CN-122013288-A - Intelligent control method and system for nickel plating thickness of diamond wire saw

CN122013288ACN 122013288 ACN122013288 ACN 122013288ACN-122013288-A

Abstract

The invention discloses an intelligent control method and system for the thickness of a nickel plating layer of a diamond wire saw, which relates to the technical field of electroplating control of the diamond wire saw, and comprises the steps of collecting current pulse, wire body displacement and slot liquid thermal imaging multisource sensing data flow of the diamond wire saw, and eliminating the transmission delay difference through space-time alignment to generate a synchronous sampling data set, identifying the axial position and the circumferential angle label, and constructing a process parameter matrix with a spatial index. And outputting an instantaneous deposition rate cloud image by inputting the matrix into a pre-training thickness prediction network, calculating an accumulated thickness deviation field along the length direction, generating a zoned voltage modulation sequence by combining with wire routing path planning, and transmitting to a rectification control unit to finish coating thickness closed-loop adjustment. The method realizes multisource data synchronization and spatial characterization, achieves accurate closed-loop regulation and control through zoned voltage modulation, and improves the coating thickness control effect.

Inventors

LI ZE
HE RONGCHUN
Ma Boshuai

Assignees

宝鸡康控新材料科技有限公司

Dates

Publication Date: 20260512
Application Date: 20260416

Claims (10)

1. An intelligent control method for the thickness of a nickel plating layer of a diamond wire saw is characterized by comprising the following steps: acquiring multi-source sensing data flow in the running process of the diamond wire saw to be controlled, wherein the multi-source sensing data flow covers a current pulse signal, a wire body displacement signal and a tank liquor thermal imaging signal; performing space-time alignment operation on the multi-source sensing data stream, eliminating transmission delay difference, and generating a synchronous sampling data set; Analyzing the synchronous sampling data set, identifying an axial position label and a circumferential angle label of the diamond wire saw to be controlled, and constructing a process parameter matrix with a spatial index; inputting the technological parameter matrix into a pre-trained thickness prediction network, and outputting an instantaneous deposition rate cloud picture of the diamond wire saw to be controlled; Calculating an accumulated thickness deviation field of the diamond wire saw to be controlled along the length direction according to the instantaneous deposition rate cloud picture; Calling the accumulated thickness deviation field, and generating a zoned voltage modulation sequence by combining wire path planning information of the diamond wire saw to be controlled; and sending the zonal voltage modulation sequence to a rectification control unit to finish the closed-loop adjustment of the coating thickness of the diamond wire saw to be controlled.
2. The intelligent control method for the nickel plating thickness of the diamond wire saw according to claim 1, wherein the collecting the multi-source sensing data flow in the operation process of the diamond wire saw to be controlled comprises the following steps: Starting a Hall current sensor array to capture a current pulse signal when the diamond wire saw to be controlled passes through the anode plate; Activating a laser vibration meter to track the surface micro-vibration of the diamond wire saw to be controlled, and generating a wire body displacement signal; starting the thermal infrared imager to scan the surface temperature distribution of the plating solution in the plating tank and output a tank solution thermal imaging signal; Packaging the current pulse signal, the line body displacement signal and the tank liquid thermal imaging signal into an original data packet, and marking an acquisition time stamp; And converging the original data packets through an industrial Ethernet switch to form the multi-source sensing data stream.
3. The intelligent control method of the nickel plating thickness of the diamond wire saw according to claim 2, wherein performing a time-space alignment operation on the multi-source sensing data stream, eliminating a transmission delay difference, generating a synchronous sampling data set, comprises: extracting hardware trigger zone bits of each signal channel in the multi-source sensing data stream; Calculating the delay difference of a transmission link among the current pulse signal, the line body displacement signal and the tank liquid thermal imaging signal; based on the transmission link delay difference, carrying out digital interpolation resampling on the line body displacement signal and the tank liquor thermal imaging signal; performing time axis translation correction on all signals by taking the sampling time of the current pulse signals as a reference; And packaging and reorganizing the corrected signal data according to the uniform time stamp to obtain the synchronous sampling data set.
4. The intelligent control method of the nickel plating thickness of the diamond wire saw according to claim 3, wherein analyzing the synchronous sampling data set, identifying an axial position label and a circumferential angle label of the diamond wire saw to be controlled, and constructing a process parameter matrix with a spatial index comprises: Reading an encoder feedback value in the synchronous sampling data set, and converting to obtain the axial travelling distance of the diamond wire saw to be controlled; Analyzing a high-frequency jitter component in the wire body displacement signal, and demodulating out the rotation phase of the diamond wire saw to be controlled; Mapping the axial travel distance to an axial position tag and the rotational phase to a circumferential angle tag; Correlating the amplitude of the current pulse signal, the frequency of the wire body displacement signal and the temperature value of the tank liquid thermal imaging signal to corresponding axial position labels and circumferential angle labels; And filling null value nodes of the process parameter matrix to form a complete multidimensional array structure.
5. The intelligent control method of the nickel plating thickness of the diamond wire saw according to claim 4, wherein inputting the process parameter matrix into a pre-trained thickness prediction network and outputting the instantaneous deposition rate cloud image of the diamond wire saw to be controlled comprises: loading a neural network weight file stored in an edge computing node, and initializing the thickness prediction network; expanding the technological parameter matrix into a sector data slice according to the circumferential angle label; sequentially feeding the sector data slices into the thickness prediction network for forward reasoning calculation; Extracting a characteristic diagram of a network interlayer, and reducing the characteristic diagram into a two-dimensional grid corresponding to the surface geometry of the diamond wire saw to be controlled; And giving a deposition rate value to each node in the two-dimensional grid, and drawing to obtain the instantaneous deposition rate cloud picture.
6. The intelligent control method of the nickel plating thickness of the diamond wire saw according to claim 5, wherein calculating the cumulative thickness deviation field of the diamond wire saw to be controlled along the length direction according to the instantaneous deposition rate cloud chart comprises: setting a target nominal thickness value of the diamond wire saw to be controlled as a thickness reference plane; Traversing each grid unit of the instantaneous deposition rate cloud image, and calculating a difference value between an actual deposition rate and a target deposition rate; Integrating the difference value by combining the residence time parameter of the diamond wire saw to be controlled to obtain local excessive thickness or excessive thinness; Summarizing integral results of all circumferential grids along the axial direction of the diamond wire saw to be controlled to generate a section average deviation curve; performing spatial domain expansion on the section average deviation curve along the length direction to construct a three-dimensional accumulated thickness deviation field; summarizing integral results of all circumferential grids along the axial direction of the diamond wire saw to be controlled to generate a section average deviation curve, wherein the method comprises the following steps of: Extracting local excessive thickness or excessive thinness of all circumferential grids on any cross section of the diamond wire saw to be controlled; calculating an arithmetic average value of all the local excessive thickness amounts or excessive thinning amounts as an average thickness deviation of the arbitrary cross section; recording an axial coordinate position corresponding to the average thickness deviation; Repeating the steps of extraction, calculation and recording until the full length range of the diamond wire saw to be controlled is traversed; and connecting all axial coordinate positions and the corresponding average thickness deviation points, and drawing to form a continuous section average deviation curve.
7. The intelligent control method of the nickel plating thickness of the diamond wire saw according to claim 6, wherein the step of calling the accumulated thickness deviation field and combining the wire path planning information of the diamond wire saw to be controlled to generate a zone voltage modulation sequence comprises the steps of: Analyzing the wire path planning information to obtain the linear velocity track of the diamond wire saw to be controlled in each electroplating interval; searching abnormal region coordinates with the deviation value exceeding a preset threshold value in the accumulated thickness deviation field; calculating a required current density compensation coefficient aiming at the abnormal region coordinates; dynamically adjusting the application time length of the current density compensation coefficient according to the change rate of the linear velocity track; And encoding the current density compensation coefficient and the application duration into time sequence instructions to form the partition voltage modulation sequence.
8. The intelligent control method of the plating thickness of the diamond wire saw according to claim 7, wherein issuing the zonal voltage modulation sequence to the rectification control unit to complete the closed-loop adjustment of the plating thickness of the diamond wire saw to be controlled comprises: Establishing a communication handshake protocol with the rectification control unit, and verifying the online state of equipment; converting the partition voltage modulation sequence into an analog quantity control signal or a digital pulse width modulation signal; Triggering the rectification control unit to output an adjusted voltage level at the moment when the diamond wire saw to be controlled enters a corresponding electroplating interval; reading back the feedback value of the output current of the rectification control unit in real time, and comparing the feedback value with an expected current value; if the comparison result exceeds the tolerance range, updating the bias parameters of the thickness prediction network, and restarting the adjustment flow of the next period.
9. The intelligent control method of the nickel plating thickness of the diamond wire saw according to claim 8, wherein analyzing the high-frequency jitter component in the wire body displacement signal and demodulating the rotation phase of the diamond wire saw to be controlled comprises: Band-pass filtering is carried out on the linear body displacement signal, and vibration waveforms of specific frequency bands are separated; Detecting zero crossing points of the vibration waveform, and counting the oscillation times in unit time; calculating the surface linear velocity fluctuation period of the diamond wire saw to be controlled according to the oscillation times; phase matching is carried out on the surface linear velocity fluctuation period and a preset wire saw circumference; and outputting the absolute rotation angle of the diamond wire saw to be controlled relative to an initial reference point as the circumferential angle label.
10. An intelligent control system for the thickness of a nickel plating layer of a diamond wire saw, comprising a memory, a processor and a computer program stored in the memory and running on the processor, wherein the processor, when executing the computer program, performs the steps of the intelligent control method for the thickness of a nickel plating layer of a diamond wire saw according to any one of claims 1 to 9.

Description

Intelligent control method and system for nickel plating thickness of diamond wire saw Technical Field The invention belongs to the technical field of electroplating control of diamond wire saw, and particularly relates to an intelligent control method and system for nickel plating thickness of a diamond wire saw. Background In the conventional diamond wire saw nickel plating coating thickness control process, only current pulse signals are collected to serve as core monitoring parameters, simple auxiliary feedback is carried out by matching with wire body displacement signals, the temperature of the groove liquid is detected only by single-point contact, global monitoring is achieved by not introducing thermal imaging signals, multiple types of sensing data are independently collected and transmitted, fixed voltage output is carried out by means of conventional rectifying equipment, the coating thickness detection is achieved in an off-line sampling mode, and real-time regulation and control requirements of continuous electroplating production cannot be adapted. In the existing control scheme, current pulse, line body displacement and tank liquor temperature signal transmission paths are different, natural transmission delay differences exist, time sequence synchronization cannot be achieved for various sensing data, and sampling data cannot accurately correspond to actual operation positions of the diamond wire saw. The technological parameter states corresponding to the axial position and the circumferential angle of the wire saw cannot be identified, the technological parameter lacks spatial index correlation, the deposition state cannot be finely characterized, the instantaneous deposition rate of the surface of the wire saw cannot be obtained in real time, and the thickness deviation of a coating can be continuously accumulated along the length direction of the wire saw. The thickness deviation can not be quantified through the deposition rate cloud picture generated by the prediction model, the voltage regulation can not be combined with the wire routing path planning to execute the partition adaptation regulation and control, the rectification control unit can only execute integral voltage regulation, the differential closed-loop regulation can not be carried out on the thickness deviation of different areas, and the uniformity and regulation and control accuracy of the thickness of the coating are difficult to guarantee. Disclosure of Invention The present invention aims to solve at least one of the technical problems existing in the prior art; Therefore, the invention provides an intelligent control method for the thickness of a nickel plating layer of a diamond wire saw, which comprises the following steps: acquiring multi-source sensing data flow in the running process of the diamond wire saw to be controlled, wherein the multi-source sensing data flow covers a current pulse signal, a wire body displacement signal and a tank liquor thermal imaging signal; performing space-time alignment operation on the multi-source sensing data stream, eliminating transmission delay difference, and generating a synchronous sampling data set; Analyzing the synchronous sampling data set, identifying an axial position label and a circumferential angle label of the diamond wire saw to be controlled, and constructing a process parameter matrix with a spatial index; inputting the technological parameter matrix into a pre-trained thickness prediction network, and outputting an instantaneous deposition rate cloud picture of the diamond wire saw to be controlled; Calculating an accumulated thickness deviation field of the diamond wire saw to be controlled along the length direction according to the instantaneous deposition rate cloud picture; Calling the accumulated thickness deviation field, and generating a zoned voltage modulation sequence by combining wire path planning information of the diamond wire saw to be controlled; and sending the zonal voltage modulation sequence to a rectification control unit to finish the closed-loop adjustment of the coating thickness of the diamond wire saw to be controlled. Further, the collecting the multi-source sensing data flow in the operation process of the diamond wire saw to be controlled comprises the following steps: Starting a Hall current sensor array to capture a current pulse signal when the diamond wire saw to be controlled passes through the anode plate; Activating a laser vibration meter to track the surface micro-vibration of the diamond wire saw to be controlled, and generating a wire body displacement signal; starting the thermal infrared imager to scan the surface temperature distribution of the plating solution in the plating tank and output a tank solution thermal imaging signal; Packaging the current pulse signal, the line body displacement signal and the tank liquid thermal imaging signal into an original data packet, and marking an acquisition time stamp; And