CN-122012911-A - Parameter digital control system and quality tracing method for plate spring heat treatment process

CN122012911ACN 122012911 ACN122012911 ACN 122012911ACN-122012911-A

Abstract

The application discloses a parameter digital control system and a quality tracing method in a leaf spring heat treatment process, wherein the parameter digital control system in the leaf spring heat treatment process comprises the following components: the sensing layer is provided with a plate spring station positioning sensor, a high-temperature-resistant temperature sensor, a high-temperature-resistant stress sensor and a medium atmosphere sensor, and the station positioning sensor is bound with a plate spring unique identifier. According to the application, the temperature change of different parts of the leaf spring can be accurately captured by arranging the layered acquisition high-temperature-resistant temperature sensor on the sensing layer and combining the acquisition frequency of not lower than 10Hz on the surface layer, the core part and the subsurface layer, the multi-parameter coupling analysis model of the edge calculation layer fuses the PID optimization algorithm and the material thermophysical parameter library, and a differential regulation and control instruction can be generated based on the temperature, stress and medium atmosphere parameters acquired in real time, so that the defects of uneven hardness, cracking and the like of the leaf spring due to parameter fluctuation are effectively avoided, and the heat treatment quality stability is remarkably improved.

Inventors

SUN HAIYAN
GAO CHANGLONG
DING YUANLIN
TANG LIHUI
WU BING
WANG LIN
WU FENG
LI JUNTAO

Assignees

安徽红旗弹簧有限公司

Dates

Publication Date: 20260512
Application Date: 20251226

Claims (9)

1. The parameter digital control system of leaf spring heat treatment process, characterized by comprising: The sensing layer is provided with a plate spring station positioning sensor, a high-temperature-resistant temperature sensor, a high-temperature-resistant stress sensor and a medium atmosphere sensor, wherein the station positioning sensor is bound with a plate spring unique identifier and is used for synchronously collecting parameters of the same plate spring in the heating, quenching and tempering processes, the collecting frequency is not lower than 10Hz, the high-temperature-resistant temperature sensor is provided with at least three layers of collecting points along the thickness direction of the section of the plate spring, the distance between the surface layer collecting points and the surface of the plate spring is not more than 1mm, the core collecting point is positioned at 1/2 of the section thickness of the plate spring, and the subsurface collecting point is positioned at the middle position between the surface layer collecting point and the core collecting point; The edge computing layer is in communication connection with the perception layer, a multi-parameter coupling analysis model and a process parameter and quality pre-judging sub-model are built in the edge computing layer, the multi-parameter coupling analysis model fuses a PID optimization algorithm and a plate spring material thermophysical parameter library, a sensor is processed in real time to collect data and generate a dynamic regulation and control instruction, the process parameter and quality pre-judging sub-model establishes an association relation between parameters and plate spring hardness and fatigue strength based on historical traceability data, and a quality pre-evaluation result is output; The execution control layer receives the regulation and control instruction of the edge calculation layer, performs closed-loop control on the heat treatment furnace temperature control unit, the cooling medium circulation unit and the conveyer belt transmission unit, and records leaf spring station information corresponding to each regulation and control action; and the traceability data layer is in bidirectional communication with the edge computing layer, the execution control layer and the quality detection equipment, stores full-flow parameter data, control instruction records, quality pre-evaluation results and leaf spring unique identification associated information in real time, and establishes traceability mapping relation between the parameter data and leaf spring finished product detection data.
2. The system for digitally controlling parameters in a heat treatment process of a leaf spring according to claim 1, wherein the high temperature resistant sensor is a high Wen Fenbu-resistant optical fiber sensor, and at least 5 acquisition points are equidistantly distributed along the length direction of the leaf spring; the high-temperature-resistant stress sensor adopts a high-temperature-resistant piezoelectric sensor; The medium atmosphere parameters comprise quenching medium concentration and tempering furnace oxygen content, and all sensor data carry time stamps and station codes corresponding to the unique identification of the leaf springs.
3. The system for digitally controlling parameters of heat treatment process of leaf spring according to claim 1, wherein the multi-parameter coupling analysis model of the edge calculation layer pre-stores reference curves of heat treatment process of leaf springs with different specifications, the reference curves are dynamically updated in combination with qualified leaf spring parameter intervals in historical traceability data, and update logic satisfies the formula: T new = α×T hist + (1-α)×T norm Wherein, T new is the target temperature value of a certain working procedure stage of the updated reference curve, T hist is the average temperature value of the working procedure stage of the qualified leaf springs with the same specification in the last three months in the historical traceability data, T norm is the initial process specification temperature value, alpha is a weighting coefficient and alpha epsilon [0.3,0.7], and the batch stability of the qualified leaf springs in the historical data is dynamically adjusted; generating differential regulation and control instructions through deviation analysis of real-time acquisition parameters and a reference curve, wherein each regulation and control instruction is associated with a corresponding leaf spring unique identifier and synchronously transmitted to a traceable data layer for storage; The input parameters of the process parameters and the quality pre-judging sub-model comprise real-time temperature fluctuation values, stress change rates and medium atmosphere concentrations.
4. The system for digitally controlling parameters of a heat treatment process of a leaf spring according to claim 1, wherein the traceable data layer comprises a block chain link point module and a quality traceable index library, the block chain node module performs encryption uplink storage on a unique leaf spring identifier, full-flow parameter data and a quality pre-evaluation result, and the unique leaf spring identifier comprises a raw material batch number, a device number and a production timestamp; the quality tracing index library establishes query mapping of the unique identification of the leaf spring, parameters of each working procedure and detection data, and the parameter change and regulation record of any working procedure are traced back through the unique identification.
5. The system for digitally controlling parameters in a heat treatment process of a leaf spring according to claim 1, wherein the execution control layer is further configured with an abnormality early warning unit and a tracing marking unit, when the acquisition parameters exceed a preset threshold value + -5% or the execution of the control instruction fails, the abnormality early warning unit synchronously triggers an audible and visual alarm and a system log record, and the tracing marking unit automatically adds an abnormality mark in tracing data corresponding to the unique identification of the leaf spring, locks parameter data of an abnormality procedure, and is associated with a key verification item of a subsequent quality detection link.
6. The quality tracing method of the leaf spring heat treatment process is applied to the parameter digital control system of the leaf spring heat treatment process as claimed in any one of claims 1 to 5, and is characterized by comprising the following steps: s1) distributing a unique identification code for a leaf spring to be heat-treated, associating raw material batches, equipment parameters and operator information, and recording a quality tracing index library of a tracing data layer; s2) synchronously acquiring temperature, stress and medium atmosphere parameters of plate spring heating, quenching and tempering procedures through a sensing layer sensor, acquiring a time stamp and a station code corresponding to the data carrying unique identification code, and transmitting the time stamp and the station code to an edge calculation layer in real time; s3) the edge calculation layer processes the acquired data through the multi-parameter coupling analysis model, generates a dynamic regulation and control instruction, sends the dynamic regulation and control instruction to the execution control layer to execute closed loop control, outputs a quality pre-evaluation result through the process parameter and quality pre-judgment sub-model, and transmits a unique identification code associated with the regulation and control instruction and the pre-evaluation result to the traceability data layer; s4) the traceability data layer stores acquisition parameters, regulation and control instructions, quality pre-evaluation results and equipment running state data in real time, encrypts a uplink through a block chain link point module and updates the mapping relation of a quality traceability index library; s5) when quality is traced, a unique identification code of the leaf spring is input, the mapping relation of a quality tracing index library is called, full-flow data stored in a block chain is obtained, and a visual tracing report containing parameter trend curves, abnormal event records, regulation action logs and raw material, process and finished product full-link associated information is generated.
7. The quality tracing method of a leaf spring heat treatment process according to claim 6, wherein in step S2, a time stamp synchronization mechanism is adopted for sensor collected data, and the time deviation of the temperature, stress and medium atmosphere parameters corresponding to the same leaf spring unique identifier does not exceed a preset time threshold, wherein the preset time threshold is configured by an edge computing layer according to the precision requirement of the leaf spring heat treatment process; and the station codes are automatically updated along with the plate spring transmission, so that parameters are matched with the working procedure stages; When the high-temperature-resistant temperature sensor is collected in the quenching process, the sampling interval is shortened to 1.5 times of the original frequency.
8. The method for tracing the quality of a heat treatment process of a plate spring according to claim 6, wherein in step S3, the logic for generating the dynamic adjustment command is: when the real-time temperature parameter deviates from the reference curve +/-1 ℃, regulating and controlling the power output of the furnace temperature control unit; When the stress parameter exceeds the threshold value, the flow rate of the cooling medium and the transmission speed of the conveyer belt are synchronously adjusted, and an execution result is fed back to the edge calculation layer after the regulation and control instruction is executed and updated to the traceable data layer.
9. The quality tracing method of a heat treatment process of a plate spring according to claim 6, wherein when the quality detection after the heat treatment of the plate spring is judged to be failed, the following operations are performed: E1 Inputting the unique identification code of the disqualified leaf spring, retrieving the whole-flow process parameter regulation record stored in the traceable data layer and acquiring data of each stage, and positioning the process stage associated with the disqualified index and the corresponding parameter fluctuation interval; E2 Secondary detection is carried out on the unqualified leaf spring, the detection items comprise mechanical performance reinspection and microstructure analysis, and secondary detection data are input into a traceable data layer and are associated with the original process parameters; E3 And if the reworking is judged to be unrepeatable, recording scrapping reasons and corresponding abnormal process parameter types in a traceable data layer, and binding and storing scrapping records and a unique plate spring identification code.

Description

Parameter digital control system and quality tracing method for plate spring heat treatment process Technical Field The invention relates to the technical field of leaf spring production, in particular to a parameter digital control system and a quality tracing method in a leaf spring heat treatment process. Background The plate spring is used as a core bearing component of equipment such as automobiles, engineering machinery and the like, the mechanical properties such as hardness, fatigue strength and deformation resistance of the plate spring directly determine the operation safety and service life of the equipment, and in the heat treatment process, heating, quenching and tempering are key links for regulating and controlling the mechanical properties of the plate spring. In the prior art, parameter control of the leaf spring heat treatment process is mostly dependent on a traditional manual monitoring or simple sensor acquisition mode, namely, a small number of temperature sensors are arranged in a heat treatment furnace body to monitor the environmental temperature in the furnace, and by combining manual timing recording of parameters such as the concentration of a quenching medium, the speed of a conveyor belt and the like, a part of enterprises introduce a basic data storage system for keeping parameter records of key processes, so that a basic basis is provided for subsequent quality inquiry. However, the prior art has the obvious defects that firstly, the parameter acquisition precision is insufficient, the traditional sensor only monitors the environmental temperature of a furnace body, the temperature difference of the section of the leaf spring per se, such as a surface layer and a core part, is not subjected to layered acquisition, the acquisition frequency is low, the instantaneous fluctuation of the temperature of the leaf spring in the quenching stage is difficult to capture, and the association degree between the parameter and the actual performance of the leaf spring is low; the quality tracing closed loop is missing, the existing data storage is used for recording key parameters of qualified leaf springs, complete data association from raw materials to finished products and factories is not formed, only partial link information is recorded sporadically, the data is easy to tamper, when unqualified leaf springs appear, abnormal procedures and sources cannot be positioned quickly, a reworking scheme cannot be generated based on historical data, fourth, an abnormal processing mechanism is imperfect, the situation that the execution of an acquisition parameter exceeds a threshold value or a regulation instruction fails can only be triggered, simple alarm is triggered, abnormal information and a unique identification of the leaf springs are not bound, and subsequent detection links cannot be used for verifying abnormal leaf springs. Therefore, a set of digital control system integrating accurate parameter acquisition, real-time dynamic regulation and control, reliable tracing of a full link and efficient exception handling is needed in the field of current leaf spring heat treatment, so that the problems of rough parameter control, non-closed loop tracing and inefficient exception handling in the prior art are solved, and the stability of the leaf spring heat treatment quality and the production efficiency are improved. Disclosure of Invention The invention aims to provide a parameter digital control system and a quality tracing method for a leaf spring heat treatment process, so as to solve the problems in the existing leaf spring heat treatment process, which are presented in the background art. In order to achieve the above purpose, the invention provides a technical scheme that the parameter digital control system for the heat treatment process of the leaf spring comprises: The sensing layer is provided with a plate spring station positioning sensor, a high-temperature-resistant temperature sensor, a high-temperature-resistant stress sensor and a medium atmosphere sensor, wherein the station positioning sensor is bound with a plate spring unique identifier and is used for synchronously collecting parameters of the same plate spring in the heating, quenching and tempering processes, the collecting frequency is not lower than 10Hz, the high-temperature-resistant temperature sensor is provided with at least three layers of collecting points along the thickness direction of the section of the plate spring, the distance between the surface layer collecting points and the surface of the plate spring is not more than 1mm, the core collecting point is positioned at 1/2 of the section thickness of the plate spring, and the subsurface collecting point is positioned at the middle position between the surface layer collecting point and the core collecting point; The edge computing layer is in communication connection with the perception layer, a multi-parameter coupling analysis model and a process p