A safety monitoring system for electroplating tanks based on hierarchical interlocking protection

Abstract

A safety monitoring system for electroplating tanks based on hierarchical interlocking protection, relating to the safety of electroplating production equipment, includes an array of electroplating tanks. Each row of electroplating tanks consists of several electroplating tank units, each independently equipped with: an anti-dry-burning electric heating element, a liquid level monitoring sensor, a temperature monitoring sensor, a PID temperature controller, and an AC contactor. At the end of each row of electroplating tanks is a front-end control cabinet with a built-in PLC controller. The PLC controller is connected to the anti-dry-burning electric heating element, the liquid level monitoring sensor, and the temperature monitoring sensor. A hierarchical protection mechanism enables early warning and power-off control: when the real-time working liquid level or real-time working temperature exceeds the first protection threshold, an early warning signal is output and the anti-dry-burning electric heating element is adjusted; when the second protection threshold is reached, an alarm signal is output and the AC contactor is shut off. The system uses the liquid level and temperature sensors to collect real-time data on the electroplating tank's operating status, combined with the hierarchical protection mechanism, to prevent dry-burning and overheating accidents.

Description

Technical Field

[0001] This utility model relates to the field of safety in electroplating production equipment, and in particular to a safety monitoring system for electroplating tanks based on hierarchical interlocking protection. Background Technology

[0002] Electroplating production workshops are facilities where metal or alloy layers are deposited on the surface of objects using the principle of electrolysis, primarily for improving the appearance and performance of objects. The process includes pre-plating surface treatment, electroplating, and post-plating treatment. Pre-plating treatment involves processes such as grinding, polishing, and degreasing to ensure a smooth and clean surface. Electroplating is the core step, where the uniform deposition of metal ions is achieved by controlling the current density and voltage. Post-plating treatment includes polishing and passivation to meet the quality requirements of the parts.

[0003] In electroplating industrial production, traditional electroplating tanks and their temperature control systems suffer from numerous safety hazards and technical defects, seriously affecting production safety and efficiency. Current mainstream electroplating tank heating systems typically rely on a single sensor for temperature monitoring. This design has significant reliability issues; if data misinterpretation or signal loss occurs, the system may fail to detect anomalies in time, leading to serious accidents such as dry burning and overheating. This not only causes direct losses such as electroplating solution evaporation and tank deformation but may also trigger major safety accidents such as fires.

[0004] Most existing temperature control systems employ simple threshold protection mechanisms, directly cutting off power when an excessive temperature is detected. While this "all or nothing" protection method can prevent accidents in extreme situations, it also brings many drawbacks. On the one hand, frequent hard power outages accelerate contactor aging and shorten equipment lifespan; on the other hand, the system cannot distinguish between slight temperature fluctuations and genuine dangerous faults, easily leading to unnecessary shutdowns due to false triggers, affecting production continuity. More importantly, traditional systems lack tiered early warning and gradual response capabilities, failing to provide warnings in the early stages of anomalies or take buffer measures in moderate-risk situations. They can only abruptly cut off power when danger is imminent, making it difficult to balance safety and production efficiency.

[0005] Furthermore, the unique environment of electroplating workshops poses a severe challenge to equipment reliability. The sulfuric acid, cyanide, and other chemicals used extensively in these workshops are highly corrosive and toxic. If critical components such as sensors and control cabinets are not effectively protected, they are easily corroded by these chemical gases, leading to performance degradation or even complete failure. This not only increases equipment maintenance and replacement costs but may also unknowingly reduce the system's safety capabilities. At the same time, traditional systems still heavily rely on manual inspections, failing to monitor key parameters in real time or remotely push alarm information, resulting in delayed responses to abnormal situations. Such delays could potentially escalate accidents. Utility Model Content

[0006] The technical problem to be solved by this utility model is to provide a safety monitoring system for electroplating tanks based on hierarchical interlocking protection. The system collects the working status of the electroplating tank in real time through liquid level monitoring sensors and temperature monitoring sensors, and combines hierarchical protection mechanisms to effectively prevent dry burning and overheating accidents.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is: a safety monitoring system for electroplating tanks based on hierarchical interlocking protection, comprising an array of multiple rows of electroplating tanks arranged in parallel. Each row of electroplating tanks is composed of several electroplating tank units arranged linearly. Each electroplating tank unit is independently equipped with: an anti-dry-burning electric heating tube evenly arranged circumferentially along the bottom of the electroplating tank; a liquid level monitoring sensor for real-time monitoring of liquid level changes in the electroplating tank; a temperature monitoring sensor for real-time monitoring of the temperature in the electroplating tank; a PID temperature controller for adjusting the power of the anti-dry-burning electric heating tube; and an AC contactor connected in series with the anti-dry-burning electric heating tube. The end is equipped with a front-end control cabinet, which has a built-in PLC controller. The PLC controller is connected to the anti-dry-burning electric heating tube, liquid level monitoring sensor and temperature monitoring sensor circuit. It realizes early warning and power-off control through a graded protection mechanism: when the real-time working liquid level is lower than the first liquid level protection threshold or the real-time working temperature exceeds the first temperature protection threshold, the PLC controller outputs an early warning signal and controls the PID temperature controller to adjust the temperature of the anti-dry-burning electric heating tube. When the real-time working liquid level is lower than the second liquid level protection threshold or the real-time working temperature exceeds the second temperature protection threshold, the PLC controller outputs an alarm signal and controls the AC contactor to cut off.

[0008] As a preferred embodiment, the first temperature protection threshold is set to the process standard temperature + 2℃, and the second temperature protection threshold is set to the process standard temperature + 5℃.

[0009] As a preferred embodiment, the PLC controller communicates with the host computer via Ethernet to achieve remote monitoring and protection threshold parameter setting.

[0010] As a preferred embodiment, the liquid level monitoring sensor is either a contact liquid level monitoring sensor or a non-contact liquid level monitoring sensor.

[0011] As a preferred embodiment, the temperature monitoring sensor is a long probe type, which is set at a distance of 5 to 10 cm from the heating tube.

[0012] As a preferred embodiment, each row of electroplating tanks is further provided with an audible and visual alarm at its end for outputting the warning signal and alarm signal, and the audible and visual alarm is connected to the PLC controller circuit.

[0013] As a preferred option, the front-end control cabinet is installed at a distance of more than 20cm from the outer wall of the electroplating tank to avoid corrosion.

[0014] As a preferred embodiment, each electroplating tank unit also includes a thermal imaging monitoring device disposed above the electroplating tank unit. The thermal imaging monitoring device is connected to the PLC controller circuit and is used to implement graded fire protection.

[0015] Based on the above technical solution, the beneficial effects of this utility model are:

[0016] 1. This application employs a dual-redundant interlocking detection mechanism. It uses level and temperature sensors to collect real-time data on the electroplating tank's operating status and combines this with a tiered protection mechanism to effectively prevent dry-burning and overheating accidents. When the real-time operating level or temperature exceeds the primary protection threshold, an early warning signal is output, and the PID temperature controller adjusts the anti-dry-burning electric heating element. When the secondary protection threshold is reached, an alarm signal is output, and the AC contactor is cut off to disconnect the power supply to the anti-dry-burning electric heating element, preventing serious accidents such as fires and tank deformation. Compared to traditional single-threshold protection mechanisms, this solution provides both early warning and precise intervention, significantly improving safety.

[0017] 2. This application adopts a progressive protection mechanism, which differs from the traditional temperature control system design that directly cuts off power in case of abnormality. It sets two levels of liquid level and temperature protection thresholds. In case of minor abnormality, it prioritizes temperature adjustment rather than direct power cut-off, reducing unnecessary downtime and extending equipment life. Power is only forcibly cut off in case of severe abnormality, ensuring safety and improving production efficiency.

[0018] 3. This application optimizes the design of key components for the highly corrosive environment of electroplating workshops. For example, the front-end control cabinet is spaced more than 20cm away from the tank to avoid chemical gas corrosion; flame-retardant materials are used for the electroplating tank body and pipeline materials, which effectively extends the life of sensors and control equipment and reduces maintenance costs.

[0019] 4. This application communicates with the host computer via a PLC controller, supporting remote real-time monitoring, parameter adjustment, and alarm information push, reducing reliance on manual inspections. Combined with audible and visual alarms and thermal imaging monitoring devices, it quickly locates anomalies and takes countermeasures, preventing response delays from escalating the accident. Attached Figure Description

[0020] Figure 1 This is a functional block diagram of the electroplating tank safety monitoring system of this utility model. Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0022] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this utility model. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.

[0023] Furthermore, it should be noted that, unless otherwise stated, "several" means two or more; the terms "upper," "lower," "left," "right," "front end," "rear end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered as within the scope of implementation of this utility model. In addition, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] like Figure 1 As shown, a safety monitoring system for electroplating tanks based on hierarchical interlocking protection includes an array of electroplating tanks arranged in parallel rows, wherein each row of electroplating tanks is composed of several electroplating tank units arranged linearly.

[0025] Each electroplating tank unit is independently equipped with: anti-dry-burning electric heating tubes evenly arranged circumferentially along the bottom of the electroplating tank, a liquid level monitoring sensor for real-time monitoring of liquid level changes in the electroplating tank, a temperature monitoring sensor for real-time monitoring of the temperature in the electroplating tank, a PID temperature controller for adjusting the power of the anti-dry-burning electric heating tubes, and an AC contactor connected in series with the anti-dry-burning electric heating tubes.

[0026] Each row of electroplating tanks is equipped with a front-end control cabinet at its end. The front-end control cabinet has a built-in PLC controller. The PLC controller is connected to the anti-dry-burning electric heating tube, liquid level monitoring sensor, and temperature monitoring sensor circuit. It realizes early warning and power-off control through a graded protection mechanism: when the real-time working liquid level is lower than the first liquid level protection threshold or the real-time working temperature exceeds the first temperature protection threshold, the PLC controller outputs an early warning signal and controls the PID temperature controller to adjust the anti-dry-burning electric heating tube. When the real-time working liquid level is lower than the second liquid level protection threshold or the real-time working temperature exceeds the second temperature protection threshold, the PLC controller outputs an alarm signal and controls the AC contactor to cut off.

[0027] In this embodiment, the first temperature protection threshold is set to the process standard temperature + 2°C, and the second temperature protection threshold is set to the process standard temperature + 5°C.

[0028] The PLC controller communicates with the host computer via Ethernet to achieve remote monitoring and protection threshold parameter setting.

[0029] The PID temperature controller is connected to a silicon controlled rectifier (SCR) power module to precisely control the on / off state and power regulation of the heater. In this embodiment, an Omron temperature controller is selected as the PID temperature controller.

[0030] In this embodiment, the liquid level monitoring sensor is either a contact liquid level monitoring sensor or a non-contact liquid level monitoring sensor. Specifically, the contact liquid level monitoring sensor is a three-pole probe metal level gauge or a dual float level gauge; the non-contact liquid level monitoring sensor is a capacitive sensor, which is installed on the outer wall of the electroplating tank.

[0031] The temperature monitoring sensor is a long probe type, which is set at a distance of 5 to 10 cm from the anti-dry-burning heating tube.

[0032] Each row of electroplating tanks is also equipped with an audible and visual alarm at its end for outputting the warning signal and alarm signal, and the audible and visual alarm is connected to the PLC controller circuit.

[0033] In this embodiment, the front-end control cabinet is installed at a distance of more than 20cm from the outer wall of the electroplating tank to avoid the corrosive effects of chemicals.

[0034] Each electroplating tank unit also includes a thermal imaging monitoring device installed above the electroplating tank unit. The thermal imaging monitoring device is connected to the PLC controller circuit and is used to implement graded fire protection. When the ambient temperature exceeds the first warning threshold, it outputs a warning signal and links the exhaust system to strengthen ventilation. When the temperature reaches the second safety threshold, it is determined to be a fire and outputs an alarm signal, while forcibly cutting off the power supply to the exhaust system.

[0035] In this embodiment, the materials for the electroplating tank and the circuit piping are selected as metallic materials or non-metallic materials with a flame retardant rating of 3 or above.

[0036] Working principle:

[0037] Heating Start: After turning on the main switch of the front control cabinet and the electroplating tank switch, press the start button to start heating when the liquid level is higher than the upper liquid level for each electroplating tank.

[0038] Stop heating: Turning off the main switch of the front-end control cabinet and the electroplating tank switch will directly stop heating.

[0039] Dual-redundancy temperature protection system:

[0040] Based on actual process requirements, the PLC controller is set with a first liquid level protection threshold (upper liquid level), a second liquid level protection threshold (lower liquid level), a first temperature protection threshold, and a second temperature protection threshold. The first temperature protection threshold is the process standard temperature + 2℃, and the second temperature threshold is set to the process standard temperature + 5℃.

[0041] Dual-redundancy temperature protection: When the electroplating tank is operating, the PID temperature controller collects temperature data from the temperature monitoring sensor in real time. Based on preset first and second temperature thresholds, a temperature gradient protection mechanism is established. When the operating temperature detected by the temperature monitoring sensor is lower than the process standard temperature, the anti-dry-burning electric heating element continues to operate. When the real-time operating temperature detected by the temperature monitoring sensor is lower than but close to the process standard temperature, the PLC controller reduces the heating power of the anti-dry-burning electric heating element. When the real-time operating temperature detected by the temperature monitoring sensor exceeds the first temperature threshold, an early warning signal is output, and the PID temperature controller is controlled to reduce the heating power output to zero. The electroplating tank automatically stops heating; this is the first-level temperature protection. When the real-time operating temperature drops below the first temperature threshold, the PLC controller controls the PID temperature controller to resume heating of the anti-dry-burning electric heating element without human intervention. When the real-time operating temperature detected by the temperature monitoring sensor exceeds the second temperature protection threshold, the PLC controller outputs an alarm signal and controls the AC contactor to cut off the power to the anti-dry-burning heating element, and the equipment stops heating. When the real-time operating temperature drops below the first temperature threshold, the site conditions must be manually checked to ensure that everything is in order before pressing the start heating button to continue heating, in order to prevent unforeseen accidents; this is the second-level temperature protection.

[0042] Dual-redundancy liquid level protection: When the electroplating tank is working, a three-level liquid level protection zone is established based on preset upper and lower liquid level values. When the liquid level monitoring sensor detects that the real-time working liquid level is higher than the upper liquid level, the anti-dry-burning electric heating tube continues to work. When the liquid level monitoring sensor detects that the real-time working liquid level is between the upper and lower liquid levels, it outputs a warning signal and controls the PID temperature controller to reduce the heating power output to zero, and the electroplating tank automatically stops heating. This is the first-level liquid level protection. When the real-time working liquid level recovers to be higher than the upper liquid level, the PLC controller controls the PID temperature controller to resume heating of the anti-dry-burning electric heating tube without human intervention. When the liquid level monitoring sensor detects that the real-time working liquid level is lower than the lower liquid level, the PLC controller outputs an alarm signal and controls the AC contactor to cut off the power to the anti-dry-burning heating tube, and the equipment stops heating. When the real-time working liquid level is higher than the upper liquid level, the site conditions must be checked manually to ensure that everything is correct before pressing the start heating button to continue heating, preventing unknown accidents. This is the second-level liquid level protection.

[0043] It should be noted that the above embodiments are only used to illustrate the present utility model, but the present utility model is not limited to the above embodiments. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model shall fall within the protection scope of the present utility model.

Claims

1. A safety monitoring system for an electroplating cell based on hierarchical interlocking protection, characterized in that: The system includes an array of multiple rows of electroplating tanks arranged in parallel. Each row of electroplating tanks is composed of several electroplating tank units arranged linearly. Each electroplating tank unit is independently equipped with: an anti-dry-burning electric heating tube evenly arranged circumferentially along the bottom of the electroplating tank; a liquid level monitoring sensor for real-time monitoring of liquid level changes in the electroplating tank; a temperature monitoring sensor for real-time monitoring of the temperature in the electroplating tank; a PID temperature controller for adjusting the power of the anti-dry-burning electric heating tube; and an AC contactor connected in series with the anti-dry-burning electric heating tube. Each row of electroplating tanks is equipped with a front-end control cabinet at its end. The front-end control cabinet has a built-in PLC controller. The PLC controller is connected to the anti-dry-burning electric heating tube, liquid level monitoring sensor, and temperature monitoring sensor circuit. It realizes early warning and power-off control through a graded protection mechanism: when the real-time working liquid level is lower than the first liquid level protection threshold or the real-time working temperature exceeds the first temperature protection threshold, the PLC controller outputs an early warning signal and controls the PID temperature controller to adjust the temperature of the anti-dry-burning electric heating tube. When the real-time working liquid level is lower than the second liquid level protection threshold or the real-time working temperature exceeds the second temperature protection threshold, the PLC controller outputs an alarm signal and controls the AC contactor to cut off.

2. The electroplating bath safety monitoring system based on hierarchical interlock protection according to claim 1, characterized in that: The first temperature protection threshold is set to the process standard temperature + 2℃, and the second temperature protection threshold is set to the process standard temperature + 5℃.

3. The electroplating tank safety monitoring system based on hierarchical interlocking protection according to claim 2, characterized in that: The PLC controller communicates with the host computer via Ethernet to achieve remote monitoring and protection threshold parameter setting.

4. The electroplating tank safety monitoring system based on hierarchical interlocking protection according to claim 1, characterized in that: The liquid level monitoring sensor can be a contact liquid level monitoring sensor or a non-contact liquid level monitoring sensor.

5. The electroplating tank safety monitoring system based on hierarchical interlocking protection according to claim 1, characterized in that: The temperature monitoring sensor is a long probe type, which is set at a distance of 5 to 10 cm from the heating tube.

6. The electroplating tank safety monitoring system based on hierarchical interlocking protection according to claim 1, characterized in that: Each row of electroplating tanks is also equipped with an audible and visual alarm at its end for outputting the warning signal and alarm signal, and the audible and visual alarm is connected to the PLC controller circuit.

7. The electroplating tank safety monitoring system based on hierarchical interlocking protection according to claim 1, characterized in that: The front-end control cabinet is installed at a distance of more than 20cm from the outer wall of the electroplating tank to avoid corrosion.

8. The electroplating tank safety monitoring system based on hierarchical interlocking protection according to claim 1, characterized in that: Each electroplating tank unit also includes a thermal imaging monitoring device installed above the electroplating tank unit. The thermal imaging monitoring device is connected to the PLC controller circuit and is used to implement graded fire protection.

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