CN-121994653-A - On-line monitoring and supplementing control system for activity of green degreasing agent of aluminum substrate

CN121994653ACN 121994653 ACN121994653 ACN 121994653ACN-121994653-A

Abstract

The invention discloses an on-line monitoring and supplementing control system for the activity of an aluminum substrate green degreasing agent, and relates to the technical field of the activity detection of the degreasing agent; the system comprises a constant-temperature bypass sampling and preprocessing module, a multidimensional interface chemical parameter synchronous sensing module, an oil pollution interference decoupling and activity correction calculation module, a bi-component asymmetric differential supplementing module, a tank liquor aging trend prediction and liquid change early warning module and a self-adaptive cleaning and zero point calibration module, wherein the dynamic surface tension spectrogram and scattered light turbidity are collected, the false influence of oil pollution on tension measurement is decoupled by using an interference model, the effective activity index representing the real oil removal capacity of a surfactant is inverted and is independently supplemented with electrolyte conductivity driving components, the predictive liquid change early warning is realized through efficiency attenuation analysis, the problem of misalignment of a traditional monitoring method under the oil pollution interference is solved, the closed-loop management from accurate sensing and intelligent regulation to predictive maintenance is realized, and the process stability and the chemical utilization rate are improved.

Inventors

CHEN DUNFA
MO ZHENYAN
PAN XIAOYING
JIANG CHAOLIN
CHENG GUOPING

Assignees

浙江旗创科技集团有限公司

Dates

Publication Date: 20260508
Application Date: 20260130

Claims (10)

1. An aluminum substrate green degreasing agent activity on-line monitoring and supplementing control system, which is characterized by comprising: The constant-temperature bypass sampling and preprocessing module is configured to draw sampling liquid from the oil removal main tank, perform multistage filtration and thermoelectric coupling temperature control, and output clean laminar flow sampling liquid which is clean and at constant temperature; Synchronously sensing chemical parameters of a multidimensional interface, namely synchronously collecting a dynamic surface tension value, a scattered light turbidity value and an electrolyte conductivity value of the clean laminar flow sample liquid at the constant temperature, wherein the dynamic surface tension value is measured under the preset bubble life; The oil stain interference decoupling and effective activity index calculating module is configured to substitute the scattered light turbidity value into a preset turbidity-tension attenuation interference model, calculate to obtain a surface tension false reduction value caused by oil stain interference, sum the dynamic surface tension value and the surface tension false reduction value to obtain a corrected effective surface tension value, substitute the effective surface tension value into a preset concentration-surface tension standard curve, and invert and calculate to obtain an effective activity index; The two-component asymmetric differential supplementing module is configured to compare the effective activity index with a target concentration of the surfactant component, calculate and supplement the surfactant component when the effective activity index is lower than a first trigger threshold value, and simultaneously compare the electrolyte conductivity value with a target conductivity of the auxiliary component, and calculate and supplement the auxiliary component when the electrolyte conductivity value is lower than a second trigger threshold value; The liquid replacement early warning module is configured to record the accumulated addition amount of the surfactant component, calculate the consumption of unit area by combining the total area of the synchronously processed aluminum substrates, and generate a liquid replacement early warning signal when the consumption of unit area exceeds a preset efficiency attenuation threshold value.
2. The on-line monitoring and replenishment control system for green degreasing agent activity of aluminum substrate as recited in claim 1, wherein the constant temperature bypass sampling and preprocessing module comprises: the constant-current sampling unit is used for stabilizing the flow rate of the extracted sample liquid in a laminar flow range through a constant-current valve; the multi-stage filtering subunit comprises a coarse filter screen and a self-cleaning type precise filter element, and the sample liquid sequentially passes through the coarse filter screen and the self-cleaning type precise filter element to be filtered, so that solid particles are removed, and clean laminar sample liquid is obtained; and when the standard deviation of temperature fluctuation of a plurality of continuous sampling periods is smaller than a set threshold value, judging to enter a state to be measured under the constant temperature, and sending a measurement-allowed trigger signal to a multidimensional interface chemical parameter synchronous sensing module.
3. The on-line monitoring and supplementing control system for the activity of the green degreasing agent of the aluminum substrate as claimed in claim 2, wherein the multidimensional interface chemical parameter synchronous sensing module comprises: The dynamic tension acquisition unit is used for generating a series of bubbles with different service lives by changing the gas flow by adopting a maximum bubble pressure method, measuring the pressure when each bubble is broken, and calculating to obtain a dynamic surface tension value under the service life of the corresponding bubble according to a Laplace equation so as to form a dynamic surface tension spectrogram; the characteristic point extraction unit is used for extracting a tension value under the service life of a specific bubble from the dynamic surface tension spectrogram, defining the tension value as a reference dynamic tension, and transmitting the reference dynamic tension to the oil pollution interference decoupling and activity correction calculation module; The system comprises a turbidity and conductivity cooperative collection unit, a double-component asymmetric differential compensation module and a double-component asymmetric differential compensation module, wherein the turbidity and conductivity cooperative collection unit is used for measuring the turbidity value of a sample liquid by utilizing an infrared scattered light turbidity meter, measuring the conductivity value of the sample liquid by utilizing a quadrupole conductivity electrode, obtaining the scattered light turbidity and the electrolyte conductivity of the clean laminar flow sample liquid, and transmitting the scattered light turbidity to an oil stain interference decoupling and activity correction calculation module.
4. The on-line monitoring and supplementing control system for the activity of the green degreasing agent of the aluminum substrate as claimed in claim 1, wherein the process for obtaining the concentration-surface tension standard curve in the oil stain interference decoupling and effective activity index calculation module comprises the following steps: Preparing a series of clean degreasing agent standard solutions with different concentration gradients by using pure water in a sample preparation process; the data acquisition process is to respectively measure the dynamic surface tension value of each standard solution at the constant temperature; And in the curve fitting process, the concentration of the degreasing agent is taken as an independent variable, the dynamic surface tension value is taken as a dependent variable, a logistic regression or linear regression algorithm is adopted for fitting, the mathematical expression and the coefficient of the concentration-surface tension standard curve are determined, and the concentration-surface tension standard curve is solidified into the operation logic of the controller.
5. The on-line monitoring and supplementing control system for the activity of the green degreasing agent of the aluminum substrate according to claim 1, wherein the acquiring process of the turbidity-tension attenuation interference model in the oil pollution interference decoupling and effective activity index calculating module comprises the following steps: Interfering with the sample preparation process, gradually dripping pollutants into the degreasing agent solution with standard concentration and emulsifying to prepare a series of pollution samples with different oil contents; a synchronous measurement process, in which the scattered light turbidity value and the dynamic surface tension value of each polluted sample are synchronously measured at the constant temperature; a deviation calculating process for calculating the surface tension decreasing amplitude of the dynamic surface tension value of each polluted sample relative to the oil-free standard solution; And in the model construction process, taking a scattered light turbidity value as an independent variable, taking a surface tension drop amplitude as a dependent variable, adopting a least square method to perform polynomial fitting, determining a mathematical expression and a coefficient of a turbidity-tension attenuation interference model, and solidifying the mathematical expression and the coefficient of the turbidity-tension attenuation interference model into an operation logic of a controller.
6. The on-line monitoring and supplementing control system for the activity of an aluminum substrate green degreasing agent as claimed in claim 4, wherein the two-component asymmetric differential supplementing module comprises: A parameter definition subunit for defining a target concentration of the surfactant component, a target conductivity of the adjuvant component, a compensation dead zone and a single compensation maximum limit; The component A supplementing logic unit is used for receiving the effective activity index, comparing the effective activity index with the target concentration to obtain a first comparison value, if the first comparison value is lower than the difference between the target concentration and the supplementing dead zone, calculating the component demand of the surfactant according to the difference and the total volume of the tank liquor, and driving the first metering pump to perform dosing; The component B supplement logic unit is used for receiving the electrolyte conductivity, comparing the electrolyte conductivity with the target conductivity to obtain a second comparison value, if the second comparison value is lower than the difference between the target conductivity and the supplement dead zone, calculating the auxiliary component demand according to the second comparison value, and driving a second metering pump to perform dosing; The cross interlocking control unit is used for monitoring the change of turbidity value when the supplementing is executed, stopping the supplementing immediately if the turbidity is abnormally suddenly increased after the component A is supplemented, and simultaneously ensuring that the supplementing actions of the component A and the component B are staggered on a time axis so as to avoid precipitation caused by overhigh local concentration.
7. The on-line monitoring and supplementing control system for green degreasing agent activity of aluminum substrate as claimed in claim 6, wherein the two-component asymmetric differential supplementing module further comprises: the supplement response checking and efficiency evaluating subunit is used for restarting the measuring process after the set mixing time after the supplement action is executed; And the self-adaptive gain adjustment subunit is used for automatically correcting the proportionality coefficient in the addition algorithm and increasing the next calculated surfactant component demand amount if the recovery rate of the continuous three additions is lower than the preset efficiency threshold value, so as to realize the self-adaptive iteration of the control parameter.
8. The on-line monitoring and supplementing control system for the activity of the green degreasing agent of the aluminum substrate as claimed in claim 6, wherein the tank liquor aging trend prediction and liquor replacement early warning module comprises: The historical data serialization unit is used for recording the accumulated value of the component demand of the surfactant, which is executed by the two-component asymmetric differential supplementing module each time, by taking the production batch as a time axis; the pollution capacity attenuation analysis unit is used for combining the total treatment area of the synchronous aluminum substrate and calculating the oil removal efficiency of the consumption of the unit surfactant; the residual life estimation unit is used for carrying out regression analysis on the turbidity baseline value and predicting a time node when the turbidity reaches a saturation threshold value; And the intelligent decision output unit is used for comprehensively judging that if the oil removal efficiency of the unit surfactant consumption is reduced by the same ratio and exceeds a set threshold or the turbidity is greater than a demulsification limit, a forced liquid change instruction is generated, and a pump is locked and supplemented and an alarm is given.
9. The on-line monitoring and supplementing control system for the activity of the green degreasing agent of the aluminum substrate as claimed in claim 8, wherein the pollution-receiving capacity attenuation analysis unit comprises: The unit consumption calculating subunit is used for obtaining the accumulated addition of the surfactant component demand in the current time window and the total treatment area of the aluminum substrate, dividing the accumulated addition by the total treatment area to obtain the surfactant mass consumed by the aluminum substrate in unit area; And the efficiency attenuation judging subunit is used for taking the mass of the surfactant consumed by the unit area aluminum substrate as a measurement index, and judging that the tank liquor pollution-receiving capacity is reduced and entering an early warning state when the index rises above a set percentage in a same ratio.
10. The aluminum substrate green degreasing agent activity online monitoring and supplementing control system as claimed in claim 1, further comprising: The self-adaptive cleaning and zero point calibration module is configured to perform gas-liquid two-phase cleaning on the sensor after the monitoring period is finished, and measure pure water to generate a zero point drift compensation value for correcting measurement data of the next monitoring period; The self-adaptive cleaning and zero point calibration module comprises: The cleaning triggering subunit is used for triggering a cleaning flow after each measurement task is completed or when the data abnormality is detected; the gas-liquid two-phase cleaning unit is used for controlling the cleaning valve group, alternately injecting pure water and compressed air into the measuring pipeline to form gas-liquid plug flow, and stripping an oil film on the surface of the sensor; A dynamic calibration subunit, configured to measure an actual measurement value of the surface tension of the pure water after the cleaning is completed; The drift compensation subunit is used for comparing the measured value with a standard value, calculating a deviation value, generating a zero drift compensation value, sending the zero drift compensation value to the multidimensional interface chemical parameter synchronous sensing module for data correction if the zero drift compensation value is within an allowable range, and giving an alarm if the zero drift compensation value is beyond the allowable range.

Description

On-line monitoring and supplementing control system for activity of green degreasing agent of aluminum substrate Technical Field The invention belongs to the technical field of oil removing agent activity detection, and particularly relates to an on-line monitoring and supplementing control system for the green oil removing agent activity of an aluminum substrate. Background The surface of the aluminum and aluminum alloy substrate can remain dirt such as lubricating oil, rust-proof oil and the like in the processing process, and the dirt must be removed before subsequent treatment. The traditional oil removing process often uses strong alkali or chemicals containing phosphorus and nitrogen, and has great environmental pollution. In recent years, a "green degreasing agent" composed of a biodegradable surfactant, an organic acid, and an auxiliary agent has been increasingly popularized. The conventional aluminum substrate degreasing process comprises the steps of enabling an aluminum substrate to enter a degreasing tank through a conveyor belt or a lifting appliance and contacting with a degreasing agent at a temperature of 40-60 ℃ in a spraying or dipping mode. The surfactant molecules in the degreasing agent quickly migrate to the oil-liquid interface, rolling oil and rust-proof oil on the surface of the aluminum substrate are peeled off and dispersed into the bath solution through wetting, infiltration, emulsification and solubilization, and then the aluminum substrate enters a washing bath to remove residual medicament. However, as the throughput increases, the accumulated oil and consumed active components in the bath directly affect the efficiency of the physicochemical process. The green degreasing agent is difficult to characterize in activity, the green degreasing agent is mainly used for degreasing by wetting and emulsifying effects of the surfactant instead of simple acid-base corrosion, the traditional pH value or conductivity monitoring cannot truly reflect the residual concentration and activity of the surfactant, 2, oil stain interference is that as production proceeds, dissolved/emulsified oil stains in the bath liquid are increased, the physical properties of the bath liquid are changed, sensor reading drifts and misjudgment is caused, 3, component consumption is uneven, the proportion of oil stain carrying-out amount on the surface of an aluminum substrate and auxiliary agents (such as corrosion inhibitors and pH buffering agents) consumed by chemical reaction is not fixed, and unbalance of the bath liquid components (such as insufficient auxiliary agents due to excessive surfactant or vice versa) is caused by single mother liquor supplement, so that a method capable of resisting oil stain interference, accurately anchoring degreasing activity and achieving fine supplement is urgently needed. Disclosure of Invention (One) solving the technical problems Aiming at the problems in the related art, the invention provides an on-line monitoring and supplementing control system for the activity of an aluminum substrate green degreasing agent, which aims to overcome the technical problems existing in the related art. (II) technical scheme In order to solve the technical problems, the invention is realized by the following technical scheme: the invention provides an on-line monitoring and supplementing control system for the activity of an aluminum substrate green degreasing agent, which comprises the following components: The constant-temperature bypass sampling and preprocessing module is configured to draw sampling liquid from the oil removal main tank, perform multistage filtration and thermoelectric coupling temperature control, and output clean laminar flow sampling liquid which is clean and at constant temperature; Synchronously sensing chemical parameters of a multidimensional interface, namely synchronously collecting a dynamic surface tension value, a scattered light turbidity value and an electrolyte conductivity value of the clean laminar flow sample liquid at the constant temperature, wherein the dynamic surface tension value is measured under the preset bubble life; The oil stain interference decoupling and effective activity index calculating module is configured to substitute the scattered light turbidity value into a preset turbidity-tension attenuation interference model, calculate to obtain a surface tension false reduction value caused by oil stain interference, sum the dynamic surface tension value and the surface tension false reduction value to obtain a corrected effective surface tension value, substitute the effective surface tension value into a preset concentration-surface tension standard curve, and invert and calculate to obtain an effective activity index; The two-component asymmetric differential supplementing module is configured to compare the effective activity index with a target concentration of the surfactant component, calculate and supplement the surfactant comp