On-line monitoring and feedback system for electroplating production line

Abstract

The utility model provides an online monitoring, feedback system of electroplating production line, main include display screen, controller, sensor, camera, alarm, first timer, automatic regulating device, second timer, third timer and electric contact type emergency stop device. When the sensor monitors and electroplates groove parameter exceeds threshold value and camera discerns no one real -time processing, first timer records data abnormal time, abnormal time reaches first threshold time, and trigger alarm sends the scene sound and light alarm and remote notice, if artificial has not intervened in time, second timer starts automatic regulating device to dynamic repair parameter in the second threshold time after the alarm, when the adjustment is invalid, third timer drives emergency stop device forced shutdown in third threshold time. The system passes the hierarchical response mechanism, effectively blocks the production risk, and promotes the reliability and industrial practicability of electroplating process.

Description

Technical Field

[0001] This utility model relates to the field of electroplating production line monitoring technology, specifically to an online monitoring and feedback system for an electroplating production line. Background Technology

[0002] The online monitoring and feedback system for electroplating production lines is an integrated solution based on sensing technology, data acquisition, and intelligent control. Its core lies in deploying various sensors to monitor key parameters such as electroplating solution composition, tank temperature, current density, deposition rate, and workpiece surface quality in real time. This system, combined with an industrial computer or PLC controller, compares and analyzes the collected data against preset process thresholds. If deviations are detected, it automatically triggers adjustment mechanisms, such as replenishing chemicals, adjusting power output, or modifying conveyor belt speed, thereby achieving dynamic optimization of the production process.

[0003] As shown in the real-time monitoring method, system and storage medium of the electroplating production process disclosed in Chinese Patent (CN118710035B), existing online monitoring and feedback systems are prone to sensor signal drift or misjudgment due to the accumulation of impurities in the plating solution, electrode passivation and fluctuations in ambient temperature and humidity. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a new online monitoring and feedback system for electroplating production lines.

[0005] To achieve the above objectives, the technical solution provided by this utility model is as follows: An online monitoring and feedback system for an electroplating production line includes a display screen electrically connected to a controller, a sensor electrically connected to the controller, the sensor monitoring corresponding data of the electroplating production line, a camera electrically connected to the display screen for monitoring real-time images of the electroplating production line, and an alarm and a first timer electrically connected to the controller. When the sensor detects that the corresponding data exceeds a threshold and the camera detects that no one is handling the data in real time, the first timer records the abnormal data time. When the abnormal data time reaches a first threshold time, the alarm is triggered.

[0006] As a preferred technical solution, the sensor includes at least one of a pH sensor, a temperature sensor, and a humidity sensor.

[0007] As a preferred technical solution, the sensor further includes at least one of a concentration sensor or a liquid level sensor; the concentration sensor is used to monitor the concentration of chemical substances in the electroplating solution, and the liquid level sensor is used to monitor the liquid level height in the electroplating tank.

[0008] As a preferred technical solution, the camera includes multiple high-definition cameras, which are respectively set at different workstations of the electroplating production line. The high-definition cameras are connected to the controller via wired or wireless means for multi-angle real-time image acquisition.

[0009] As a preferred technical solution, the alarm includes an audible and visual alarm and a remote notification module. The audible and visual alarm is installed on the production line site, and the remote notification module is connected to a mobile terminal or a central control system through a communication interface.

[0010] As a preferred technical solution, the controller further includes a data storage unit and a network interface. The data storage unit is electrically connected to the controller and is used to record monitoring data. The network interface supports data transmission with an external server or cloud platform.

[0011] As a preferred technical solution, the controller is also electrically connected to an automatic adjustment device and a second timer. The automatic adjustment device includes a water pump, a chemical dosing tank, and a chemical dosing pump installed in the electroplating production line and connected to the electroplating tank. The second timer starts the automatic adjustment device after a second threshold time following the detection of an alarm triggered by the first timer.

[0012] As a preferred technical solution, the controller is also electrically connected to a third timer and an electrical contact-type emergency stop device. When the third timer detects that the automatic adjustment device has failed to restore the sensor monitoring data to normal within a third threshold time, the automatic adjustment device causes the system to stop suddenly.

[0013] As a preferred technical solution, the first timer is integrated inside the controller and connected to a programmable threshold setting unit, which is used to adjust the threshold for data abnormality time.

[0014] The advantages and beneficial effects of this utility model are as follows: When the sensor data is abnormal and the camera identification is not handled by anyone, the first timer triggers an audible and visual alarm and a remote notification in the online monitoring and feedback system of this utility model; if no human intervention is timely, the second timer starts the automatic adjustment device to dynamically repair the electroplating solution parameters; when the adjustment fails, the third timer drives the electrical contact emergency stop device to force the machine to stop, thus blocking the production risk of the electroplating system, and has both high reliability and industrial applicability. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a circuit connection diagram of this utility model.

[0016] Figure label: 1-Electroplating tank, 2-pH sensor, 3-Temperature sensor, 4-Level sensor, 5-Concentration sensor, 6-Camera, 7-Alarm, 8-Dosing pump, 9-Dosing storage tank, 10-Water pump, 11-Electric contact type emergency stop device. Detailed Implementation

[0017] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solution of this utility model and should not be construed as limiting the scope of protection of this utility model.

[0018] Example 1 This embodiment provides an online monitoring and feedback system for an electroplating production line, including a display screen and a controller electrically connected to it. The controller is also electrically connected to sensors, including: a pH sensor 2 installed in the electroplating tank 1, detecting a normal pH threshold range of 8.5-9.5; a temperature sensor 3 installed on the inner side of the tank wall, monitoring the normal threshold range of the electroplating solution temperature of 25-35℃; a liquid level sensor 4 fixed on the inner side of the electroplating tank, monitoring the normal threshold range of the liquid level height of 80-100cm; and: Two high-definition cameras (model Hikvision DS-2CD2343G0-I) are installed at the workstations above the pre-plating tank and the main plating tank, respectively. They are connected to the controller via Wi-Fi to achieve real-time image capture from multiple angles with a resolution of 1080p.

[0019] The audible and visual alarm 7 (model Siemens SIR1) is placed on the production line site, and the remote notification module is connected to the workshop director's mobile terminal via a 4G module.

[0020] The controller uses a PLC controller (Siemens S7-1200) and integrates a data storage unit (SD card, 64GB capacity) to record monitoring data. The network interface supports uploading data to a cloud platform. The first timer is integrated inside the controller, and the programmable threshold setting unit sets the first threshold time to 5 minutes.

[0021] Assuming an electroplating production line is in operation, and the pH sensor detects a pH value rising to 10.0, while the camera captures an image of the pre-plating tank showing no one handling the situation, the system initiates the following response actions: The first timer begins recording the abnormal data time. When the abnormal time reaches 5 minutes (the first threshold), the controller triggers an alarm: an on-site audible and visual alarm flashes and sounds, and a remote notification module sends an SMS to a mobile terminal. The controller displays the pH data, abnormal time, and camera image in real time on the screen, and the data storage unit records the event log. If personnel arrive to handle the situation within 5 minutes, the system resets; otherwise, only the alarm notification is received, and no further action is taken.

[0022] Example 2 Based on Example 1, the controller is also electrically connected to: a dosing pump (model Grundfos DME), a dosing tank (50L capacity, containing copper sulfate solution), a water pump (model Wilo MHI), and water pipes, which are connected to the inlet pipe of the electroplating tank; a second timer is integrated into the controller, with a second threshold time set to 10 minutes; a third timer and an emergency stop device (model Sick S3000) are installed in the main circuit of the production line, with the third timer set to a third threshold time of 3 minutes. Concentration sensor 5 (model Hach SenSION+) monitors the copper ion concentration in the electroplating solution, and the programmable threshold setting unit of the first timer allows adjustment of the first threshold time (8 minutes) to adapt to different production environments.

[0023] Assume the concentration sensor in the main plating tank detects that the copper ion concentration has dropped to the lower threshold, and the camera detects no one is handling the situation. The system initiates a tiered response: In the first level response, the first timer records the abnormal time and triggers an alarm after 8 minutes; in the second level response, if no intervention occurs within 10 minutes (the second threshold time), the second timer activates the automatic adjustment device, and the dosing pump 8 draws copper sulfate solution from the dosing tank 9 and injects it into the electroplating tank; the water pump 10 adjusts the circulation flow rate within the tank; the controller displays the adjustment progress on the screen in real time; in the third level response, if the concentration does not return to the normal range within 3 minutes (the third threshold time), the controller drives the electrical contact emergency stop device 11 to forcibly stop the machine, cut off the power supply to the production line, and upload a fault report to the cloud platform via the network interface. Throughout the entire process, the data storage unit records the concentration change curve, adjustment actions, and emergency stop events.

[0024] The working principle of this invention is as follows: sensors monitor the parameters of the electroplating tank in real time, while a camera captures the scene. When the sensor detects data exceeding a preset threshold and the camera recognizes no one handling the situation, a first timer starts recording the abnormal time. If the abnormality continues until the first threshold time, the controller triggers an alarm, simultaneously activating an audible and visual alarm and remote notification, enabling rapid response for manual intervention. If no manual intervention is initiated within the second threshold time, a second timer activates an automatic adjustment device to dynamically restore the electroplating solution parameters. If the automatic adjustment fails to restore the data to normal within the third threshold time, a third timer drives an electrical contact-type emergency stop device to forcibly shut down the machine, completely eliminating production risks.

[0025] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. An online monitoring and feedback system for an electroplating production line, comprising a display screen, wherein the display screen is electrically connected to a controller, and the controller is electrically connected to a sensor, characterized in that, The display screen is also electrically connected to a camera, and the controller is also electrically connected to an alarm and a first timer.

2. The online monitoring and feedback system for the electroplating production line according to claim 1, characterized in that, The sensor includes at least one of a pH sensor, a temperature sensor, and a humidity sensor.

3. The online monitoring and feedback system for the electroplating production line according to claim 2, characterized in that, The sensor also includes at least one of a concentration sensor or a liquid level sensor.

4. The online monitoring and feedback system for the electroplating production line according to claim 1, characterized in that, The camera system includes multiple high-definition cameras, which are respectively installed at different workstations on the electroplating production line. The high-definition cameras are connected to the controller via wired or wireless means.

5. The online monitoring and feedback system for the electroplating production line according to claim 1, characterized in that, The alarm system includes an audible and visual alarm and a remote notification module. The audible and visual alarm is installed on the production line site, and the remote notification module is connected to a mobile terminal or a central control system via a communication interface.

6. The online monitoring and feedback system for the electroplating production line according to claim 1, characterized in that, The controller also includes a data storage unit and a network interface, the data storage unit being electrically connected to the controller.

7. The online monitoring and feedback system for the electroplating production line according to claim 1, characterized in that, The controller is also electrically connected to an automatic adjustment device and a second timer. The automatic adjustment device includes a water pump, a chemical dosing tank, and a chemical dosing pump that are installed in the electroplating production line and connected to the electroplating tank.

8. The online monitoring and feedback system for the electroplating production line according to claim 7, characterized in that, The controller is also electrically connected to a third timer and an electrical contact type emergency stop device.

9. The online monitoring and feedback system for the electroplating production line according to claim 8, characterized in that, The first timer is integrated inside the controller and is connected to a programmable threshold setting unit.

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