CN-121977295-A - Method and system for controlling heating of treatment tank liquid of electrophoresis drying room

CN121977295ACN 121977295 ACN121977295 ACN 121977295ACN-121977295-A

Abstract

The invention discloses a method and a system for controlling heating of bath liquid in an electrophoresis drying room, and relates to the technical field of coating processes, wherein the method comprises the steps of obtaining internal state parameters of the bath liquid in the electrophoresis drying room, establishing a digital twin body with multiple physical fields of the bath liquid, calculating a momentum and energy transport coupling control equation of the digital twin body, and generating a real-time three-dimensional temperature field-flow field association state space of the whole region of the bath liquid; and based on the optimal fluid migration path for delivering heat to the target correction area, taking the error of uniformity of a three-dimensional temperature field of the whole tank liquid domain as process constraint and the lowest energy consumption cost as a target, establishing a tank liquid heating dynamic optimization model, and obtaining an optimal power set value sequence of each independent partition heating module of the tank liquid. The invention improves the intellectualization of the production process.

Inventors

CHEN ZHIPENG
XU HUA
CHEN HAIWEN

Assignees

安徽捷步工业有限公司

Dates

Publication Date: 20260505
Application Date: 20260408

Claims (10)

1. The method for controlling the heating of the treatment tank liquid of the electrophoresis drying room is characterized by comprising the following steps: s1, acquiring internal state parameters of bath liquid of an electrophoresis drying room, establishing a digital twin body with multiple physical fields of the bath liquid of the electrophoresis drying room, calculating a coupling control equation of momentum and energy transportation in the bath liquid of the electrophoresis drying room, and generating a real-time three-dimensional temperature field-flow field associated state space of the bath liquid of the electrophoresis drying room; s2, based on the obtained real-time three-dimensional temperature field-flow field associated state space of the bath solution domain of the electrophoresis drying room, identifying a deviation area of a fusion process reference range in the current state space, predicting a dynamic evolution track of the deviation area in a future production period, and determining an optimal fluid migration path for conveying heat to a target correction area; And S3, based on determining an optimal fluid migration path for conveying heat to a target correction area, taking the process constraint that the uniformity error of the three-dimensional temperature field of the whole area of the bath solution of the electrophoresis drying room is smaller than a preset threshold value and the minimum cost of the total heating energy consumption as an optimization target, establishing a dynamic optimization model for heating the bath solution of the electrophoresis drying room, and obtaining an optimal power set value sequence of each independent partition heating module of the bath solution of the electrophoresis drying room.
2. The method for controlling the heating of the bath solution in the electrophoresis drying chamber according to claim 1, wherein the step S1 specifically comprises: Based on a sensor network deployed in an electrophoresis drying room, acquiring internal state parameters of the bath liquid of the electrophoresis drying room in real time, and preprocessing data of the internal state parameters to obtain a mapping relation between three-dimensional space coordinates of a bath body of the electrophoresis drying room and the position of the sensor; The internal state parameters comprise conductivity, pH value, solid content, circulating pump flow and pressure; Based on SolidWorks processing software, a three-dimensional solid model of a main tank body, an internal baffle/filter screen, a circulating pipeline, a heater and a workpiece basket frame of the electrophoresis drying room is established, and is imported into grid generating software for unstructured grid division; Based on unstructured grids, discretizing Navier-Stokes momentum equations and energy equations by using a finite volume method, and processing convection terms and diffusion terms of each unstructured grid by using a central differential format.
3. The method for controlling heating of bath solution in an electrophoresis drying chamber according to claim 2, wherein step S1 further comprises: taking the internal state parameters of the bath liquid of the electrophoresis drying room as input, setting an inlet speed boundary condition according to the actually measured flow and pressure data, setting a constant temperature boundary condition for the surface of a heating module to simulate the heating process, and setting an adiabatic boundary condition for the boundary of the bath wall; According to experimental data and literature data of bath liquid in an electrophoresis drying room, establishing a correlation model of physical parameters, conductivity, pH value and solid content of the bath liquid; The physical parameters comprise density, dynamic viscosity, heat conductivity coefficient and specific heat capacity.
4. The method for controlling bath solution heating in an electrophoresis drying chamber according to claim 3, wherein step S1 further comprises: Using a PISO transient pressure base solver to iteratively calculate a discretized Navier-Stokes momentum equation and an energy equation so as to realize pressure-speed coupling between equations; Based on N time steps per propulsion, reading average pH value, solid content and real-time temperature data of a current calculation domain, correlating paired tank liquid physical property parameters with conductivity, pH value and solid content correlation models, updating physical property parameters of each unstructured grid unit in real time, feeding back to a Navier-Stokes momentum equation and an energy equation to calculate a temperature field and a flow field of the next time step, and generating a real-time three-dimensional temperature field-flow field correlation state space of the whole area of the tank liquid of the electrophoresis drying room by continuous iterative updating.
5. The method for controlling bath solution heating in an electrophoresis drying chamber according to claim 4, wherein step S2 specifically comprises: determining a target temperature t and an allowable deviation range of the electrophoresis drying room based on the electrophoresis drying room bath process design requirement file and historical normal production data, and defining a process reference interval; collecting temperature field data of the bath liquid of the electrophoresis drying room during normal production for 3 months, substituting the temperature field data into a real-time three-dimensional temperature field-flow field associated state space of the bath liquid of the electrophoresis drying room by combining internal state parameters of the bath liquid of the electrophoresis drying room, and establishing a mapping relation between the state parameters of the electrophoresis drying room and the temperature fields; And (3) carrying out centering treatment on the state parameters in the bath liquid of the electrophoresis drying room, calculating covariance matrixes of the state parameters, carrying out eigenvalue decomposition on the covariance matrixes of the state parameters to obtain eigenvalues and eigenvalue vectors of the covariance matrixes of the state parameters, selecting main components corresponding to the first k eigenvalues, analyzing the load of the state parameters on the main components, and identifying the key state parameters with the largest contribution degree to the change of the temperature field.
6. The method for controlling bath solution heating in an electrophoresis drying chamber according to claim 5, wherein step S2 further comprises: based on the real-time three-dimensional temperature field-flow field associated state space of the bath liquid domain of the electrophoresis drying room, extracting the temperature value of each unstructured grid at the current moment, comparing the temperature value with a process reference interval, calculating the unit deviation degree of the temperature of each unstructured grid at the current moment and the reference interval, carrying out standardization processing, setting a deviation degree threshold according to the 3 sigma principle of the historical statistical temperature of each unstructured grid, identifying a deviation region fused with the process reference range in the current state space, and establishing an initial deviation region set; and aggregating the space adjacent abnormal grid cells on the initial deviation area set into a continuous abnormal deviation area by using a three-dimensional connected area analysis algorithm.
7. The method for controlling bath solution heating in an electrophoresis drying chamber according to claim 6, wherein step S2 further comprises: Based on the continuous abnormal deviation area, defining an abnormal temperature scalar field of the abnormal deviation area as a temperature difference value of a deviation process reference interval as an abnormal temperature field, taking the current abnormal deviation area as initial distribution of the scalar field, combining with a real-time three-dimensional temperature field-flow field associated state space of a bath solution area of an electrophoresis drying room, calculating a transient convection-diffusion control equation of the abnormal temperature scalar field, carrying out time simulation deduction, extracting the abnormal temperature field at the future moment, identifying and predicting the abnormal deviation area, calculating a centroid migration path of the abnormal deviation area, predicting a dynamic evolution track of a heat accumulation area, drawing an evolution trend graph of the abnormal deviation area, and predicting a dynamic evolution track of the abnormal deviation area in a future production period; Based on an equipment database, acquiring the positions of all heating modules of the bath liquid of the electrophoresis drying room and the real-time heat supply capacity parameters of each heating source, combining the dynamic evolution track of a heat aggregation area, abstracting the communication relation of adjacent grid cells into a network diagram according to an unstructured grid topological structure, and taking the flow resistance among the grid cells as an edge weight; The Dijkstra algorithm is utilized to calculate the minimum accumulated flow resistance path from each unstructured grid cell heating source to the mass center of the abnormal deviation area, and the actual channel inside the equipment is used as a constraint to determine the optimal fluid migration path for conveying heat to the target correction area.
8. The method for controlling the heating of a bath solution in an electrophoresis drying chamber according to claim 7, wherein the step S3 specifically comprises: dividing the bath solution of the electrophoresis drying room into a plurality of independent partitions based on determining an optimal fluid migration path for delivering heat to the target correction area, and setting an independent heating module for each partition; setting a temperature field uniformity threshold f, taking the fact that the error of the uniformity of the three-dimensional temperature field of the whole area of the bath liquid of the electrophoresis drying room is smaller than the threshold as a process constraint, taking the lowest heating total energy consumption cost as an optimization target, and establishing a dynamic optimization model for heating the bath liquid of the electrophoresis drying room.
9. The method for controlling bath solution heating in an electrophoresis drying chamber according to claim 8, wherein step S3 further comprises: Based on the establishment of a dynamic optimization model for heating the bath liquid of the electrophoresis drying room, a plurality of heating power distribution schemes are randomly generated, each set of power scheme is input into a real-time three-dimensional temperature field-flow field associated state space of the bath liquid of the electrophoresis drying room for transient simulation, cross mutation operation is selected, the maximum iteration times are set, the individual with the highest fitness is obtained, the optimal power set value sequence of each independent partition heating module of the bath liquid of the electrophoresis drying room is obtained, and corresponding power values are output.
10. An electrophoresis drying chamber treatment tank liquid heating control system, which is used for realizing the electrophoresis drying chamber treatment tank liquid heating control method according to any one of claims 1-9, and comprises the following steps: a correlation state space module, an optimal fluid migration path module, and an optimal power module; The optimal fluid migration path module is electrically connected with the associated state space module, and the optimal power module is electrically connected with the optimal fluid migration path module and the associated state space module; The association state space module is used for acquiring internal state parameters of the bath liquid of the electrophoresis drying room, establishing a digital twin body with multiple physical fields of the bath liquid of the electrophoresis drying room, calculating a coupling control equation of momentum and energy transportation in the bath liquid of the electrophoresis drying room, and generating a real-time three-dimensional temperature field-flow field association state space of the bath liquid of the electrophoresis drying room; The optimal fluid migration path module is used for identifying a deviation area fusing a process reference range under the current state space based on the obtained real-time three-dimensional temperature field-flow field associated state space of the bath solution domain of the electrophoresis drying room, predicting a dynamic evolution track of the deviation area in a future production period, and determining an optimal fluid migration path for conveying heat to a target correction area; And the optimal power module establishes a dynamic optimal model for heating the bath liquid of the electrophoresis drying chamber based on determining an optimal fluid migration path for conveying heat to a target correction area, taking the process constraint that the uniformity error of the three-dimensional temperature field of the bath liquid of the electrophoresis drying chamber is smaller than a preset threshold and the minimum cost of total heating energy consumption as an optimal target, and obtains an optimal power set value sequence of each independent partition heating module of the bath liquid of the electrophoresis drying chamber.

Description

Method and system for controlling heating of treatment tank liquid of electrophoresis drying room Technical Field The invention relates to the technical field of coating processes, in particular to a method and a system for controlling heating of bath liquid in an electrophoresis drying room. Background In traditional electrophoresis drying room tank liquor heating control, generally, manual experience or a simple temperature control loop is relied on for adjustment, dynamic modeling and analysis capability of a tank liquor internal momentum and energy transport coupling process is lacked, the rough control mode is difficult to sense and predict actual distribution and evolution of a tank liquor three-dimensional temperature field and a flow field in real time, the heat transport path is ambiguous, temperature uniformity is regulated and controlled later, local areas are prone to process deviation, meanwhile, global synergy and energy consumption optimization of a heating process cannot be realized on the premise of meeting uniformity process requirements, and systematic defects of low energy efficiency, poor process stability, insufficient control precision and the like exist. Disclosure of Invention In order to solve the technical problems, the technical scheme provides a method and a system for controlling the heating of the treatment tank liquid of the electrophoresis drying room, and solves the systematic problems of low energy efficiency, poor process stability, insufficient control precision and the like. In order to achieve the above purpose, the invention adopts the following technical scheme: A method and a system for controlling the heating of treatment tank liquid in an electrophoresis drying room comprise the following steps: s1, acquiring internal state parameters of bath liquid of an electrophoresis drying room, establishing a digital twin body with multiple physical fields of the bath liquid of the electrophoresis drying room, calculating a coupling control equation of momentum and energy transportation in the bath liquid of the electrophoresis drying room, and generating a real-time three-dimensional temperature field-flow field associated state space of the bath liquid of the electrophoresis drying room; s2, based on the obtained real-time three-dimensional temperature field-flow field associated state space of the bath solution domain of the electrophoresis drying room, identifying a deviation area of a fusion process reference range in the current state space, predicting a dynamic evolution track of the deviation area in a future production period, and determining an optimal fluid migration path for conveying heat to a target correction area; And S3, based on determining an optimal fluid migration path for conveying heat to a target correction area, taking the process constraint that the uniformity error of the three-dimensional temperature field of the whole area of the bath solution of the electrophoresis drying room is smaller than a preset threshold value and the minimum cost of the total heating energy consumption as an optimization target, establishing a dynamic optimization model for heating the bath solution of the electrophoresis drying room, and obtaining an optimal power set value sequence of each independent partition heating module of the bath solution of the electrophoresis drying room. Preferably, step S1 specifically includes: Based on a sensor network deployed in an electrophoresis drying room, acquiring internal state parameters of the bath liquid of the electrophoresis drying room in real time, and preprocessing data of the internal state parameters to obtain a mapping relation between three-dimensional space coordinates of a bath body of the electrophoresis drying room and the position of the sensor; The internal state parameters comprise conductivity, pH value, solid content, circulating pump flow and pressure; Based on SolidWorks processing software, a three-dimensional solid model of a main tank body, an internal baffle/filter screen, a circulating pipeline, a heater and a workpiece basket frame of the electrophoresis drying room is established, and is imported into grid generating software for unstructured grid division; Based on unstructured grids, discretizing Navier-Stokes momentum equations and energy equations by using a finite volume method, and processing convection terms and diffusion terms of each unstructured grid by using a central differential format. Preferably, step S1 further includes: taking the internal state parameters of the bath liquid of the electrophoresis drying room as input, setting an inlet speed boundary condition according to the actually measured flow and pressure data, setting a constant temperature boundary condition for the surface of a heating module to simulate the heating process, and setting an adiabatic boundary condition for the boundary of the bath wall; According to experimental data and literature data of bath liquid in an