A kind of plating solution liquid level automatic control device

Abstract

This utility model discloses an automatic control device for plating solution level, belonging to the field of bolt anti-collision technology. It includes a storage tank with a plating solution containing cavity; a level detection component installed on the inner wall of the storage tank, comprising an ultrasonic level sensor and a conductive level switch. The ultrasonic level sensor is located at the top of the plating solution containing cavity, and the conductive level switch includes a high-level probe and a low-level probe, corresponding to the preset highest and lowest liquid levels in the plating solution containing cavity, respectively. A microcontroller starts a peristaltic pump via a relay drive circuit. The peristaltic pump then delivers the plating solution from the replenishment tank to the storage tank through a delivery pipe. The ultrasonic level sensor continuously monitors the liquid level changes and provides real-time feedback to the microcontroller. When the liquid level reaches the preset upper limit, the microcontroller controls the relay drive circuit to shut down the peristaltic pump, stopping the replenishment, thereby achieving stable control of the plating solution level within a preset range.

Description

Technical Field

[0001] This utility model belongs to the field of bolt anti-collision technology, specifically an automatic control device for plating solution level. Background Technology

[0002] In the electroplating process, the stability of the plating bath level directly affects the plating quality, electroplating efficiency, and production costs. Traditional plating bath level control mostly relies on float-type level switches. These devices control the replenishment of plating solution by triggering the switch action as the float rises and falls with the liquid level. However, this method has several drawbacks. First, the float is constantly immersed in the plating solution, making it susceptible to corrosion from the corrosive solution and entanglement by impurities, leading to mechanical malfunction and level control failure. Second, float-type level switches have low control precision, making it difficult to meet the requirements of modern precision electroplating for accurate level control. Large fluctuations in the liquid level can cause uneven plating thickness and poor surface quality. Third, traditional devices lack a robust abnormal liquid level alarm mechanism. When the liquid level is abnormal (such as being consistently too high or too low), it cannot issue an alarm and take timely measures, which can easily lead to serious consequences such as scrapped parts and equipment damage. Fourth, existing replenishment methods usually involve directly injecting the plating solution into the storage tank. This results in a large impact and generates a large amount of foam. This foam not only affects the electroplating effect but may also cause the plating solution components to evaporate, affecting the performance of the plating solution. Furthermore, traditional devices are difficult to integrate with the control systems of automated production lines, making them unable to adapt to the development trend of intelligent manufacturing. Therefore, there is an urgent need to design a new type of plating solution level control device to solve the above problems. Utility Model Content

[0003] The purpose of this invention is to solve the problems mentioned in the background.

[0004] To achieve the above objectives, the technical solution provided by this utility model is as follows:

[0005] This utility model discloses an automatic control device for plating solution level, characterized in that it comprises:

[0006] A liquid storage tank, wherein the liquid storage tank is provided with a plating solution containing a cavity;

[0007] A liquid level detection component is installed on the inner wall of the liquid storage tank. The liquid level detection component includes an ultrasonic liquid level sensor and a conductive liquid level switch. The ultrasonic liquid level sensor is set at the top of the plating solution receiving cavity. The conductive liquid level switch includes a high-level probe and a low-level probe, which correspond to the preset highest and lowest liquid level positions of the plating solution receiving cavity, respectively.

[0008] The fluid replenishment system includes a fluid replenishment tank, an infusion tubing, and a peristaltic pump. The fluid replenishment tank is connected to the storage tank via the infusion tubing, and the peristaltic pump is mounted on the infusion tubing.

[0009] The control module is electrically connected to the liquid level detection component and the peristaltic pump respectively. The control module includes a microcontroller, a comparator circuit and a relay drive circuit. The comparator circuit compares the detection value of the ultrasonic liquid level sensor with a preset liquid level range. The microcontroller controls the start and stop of the peristaltic pump through the relay drive circuit according to the comparison result.

[0010] An alarm device is connected to the control module and triggers an alarm when the conductive liquid level switch detects an abnormal liquid level.

[0011] Preferably, the outlet end of the infusion tube is provided with a splash-proof diffuser, which has an umbrella-shaped structure and a diameter ranging from 50 to 80 mm.

[0012] Preferably, the replenishment tank is equipped with a stirring device, which consists of a drive motor and a stirring paddle, and the surface of the stirring paddle blades is coated with a Teflon coating.

[0013] Preferably, the control module further includes a wireless communication module, which supports the RS485 / MODBUS protocol for data transmission with the host computer.

[0014] Preferably, the bottom of the liquid storage tank is provided with an inclined guide plate, the inclination angle of the guide plate is 5-10°, and the lowest point of the guide plate is provided with a drain port.

[0015] Preferably, the ultrasonic level sensor has a measurement range of 0-5m, a measurement accuracy of ±3mm, and outputs level data via a 4-20mA signal.

[0016] Preferably, the probe of the conductive liquid level switch is made of 316L stainless steel and plated with a ruthenium-iridium alloy layer, and its response time does not exceed 10ms.

[0017] Compared with the prior art, the technical solution provided by this utility model has the following advantages:

[0018] (1) The present invention provides an automatic control device for plating solution level. The microcontroller starts the peristaltic pump through the relay drive circuit. The peristaltic pump starts working and delivers the plating solution in the replenishment tank to the storage tank through the delivery pipe. During the replenishment process, the ultrasonic level sensor continuously monitors the liquid level change and feeds it back to the microcontroller in real time. When the liquid level reaches the preset upper limit value, the microcontroller controls the relay drive circuit to shut down the peristaltic pump and stop replenishment, thereby achieving stable control of the plating solution level within the preset range.

[0019] (2) The present invention provides an automatic control device for plating solution level. The host computer can obtain the operating status, level data, alarm information, etc. of the plating solution level control device in real time. Operators can remotely set the level control parameters, start and stop the equipment, etc. through the host computer, so as to realize remote monitoring and automated integrated control of the plating solution level control device, and improve the efficiency and intelligence level of production management. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of an automatic control device for plating solution level according to the present invention;

[0021] Figure 2 This is a schematic diagram of the anti-splash diffusion head of an automatic plating solution level control device according to the present invention.

[0022] Explanation of the labels in the diagram:

[0023] 100. Liquid storage tank; 110. Plating solution volume chamber; 120. Inclined guide plate; 130. Drain outlet;

[0024] 200. Liquid level detection component; 210. Ultrasonic liquid level sensor; 220. Conductive liquid level switch; 221. High-level probe; 222. Low-level probe;

[0025] 300. Fluid replenishment system; 310. Fluid replenishment tank; 320. Infusion tubing; 330. Peristaltic pump; 340. Splash-proof diffuser head; 350. Stirring device; 351. Drive motor; 352. Stirring paddle. Detailed Implementation

[0026] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0027] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0028] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0029] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0030] Furthermore, the terms "installation," "setup," "equipped with," "connection," "linking," and "socketing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0031] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments. Example

[0032] See attached document Figure 1-2 An automatic plating solution level control device according to this embodiment includes:

[0033] The liquid storage tank 100 is provided with a plating solution receiving cavity inside the liquid storage tank 100;

[0034] The liquid level detection component 200 is installed on the inner wall of the liquid storage tank 100. The liquid level detection component 200 includes an ultrasonic liquid level sensor 210 and a conductive liquid level switch 220. The ultrasonic liquid level sensor 210 is set at the top of the plating solution receiving cavity. The conductive liquid level switch 220 includes a high-level probe 221 and a low-level probe 222, which correspond to the preset highest and lowest liquid levels of the plating solution receiving cavity, respectively.

[0035] The fluid replenishment system 300 includes a fluid replenishment tank 310, an infusion tube 320, and a peristaltic pump 330. The fluid replenishment tank 310 is connected to the storage tank 100 through the infusion tube 320, and the peristaltic pump 330 is installed on the infusion tube 320.

[0036] The control module is electrically connected to the liquid level detection component 200 and the peristaltic pump 330 respectively. The control module includes a microcontroller, a comparator circuit and a relay drive circuit. The comparator circuit compares the detection value of the ultrasonic liquid level sensor 210 with the preset liquid level range. The microcontroller controls the start and stop of the peristaltic pump 330 through the relay drive circuit according to the comparison result.

[0037] An alarm device is connected to the control module and triggers an alarm when the conductive liquid level switch 220 detects an abnormal liquid level.

[0038] In this embodiment, the outlet end of the infusion tube 320 is provided with a splash-proof diffuser head 340, which has an umbrella-shaped structure and a diameter range of 50-80mm.

[0039] In this embodiment, the replenishment tank 310 is equipped with a stirring device 350, which consists of a drive motor 251 and a stirring paddle 352. The surface of the blades of the stirring paddle 352 is coated with a Teflon coating.

[0040] The control module in this embodiment also includes a wireless communication module, which supports the RS485 / MODBUS protocol and is used to transmit data with the host computer.

[0041] In this embodiment, the bottom of the liquid storage tank 100 is provided with an inclined guide plate 120, the inclined angle of the guide plate is 5-10°, and the lowest point of the guide plate is provided with a drain port 130.

[0042] The ultrasonic level sensor 210 in this embodiment has a measurement range of 0-5m and a measurement accuracy of ±3mm. It outputs level data via a 4-20mA signal.

[0043] The probe of the conductive liquid level switch 220 in this embodiment is made of 316L stainless steel and plated with a ruthenium-iridium alloy layer, and its response time is no more than 10ms.

[0044] This plating solution level control device mainly consists of a storage tank 100, a level detection component 200, a replenishment system 300, a control module, and an alarm device.

[0045] Storage Tank 100: The storage tank 100 has an internal plating solution containing cavity for storing the plating solution required for electroplating production. The storage tank 100 is made of PPH reinforced polypropylene, which has excellent corrosion resistance, can adapt to various corrosive plating solution environments, and possesses high strength and toughness. Its wall thickness is set at 8-10mm to ensure the structural stability and durability of the storage tank 100. Furthermore, the bottom of the storage tank 100 is equipped with an inclined guide plate 120 with an inclination angle of 5-10°, and a drain port 130 is located at the lowest point of the guide plate. This design facilitates the discharge and cleaning of the plating solution, allowing for quick and thorough drainage when the plating solution needs to be replaced or the storage tank 100 needs maintenance.

[0046] Liquid level detection component 200: Installed on the inner wall of the liquid storage tank 100, it includes an ultrasonic liquid level sensor 210 and a conductive liquid level switch 220. The ultrasonic liquid level sensor 210 is located at the top of the plating solution containing cavity, using a US-100 sensor with a measurement range of 0-5m and a measurement accuracy of ±3mm. It outputs liquid level data via a 4-20mA signal, enabling real-time and accurate monitoring of changes in the plating solution level. The conductive liquid level switch 220 includes a high-level probe 221 and a low-level probe 222, corresponding to the preset highest and lowest liquid levels in the plating solution containing cavity, respectively. The probes are made of 316L stainless steel with a ruthenium-iridium alloy plating layer, providing excellent corrosion resistance and conductivity. The response time is no more than 10ms. When the liquid level touches the high-level or low-level probe 222, it can quickly generate an electrical signal change to detect abnormal liquid levels.

[0047] The replenishment system 300 consists of a replenishment tank 310, a delivery pipe 320, and a peristaltic pump 330. The replenishment tank 310 stores the plating solution to be replenished, with a volume of 1 / 3 to 1 / 2 that of the storage tank 100. It is made of the same PPH material as the storage tank 100 to ensure consistent corrosion resistance. The replenishment tank 310 is connected to the storage tank 100 via the delivery pipe 320. The outlet end of the delivery pipe 320 is equipped with a splash-proof diffuser 340, which has an umbrella-shaped structure and a diameter of 50-80mm. This diffuser ensures uniform dispersion of the replenished solution, reduces the impact during injection, and prevents the formation of excessive foam. The peristaltic pump 330, a BT100M model, is installed on the delivery pipe 320 and has a flow rate range of 0.006-460ml / min. Precise control of the start / stop and flow rate of the peristaltic pump 330 allows for accurate replenishment of the plating solution in the storage tank 100. In addition, the replenishment tank 310 is equipped with a stirring device 350, which consists of a drive motor 251 and a stirring paddle 352. The blade surface of the stirring paddle 352 is coated with a Teflon coating. During the replenishment process, the drive motor 251 drives the stirring paddle 352 to run at a speed of 50-100 rpm, which can ensure that the composition of the plating solution in the replenishment tank 310 is uniform and prevent the plating solution from settling or separating.

[0048] The control module, electrically connected to the level detection component 200 and the peristaltic pump 330, includes a microcontroller, comparator circuit, relay driver circuit, and wireless communication module. The microcontroller uses an STM32F103 microcontroller with a built-in PID control algorithm and a sampling period of 100ms, enabling fast and accurate processing of level data. The comparator circuit compares the detection value from the ultrasonic level sensor 210 with a preset level range; its hysteresis bandwidth is 5mm, effectively preventing frequent fluctuations in level control. The relay driver circuit uses an SSR solid-state relay with a contact capacity of 10A / 250VAC, controlling the start and stop of the peristaltic pump 330 based on the output signal from the comparator circuit. The wireless communication module supports RS485 / MODBUS protocols for data transmission with a host computer, facilitating remote monitoring and integrated control of automated production lines.

[0049] Alarm device: Connected to the control module, when the conductive liquid level switch 220 detects an abnormal liquid level and the liquid level touches the high-level probe 221 or the low-level probe 222, the control module immediately triggers the alarm device. The alarm device includes an audible and visual alarm with a sound intensity ≥85dB and a light brightness ≥300cd, which can promptly remind operators to take measures to avoid production accidents.

[0050] Working principle:

[0051] Normal liquid level control process: The ultrasonic liquid level sensor 210 continuously monitors the plating solution level in the storage tank 100 in real time and transmits the detected liquid level height signal to the microcontroller in the control module in the form of a 4-20mA current signal. The microcontroller compares the received liquid level signal with the preset upper and lower limits of the liquid level. When the liquid level is lower than the preset lower limit, the microcontroller starts the peristaltic pump 330 through the relay drive circuit. The peristaltic pump 330 starts working and delivers the plating solution in the replenishment tank 310 to the storage tank 100 through the delivery pipe 320. During the replenishment process, the ultrasonic liquid level sensor 210 continuously monitors the liquid level change and feeds it back to the microcontroller in real time. When the liquid level reaches the preset upper limit, the microcontroller controls the relay drive circuit to shut down the peristaltic pump 330 and stop the replenishment, thereby achieving stable control of the plating solution level within the preset range.

[0052] Abnormal Liquid Level Handling Mechanism: The high-level probe 221 and low-level probe 222 of the conductive liquid level switch 220 monitor abnormally high and low levels of the plating solution in the storage tank 100, respectively. When the liquid level rises and touches the high-level probe 221, or falls and touches the low-level probe 222, due to sensor failure, replenishment system 300 failure, or other abnormal reasons, the conductive liquid level switch 220 generates an electrical signal change and transmits this signal to the control module. Upon receiving the abnormal liquid level signal, the control module immediately triggers the alarm device to promptly notify the operator through audible and visual alarms. Simultaneously, the control module cuts off the electroplating power supply to prevent serious consequences such as scrapped plating parts or equipment damage caused by abnormal liquid levels, ensuring the safety of the electroplating production process.

[0053] Uniformity of plating solution replenishment: During the replenishment process, the stirring device 350 inside the replenishment tank 310 plays its role. The drive motor 251 drives the stirring paddle 352 to operate continuously at a speed of 50-100 rpm. The Teflon coating on the surface of the stirring paddle 352 blades has good non-stick properties and chemical stability, which can effectively prevent plating solution adhesion and corrosion. Through the stirring action of the stirring paddle 352, the components of the plating solution in the replenishment tank 310 are uniformly mixed, avoiding solute precipitation or stratification in the plating solution, ensuring that the composition of the plating solution replenished to the storage tank 100 is consistent, thereby maintaining the stability of the electroplating process and the consistency of the plating layer quality.

[0054] System Integration and Remote Monitoring: The wireless communication module in the control module supports RS485 / MODBUS protocols, enabling data communication with the host computer on the automated production line. The host computer can acquire real-time operating status, level data, and alarm information of the plating solution level control device. Operators can remotely set level control parameters and start / stop equipment via the host computer, achieving remote monitoring and automated integrated control of the plating solution level control device, thus improving the efficiency and intelligence level of production management.

[0055] The above-described embodiments are merely illustrative of certain implementations of this utility model, and their descriptions are relatively specific and detailed. However, they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these modifications and improvements all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. An automatic control device for plating solution level, characterized in that: include: A liquid storage tank (100) is provided with a plating solution containing cavity; A liquid level detection component (200) is installed on the inner wall of the liquid storage tank (100). The liquid level detection component (200) includes an ultrasonic liquid level sensor (210) and a conductive liquid level switch (220). The ultrasonic liquid level sensor (210) is located at the top of the plating solution receiving cavity. The conductive liquid level switch (220) includes a high-level probe (221) and a low-level probe (222), which correspond to the preset highest and lowest liquid levels of the plating solution receiving cavity, respectively. The fluid replenishment system (300) includes a fluid replenishment tank (310), an infusion tube (320), and a peristaltic pump (330). The fluid replenishment tank (310) is connected to the storage tank (100) through the infusion tube (320), and the peristaltic pump (330) is installed on the infusion tube (320). The control module is electrically connected to the liquid level detection component (200) and the peristaltic pump (330) respectively. The control module includes a microcontroller, a comparator circuit and a relay drive circuit. The comparator circuit compares the detection value of the ultrasonic liquid level sensor (210) with a preset liquid level range. The microcontroller controls the start and stop of the peristaltic pump (330) through the relay drive circuit according to the comparison result. An alarm device is connected to the control module and triggers an alarm when the conductive liquid level switch (220) detects an abnormal liquid level.

2. The automatic control device for plating solution level according to claim 1, characterized in that, The outlet end of the infusion tube (320) is provided with a splash-proof diffuser (340), which has an umbrella-shaped structure and a diameter range of 50-80mm.

3. The automatic control device for plating solution level according to claim 1, characterized in that, The replenishment tank (310) is equipped with a stirring device (350), which consists of a drive motor (251) and a stirring paddle (352). The surface of the blades of the stirring paddle (352) is coated with a Teflon coating.

4. The automatic control device for plating solution level according to claim 1, characterized in that, The control module also includes a wireless communication module, which supports the RS485 / MODBUS protocol for data transmission with the host computer.

5. The automatic control device for plating solution level according to claim 1, characterized in that, The bottom of the liquid storage tank (100) is provided with an inclined guide plate (120), the inclined angle of the guide plate is 5-10°, and the lowest point of the guide plate is provided with a drain port (130).

6. The automatic control device for plating solution level according to claim 1, characterized in that, The ultrasonic level sensor (210) has a measurement range of 0-5m and a measurement accuracy of ±3mm. It outputs level data through a 4-20mA signal.

7. The automatic control device for plating solution level according to claim 1, characterized in that, The probe of the conductive liquid level switch (220) is made of 316L stainless steel and plated with a ruthenium-iridium alloy layer, and its response time is no more than 10ms.

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