation module, a sealing assembly association module, and an airtightness detection and layered backtracking module. The proportioning determination module is used to obtain raw material batch test results and production task information, and generate candidate proportioning schemes based on product material standards. The purpose of this invention is to solve the problems of a lack of continuous connection between raw material proportioning prediction, material verification after melting, sealing assembly association of cylinders and lower cover bearings, and layered backtracking of leakage rate anomalies during the production process of air conditioning compressor cylinders and lower cover bearings. This leads to difficulties in identifying boundary risks of proportioning before material input, difficulty in verifying the source of material deviation after melting, difficulty in timely judging sealing risks after assembly even when a single part is qualified, and a lack of sequential data basis for investigating the source of leakage rate anomalies.

Description

Technical Field

[0001] This invention relates to the field of intelligent management technology, specifically to an intelligent management system for the production process of cylinders and lower cover bearings of an air conditioning compressor. Background Technology

[0002] In the manufacturing of air conditioning compressor components, cylinders and lower cover bearings typically undergo a series of processes, including raw material intake, batching and smelting, casting, precision machining, heat treatment, assembly inspection, and airtightness testing. Their final quality depends not only on whether individual cylinders or lower cover bearings meet dimensional, hardness, and appearance requirements, but also on the continuous influence of factors such as raw material composition, proportioning results, material deviations after smelting, heat treatment cooling conditions, sealing fit dimensions, and assembly pressure. Current production management methods primarily rely on batch records, product numbers, test results, and non-conforming labels. While these methods can record the processes a product has undergone, it is often difficult to determine whether candidate proportions are close to the product's material standard boundaries before material input, and it is also difficult to verify the actual material results against pre-input predictions after smelting. This results in fluctuations in raw material composition, weighing deviations, or smelting process deviations often requiring further confirmation in subsequent testing. Meanwhile, cylinders and lower cover bearings are typically inspected as individual products before assembly. Even if the dimensions of both are within tolerance, leaks may still occur during airtightness testing due to differences in the dimensions of the sealing fit, the roughness of the sealing surface, the flatness of the lower cover bearing, or mismatches in assembly pressure. Furthermore, when the leak rate exceeds the standard, existing methods usually rely on manual checks of dimensions, heat treatment, material, and raw material records. This lack of a layered backtracking path using the sealing assembly traceability code as an entry point makes it difficult to establish a sequential association between leak rate anomalies and the sealing fit dimension layer, heat treatment status layer, smelting material layer, and raw material ratio layer. This results in lengthy anomaly source location, insufficient focus of verification, and inadequate data for handling recommendations. Therefore, an intelligent management system and its operation method for the air conditioning compressor cylinder and lower cover bearing production process are needed, capable of continuously linking raw material ratio prediction, post-smelting material verification, cylinder and lower cover bearing sealing assembly association, and layered backtracking of leak rate anomalies. Summary of the Invention

[0003] This invention provides an intelligent management system for the production process of cylinders and lower cover bearings of air conditioner compressors. The purpose of this invention is to solve the problems of lack of continuous connection between raw material ratio prediction, material verification after melting, cylinder and lower cover bearing sealing assembly correlation, and leakage rate anomaly stratified backtracking in the production process of air conditioner compressor cylinders and lower cover bearings. This leads to difficulties in identifying the boundary risks of the ratio before feeding materials, difficulty in verifying the source of material deviation after melting, difficulty in timely judging the sealing risk after a single qualified part is assembled, and lack of sequential data basis for the investigation of the source of abnormality after the occurrence of leakage rate anomalies.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0005] An intelligent management system for the production process of cylinder and lower cover bearings of an air conditioner compressor includes a proportioning determination module, a melting verification and product traceability code generation module, a sealing assembly association module, and an airtightness detection and layered backtracking module. The proportioning determination module is used to obtain raw material batch test results and production task information, generate candidate proportioning schemes according to product material standards, calculate the predicted element content and material boundary margin of the candidate proportioning schemes, and determine the final proportioning scheme when the candidate proportioning schemes meet the product material standards and the material boundary margins meet the margin threshold, and generate smelting batch traceability codes. The smelting verification and product traceability code generation module is used to receive the smelting batch traceability code generated by the proportion determination module, collect smelting and casting process parameters and material test results after smelting based on the smelting batch traceability code, compare the material test results after smelting with the predicted element content, generate a smelting deviation verification task or a smelting material qualification record, and generate a cylinder product traceability code or a lower cover bearing product traceability code based on the smelting batch traceability code. The sealing assembly association module is used to receive the cylinder product traceability code and the lower cover bearing product traceability code generated by the melting verification and product traceability code generation module. Based on the cylinder product traceability code and the lower cover bearing product traceability code, it collects precision machining data and heat treatment status data. When the cylinder and the lower cover bearing meet the pre-assembly conditions, it binds and generates a sealing assembly traceability code and records the sealing fit deviation index and assembly parameters. The airtightness detection and layered backtracking module is used to receive the sealing assembly traceability code generated by the sealing assembly association module, perform airtightness detection based on the sealing assembly traceability code, and when the leakage rate detection value exceeds the leakage rate standard, call the sealing fit size data, heat treatment status data, melting material data and raw material ratio data associated with the sealing assembly traceability code to perform layered backtracking, and generate anomaly source sorting and handling suggestions.

[0006] In one aspect of the present invention, the proportioning determination module, the smelting verification and product traceability code generation module, the sealing assembly association module, and the airtightness detection and layered backtracking module are all communicatively connected to the production data management platform. The production data management platform includes a relational database and a time-series database; The relational database is used to store raw material batch traceability codes, smelting batch traceability codes, cylinder product traceability codes, lower cover bearing product traceability codes, sealing assembly traceability codes, candidate proportioning schemes, final proportioning schemes, material boundary margins, smelting deviation verification tasks, smelting material qualification records, sealing fit deviation indicators, abnormal source sorting and handling suggestions. The time-series database is used to store melting temperature, casting pressure, spindle speed, machining torque, acoustic emission signal, furnace temperature uniformity index, cooling rate, and airtightness test curve; The production data management platform is configured to associate the smelting batch traceability code with the corresponding raw material batch traceability code and the final proportioning scheme, to associate the cylinder product traceability code or the lower cover bearing product traceability code with the corresponding smelting batch traceability code, to associate the sealing assembly traceability code with the corresponding cylinder product traceability code and the lower cover bearing product traceability code, and, when the leakage rate detection value exceeds the leakage rate standard, to reverse-call the corresponding sealing fit dimension data, heat treatment status data, smelting material data and raw material proportioning data through the sealing assembly traceability code.

[0007] In one aspect of the invention, the raw material batch testing results include the raw material batch traceability code, raw material category, supplier information, measured carbon content, measured copper content, measured iron content, and factory acceptance conclusion for at least one of the raw materials: pig iron, scrap steel, and electrolytic copper. Before generating a candidate blending scheme, the corresponding raw material factory acceptance standard is called according to the raw material category for judgment. Raw material batches that meet the corresponding raw material factory acceptance standard are marked as usable for batching, while raw material batches that do not meet the corresponding raw material factory acceptance standard are marked as unqualified and awaiting isolation. The raw material factory acceptance standard and the product material standard are stored separately, and the single raw material testing results of pig iron, scrap steel, and electrolytic copper are not directly judged as qualified according to the product material standard of the cylinder or lower cover bearing.

[0008] In one aspect of the invention, the candidate formulation includes the batch traceability code of the raw materials involved in the feeding, the mass ratio of each raw material, the expected feeding weight, and the target product type; the predicted element content is obtained by weighting the measured element content of each raw material and the mass ratio of each raw material; the material boundary margin is the smaller of two distances between the predicted element content and the lower limit and the upper limit of the product material standard; when the predicted element content of any controlled element exceeds the product material standard, the candidate formulation is marked as not meeting the product material standard; when the material boundary margin of any controlled element is less than the corresponding margin threshold, the candidate formulation is marked as a boundary risk formulation.

[0009] In one aspect of the invention, when the candidate blending scheme is marked as a boundary risk blending scheme, the production data management platform generates an alternative blending scheme based on the type of controlled element; when the predicted carbon content is close to the upper limit of carbon content, an alternative blending scheme that reduces the pig iron mass ratio and increases the low-carbon scrap steel mass ratio is generated first; when the predicted copper content is close to the upper limit of copper content, an alternative blending scheme that reduces the electrolytic copper mass ratio and supplements the mass ratio with low-copper scrap steel or low-copper iron-based raw materials that meet the factory acceptance standards is generated first; the alternative blending scheme re-executes the predicted element content calculation and material boundary margin determination, and is determined as the final blending scheme after meeting the product material standards and the material boundary margin meets the margin threshold.

[0010] In one aspect of the invention, the material testing results after smelting include the measured carbon content, measured copper content, and measured iron content of the smelted sample; the smelting deviation verification task is generated based on the absolute difference between the material testing results after smelting and the predicted element content in the final proportioning scheme; when the difference of any controlled element exceeds the corresponding smelting deviation threshold, the production data management platform generates a smelting deviation verification task, which includes verifying the raw material batch traceability code, raw material weighing record, smelting temperature curve, feeding sequence, testing equipment calibration status, and testing sample number; when the material testing results after smelting meet the product material standard and the difference does not exceed the corresponding smelting deviation threshold, a smelting material qualification record is generated.

[0011] In one aspect of the invention, the precision machining data includes the measured dimensions of the cylinder seal mating position, the cylinder seal surface roughness, the measured dimensions of the lower cover bearing seal mating position, the lower cover bearing flatness, machining torque, and acoustic emission signal; the heat treatment status data includes furnace temperature uniformity index, cooling rate, hardness test value, and crack marking results; when the machining torque exceeds the upper limit of the machining torque or the acoustic emission signal exceeds the acoustic emission signal threshold, a tool wear risk warning is generated; when the cooling rate exceeds the upper limit of the cooling rate or is lower than the lower limit of the cooling rate, a cooling rate abnormality warning is generated, and the tool wear risk warning and the cooling rate abnormality warning are respectively written into the corresponding cylinder product traceability code or lower cover bearing product traceability code.

[0012] In one aspect of the invention, the sealed assembly traceability code is generated by binding the cylinder product traceability code and the lower cover bearing product traceability code. Before binding, the production data management platform determines whether the cylinder and the lower cover bearing have any material abnormalities, size abnormalities, heat treatment abnormalities, or isolation states that are not closed. If any exist, the generation of the sealed assembly traceability code is prevented. If none exist, the sealed assembly traceability code is generated, and the measured dimensions of the cylinder sealing fit position, the measured dimensions of the lower cover bearing sealing fit position, the assembly pressure, the assembly displacement, and the assembly time are written into the sealed assembly traceability code. The sealing fit deviation index is determined based on the difference between the measured dimensions of the cylinder sealing fit position and the measured dimensions of the lower cover bearing sealing fit position. When the sealing fit deviation index exceeds the sealing fit deviation threshold, the corresponding assembly combination is marked as a sealing fit risk combination.

[0013] In one aspect of the invention, the layered backtracking is performed in the following order: sealing fit dimension layer, heat treatment state layer, smelting material layer, and raw material proportioning layer. The sealing fit dimension layer is used to verify the measured dimensions of the cylinder sealing fit position, the cylinder sealing surface roughness, the measured dimensions of the lower cover bearing sealing fit position, the lower cover bearing flatness, the sealing fit deviation index, and the assembly pressure. The heat treatment state layer is used to verify the furnace temperature uniformity index, cooling rate, hardness test value, and crack marking results. The smelting material layer is used to verify the material test results after smelting, the predicted element content, the material boundary margin, and the smelting deviation verification task. The raw material proportioning layer is used to verify the raw material batch test results, raw material weighing records, the final proportioning scheme, and the boundary risk proportioning scheme. The production data management platform generates an anomaly source ranking based on the verification results of each layer and generates disposal suggestions based on the ranking results.

[0014] Compared with the prior art, the present invention has the following beneficial effects: This invention first generates candidate formulation schemes based on raw material batch testing results and production task information before material input, and further calculates and predicts element content and material boundary margins. This allows the production data management platform to screen formulation schemes before raw materials enter the smelting process. When a candidate formulation scheme meets product material standards but is close to the standard boundary, the system can mark it as a boundary risk formulation scheme and generate an alternative formulation scheme or prompt manual review based on the controlled element type. This can, to a certain extent, reduce the risk of subsequent material deviations caused by fluctuations in raw material composition, weighing errors, or improper formulation selection.

[0015] Secondly, by comparing the material testing results after smelting with the predicted elemental content formed before feeding, and generating a smelting deviation verification task when the deviation exceeds the corresponding threshold, the quality judgment of the smelting batch not only depends on whether the final test value falls within the product material standard, but also on the deviation between the predicted and measured results. This method helps to distinguish whether the deviation may originate from raw material testing, raw material weighing, feeding sequence, smelting process, or the status of testing equipment, providing clearer data basis for the handling of smelting batches.

[0016] Furthermore, by establishing a binding relationship between the cylinder product traceability code and the lower cover bearing product traceability code, a sealing assembly traceability code is generated. This allows the previously separately recorded production data for the cylinder side and the lower cover bearing side to be linked together around the sealing assembly relationship. The sealing assembly traceability code simultaneously links the measured dimensions of the cylinder sealing fit position, the measured dimensions of the lower cover bearing sealing fit position, sealing fit deviation indicators, assembly pressure, assembly displacement, and airtightness test data. This is beneficial for identifying situations where individual parts are dimensionally acceptable but the assembly has sealing risks.

[0017] Finally, when the leakage rate detection value exceeds the leakage rate standard, a layered backtracking process is performed according to the sealing fit dimension layer, heat treatment state layer, smelting material layer, and raw material ratio layer, giving the anomaly analysis process a clearer review sequence. The system can retrieve corresponding sealing fit dimension data, heat treatment state data, smelting material data, and raw material ratio data based on the sealing assembly traceability code, and generate anomaly source ranking and handling suggestions accordingly. This approach helps reduce random manual investigation, improves the targeting of review objects, and provides data support for subsequent adjustments to the ratio, review of the heat treatment cooling process, inspection of sealing fit dimensions, or correction of assembly parameters. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 This is a block diagram of an intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioner compressor according to the present invention.

[0020] Figure 2 This is a flowchart illustrating the steps of an intelligent management system for the production process of an air conditioner compressor cylinder and lower cover bearing, as described in this invention.

[0021] Figure 3This is a flowchart illustrating step 1 of the operation method of the intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioner compressor according to the present invention.

[0022] Figure 4 This is a flowchart illustrating step 2 of the operation method of the intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioner compressor according to the present invention.

[0023] Figure 5 This is a flowchart illustrating step 3 of the operation method of the intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioner compressor according to the present invention.

[0024] Figure 6 This is a flowchart illustrating step 4 of the operation method of the intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioner compressor according to the present invention. Detailed Implementation

[0025] The present invention will be further described below with reference to embodiments. These embodiments are merely some, not all, of the embodiments described. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the protection scope of the present invention.

[0026] Please see Figure 1 As shown, this embodiment discloses an intelligent management system for the production process of cylinders and lower cover bearings of an air conditioning compressor. The system includes a production data management platform, a proportioning determination module, a smelting verification and product traceability code generation module, a sealing assembly association module, and an airtightness detection and stratified backtracking module. The proportioning determination module includes a raw material detection unit and a proportioning calculation unit; the smelting verification and product traceability code generation module includes a smelting verification unit and a product traceability code generation unit; the sealing assembly association module includes a precision machining data acquisition unit, a heat treatment status data acquisition unit, and an assembly binding unit; the airtightness detection and stratified backtracking module includes a finished product airtightness detection unit and a leakage rate anomaly stratified backtracking unit. All the above units perform data storage, data retrieval, status determination, and traceability association through the production data management platform.

[0027] The production data management platform comprises a relational database and a time-series database. The relational database stores raw material batch traceability codes, smelting batch traceability codes, cylinder product traceability codes, lower cover bearing product traceability codes, sealing assembly traceability codes, candidate mix proportions, final mix proportions, material boundary margins, smelting deviation verification tasks, sealing fit deviation indicators, anomaly source ranking, and handling suggestions. The time-series database stores smelting temperature, casting pressure, spindle speed, machining torque, acoustic emission signals, furnace temperature uniformity indicators, cooling rate, and airtightness test curves. The relational and time-series databases are linked through traceability codes, preventing isolated queries based on single product numbers.

[0028] The raw material testing module acquires batch testing results for raw materials and sends batches that meet the raw material acceptance standards to the proportioning calculation module. The raw material testing module may include a spark direct-reading spectrometer, a combustion infrared carbon-sulfur analyzer, and an X-ray fluorescence spectrometer. The spark direct-reading spectrometer is used to detect carbon, copper, iron, and other alloying elements in pig iron and scrap steel. The combustion infrared carbon-sulfur analyzer is used to verify carbon content. The X-ray fluorescence spectrometer is used to detect copper, iron, and other metallic elements in electrolytic copper. The applicable element range and detection accuracy of each testing device are derived from the equipment manual, equipment calibration records, and testing laboratory verification records.

[0029] The proportioning calculation module generates candidate proportioning schemes based on raw material batch testing results and production task information. It calculates the predicted elemental content and material boundary margin of each candidate proportioning scheme, and determines the final proportioning scheme when the candidate proportioning scheme meets product material standards and the material boundary margin meets the margin threshold. The proportioning calculation module also generates alternative proportioning schemes when a candidate proportioning scheme is marked as a boundary risk scheme. The rules for generating alternative proportioning schemes are derived from the company's batching process documents and process department confirmation records.

[0030] The smelting verification module is used to collect smelting and casting process parameters and post-smelting material testing results based on the smelting batch traceability code, and compares the post-smelting material testing results with the predicted element content. The results generated by the smelting verification module include smelting deviation review tasks or smelting material qualification records. The smelting verification module also associates smelting and casting process anomaly alerts with the smelting batch traceability code.

[0031] The precision machining monitoring module is used to generate traceability codes for cylinder products or lower cover bearing products based on the smelting batch traceability code, and to collect corresponding precision machining data. For cylinders, the precision machining data includes the measured dimensions of the cylinder sealing fit position, the cylinder sealing surface roughness, machining torque, and acoustic emission signals. For lower cover bearings, the precision machining data includes the measured dimensions of the lower cover bearing sealing fit position, the lower cover bearing flatness, machining torque, and acoustic emission signals. The upper limit of machining torque and the threshold of acoustic emission signals are derived from precision machining process documents, tool wear test records, historical statistics of qualified machining batches, and equipment department confirmation records.

[0032] The heat treatment monitoring module is used to collect heat treatment status data. This data includes furnace temperature uniformity indicators, cooling rate, hardness test values, and crack marking results. The furnace temperature uniformity threshold, upper and lower limits of cooling rate, and hardness range are all derived from heat treatment process documents, equipment manuals, historical qualified batch data, and quality department confirmation records. Crack marking results can be generated by a visual inspection system or non-destructive testing equipment; the identification conditions for the testing equipment are derived from the equipment manual and quality department confirmation records.

[0033] The sealing assembly association module is used to bind the cylinder product traceability code and the lower cover bearing product traceability code to generate a sealing assembly traceability code when the cylinder and lower cover bearing meet the pre-assembly conditions, and to record the sealing fit deviation index and assembly parameters. Before binding, the sealing assembly association module checks whether there are any unclosed anomaly records on the cylinder and lower cover bearing. These unclosed anomaly records originate from material anomaly records, dimensional anomaly records, heat treatment anomaly records, and isolation records in the production data management platform.

[0034] The finished product inspection module performs airtightness testing based on the sealed assembly traceability code and generates leakage rate test values. The airtightness test pressure, holding time, and leakage rate standards are derived from the finished product inspection process quality control standards, customer acceptance documents, historical airtightness-qualified batch test records, and quality department confirmation records. The finished product inspection module can also perform appearance inspection, dimensional inspection, and hardness testing; the test results are written to the corresponding traceability codes.

[0035] The leakage rate anomaly stratified backtracking module is used to perform stratified backtracking when the detected leakage rate value exceeds the leakage rate standard, by calling the sealing fit dimension data, heat treatment status data, smelting material data, and raw material ratio data associated with the sealing assembly traceability code. This module executes in the order of sealing fit dimension layer, heat treatment status layer, smelting material layer, and raw material ratio layer. The module outputs anomaly source ranking and handling suggestions. These anomaly source ranking and handling suggestions are confirmed by quality management personnel and then written into the sealing assembly traceability code.

[0036] It should be noted that, in this embodiment, the production data management platform is used to perform data storage, data association, calculation and judgment, anomaly alerts, and traceability queries. The production data management platform is communicatively connected to the raw material testing module, proportioning calculation module, smelting verification module, precision machining monitoring module, heat treatment monitoring module, sealing assembly association module, finished product testing module, and leakage rate anomaly hierarchical backtracking module. The raw material testing module is used to acquire batch testing results of raw materials. The proportioning calculation module is used to generate candidate proportioning schemes, predict element content, and material boundary margins. The smelting verification module is used to collect smelting and casting process parameters and material testing results after smelting. The precision machining monitoring module is used to collect precision machining data for cylinders and lower cover bearings. The heat treatment monitoring module is used to collect furnace temperature uniformity indicators, cooling rate, hardness test values, and crack marking results. The sealing assembly association module is used to bind cylinder product traceability codes and lower cover bearing product traceability codes and generate sealing assembly traceability codes. The finished product testing module is used to perform appearance inspection, dimensional inspection, hardness testing, and airtightness testing. The leakage rate anomaly layered backtracking module is used to backtrack according to the sealing fit size layer, heat treatment state layer, melting material layer and raw material ratio layer when the leakage rate detection value exceeds the leakage rate standard.

[0037] The terms used in this embodiment are defined as follows: A raw material batch traceability code is an identifier for a single batch of pig iron, scrap steel, electrolytic copper, or other metal raw materials entering the factory. The raw material batch traceability code must be associated with at least the raw material category, supplier information, arrival time, raw material weight, test results, factory entry judgment conclusion, and warehouse location information.

[0038] A smelting batch traceability code is an identifier corresponding to a single smelting feeding and smelting casting process. A smelting batch traceability code must be associated with at least the final proportioning scheme, the batch traceability codes of the raw materials involved in the feeding, the mass ratio of each raw material, the predicted element content, the material boundary margin, the smelting and casting process parameters, the material testing results after smelting, and the smelting deviation verification task.

[0039] The cylinder product traceability code refers to the identifier corresponding to a single cylinder. The cylinder product traceability code is associated with at least the smelting batch traceability code, the production batch of the cylinder, the cylinder precision machining data, the cylinder heat treatment status data, the cylinder size inspection results, the cylinder hardness inspection results, and the cylinder appearance inspection results. The same smelting batch or the same production batch is used as the superior associated field of the cylinder product traceability code, and does not replace the product traceability code of a single cylinder.

[0040] The product traceability code for the lower cover bearing refers to the identifier corresponding to a single lower cover bearing. The product traceability code for the lower cover bearing is associated with at least the smelting batch traceability code, the production batch of the lower cover bearing, the precision machining data of the lower cover bearing, the heat treatment status data of the lower cover bearing, the dimensional inspection results of the lower cover bearing, the hardness inspection results of the lower cover bearing, and the appearance inspection results of the lower cover bearing. The same smelting batch or the same production batch is used as the superior associated field of the product traceability code for the lower cover bearing, and does not replace the product traceability code of a single lower cover bearing.

[0041] The sealed assembly traceability code is an identifier generated by binding the cylinder product traceability code and the lower cover bearing product traceability code after the cylinder and the lower cover bearing form a sealed fit. The sealed assembly traceability code must be associated with at least the cylinder product traceability code, the lower cover bearing product traceability code, the measured dimensions of the cylinder sealing fit position, the measured dimensions of the lower cover bearing sealing fit position, the sealing fit deviation index, the assembly pressure, the assembly displacement, the assembly time, the airtightness test pressure, the pressure holding time, and the leakage rate test value.

[0042] The raw material receiving acceptance standard refers to the receiving inspection standards set separately for pig iron, scrap steel, electrolytic copper, or other metal raw materials. The raw material receiving acceptance standard is derived from the company's raw material procurement technical agreement, supplier quality agreement, and the inspection records of no less than 20 recent qualified batches of incoming materials, and is entered into the production data management platform after being confirmed by the quality department.

[0043] Product material standards refer to the target element content range set for cylinders or lower cover bearings. Product material standards are derived from product design documents, enterprise material process documents, spectral test records of historical qualified batches, and customer technical requirements, and are entered into the production data management platform after being confirmed by the process department and quality department.

[0044] Process quality control standards refer to the parameter ranges or judgment conditions set for smelting and casting, precision machining, heat treatment, assembly inspection, and finished product inspection. Process quality control standards are derived from equipment manuals, company process documents, historical qualified batch data, equipment calibration records, and quality department confirmation records.

[0045] Material boundary margin refers to the minimum distance between the predicted element content in a candidate formulation and the upper or lower limit of the product material standard. Material boundary margin is used to determine whether a candidate formulation, while within the product material standard range, is close to the standard boundary. The margin threshold for material boundary margin is derived from elemental fluctuation data of historical qualified batches, weighing equipment calibration errors, spectral detection repeatability errors, and process department confirmation records.

[0046] The smelting deviation verification task refers to a verification task generated when the deviation between the material test results after smelting and the predicted element content exceeds the corresponding smelting deviation threshold. The smelting deviation threshold is derived from the difference data between the predicted element content and the actual measured element content after smelting in historical qualified smelting batches, the repeatability error of the spectral detection equipment, the calibration records of the weighing equipment, and the confirmation records of the quality department.

[0047] The sealing fit deviation index refers to the difference between the measured dimensions of the cylinder sealing fit position and the measured dimensions of the lower cover bearing sealing fit position. The sealing fit deviation threshold is derived from the assembly process documents of the cylinder and the lower cover bearing, the sealing structure design requirements, the dimensional data of historical airtightness qualified assemblies, and the confirmation records of the quality department.

[0048] Leakage rate anomaly stratified backtracking refers to the process where, when the leakage rate detection value corresponding to the sealing assembly traceability code exceeds the leakage rate standard, the production data management platform reviews the data in the order of sealing fit size layer, heat treatment state layer, melting material layer, and raw material ratio layer, and generates anomaly source sorting and handling suggestions.

[0049] like Figure 2 As shown, in some embodiments, this embodiment discloses an intelligent management method and system for the production process of the cylinder and lower cover bearing of an air conditioner compressor, wherein the method includes: S1. Obtain raw material batch test results and production task information, generate the final proportioning scheme and generate smelting batch traceability code; S2. Based on the smelting batch traceability code, collect smelting and casting process parameters and material test results after smelting, generate smelting deviation verification tasks or smelting material qualification records, and generate cylinder product traceability codes or lower cover bearing product traceability codes. S3. Based on the cylinder product traceability code and the lower cover bearing product traceability code, collect precision machining data and heat treatment status data, generate a sealing assembly traceability code when the pre-assembly conditions are met, and record the sealing fit deviation index and assembly parameters. S4. Based on the sealing assembly traceability code, perform airtightness testing, and when the leakage rate detection value exceeds the leakage rate standard, perform hierarchical backtracking to generate anomaly source ranking and handling suggestions.

[0050] In this embodiment, it should be noted that in S1, to address the issue that batch composition fluctuations in raw materials during cylinder and lower cover bearing production can easily be transmitted to the smelted material, the system first determines the raw materials such as pig iron, scrap steel, and electrolytic copper according to their respective raw material acceptance standards, and then inputs the raw materials that meet the raw material acceptance standards into the proportioning calculation module. The key to S1 is not generating a simple material feeding record, but rather obtaining the predicted element content based on the measured element content of the raw materials and the mass ratio of each raw material, and further determining the distance between the predicted element content and the product material standard boundary. The reason for this is that even if the same candidate proportioning scheme numerically meets the product material standard, it may still be sensitive to sizing errors, raw material composition fluctuations, and smelting losses because it is close to the upper or lower limit. The production data management platform identifies boundary risk proportioning schemes through material boundary margins and generates alternative proportioning schemes or manual review prompts for boundary risk proportioning schemes. After the final proportioning scheme is determined, the system generates a smelting batch traceability code. The smelting batch traceability code not only records the final proportioning scheme, but also the batch traceability codes of the raw materials involved in the feeding, the predicted element content, the material boundary margin, and the weighing records, so that the subsequent material verification after smelting can reverse the data before feeding.

[0051] In S2, to address the issue of potential discrepancies between the temperature, pressure, pouring time, and actual melting results during the smelting and casting process and the predicted results before material feeding, the system collects smelting and casting process parameters using the smelting batch traceability code as the entry point and obtains the material testing results after smelting. This step does not merely record the smelting temperature or spectral detection results; instead, it compares the measured elemental content after smelting with the predicted elemental content obtained in S1. When the deviation exceeds the smelting deviation threshold, the system does not directly deem the entire batch unusable but generates a smelting deviation verification task. The smelting deviation verification task accesses the raw material batch traceability code, raw material weighing record, smelting temperature curve, feeding sequence, testing equipment calibration status, and test sample number. This task determines whether the deviation originates from weighing error, raw material testing deviation, smelting loss, insufficient sample representativeness, or abnormal testing equipment status. If the material testing results after smelting meet the product material standards and the deviation from the predicted elemental content does not exceed the smelting deviation threshold, the system generates a smelting material qualification record and generates subsequent cylinder product traceability codes or lower cover bearing product traceability codes based on the smelting batch traceability code.

[0052] In S3, to address the issue of potential sealing risks after assembly of individual cylinders and lower cover bearings that are individually qualified, the system no longer traces back to individual products. Instead, it uses the cylinder and lower cover bearing product traceability codes as inputs for subsequent sealing assembly traceability. The production data management platform first collects precision machining and heat treatment status data from both the cylinder and lower cover bearing sides. Cylinder-side data includes measured dimensions of the cylinder seal mating position, cylinder seal surface roughness, machining torque, acoustic emission signal, furnace temperature uniformity index, cooling rate, hardness test value, and crack marking results. Lower cover bearing-side data includes measured dimensions of the lower cover bearing seal mating position, lower cover bearing flatness, machining torque, acoustic emission signal, furnace temperature uniformity index, cooling rate, hardness test value, and crack marking results. Before assembly, the system checks the cylinder and lower cover bearing for any unclosed material abnormalities, dimensional abnormalities, heat treatment abnormalities, or isolation conditions. Once the pre-assembly conditions are met, the system binds the cylinder product traceability code and the lower cover bearing product traceability code to generate a sealing assembly traceability code, and calculates the sealing fit deviation index. The sealing assembly traceability code becomes the data entry point for airtightness testing and anomaly backtracking in S4.

[0053] In S4, to address the issue of disorganized troubleshooting after anomalies in leakage rates, the system performs airtightness testing based on the seal assembly traceability code and compares the leak rate detection value with a leakage rate standard. The leakage rate standard, for example, is no more than 0.01 kPa / s. This threshold is derived from the product inspection standards for the cylinder and lower cover bearing seal assemblies, customer acceptance documents, and historical airtightness-compliant batch test records, and is written into the finished product inspection process quality control standards after confirmation by the quality department. When the leak rate detection value does not exceed the leakage rate standard, the system generates an airtightness-compliant record. When the leak rate detection value exceeds the leakage rate standard, the system does not simply generate a non-compliance warning, but performs layered backtracking according to the seal fit dimension layer, heat treatment state layer, smelting material layer, and raw material ratio layer. The seal fit dimension layer is used to prioritize the verification of assembly fit data for the cylinder and lower cover bearing. The heat treatment state layer is used to verify cooling rate, hardness, and crack markings. The smelting material layer is used to verify the material test results after smelting and the smelting deviation verification task. The raw material proportioning layer is used to verify the final proportioning scheme, the boundary risk proportioning scheme, and the raw material weighing records. Based on the verification results of each layer, the system generates a ranking of anomaly sources and handling suggestions.

[0054] like Figure 3 As shown, in one specific embodiment, S1 includes: S11. Obtain batch test results for raw materials; S12. Refer to the raw material receiving and acceptance standards according to the raw material category; S13. Generate candidate formulation schemes; S14. Calculate and predict the element content; S15. Determine the candidate formulation schemes based on the product material standards; S16. Calculate the material boundary margin and identify the boundary risk allocation scheme; S17. Generate alternative formulation schemes or determine the final formulation scheme; S18. Generate a batch traceability code for smelting and lock the weighing record.

[0055] For S11, the production data management platform receives batch testing results of raw materials uploaded by the raw material testing module. These results must include at least the raw material batch traceability code, raw material category, supplier information, arrival time, raw material weight, measured carbon content, measured copper content, measured iron content, other element test values, testing equipment number, testing personnel, and testing time. Carbon, copper, iron, and other alloying elements in pig iron and scrap steel can be detected using a spark direct-reading spectrometer; when the carbon content approaches the boundary of the raw material acceptance standard, a combustion infrared carbon-sulfur analyzer can be used for verification. Copper, iron, and other metallic elements in electrolytic copper can be detected using an X-ray fluorescence spectrometer. The X-ray fluorescence spectrometer is used to detect copper, iron, and other suitable metallic elements in electrolytic copper; carbon content detection is based on spark direct-reading spectroscopy, combustion infrared carbon-sulfur analysis, or supplier material certificates and arrival verification records, and is not solely determined by X-ray fluorescence spectrometry. The testing accuracy of the raw material testing equipment is derived from the equipment manual, the most recent equipment calibration record, and the internal verification records of the testing laboratory. After the test results are uploaded, the production data management platform does not immediately determine the single raw material according to the product material standard of the cylinder or lower cover bearing, but instead proceeds to S12.

[0056] For S12, the production data management platform calls upon the corresponding raw material receiving acceptance standards based on the raw material category. Pig iron uses the pig iron receiving acceptance standards, scrap steel uses the scrap steel receiving acceptance standards, and electrolytic copper uses the electrolytic copper receiving acceptance standards. These raw material receiving acceptance standards are derived from the company's raw material procurement technical agreements, supplier quality agreements, and inspection records of at least 20 recent qualified batches of incoming materials, and are written into the production data management platform after confirmation by the quality department. This process avoids directly applying the product material standards for cylinders or lower cover bearings to the single inspection results of pig iron, scrap steel, or electrolytic copper. For example, the carbon content of pig iron itself may be higher than the target product's carbon content range, but it can still participate in smelting as a high-carbon source in the batching process. The system only determines whether a single raw material meets the receiving and use conditions for its corresponding raw material category, and marks batches of raw materials that meet the conditions as usable for batching.

[0057] For S13, the production data management platform generates candidate blending schemes based on production task information. Production task information includes at least the target product type, product model, production quantity, planned production time, and corresponding product material standard version. Candidate blending schemes include at least the batch traceability codes of the raw materials involved in the input, the mass ratio of each raw material, the expected input weight, and the target product type. Candidate blending schemes can be entered by process engineers or generated by the production data management platform based on current available raw material inventory and product material standards. After the candidate blending scheme is generated, the system uses the measured element content corresponding to the raw material batch traceability code as input for S14. At this point, the candidate blending scheme cannot be directly used for input; it must undergo continuous determination based on predicted element content, product material standards, and material boundary margins.

[0058] For S14, the proportioning calculation module calculates the predicted element content of controlled elements in the target material based on the measured element content of each raw material and the mass proportion of each raw material. Controlled elements include at least carbon, copper, and iron, and may also include other elements controlled according to product material standards. The predicted element content is calculated using the following formula:

[0059] in, Indicates the elements in the target material under the candidate ratio scheme. The predicted quality percentage content; Represents a controlled element, the controlled element including , , And other elements controlled by product material standards; This refers to the set of raw materials participating in the same candidate formulation. Represents the set of raw materials Any raw material in it; Indicates raw materials The mass ratio in the candidate formulation scheme; Indicates raw materials medium elements The measured percentage content of mass; Represents the set of raw materials Summing up all the raw materials in the solution.

[0060] For S15, the production data management platform retrieves the product material standard based on the target product type. The product material standard originates from product design documents, company material and process documents, historical qualified batch spectral testing records, and customer technical requirements, and is written into the production data management platform after confirmation by the process and quality departments. For cylinder products, the carbon content range can be set to 0.4% to 1.0%, the copper content range can be set to 0% to 2.5%, with iron and unavoidable impurities as the margin. The aforementioned carbon and copper content ranges are derived from the cylinder product material standard table, spectral testing records after melting of at least 20 recent qualified cylinder batches, and customer technical documents. For lower cover bearing products, the system retrieves the corresponding product material standard based on the lower cover bearing product model. If the predicted element content of any controlled element exceeds the corresponding product material standard, the system marks the candidate formulation as not meeting the product material standard.

[0061] When iron and unavoidable impurities are recorded as margins in the product material standard, the iron content is used for component closure verification and traceability recording, and is not used as a material judgment indicator with upper and lower limits on its own. Only when the product material standard sets a clear upper or lower limit for the iron content will the production data management platform treat the iron content as a controlled element that needs to be judged according to the upper and lower limits.

[0062] For S16, after the candidate formulation meets the product material standards, the production data management platform further calculates the material boundary margin. The material boundary margin is determined using a textual rule: for the same controlled element, the distance between the predicted element content and the lower limit and the upper limit of the product material standard are calculated separately, and the smaller distance is taken as the material boundary margin for that controlled element. The margin threshold for the material boundary margin is derived from historical qualified batch element fluctuation data, weighing equipment calibration errors, spectral detection repeatability errors, and process department confirmation records. For example, the margin threshold for carbon can be set to 0.06%, which is derived from the fluctuation statistics of predicted and measured carbon content in at least 20 recent qualified cylinder smelting batches, weighing equipment calibration records, and quality department confirmation records. The margin threshold for copper can be set to 0.10%, which is derived from the fluctuation statistics of predicted and measured copper content in at least 20 recent qualified cylinder smelting batches, spectral detection repeatability records, and quality department confirmation records. If the material boundary margin of any controlled element is less than the corresponding margin threshold, the system will mark the candidate mix design as a boundary risk mix design.

[0063] The margin threshold is calculated based on a limited number of historical qualified batches. The production data management platform selects at least 20 recent smelting batches that passed both material quality and subsequent airtightness testing. For each batch, it reads the predicted element content and the actual measured element content after smelting, calculates the absolute difference between the two, and removes batches with abnormal testing equipment calibration, abnormal sample numbers, or missing weighing records. The average and standard deviation of the absolute differences for the retained batches are calculated. The average plus one standard deviation is used as the initial margin threshold, which is then verified by the process department based on the maximum permissible error of the weighing equipment and the repeatability error of the spectral detection. For example, if the average absolute difference between the predicted and measured carbon content in the most recent 20 qualified cylinder batches is 0.035% and the standard deviation is 0.018%, then the initial margin threshold for carbon is 0.053%, rounded down to 0.06% after considering the weighing equipment calibration error, and then written into the production data management platform.

[0064] For S17, the boundary risk proportioning scheme is not directly determined as the final proportioning scheme. The production data management platform generates alternative proportioning schemes based on the type of controlled element. When the predicted carbon content is close to the upper limit, the system prioritizes generating alternative proportioning schemes that reduce the proportion of pig iron and increase the proportion of low-carbon scrap steel. When the predicted copper content is close to the upper limit, the system prioritizes generating alternative proportioning schemes that reduce the proportion of electrolytic copper. The determination of being close to the upper limit is based on the material boundary margin threshold of the corresponding controlled element; that is, when the distance between the predicted element content and the upper limit of the product material standard is less than the corresponding margin threshold, the system determines that it is close to the upper limit. The alternative proportioning scheme requires re-execution of the predicted element content calculation, product material standard determination, and material boundary margin determination. Only proportioning schemes that meet the product material standard and whose material boundary margin is not less than the margin threshold can be determined as the final proportioning scheme. If the boundary risk proportioning scheme needs to be adopted on the production site, the system requires technicians to enter confirmation information and explanations, and this confirmation information is written into the smelting batch traceability code.

[0065] For S18, after the final proportioning scheme is determined, the production data management platform generates a smelting batch traceability code. The smelting batch traceability code is linked to at least the final proportioning scheme, the batch traceability codes of the raw materials involved in the feeding, the mass ratio of each raw material, the expected feeding weight, the predicted element content, the material boundary margin, the product material standard version, and the feeding time. Before actual feeding, the weighing equipment collects the actual weighing weight of each raw material. The weighing deviation threshold is derived from the weighing equipment manual, the most recent weighing equipment calibration record, and the company's batching process documents. For example, the allowable weighing deviation for a certain weighing equipment is no more than 0.5% of the planned weighing weight; this threshold is derived from the weighing equipment calibration record and the company's batching process documents. If the deviation between the actual weighing weight and the expected feeding weight exceeds the weighing deviation threshold, the system prevents feeding and prompts for re-weighing. If the weighing deviation is within the allowable range, the system writes the weighing record into the smelting batch traceability code and allows entry into the smelting and casting process.

[0066] The weighing deviation threshold is determined based on the weighing equipment calibration records and a limited number of on-site weighing verification records. The production data management platform selects at least 20 recent planned and actual weighing weight records of the same type of raw materials, calculates the relative deviation for each weighing, and excludes records of equipment alarms, manual reweighing, and abnormal raw material adhesion. The maximum, average, and standard deviation of the relative deviation are then calculated, and the larger of the allowable error in the equipment manual and the on-site statistical value is used as the initial weighing deviation threshold. For example, if the allowable error in the weighing equipment manual is 0.4%, and the average relative deviation of 20 on-site verifications is 0.18% and the standard deviation is 0.09%, then the average plus three times the standard deviation is 0.45%. Therefore, the weighing deviation threshold is set at 0.5% and recorded in the company's batching process parameter table.

[0067] In some optional embodiments, regarding S1, assume that a cylinder production task requires the use of pig iron, scrap steel, and electrolytic copper. The test results uploaded by the raw material testing module are as follows: pig iron: carbon content 3.8%, copper content 0.1%, iron content 96.1%; scrap steel: carbon content 0.2%, copper content 0.05%, iron content 99.75%; electrolytic copper: carbon content 0%, copper content 99.95%, iron content 0.05%. The system generates a candidate blending scheme, in which the mass ratio of pig iron is 20%, the mass ratio of scrap steel is 78%, and the mass ratio of electrolytic copper is 2%. According to the predicted element content formula, the predicted carbon content is 0.916%, the predicted copper content is 2.058%, and the predicted iron content is 97.026%. If the carbon content range in the cylinder product material standard is 0.4% to 1.0%, and the copper content range is 0% to 2.5%, then the candidate blending scheme meets the product material standard. If the carbon margin threshold is 0.06%, and the data is derived from the carbon content fluctuation statistics of at least 20 recent qualified cylinder smelting batches, weighing equipment calibration records, and quality department confirmation records, then the carbon content in this scheme is 0.084% away from the upper limit of 1.0%, which is not less than 0.06%, and the system will not mark it as a boundary risk allocation scheme.

[0068] like Figure 4 As shown, in one specific embodiment, S2 includes: S21. Collect smelting and casting process parameters based on smelting batch traceability codes; S22. Apply the quality control standards for the smelting and casting process; S23. Perform material testing after smelting; S24. Compare the material test results after melting with the predicted element content; S25. Generate a smelting deviation verification task or a smelting material qualification record; S26. Generate a cylinder product traceability code or a lower cover bearing product traceability code based on the smelting batch traceability code.

[0069] For S21, after the batch traceability code enters the smelting and casting process, the smelting temperature sensor, casting pressure sensor, and pouring time recording unit begin collecting data. The smelting temperature sensor's measurement range is 0℃ to 1800℃, derived from the thermocouple sensor's instruction manual and calibration records. The smelting temperature data upload frequency can be set to once per second, determined by the smelting furnace control system's acquisition cycle, the production data management platform's time-series database writing capability, and the company's smelting process monitoring requirements. The casting pressure sensor's range is 0MPa to 10MPa, derived from the pressure sensor's instruction manual and the casting equipment's user manual. The casting pressure data upload frequency can also be set to once per second, determined by the pressure sensor's sampling capability and the company's smelting and casting process quality control standards. The pouring time recording unit records the pouring start time, pouring end time, and pouring duration.

[0070] For S22, the production data management platform calls upon the quality control standards for the melting and casting process based on the target product type. For cylinders, the melting temperature range can be 1400℃ to 1550℃, the casting pressure range can be 0.5MPa to 2.0MPa, and the pouring time range can be 10 seconds to 30 seconds. These ranges are derived from cylinder melting and casting process documents, historical records of qualified cylinder casting batches, and equipment process confirmation records. For lower cover bearings, the melting temperature range can be 1450℃ to 1600℃, and the casting pressure range can be 0.3MPa to 1.5MPa. These ranges are derived from lower cover bearing melting and casting process documents, historical records of qualified lower cover bearing casting batches, and equipment process confirmation records. When the melting temperature, casting pressure, or pouring time exceeds the corresponding range, and the abnormal duration reaches 5 seconds, the system generates an abnormal prompt for the melting and casting process. The 5-second abnormal duration is derived from the melting furnace control system response cycle, sensor signal stability test records, and process department confirmation records.

[0071] For S23, after smelting, inspectors randomly select at least three samples from the blanks produced in the same smelting batch. The sampling quantity of at least three samples is derived from the company's material sampling inspection procedures after smelting and the confirmation records of the quality department. Inspectors use spark direct-reading spectroscopy to detect the content of carbon, copper, iron, and other alloying elements. When the carbon content is close to the product material standard boundary, the carbon content is verified using combustion infrared carbon-sulfur analysis. The determination of being close to the product material standard boundary is based on the margin threshold of the corresponding element; that is, when the distance between the measured element content and the upper or lower limit of the product material standard is less than the corresponding margin threshold, the system prompts for verification. After the inspection is completed, the material inspection results after smelting are uploaded to the production data management platform and associated with the smelting batch traceability code.

[0072] The melting temperature range, casting pressure range, pouring time range, and abnormal duration are determined jointly based on process documents, historical qualified batch curves, and equipment response records. The production data management platform selects no fewer than 20 recent melting batches that have passed casting appearance, material inspection, and subsequent processing, and statistically analyzes the stable operating ranges of melting temperature, casting pressure, and pouring time, excluding batches with sensor disconnections, furnace shutdowns, and trial production. For abnormal duration, the system calculates the upper limit of short-term fluctuations during normal operation and sets a confirmation value based on the sensor sampling period. For example, among the 20 qualified cylinder batches, the longest normal short-term temperature fluctuation lasts 3 seconds, and the longest short-term pressure fluctuation lasts 4 seconds. Considering the 1-second sampling period and control system response delay, the abnormal duration is determined to be 5 seconds.

[0073] For S24, the production data management platform reads the predicted element content corresponding to the final proportioning scheme in S1 and compares the material testing results after smelting with the predicted element content. The comparison rules are executed in text form: for the same controlled element, the difference between the measured element content after smelting and the predicted element content is calculated, and it is determined whether this difference exceeds the corresponding smelting deviation threshold. The smelting deviation threshold is derived from the difference data between the predicted and measured element content in historical qualified smelting batches, the repeatability error of the spectral detection equipment, the calibration records of the weighing equipment, and the confirmation records of the quality department. For example, the carbon element smelting deviation threshold can be set to 0.05%, which is derived from the statistical difference between the predicted and measured carbon content in at least 20 recent qualified cylinder smelting batches, the verification records of the combustion infrared carbon-sulfur analyzer, and the confirmation records of the quality department. The copper element smelting deviation threshold can be set to 0.08%, which is derived from the statistical difference between the predicted and measured copper content in at least 20 recent qualified cylinder smelting batches, the repeatability records of the spectral detection, and the confirmation records of the quality department.

[0074] The smelting deviation threshold is calculated based on a limited number of historical qualified smelting batches. The production data management platform selects no fewer than 20 batches with qualified materials after smelting and normal calibration status of the testing equipment. For each batch, the absolute difference between the measured and predicted element content after smelting is calculated for the same controlled element. After excluding batches with missing feeding sequence records, abnormal weighing records, and inconsistent test sample verification, the initial smelting deviation threshold is determined by adding one standard deviation to the average of the absolute differences. This threshold is then confirmed by the quality department in conjunction with the repeatability error of the testing equipment. For example, if the average absolute difference in carbon content among 20 qualified cylinder smelting batches is 0.030% and the standard deviation is 0.015%, the initial threshold is 0.045%. After verifying the error using a combustion infrared carbon-sulfur analyzer, the carbon smelting deviation threshold is determined to be 0.05%.

[0075] For S25, when the measured element content of any controlled element after smelting does not meet the product material standard, the production data management platform marks the smelting batch as having material anomalies and requiring processing. When the measured element content after smelting meets the product material standard, but the difference between the measured element content and the predicted element content exceeds the corresponding smelting deviation threshold, the production data management platform generates a smelting deviation review task. The smelting deviation review task includes reviewing the raw material batch traceability code, raw material weighing record, smelting temperature curve, feeding sequence, calibration status of testing equipment, and test sample number. When the measured element content after smelting meets the product material standard, and the difference between the measured element content and the predicted element content does not exceed the corresponding smelting deviation threshold, the production data management platform generates a smelting material qualification record. The smelting material qualification record includes at least the smelting batch traceability code, predicted element content, smelting material test results, difference judgment conclusion, testing equipment number, and testing time.

[0076] For S26, after the qualified record of the smelted material is generated, the production data management platform generates a cylinder product traceability code or a lower cover bearing product traceability code based on the smelting batch traceability code. If the smelting batch is used for cylinder production, a cylinder product traceability code is generated and bound to the smelting batch traceability code. If the smelting batch is used for lower cover bearing production, a lower cover bearing product traceability code is generated and bound to the smelting batch traceability code. The cylinder product traceability code and the lower cover bearing product traceability code serve as the entry points for collecting precision machining data and heat treatment status data in S3.

[0077] In some optional embodiments, regarding S2, it is assumed that the predicted carbon content corresponding to the final proportioning scheme in S1 is 0.916%, and the predicted copper content is 2.058%. After smelting, three samples are taken for testing, and the average measured carbon content is 0.930%, and the average measured copper content is 2.070%. The system calculates the carbon content difference as 0.014% and the copper content difference as 0.012%. If the carbon element smelting deviation threshold is 0.05%, derived from the statistical difference of at least 20 recent qualified cylinder smelting batches and equipment verification records, and the copper element smelting deviation threshold is 0.08%, derived from the statistical difference of at least 20 recent qualified cylinder smelting batches and spectral detection repeatability records, then the system determines that the difference between the predicted and measured results of the smelting batch is within the allowable range and generates a qualified smelting material record.

[0078] like Figure 5 As shown, in one specific embodiment, S3 includes: S31. Collect cylinder precision machining data and cylinder heat treatment status data based on cylinder product traceability code; S32. Collect precision machining data and heat treatment status data of the lower cover bearing based on the product traceability code of the lower cover bearing; S33. Determine whether the cylinder and lower cover bearing meet the pre-assembly conditions. S34. Generate a sealed assembly traceability code by binding the cylinder product traceability code and the lower cover bearing product traceability code. S35. Calculate the sealing fit deviation index; S36. Record assembly parameters.

[0079] For S31, after the cylinder enters the precision machining process, the precision machining monitoring module collects the measured dimensions of the cylinder's inner diameter, outer diameter, depth, and the cylinder seal mating position, as well as the cylinder seal surface roughness, spindle speed, machining torque, and acoustic emission signals. The measured dimensions of the cylinder's inner diameter, outer diameter, depth, and seal mating position can be obtained using a laser measuring instrument with a measurement accuracy of ±0.005mm, derived from the instrument's instruction manual and the most recent calibration record. The cylinder seal surface roughness can be obtained using a roughness testing device, with roughness control values ​​derived from the cylinder finished product inspection process quality control standards, product design documents, and historical qualified batch inspection records. The upper limit of the machining torque is derived from precision machining process documents, tool supplier usage parameters, historical qualified machining batch records, and equipment department confirmation records. The acoustic emission signal threshold is derived from tool wear test records, historical qualified machining batch acoustic emission signal statistics, and equipment department confirmation records.

[0080] For S32, after the lower cover bearing enters the precision machining process, the precision machining monitoring module collects data on the lower cover bearing thickness, flatness, measured dimensions of the sealing fit position, spindle speed, machining torque, and acoustic emission signals. The lower cover bearing flatness threshold is derived from the lower cover bearing product design documents, assembly process documents, and historical airtightness-qualified assembly inspection records. The measured dimensions of the lower cover bearing sealing fit position are used for subsequent calculation of sealing fit deviation indicators. For the lower cover bearing heat treatment status data, the heat treatment monitoring module collects furnace temperature uniformity indicators, cooling rate, hardness test values, and crack marking results. The hardness range is derived from the lower cover bearing product material process documents, heat treatment process documents, and historical qualified batch hardness test records. The upper and lower limits of the cooling rate are derived from the heat treatment process documents, historical qualified batch cooling curves, and quality department confirmation records.

[0081] The upper limit of machining torque and the threshold of acoustic emission signal are obtained based on a limited number of tool wear tests and statistics of historical qualified machining batches. The production data management platform selects no fewer than 20 recent machining batches that have passed dimensional inspection, surface roughness testing, and tool condition testing, and statistically analyzes the peak values ​​of machining torque and acoustic emission signal, excluding records of tool changes, equipment downtime, and fixture loosening. The average value of the machining torque peak plus twice the standard deviation is used as the initial value of the upper limit of machining torque, and the average value of the acoustic emission signal peak plus twice the standard deviation is used as the initial value of the acoustic emission signal threshold. These values ​​are then confirmed by the equipment department in conjunction with the tool supplier's parameters. For example, if the average peak value of machining torque in 20 qualified cylinder sealing surface machining batches is 18 N·m and the standard deviation is 2 N·m, then the initial value of the upper limit of machining torque is 22 N·m; if the average peak value of acoustic emission signal is 62 dB and the standard deviation is 4 dB, then the initial value of the acoustic emission signal threshold is 70 dB.

[0082] For S33, before the cylinder and lower cover bearing enter the assembly and inspection stage, the production data management platform reads the data status corresponding to the product traceability codes of the cylinder and lower cover bearing, respectively. If the cylinder has an unclosed material abnormality, dimensional abnormality, heat treatment abnormality, or isolation state, the system prevents it from entering the assembly stage. Similarly, if the lower cover bearing has an unclosed material abnormality, dimensional abnormality, heat treatment abnormality, or isolation state, the system also prevents it from entering the assembly stage. The unclosed abnormality status originates from the abnormality handling records in the production data management platform and the quality department's review records. The system only allows traceability code binding to be performed when neither the cylinder nor the lower cover bearing has an unclosed abnormality status.

[0083] For S34, the production data management platform binds the cylinder product traceability code and the lower cover bearing product traceability code that meet the pre-assembly conditions to generate a sealed assembly traceability code. The sealed assembly traceability code is associated with at least the cylinder product traceability code, the lower cover bearing product traceability code, the measured dimensions of the cylinder seal mating position, the measured dimensions of the lower cover bearing seal mating position, the cylinder seal surface roughness, the lower cover bearing flatness, the cylinder heat treatment status data, the lower cover bearing heat treatment status data, the assembly equipment number, the assembly personnel, the assembly time, and the assembly process version. Through the sealed assembly traceability code, the system can simultaneously trace back the cylinder-side data and the lower cover bearing-side data in the event of subsequent airtightness anomalies.

[0084] For the S35, the production data management platform calculates the sealing fit deviation index based on the measured dimensions of the cylinder seal fit position and the lower cover bearing seal fit position. The sealing fit deviation index is calculated according to the following formula:

[0085] in, Indicates the sealing fit deviation index; The measured dimensions indicate the position of the cylinder seal mating area; This indicates the measured dimensions of the sealing fit position of the lower cover bearing; This represents absolute value operations.

[0086] The sealing fit deviation threshold is derived from the assembly process documents of the cylinder and the lower cover bearing, the sealing structure design requirements, the dimensional data of historical airtightness-qualified assemblies, and the quality department's confirmation records. For example, the sealing fit deviation threshold can be set to 0.030 mm. This threshold is derived from the statistical differences between the cylinder sealing fit position dimensions and the lower cover bearing sealing fit position dimensions of at least 20 recently airtightness-qualified assemblies, the assembly process documents, and the quality department's confirmation records. When the sealing fit deviation index exceeds the sealing fit deviation threshold, the production data management platform marks the assembly as a sealing fit risk assembly. Even if the individual dimensions of the cylinder and the lower cover bearing are within the corresponding dimensional tolerance range, as long as the sealing fit deviation index exceeds the threshold, the system will still prompt for priority review of the airtightness of the assembly.

[0087] The sealing fit deviation threshold is determined based on the dimensional data of a limited number of qualified airtightness components. The production data management platform selects at least 20 airtightness-tested sealing assembly traceability codes, reads the corresponding measured dimensions of the cylinder sealing fit position and the lower cover bearing sealing fit position, calculates the absolute difference between the two, and removes assemblies with abnormal assembly pressure, abnormal assembly displacement, and inconsistent repeated tests. The average and standard deviation of the absolute differences of the retained assemblies are calculated, and the average plus twice the standard deviation is used as the initial sealing fit deviation threshold, which is then confirmed in conjunction with the sealing structure design requirements. For example, if the average absolute difference of the dimensions of the 20 qualified airtightness components is 0.018 mm and the standard deviation is 0.005 mm, the initial threshold is 0.028 mm, and after confirmation by the quality department, 0.030 mm is taken as the sealing fit deviation threshold.

[0088] For S36, the assembly equipment collects assembly pressure, assembly displacement, and assembly time. The assembly pressure range is derived from the assembly equipment manual, the cylinder and lower cover bearing assembly process documents, and historical airtightness-compliant assembly pressure records. For example, the assembly pressure control range can be calibrated by the company's assembly process documents and verified through the assembly pressure records of at least 20 recent airtightness-compliant assemblies. The assembly displacement range is derived from the assembly process documents and the assembly equipment displacement sensor calibration records. The assembly time is derived from the assembly cycle time records and production process documents. The production data management platform writes the assembly parameters into the sealing assembly traceability code, which serves as the sealing fit dimension layer data for the stratified backtracking of leakage rate anomalies in S4.

[0089] In some optional embodiments, regarding S3, it is assumed that the measured dimension of the cylinder sealing fit position corresponding to the cylinder product traceability code is 50.020mm, and the measured dimension of the lower cover bearing sealing fit position corresponding to the lower cover bearing product traceability code is 50.000mm. After the production data management platform binds the two, it generates a sealing assembly traceability code and calculates the sealing fit deviation index as 0.020mm according to the formula. If the sealing fit deviation threshold is 0.030mm, and it comes from the dimensional difference statistics of no less than 20 airtight qualified assemblies recently, assembly process documents, and quality department confirmation records, then the system determines that the assembly does not exceed the sealing fit deviation threshold and allows it to enter the airtightness test.

[0090] like Figure 6 As shown, in one specific embodiment, S4 includes: S41. Perform airtightness testing based on the sealed assembly traceability code; S42. Determine whether the leak rate detection value exceeds the leak rate standard; S43. Perform a backtracking of the sealing fit dimension layer; S44, Perform heat treatment state layer backtracking; S45, Perform a backtracking of the smelting material layer; S46. Perform raw material ratio layer backtracking; S47. Generate anomaly source sorting and handling suggestions.

[0091] For S41, the finished product inspection module reads the sealing assembly traceability code and retrieves the corresponding assembly record. The airtightness tester tests the assembly after the cylinder and lower cover bearing form a sealed fit. The airtightness test pressure can be set to 0.5 MPa, which is derived from the finished product inspection standard for the cylinder and lower cover bearing sealing assembly, customer acceptance documents, and the airtightness tester's instruction manual. The pressure holding time can be set to 30 seconds, which is derived from the finished product inspection process quality control standard, historical airtightness test records, and quality department confirmation records. After the test is completed, the airtightness tester uploads the leakage rate detection value to the production data management platform and associates it with the sealing assembly traceability code.

[0092] For S42, the production data management platform compares the leak rate detection value with the leak rate standard. The leak rate standard can be set to no more than 0.01 kPa per second. This standard is derived from the product inspection standards for cylinder and lower cover bearing seals, customer acceptance documents, historical airtightness-compliant batch inspection records, and quality department confirmation records. When the leak rate detection value does not exceed the leak rate standard, the system generates an airtightness-compliant record. When the leak rate detection value exceeds the leak rate standard, the system marks the seal status as leak rate abnormal and pending backtracking, triggering subsequent hierarchical backtracking. The leak rate abnormality does not point to a single cause, but rather involves reviewing multiple layers of data through the seal assembly traceability code.

[0093] The standards for airtightness testing pressure, holding time, and leakage rate are determined based on customer acceptance documents, finished product inspection standards, and a limited number of historical testing records. The production data management platform selects at least 20 assemblies that have recently passed customer acceptance and have not subsequently reported any sealing failures. It reads the airtightness testing pressure, holding time, and leakage rate values, and after removing abnormal airtightness tester calibrations, abnormal differences from repeated tests, and rework parts, it statistically analyzes the distribution of leakage rate values. The stricter of the customer acceptance upper limit and the historical acceptable batch leakage rate upper limit is used as the leakage rate standard. For example, if the customer acceptance document requires a leakage rate not exceeding 0.01 kPa / s, and the maximum leakage rate of the 20 historical acceptable assemblies is 0.008 kPa / s, then the system uses 0.01 kPa / s as the leakage rate standard. The testing pressure of 0.5 MPa and the holding time of 30 seconds are written into the finished product inspection process quality control standards according to the customer acceptance documents and the airtightness testing equipment manual.

[0094] For S43, the sealing fit dimension layer backtracking prioritizes the use of the measured dimensions of the cylinder sealing fit position, cylinder sealing surface roughness, measured dimensions of the lower cover bearing sealing fit position, lower cover bearing flatness, sealing fit deviation index, assembly pressure, and assembly displacement from the sealing assembly traceability code. When the sealing fit deviation index exceeds the sealing fit deviation threshold, or when the cylinder sealing surface roughness, lower cover bearing flatness, assembly pressure, or assembly displacement exceeds the corresponding process quality control standard, the system will prioritize the sealing fit dimension layer for review. The cylinder sealing surface roughness threshold is derived from the cylinder product design documents, sealing fit surface machining process documents, and historical airtightness qualified batch roughness test records. The lower cover bearing flatness threshold is derived from the lower cover bearing product design documents, assembly process documents, and historical airtightness qualified batch flatness test records.

[0095] For S44, the heat treatment status layer retrospectively retrieves the furnace temperature uniformity index, cooling rate, hardness test value, and crack marking results associated with the cylinder product traceability code and the lower cover bearing product traceability code. The furnace temperature uniformity threshold can be set to no more than 50℃, derived from the heat treatment furnace equipment manual, heat treatment process documents, historical qualified heat treatment batch furnace temperature records, and process department confirmation records. The upper and lower limits of the cooling rate are derived from the heat treatment process documents, historical qualified batch cooling curves, and quality department confirmation records. The hardness range is derived from the product material process documents and historical qualified batch hardness test records. For example, the cylinder hardness range can be set to 55HRC to 65HRC, derived from the cylinder product material process documents, heat treatment process documents, and hardness test records of at least 20 recent qualified cylinder batches. The lower cover bearing hardness range can be set to 60HRC to 70HRC, derived from the lower cover bearing product material process documents, heat treatment process documents, and hardness test records of at least 20 recent qualified lower cover bearing batches. When the cooling rate is abnormal, the hardness value is close to or exceeds the hardness range boundary, and the visual inspection system marks cracks on the sealing mating surface or its adjacent area, the system will list the heat treatment state layer as the priority review layer.

[0096] The furnace temperature uniformity threshold, upper and lower limits of cooling rate, and hardness range are determined based on data from a limited number of qualified heat treatment batches. The production data management platform selects at least 20 batches that passed hardness, crack detection, and subsequent airtightness testing after heat treatment. For each batch, the multi-point temperature difference, cooling rate, and hardness test values ​​within the furnace are statistically analyzed, and batches with abnormal furnace door opening, sensor calibration errors, or requiring rework are excluded. The furnace temperature uniformity threshold is confirmed based on the maximum qualified value of the multi-point temperature difference in conjunction with the equipment manual. The upper and lower limits of cooling rate are determined based on the 5th and 95th percentiles of the cooling rate distribution of qualified batches. The hardness range is confirmed based on the product material process documents and the historical distribution of qualified batches. For example, if the maximum multi-point temperature difference within the furnace in 20 qualified cylinder heat treatment batches is 46℃, and the furnace temperature uniformity threshold is determined to be 50℃ based on the heat treatment furnace equipment manual, and the 5th percentile of the cooling rate is 18℃ / s and the 95th percentile is 32℃ / s, then the cooling rate control range is determined to be 18℃ / s to 32℃ / s.

[0097] For S45, the smelting material layer retrospectively calls back the predicted element content, material boundary margin, post-smelting material test results, smelting deviation verification tasks, and smelting material qualification records associated with the smelting batch traceability code. When the measured element content after smelting is close to the product material standard boundary, or when the difference between the measured element content and the predicted element content of a certain controlled element after smelting exceeds the corresponding smelting deviation threshold, the system will list the smelting material layer as a priority verification layer. The determination of being close to the product material standard boundary is based on the margin threshold of the corresponding controlled element. The smelting deviation threshold is derived from historical qualified smelting batch difference data, repeatability error of testing equipment, weighing equipment calibration records, and quality department confirmation records.

[0098] For S46, the raw material proportioning layer retrospectively retrieves raw material batch traceability codes, raw material batch test results, final proportioning schemes, boundary risk proportioning schemes, raw material weighing records, and technical personnel confirmation records. When the final proportioning scheme was previously marked as a boundary risk proportioning scheme, or when the deviation between the actual weighed weight and the expected feed weight exceeds the weighing deviation threshold, the system prioritizes the raw material proportioning layer for review. If the raw material batch test results are related to subsequent smelting deviation review tasks, the system includes the corresponding raw material batch traceability code in the handling recommendations. The weighing deviation threshold is derived from weighing equipment calibration records, equipment manuals, and the company's batching process documents.

[0099] For S47, the leakage rate anomaly stratified backtracking module generates anomaly source ranking based on the verification results of the sealing fit dimension layer, heat treatment state layer, smelting material layer, and raw material ratio layer. The anomaly source ranking does not directly identify a single layer of data as the sole cause, but rather outputs a priority verification order based on whether each layer contains data exceeding thresholds, whether there are unclosed anomaly records, and whether it is related to the time of leakage rate anomaly occurrence and product batch. Handling suggestions may include verifying the cylinder sealing fit position machining parameters, verifying the lower cover bearing flatness, verifying the assembly pressure, verifying the cooling rate, supplementing non-destructive testing, verifying the smelting samples, verifying the weighing records, and verifying the raw material batch test results. After quality management personnel confirm the anomaly source, the production data management platform writes the confirmation result into the sealing assembly traceability code and updates the corresponding process quality control standards or verification rules based on the confirmation result. Rule updates originate from the quality department's confirmation records and are not directly written by the system without confirmation.

[0100] In this embodiment, the anomaly source ranking adopts a ranking model based on rule triggering and hierarchical scoring. The production data management platform records the sealing fit dimension layer, heat treatment state layer, smelting material layer, and raw material ratio layer as traceability layers. And for each backtracking layer Calculate the anomaly source score The anomaly source score It is obtained using the following formula:

[0101] in, Indicates the first A backtracking layer Anomaly source score; It refers to any of the following back layers: sealing fit dimension layer, heat treatment state layer, smelting material layer, or raw material proportioning layer; Indicates the first The number of indicators in each traceback layer that exceed the corresponding threshold or the process quality control standard; Indicates the first The number of unclosed exception records in each backtracking layer; Indicates the first The number of abnormal records in each backtracking layer that occur within the same production time window as the current leakage rate anomaly. Indicates the first The number of abnormal records in each traceback layer that belong to the same smelting batch, the same heat treatment batch, or the same assembly batch as the current sealed assembly traceability code; , , , These represent the weights of the number of indicators exceeding the threshold, the number of unclosed abnormal records, the number of time-related abnormal records, and the number of batch-related abnormal records, respectively. The production data management platform is based on... The anomaly sources are sorted from largest to smallest; when two backtracking layers... When the same conditions are met, the execution order is determined according to the sequence of the sealing fit dimension layer, heat treatment state layer, smelting material layer, and raw material ratio layer. The disposal recommendation is generated by calling a preset recommendation table based on the first-ranked retrospective layer. This preset recommendation table at least records the following: verification of cylinder sealing fit position machining parameters, verification of lower cover bearing flatness, verification of assembly pressure, verification of cooling rate, supplementary non-destructive testing, verification of smelting samples, verification of weighing records, and verification of raw material batch test results.

[0102] Among them, the weights in the anomaly source score , , , Based on a limited number of historical leakage rate anomaly samples, the production data management platform selects no fewer than 20 leakage rate anomaly assemblies whose anomaly sources have been confirmed by the quality department. It then calculates the correspondence between the number of indicators exceeding thresholds, the number of unclosed anomaly records, the number of time-related anomaly records, and the number of batch-related anomaly records in each traceback layer, and the finally confirmed anomaly source. Initial weights are determined through manual review. When there are fewer than 20 historical samples, the initial weights can be set to [value missing]. , , , The data is then re-evaluated after 20 samples have been collected. For example, among the 20 confirmed abnormal leakage rate samples, the threshold exceedance indicator has the highest hit rate for identifying the source of the abnormality, followed by the unclosed abnormal records. Time correlation and batch correlation are used as auxiliary factors. Therefore, the weight of the threshold exceedance indicator is set to 0.4, the weight of the unclosed abnormal records is set to 0.3, the weight of time correlation is set to 0.2, and the weight of batch correlation is set to 0.1.

[0103] In some optional embodiments, regarding S4, assuming the leakage rate detection value corresponding to a certain sealing assembly traceability code is 0.015 kPa / s, and the leakage rate standard is no more than 0.01 kPa / s, this leakage rate standard is derived from the finished product inspection standard, customer acceptance documents, and historical airtightness qualified batch inspection records. The system triggers layered backtracking. The sealing fit dimension layer data shows that the sealing fit deviation index is 0.020 mm, which does not exceed the sealing fit deviation threshold of 0.030 mm. The heat treatment status layer data shows that the cylinder cooling rate once exceeded the upper limit of cooling rate, and the hardness detection value is close to 65 HRC. The visual inspection system marks the crack in the area near the sealing fit surface. The upper limit of cooling rate is derived from the heat treatment process document and the cooling curve of historical qualified batches, and the upper limit of hardness of 65 HRC is derived from the cylinder product material process document and the hardness detection records of historical qualified batches. The system lists the heat treatment status layer as the priority review layer and generates disposal suggestions for reviewing the cooling rate record, supplementing non-destructive testing, and reviewing the heat treatment record of the same batch of cylinders.

[0104] In some embodiments, this embodiment illustrates the operation process of the present invention in cylinder production using specific data.

[0105] After a batch of cylinder production orders is issued, the production data management platform reads the batch test results of pig iron, scrap steel, and electrolytic copper raw materials that can be used for batching. The pig iron has a carbon content of 3.8%, a copper content of 0.1%, and an iron content of 96.1%. The scrap steel has a carbon content of 0.2%, a copper content of 0.05%, and an iron content of 99.75%. The electrolytic copper has a carbon content of 0%, a copper content of 99.95%, and an iron content of 0.05%. These test values ​​are from the test records uploaded by the raw material testing module, which include the testing equipment number, testing time, sample number, and testing personnel.

[0106] The material standard for cylinder products is a carbon content of 0.4% to 1.0%, a copper content of 0% to 2.5%, with iron and unavoidable impurities as the balance. This material standard is derived from the cylinder product material standard table, product design documents, company material and process documents, historical qualified cylinder batch spectral test records, and customer technical documents, and has been confirmed by the process department and quality department.

[0107] The production data management platform generates candidate blending schemes, in which the mass ratio of pig iron is 20%, the mass ratio of scrap steel is 78%, and the mass ratio of electrolytic copper is 2%. Based on the predicted element content formula, the blending calculation module calculates the predicted carbon content to be 0.916%, the predicted copper content to be 2.058%, and the predicted iron content to be 97.026%. The predicted carbon and copper contents in this candidate blending scheme are both within the material standard range for cylinder products.

[0108] The system then determines the material boundary margin. The predicted carbon content is 0.916%, which is 0.084% away from the upper limit of 1.0% and 0.516% away from the lower limit of 0.4%. Therefore, the material boundary margin for carbon is 0.084%. The carbon margin threshold is 0.06%, which is derived from the statistical analysis of the fluctuation between predicted and measured carbon content in at least 20 recent qualified smelting batches of cylinders, weighing equipment calibration records, and quality department confirmation records. Since 0.084% is not less than 0.06%, the system does not mark this scheme as a carbon boundary risk proportioning scheme.

[0109] The predicted copper content is 2.058%, which is 0.442% below the upper limit of 2.5% and 2.058% below the lower limit of 0%. Therefore, the material boundary margin for copper is 0.442%. The copper margin threshold is 0.10%, which is derived from statistical analysis of the fluctuations between predicted and measured copper content in at least 20 recent qualified smelting batches of cylinders, records of spectral repeatability testing, and confirmation records from the quality department. Since 0.442% is not less than 0.10%, the system does not mark this scheme as a copper boundary risk proportioning scheme. The production data management platform determines this candidate proportioning scheme as the final proportioning scheme and generates a smelting batch traceability code.

[0110] After smelting, inspectors extracted three samples from the cylinder blanks produced in the same smelting batch. The selection of these three samples was based on the company's post-smelting material sampling procedures and quality department confirmation records. The average measured carbon content was 0.930%, the average measured copper content was 2.070%, and the average measured iron content was 96.980%. Other unavoidable impurities and rounding errors totaled 0.020%, with the total content of the above components being 100.000%. The system compared the post-smelting measured results with the predicted elemental content. The carbon content difference was 0.014%, which did not exceed the carbon element smelting deviation threshold of 0.05%. The carbon element smelting deviation threshold of 0.05% was derived from statistical analysis of differences in at least 20 recent qualified cylinder smelting batches, verification records from the combustion infrared carbon-sulfur analyzer, and quality department confirmation records. The copper content difference was 0.012%, which did not exceed the copper element smelting deviation threshold of 0.08%. The copper element smelting deviation threshold of 0.08% is derived from statistical analysis of differences in at least 20 recent qualified smelting batches of cylinders, records of spectral repeatability testing, and confirmation records from the quality department. Therefore, the system generates a qualified record for the smelted material and generates a cylinder product traceability code based on the smelting batch traceability code.

[0111] After the cylinder enters the precision machining process, the precision machining monitoring module collects the measured dimensions of the cylinder's sealing fit position, the roughness of the cylinder's sealing surface, the machining torque, and the acoustic emission signal. Similarly, after the lower cover bearing enters the precision machining process, the precision machining monitoring module collects the measured dimensions of the lower cover bearing's sealing fit position, the lower cover bearing's flatness, the machining torque, and the acoustic emission signal. Assuming the measured dimension of a cylinder's sealing fit position is 50.020 mm and the measured dimension of a lower cover bearing's sealing fit position is 50.000 mm, the system generates a sealing assembly traceability code and calculates the sealing fit deviation index as 0.020 mm. The sealing fit deviation threshold is 0.030 mm, which is derived from the statistical analysis of dimensional differences in at least 20 recently airtightness-qualified assemblies, assembly process documents, and quality department confirmation records. Since 0.020 mm does not exceed 0.030 mm, the system allows this sealing assembly traceability code to enter the airtightness testing.

[0112] The airtightness test pressure is 0.5 MPa, derived from the finished product inspection process quality control standards, the airtightness testing equipment manual, and customer acceptance documents. The pressure holding time is 30 seconds, derived from the finished product inspection process quality control standards, historical airtightness test records, and quality department confirmation records. The leakage rate standard is no more than 0.01 kPa / s, derived from customer acceptance documents, finished product inspection standards, and historical airtightness-compliant batch test records. If the leakage rate detected by the airtightness tester is 0.015 kPa / s, the system determines the leakage rate is abnormal and triggers tiered backtracking.

[0113] In the layered backtracking, the sealing fit dimension layer shows that the sealing fit deviation index did not exceed the sealing fit deviation threshold, and the cylinder sealing surface roughness, lower cover bearing flatness, and assembly pressure were all within the corresponding process quality control standard range. The heat treatment status layer shows that the cylinder cooling rate briefly exceeded the upper limit of the cooling rate, the hardness test value was close to the upper limit of the cylinder hardness range, and the visual inspection system marked cracks in the area near the cylinder sealing fit surface. The upper limit of the cooling rate was derived from the heat treatment process documents, the cooling curves of historical qualified batches, and the quality department confirmation records. The upper limit of the cylinder hardness range of 65HRC was derived from the cylinder product material process documents, the heat treatment process documents, and the hardness test records of at least 20 recent qualified cylinder batches. The system listed the heat treatment status layer as the priority review layer and generated disposal suggestions, which included reviewing the cooling rate records of this batch of cylinders, supplementing non-destructive testing on the same batch of cylinders, and reviewing the cooling control parameters of the heat treatment furnace.

[0114] 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. An intelligent management system for the production process of cylinder and lower cover bearings of an air conditioner compressor, characterized in that, This includes a proportioning determination module, a smelting verification and product traceability code generation module, a sealing assembly association module, and an airtightness testing and layered backtracking module; The proportioning determination module is used to obtain raw material batch test results and production task information, generate candidate proportioning schemes according to product material standards, calculate the predicted element content and material boundary margin of the candidate proportioning schemes, and determine the final proportioning scheme when the candidate proportioning schemes meet the product material standards and the material boundary margins meet the margin threshold, and generate smelting batch traceability codes. The smelting verification and product traceability code generation module is used to receive the smelting batch traceability code generated by the proportion determination module, collect smelting and casting process parameters and material test results after smelting based on the smelting batch traceability code, compare the material test results after smelting with the predicted element content, generate a smelting deviation verification task or a smelting material qualification record, and generate a cylinder product traceability code or a lower cover bearing product traceability code based on the smelting batch traceability code. The sealing assembly association module is used to receive the cylinder product traceability code and the lower cover bearing product traceability code generated by the melting verification and product traceability code generation module. Based on the cylinder product traceability code and the lower cover bearing product traceability code, it collects precision machining data and heat treatment status data. When the cylinder and the lower cover bearing meet the pre-assembly conditions, it binds and generates a sealing assembly traceability code and records the sealing fit deviation index and assembly parameters. The airtightness detection and layered backtracking module is used to receive the sealing assembly traceability code generated by the sealing assembly association module, perform airtightness detection based on the sealing assembly traceability code, and when the leakage rate detection value exceeds the leakage rate standard, call the sealing fit size data, heat treatment status data, melting material data and raw material ratio data associated with the sealing assembly traceability code to perform layered backtracking, and generate anomaly source sorting and handling suggestions.

2. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 1, characterized in that, The proportioning determination module, the smelting verification and product traceability code generation module, the sealing assembly association module, and the airtightness detection and layered backtracking module are all connected to the production data management platform. The production data management platform includes a relational database and a time-series database; The relational database is used to store raw material batch traceability codes, smelting batch traceability codes, cylinder product traceability codes, lower cover bearing product traceability codes, sealing assembly traceability codes, candidate proportioning schemes, final proportioning schemes, material boundary margins, smelting deviation verification tasks, smelting material qualification records, sealing fit deviation indicators, abnormal source sorting and handling suggestions. The time-series database is used to store melting temperature, casting pressure, spindle speed, machining torque, acoustic emission signal, furnace temperature uniformity index, cooling rate, and airtightness test curve; The production data management platform is configured to associate the smelting batch traceability code with the corresponding raw material batch traceability code and the final proportioning scheme, to associate the cylinder product traceability code or the lower cover bearing product traceability code with the corresponding smelting batch traceability code, to associate the sealing assembly traceability code with the corresponding cylinder product traceability code and the lower cover bearing product traceability code, and, when the leakage rate detection value exceeds the leakage rate standard, to reverse-call the corresponding sealing fit dimension data, heat treatment status data, smelting material data and raw material proportioning data through the sealing assembly traceability code.

3. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 1, characterized in that, The raw material batch test results include the raw material batch traceability code, raw material category, supplier information, measured carbon content, measured copper content, measured iron content, and factory acceptance judgment conclusion for at least one of the raw materials: pig iron, scrap steel, and electrolytic copper. Before generating candidate formulation schemes, the corresponding raw material factory acceptance standards are called according to the raw material category for judgment. Raw material batches that meet the corresponding raw material factory acceptance standards are marked as usable for batching, while raw material batches that do not meet the corresponding raw material factory acceptance standards are marked as unqualified and await isolation. The raw material factory acceptance standards and the product material standards are stored separately, and the test results of a single raw material such as pig iron, scrap steel, and electrolytic copper are not directly judged as qualified according to the product material standards of cylinders or lower cover bearings.

4. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 1, characterized in that, The candidate formulation scheme includes the batch traceability code of the raw materials involved in the feeding, the mass ratio of each raw material, the expected feeding weight, and the target product type; the predicted element content is obtained by weighting the measured element content of each raw material and the mass ratio of each raw material; the material boundary margin is the smaller of two distances between the predicted element content and the lower limit and upper limit of the product material standard; when the predicted element content of any controlled element exceeds the product material standard, the candidate formulation scheme is marked as not meeting the product material standard; when the material boundary margin of any controlled element is less than the corresponding margin threshold, the candidate formulation scheme is marked as a boundary risk formulation scheme.

5. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 4, characterized in that, When a candidate blending scheme is marked as a boundary risk blending scheme, the production data management platform generates an alternative blending scheme based on the type of controlled element. When the predicted carbon content is close to the upper limit of carbon content, an alternative blending scheme that reduces the mass ratio of pig iron and increases the mass ratio of low-carbon scrap steel is generated first. When the predicted copper content is close to the upper limit of copper content, an alternative blending scheme that reduces the mass ratio of electrolytic copper and supplements the mass ratio with low-copper scrap steel or low-copper iron-based raw materials that meet the factory acceptance standards is generated first. The alternative blending scheme re-executes the predicted element content calculation and material boundary margin determination, and is determined as the final blending scheme after meeting the product material standards and the material boundary margin meets the margin threshold.

6. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 1, characterized in that, The material testing results after smelting include the measured carbon content, measured copper content, and measured iron content of the smelted sample. The smelting deviation verification task is generated based on the absolute difference between the material testing results after smelting and the predicted element content in the final proportioning scheme. When the difference of any controlled element exceeds the corresponding smelting deviation threshold, the production data management platform generates a smelting deviation verification task, which includes verifying the raw material batch traceability code, raw material weighing record, smelting temperature curve, feeding sequence, testing equipment calibration status, and testing sample number. When the material testing results after smelting meet the product material standard and the difference does not exceed the corresponding smelting deviation threshold, a smelting material qualification record is generated.

7. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 1, characterized in that, The precision machining data includes the measured dimensions of the cylinder seal mating position, the cylinder seal surface roughness, the measured dimensions of the lower cover bearing seal mating position, the lower cover bearing flatness, machining torque, and acoustic emission signal; the heat treatment status data includes furnace temperature uniformity index, cooling rate, hardness test value, and crack marking results; when the machining torque exceeds the upper limit of the machining torque or the acoustic emission signal exceeds the acoustic emission signal threshold, a tool wear risk warning is generated; when the cooling rate exceeds the upper limit of the cooling rate or is lower than the lower limit of the cooling rate, a cooling rate abnormality warning is generated, and the tool wear risk warning and the cooling rate abnormality warning are respectively written into the corresponding cylinder product traceability code or lower cover bearing product traceability code.

8. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 1, characterized in that, The sealed assembly traceability code is generated by binding the cylinder product traceability code and the lower cover bearing product traceability code. Before binding, the production data management platform determines whether the cylinder and lower cover bearing have any material abnormalities, size abnormalities, heat treatment abnormalities, or isolation states that are not closed. If any exist, the generation of the sealed assembly traceability code is prevented. If none exist, the sealed assembly traceability code is generated, and the measured dimensions of the cylinder sealing fit position, the measured dimensions of the lower cover bearing sealing fit position, the assembly pressure, the assembly displacement, and the assembly time are written into the sealed assembly traceability code. The sealing fit deviation index is determined based on the difference between the measured dimensions of the cylinder sealing fit position and the measured dimensions of the lower cover bearing sealing fit position. When the sealing fit deviation index exceeds the sealing fit deviation threshold, the corresponding assembly combination is marked as a sealing fit risk combination.

9. The intelligent management system for the production process of the cylinder and lower cover bearing of an air conditioning compressor according to claim 1, characterized in that, The layered retrospective analysis is performed in the following order: sealing fit dimension layer, heat treatment state layer, smelting material layer, and raw material proportioning layer. The sealing fit dimension layer is used to verify the measured dimensions of the cylinder sealing fit position, the roughness of the cylinder sealing surface, the measured dimensions of the lower cover bearing sealing fit position, the flatness of the lower cover bearing, the sealing fit deviation index, and the assembly pressure. The heat treatment state layer is used to verify the furnace temperature uniformity index, cooling rate, hardness test value, and crack marking results. The smelting material layer is used to verify the material test results after smelting, the predicted element content, the material boundary margin, and the smelting deviation verification task. The raw material proportioning layer is used to verify the raw material batch test results, raw material weighing records, the final proportioning scheme, and the boundary risk proportioning scheme. The production data management platform generates a ranking of anomaly sources based on the review results at each level, and then generates handling suggestions based on the ranking results.

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