A data acquisition control system for a vacuum brazing apparatus

Abstract

The utility model relates to the field of industrial automation, concretely relates to a data acquisition control system of vacuum brazing equipment, data acquisition unit is connected with paperless recorder, is used for receiving and conditioning the signal from vacuum brazing furnace sensor, the data acquisition unit includes controller, signal conditioning module, AD conversion module, protocol conversion module and power module, host computer is connected with data acquisition module unit, is used for processing the signal from data acquisition unit and generates interface parameter. Through the reform on the basis of existing equipment, utilize the data acquisition unit of increasing to process the data collected, need not to improve the whole system, has reduced the reform cost, through the data acquisition unit that sets up can transmit the data from paperless recorder to host computer, carries out data storage through the storage module built -in of host computer, replaces the floppy disk storage of paperless recorder, thereby realized the long -term stable storage of technological parameter.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation, specifically to a data acquisition and control system for a vacuum brazing equipment. Background Technology

[0002] As a core production equipment in the field of arc-extinguishing chamber manufacturing, the performance of the control system of the vacuum brazing furnace directly affects the product quality and production efficiency. Quality and production efficiency are the foundation of an enterprise's survival. Therefore, the advancement and stability of the vacuum brazing furnace control system are of paramount importance to arc-extinguishing chamber manufacturing enterprises.

[0003] However, existing vacuum brazing furnace control systems generally use button control systems and paperless recorders. This technology is far behind modern industrial automation. Although button control systems are simple and intuitive to operate, they are inadequate when faced with complex and ever-changing production processes and parameter adjustments. A large number of operations still need to be completed manually, which not only increases the workload of operators but also reduces efficiency. During long periods of manual operation, human error occurs frequently, which affects product quality and leads to unstable product performance. Large-scale transformation will further increase enterprise costs.

[0004] Paperless recorders, as data recording devices in the production process, are responsible for recording various key data during the operation of vacuum brazing furnaces. However, due to the harsh working environment they operate in, their internal electronic components are prone to damage and frequent malfunctions, increasing maintenance costs and disrupting normal production processes. Furthermore, existing paperless recorders still use floppy disks for data storage. Firstly, floppy disks have limited storage capacity, which can lead to insufficient storage space as production data accumulates, failing to meet the company's long-term data preservation needs. Secondly, floppy disks have slow read / write speeds, consuming significant time and reducing efficiency when rapidly querying and analyzing large amounts of production data. Additionally, floppy disks are susceptible to physical damage and data loss; scratches, dust, and magnetic interference on the disk surface can cause data to be unreadable or lost. Once a floppy disk is damaged or data is lost, historical production data cannot be recovered. Utility Model Content The purpose of this invention is to provide a data acquisition and control system for vacuum brazing equipment to solve problems in the background technology, such as the inability of the system to be automated and the use of floppy disks for storage in paperless recorders.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: This utility model proposes a data acquisition and control system for a vacuum brazing equipment, comprising: Paperless recorder, used to display process parameters of vacuum brazing furnace in real time; A data acquisition unit, connected to a paperless recorder, is used to receive and condition signals from sensors in a vacuum brazing furnace; the data acquisition unit includes a controller, a signal conditioning module, an analog-to-digital conversion module, a protocol conversion module, and a power supply module; The host computer, connected to the data acquisition module, is used to process signals from the data acquisition unit and generate interface parameters.

[0006] As a further improvement, the data acquisition unit includes at least four analog input channels.

[0007] As a further improvement, the signal conditioning module includes at least one operational amplifier.

[0008] As a further improvement, the power supply module is 220V AC.

[0009] As a further improvement, the protocol conversion module supports one of the following protocols: TCP / IP, RS-485, and CAN bus.

[0010] As a further improvement, the host computer and the data acquisition unit are connected via an RS-485 bus.

[0011] As a further improvement, the host computer is also connected to the mobile terminal via a communication module.

[0012] As a further improvement, the process parameters include pressure, temperature, low vacuum, and high vacuum.

[0013] As a further improvement, the host computer is also equipped with a storage module for long-term storage of historical data on temperature, pressure and vacuum, and supports querying and exporting process curves.

[0014] As a further improvement, an isolation converter is also provided between the host computer and the data acquisition unit.

[0015] Compared with the prior art, this utility model achieves the following technical effects: This invention modifies existing equipment by adding a data acquisition unit to process the acquired data, eliminating the need to modify the entire system and reducing modification costs. The data acquisition unit transmits data from the paperless recorder to a host computer, where it stores the data using a built-in storage module, replacing the floppy disk storage of the paperless recorder and thus achieving long-term stable storage of process parameters.

[0016] This utility model's data acquisition unit supports parallel acquisition of signals from multiple sensors. Through a signal conditioning module, the raw signals are filtered and amplified. Combined with a high-precision analog-to-digital converter, noise interference is effectively reduced, ensuring the accuracy of the acquired data and meeting the real-time monitoring needs of complex process parameters.

[0017] This utility model integrates a human-machine interface into the host computer, which intuitively displays the changing trends of parameters such as temperature, pressure, and vacuum in a graphical manner, simplifying the operation process and achieving automation compared to traditional button control systems. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the data acquisition unit structure of this utility model.

[0019] Reference numerals in the attached diagram: 1. Data acquisition unit; 2. Paperless recorder; 3. Host computer; 4. Controller; 5. Signal conditioning module; 6. Analog-to-digital conversion module; 7. Protocol conversion module; 8. Power supply module; 9. Isolation converter. Detailed Implementation

[0020] The embodiments of this application are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application. Rather, the embodiments of this application include all variations, modifications, and equivalents falling within the spirit and scope of the appended claims.

[0021] Vacuum brazing technology is widely used in aerospace, electronic device manufacturing, and other fields. The process parameters of the vacuum brazing furnace (such as temperature, pressure, and vacuum level) directly affect product quality. Traditional control systems rely on manual operation and floppy disk storage of paperless recorders, resulting in low efficiency and easy data loss. This invention proposes a data acquisition and control system for vacuum brazing equipment, which realizes real-time acquisition, processing, storage, and remote monitoring of process parameters, significantly improving production efficiency and data security.

[0022] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0023] like Figure 1 As shown, the paperless recorder 2 is used to display the process parameters of the vacuum brazing furnace in real time; the data acquisition unit 1 is connected to the paperless recorder 2 and is used to receive and condition signals from the sensors of the vacuum brazing furnace; the data acquisition unit 1 includes a controller 4, a signal conditioning module 5, an analog-to-digital conversion module 6, a protocol conversion module 7, and a power supply module 8; the host computer 3 is connected to the data acquisition unit and is used to process the signals from the data acquisition unit 1 and generate interface parameters.

[0024] In this embodiment, the system consists of the following components: a paperless recorder 2, a data acquisition unit 1, and a host computer 3. The entire system utilizes a modular design to achieve sensor signal acquisition, data processing and storage, and human-computer interaction functions. The following are detailed implementation methods for each part: In this embodiment, the paperless recorder 2, as part of the prior art, displays the process parameters of the vacuum brazing furnace in real time. Each analog input channel corresponds to a pressure signal, a temperature signal, a low vacuum signal, and a high vacuum signal, respectively. Its built-in LCD screen can display real-time parameters, including pressure, temperature, low vacuum, and high vacuum. In this embodiment, the paperless recorder 2 actually serves as the signal source of the data acquisition unit 1, transmitting sensor signals to the data acquisition unit 1.

[0025] In this embodiment, the data acquisition unit 1 consists of a controller 4, a signal conditioning module 5, an analog-to-digital conversion module 6, a protocol conversion module 7, and a power supply module 8. The controller 4 preferably uses a Siemens S7-1200 series PLC (ARM Cortex-M4 core, 1.2 GHz), which supports multi-task parallel processing and is responsible for coordinating the work of each module, including issuing signal acquisition commands, data buffering, and protocol encapsulation.

[0026] In the embodiment, the signal conditioning module 5 preferably consists of two operational amplifiers, each corresponding to a different operational amplifier. The operational amplifier is preferably an AD8221ARZ amplifier, with four channels corresponding to the four analog input channels. The filtering circuit in this embodiment uses a second-order Butterworth low-pass filter with a cutoff frequency set to 10Hz. The signal conditioning module 5 can amplify, filter, and linearize the original signal.

[0027] The preferred model of the analog-to-digital converter module 6 in the embodiment is ADS1256IDBR, which has a sampling rate of 30kSPS and is used to convert the conditioned analog signal into a digital signal.

[0028] The protocol conversion module 7 in this embodiment can be any one of TCP / IP protocol, RS-485 protocol and CAN bus protocol. In this embodiment, RS-485 protocol is preferred. Therefore, the protocol conversion module 7 is a MAX3485ESA+ chip with a transmission rate between 10 and 12 Mbps.

[0029] The power module 8 in this embodiment can provide a stable power supply for the data acquisition unit 1. It is preferably an LRS-200-24 switching power supply with an input of 220V AC, an output of 24V DC, and a power of 200W.

[0030] In this embodiment, the host computer 3 is preferably an Advantech UNO-2484G industrial control computer, equipped with an Intel Core i5 processor and pre-installed with self-developed data acquisition and monitoring software, capable of processing data from the data acquisition unit 1 in real time. The storage module in the host computer 3 is a Seagate series mechanical hard drive, which supports long-term storage of historical data on temperature, pressure, and vacuum, and the data is saved in CSV database format. The human-machine interface is developed using WinCC Professional V16 and is divided into three main functional areas: a real-time monitoring area that can dynamically display the changing trends of temperature, pressure, and vacuum in curves or other forms (such as temperature-time, pressure-vacuum curves); a parameter setting area that supports setting parameters such as the preset heating rate, holding time, and vacuum degree based on the process curve; and an alarm management area for preset parameters, triggering audible and visual alarms based on the preset parameters and recording them, while also supporting historical data query and export.

[0031] The communication module in this embodiment is a 4G module, which supports remote connection with mobile devices such as mobile phones and tablets, enabling remote monitoring outside the workshop. Staff can monitor real-time parameters or receive alarm push notifications through a mobile APP.

[0032] This application connects multiple sensors installed in a vacuum brazing furnace to a paperless recorder 2 via shielded cables. The input terminal of the signal conditioning module 5 in the data acquisition unit 1 is connected to the output terminal of the paperless recorder 2. The analog-to-digital conversion module 6 communicates with the controller 4 via an SPI interface. The protocol conversion module 7 is connected to the port of the host computer 3 via an RS485 bus. The host computer 3 receives data packets from the data acquisition unit 1.

[0033] In this application, an isolation converter 9 is also provided between the host computer 3 and the data acquisition unit 1. The isolation converter 9 is model ADUM5401 and integrates a TVS tube and a common mode choke. Since there are high-power motor start-up and shutdown, arc discharge and other working conditions in the vacuum furnace, the isolation converter 9 can protect the safety of the host computer 3.

[0034] In addition, the common-mode choke can reduce the bit error rate during data transmission and ensure the integrity of signal transmission.

[0035] In use, multiple sensors detect the process parameter signals of the vacuum brazing furnace in real time. After preliminary processing by the paperless recorder 2, the signals are output as current signals. The signal conditioning module 5 amplifies and filters the current signals, and then converts the processed signals into digital data through the analog-to-digital converter module 6. The controller 4 uploads the digital data to the host computer 3 via the RS-485 bus. The host computer 3 analyzes the data and displays the data parameter curves through the human-machine interface.

[0036] This device was specifically applied in the company's horizontal rapid cooling vacuum brazing furnace manufactured by Seven Stars Technology. Compared with traditional systems, it improved production efficiency and further enhanced product performance stability.

[0037] It should be noted that in the description of this application, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, in the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0038] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing a particular logical function or process, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the function involved, as will be understood by those skilled in the art to which embodiments of this application pertain.

[0039] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0040] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A data acquisition control system for a vacuum brazing apparatus, characterized by, include: Paperless recorder, used to display process parameters of vacuum brazing furnace in real time; A data acquisition unit, connected to a paperless recorder, is used to receive and condition signals from sensors in a vacuum brazing furnace; the data acquisition unit includes a controller, a signal conditioning module, an analog-to-digital conversion module, a protocol conversion module, and a power supply module; The host computer, connected to the data acquisition module, is used to process signals from the data acquisition unit and generate interface parameters.

2. The data acquisition and control system for a vacuum brazing apparatus of claim 1, wherein, The data acquisition unit includes at least four analog input channels.

3. The data acquisition and control system for a vacuum brazing apparatus of claim 1, wherein, The signal conditioning module includes at least one operational amplifier.

4. The data acquisition and control system for a vacuum brazing equipment according to claim 3, characterized in that, The power module is powered by 220V AC.

5. The data acquisition and control system for a vacuum brazing equipment according to claim 1, characterized in that, The protocol conversion module supports one of the following protocols: TCP / IP, RS-485, and CAN bus.

6. The data acquisition and control system for a vacuum brazing equipment according to claim 1, characterized in that, The host computer and the data acquisition unit are connected via an RS-485 bus.

7. The data acquisition and control system for a vacuum brazing equipment according to claim 1, characterized in that, The host computer is also connected to the mobile terminal via a communication module.

8. The data acquisition and control system for a vacuum brazing equipment according to claim 1, characterized in that, The process parameters include pressure, temperature, low vacuum, and high vacuum.

9. The data acquisition and control system for a vacuum brazing equipment according to claim 1, characterized in that, The host computer is also equipped with a storage module for long-term storage of historical data on temperature, pressure and vacuum, and supports querying and exporting process curves.

10. The data acquisition and control system for a vacuum brazing equipment according to claim 1, characterized in that, An isolation converter is also provided between the host computer and the data acquisition unit.

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