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CN-122018283-A - Wire rod baking finish control method and system

CN122018283ACN 122018283 ACN122018283 ACN 122018283ACN-122018283-A

Abstract

The application provides a wire rod paint baking control method and system, which relate to the technical field of control and have the technical scheme that basic parameters of a wire rod to be painted are obtained, database matching is invoked to obtain paint baking process parameters, the basic parameters comprise wire rod materials, wire rod diameters, paint film preset thickness and paint types, the paint baking process parameters comprise temperature of each partition of a paint baking furnace, hot air circulation speed, wire rod conveying speed and paint baking time, wire rod paint baking is implemented according to the paint baking process parameters, and dynamic parameters in the paint baking process are acquired in real time. The wire rod baking finish control method and system provided by the application have the advantages of accurately adapting to an initial process to reduce quality fluctuation, improving process control efficiency through grading risk control and grading correction, and guaranteeing the quality integrity of a paint film by means of grading cooling and stress control.

Inventors

  • DENG GUANGHONG
  • Deng Ruihan

Assignees

  • 佛山市三水金得力实业有限公司

Dates

Publication Date
20260512
Application Date
20260205

Claims (10)

  1. 1. A wire rod varnish baking control method, characterized in that the method comprises the following steps: The method comprises the steps of obtaining basic parameters of wires to be lacquered, calling a database to match to obtain lacquering process parameters, wherein the basic parameters comprise wire materials, wire diameters, preset thickness of a paint film and paint types, and the lacquering process parameters comprise temperatures of all partitions of a lacquering furnace, hot air circulation speed, wire conveying speed and lacquering duration; Carrying out wire rod baking finish according to baking finish technological parameters, and collecting dynamic parameters in the baking finish process in real time, wherein the dynamic parameters comprise real-time temperature of each partition in a baking finish furnace, atmosphere humidity of each partition, real-time temperature of wire rod surface, curing progress of a paint film and real-time speed of wire rod transmission; Inputting the basic parameters and the dynamic parameters into a baking finish quality pre-judging model, and outputting a pre-judging result of the baking finish quality, wherein the pre-judging result comprises an adhesion level pre-judging value, a thickness uniformity pre-judging value and a corrosion resistance pre-judging value; analyzing the deviation between the prejudging result and a preset quality standard, and dynamically correcting the baking finish process parameters through an improved fuzzy PID algorithm, wherein the preset quality standard comprises an adhesion level standard value, a thickness uniformity standard value and a corrosion resistance standard value; Collecting the cooling temperature of the surface of the solidified wire rod in real time, and dynamically adjusting cooling parameters according to a preset cooling curve, wherein the cooling parameters comprise the flow and the temperature of a cooling medium; and (3) detecting the baking finish quality qualification rate of the cooled finished product, when the qualification rate is 100%, associating and storing data and updating a database, and when the qualification rate is less than 100%, generating a process optimization suggestion and iterating a baking finish quality pre-judging model.
  2. 2. The wire rod varnish control method as recited in claim 1, wherein after the step of obtaining basic parameters of the wire rod to be varnished, before the step of performing wire rod varnish baking according to varnish baking process parameters, further comprises: Detecting the painting uniformity of the surface of the wire rod before entering the oven and judging whether a preset uniformity threshold value is reached; when the painting uniformity does not reach a preset uniformity threshold, generating a painting correction signal and feeding back to the front painting process, and simultaneously suspending paint baking feeding; S103, when the paint uniformity reaches a preset uniformity threshold, starting a subsequent paint baking process.
  3. 3. The wire rod paint baking control method according to claim 2, wherein the step of inputting the basic parameter and the dynamic parameter into the paint baking quality pre-judging model and outputting the pre-judging result of the paint baking quality further comprises: Detecting whether a pre-judging result exceeds a pre-judging abnormal early warning threshold of a baking finish quality pre-judging model, wherein the pre-judging abnormal early warning threshold is set according to basic parameters and dynamic parameters; When the deviation value of the continuous 5 groups of prejudging results and the actual spot check results exceeds a preset threshold, automatically triggering a re-training process of the baking finish quality prejudging model, and synchronously outputting an early warning signal to prompt a worker to check a data acquisition link.
  4. 4. The wire rod paint control method of claim 3, wherein the step of automatically triggering the paint quality pre-determined model retraining process when the deviation value of the continuous 5 sets of pre-determined results from the actual spot check results exceeds a preset threshold value further comprises: collecting historical basic parameters and historical dynamic parameters as input samples, collecting corresponding finished product baking finish quality detection results as label samples, and training a baking finish quality pre-judging model by adopting a CNN-LSTM hybrid neural network; in the training process, parameters of the baking varnish quality pre-judging model are optimized through a cross verification method, so that the pre-judging accuracy of the baking varnish quality pre-judging model is ensured.
  5. 5. The wire rod paint baking control method of claim 4 wherein the step of analyzing the deviation of the pre-determined result from the pre-set quality standard and dynamically modifying the paint baking process parameters by means of a modified fuzzy PID algorithm further comprises: According to the prejudgment result and the dynamic parameter analysis, calculating the influence factors of each dynamic parameter on the deviation of different quality indexes, wherein the formula is as follows: ; Wherein F i,j is the influence factor of the j-th dynamic parameter on the i-th quality index deviation, deltaQ j is the pre-judgment deviation value of the i-th quality index, namely the deviation of the pre-judgment result and the preset quality standard, D j is the real-time acquisition value of the j-th dynamic parameter, and the quality index is the adhesive force grade, thickness uniformity and corrosion resistance; establishing a baking finish quality risk grading standard according to the influence factors, namely, ranking a single quality index deviation value which is less than or equal to 1% and no high influence factor (F i,j is more than or equal to 0.6) dynamic parameter as low risk, ranking a single quality index deviation value which is 1% -3% or 1 high influence factor dynamic parameter as medium risk, ranking any quality index deviation value which is more than 3% or 2 or more high influence factor dynamic parameters as high risk; the method comprises the steps of outputting grading response instructions according to baking finish quality risk grading standards, outputting conventional correction instructions and simplified version analysis reports only comprising deviation values when the risks are low, outputting reinforced correction instructions and complete version analysis reports comprising deviation values and influence factor ordering when the risks are medium, outputting emergency correction instructions, complete version analysis reports and acquisition abnormality investigation suggestions of high influence factor dynamic parameters when the risks are high, and suspending feeding and rechecking.
  6. 6. The wire rod varnish control method as recited in claim 5, wherein the step of outputting a classification response command according to a varnish quality risk classification criterion further comprises: According to the grading response instruction and the corresponding influence factors, taking the corresponding prejudgement result, the deviation of the preset quality standard and the deviation change rate as core input of the fuzzy controller, and simultaneously adapting the correction strength by combining the grading response instruction, wherein the conventional correction step length is adopted when the conventional correction instruction is combined, the correction step length is increased by 1.2-1.5 times when the correction instruction is intensified, and the preliminary correction is firstly carried out according to the maximum safety step length when the emergency correction instruction is carried out; and (3) obtaining correction amounts of a proportional coefficient, an integral coefficient and a differential coefficient of the PID controller through fuzzy rule reasoning, and dynamically adjusting initial PID parameters to realize accurate correction of the baking finish process parameters.
  7. 7. The wire rod varnish control method as recited in claim 6, wherein the step of collecting the solidified wire rod surface cooling temperature in real time and dynamically adjusting the cooling parameters according to a preset cooling curve further comprises: Setting a grading adaptation rule of a preset cooling curve based on basic parameters of wires to be lacquered, and constructing the preset cooling curve according to the grading adaptation rule, wherein a rapid cooling mode is adopted in the initial cooling stage, and the cooling rate is controlled to be 5-8 ℃ per second; Setting a cooling stop judging condition and collecting the surface temperature of the wire rod in real time, namely stopping cooling and recording all parameters of the complete cooling process when the surface temperature of the wire rod is reduced to the room temperature of +/-5 ℃.
  8. 8. The wire rod varnish control method as recited in claim 7, wherein after the step of setting a hierarchical adaptation rule of a preset cooling curve based on a basic parameter of the wire rod to be varnish-baked and constructing the preset cooling curve according to the hierarchical adaptation rule, the step of setting a cooling stop judgment condition and collecting the surface temperature of the wire rod in real time further comprises: presetting two cooling mediums with different cooling modes according to basic parameters of wires to be lacquered, wherein the two cooling mediums comprise an air cooling medium with a rapid cooling mode and an inert gas cooling medium with a slow cooling mode, and simultaneously presetting an adaptive temperature interval and a switching judgment condition of each cooling medium; acquiring the surface temperature of the wire rod in the cooling process in real time, comparing the surface temperature with the adaptive temperature interval and the switching judgment condition of each cooling medium, and synchronously acquiring the inlet and outlet temperature of the cooling medium, the temperature and humidity of the cooling environment and the real-time speed of wire rod transmission to form a multidimensional dynamic parameter set in the cooling process; when the surface temperature of the wire rod is reduced from a rapid cooling mode to a slow cooling mode threshold value, automatically triggering a cooling medium switching process, synchronously starting a cooling medium blowing and replacing program, ensuring that no residual air cooling medium exists in a cooling channel, and starting inert gas cooling medium supply after replacement is completed; after the cooling medium is switched, based on a multidimensional dynamic parameter set in the cooling process, the supply pressure, temperature and flow of the inert gas cooling medium are synchronously regulated through an improved PID cooperative control algorithm, so that the cooling rate of the wire is stably maintained in a target interval, and the surface stress value of a paint film is synchronously monitored in real time; When the stress value exceeds a preset safety threshold, dynamically fine-tuning the temperature of the inert gas cooling medium, wherein the fine-tuning amplitude is +/-2 ℃, until the stress value is lower than the preset safety threshold.
  9. 9. The wire rod paint control method of claim 8, wherein the step of generating a process optimization suggestion and iterating a paint quality pre-determined model when the yield is <100% further comprises: acquiring specific parameters of the unqualified finished product, analyzing unqualified factors and generating an adjustment direction and an adjustment amplitude of the specific parameters; when the disqualified factor is insufficient paint film adhesion, the generated process optimization proposal is to increase the temperature of a curing area of a paint baking furnace by 5-10 ℃ and prolong the curing time by 10-20s; when the disqualified factors are uneven thickness of the paint film, the generated process optimization proposal is to adjust the hot air circulation speed to +/-0.5 m/s and correct the wire conveying speed to +/-0.2 m/min.
  10. 10. A wire enamel control system, the system comprising: the first acquisition module (201) is used for acquiring basic parameters of wires to be lacquered, and calling a database to match to obtain lacquering process parameters, wherein the basic parameters comprise wire materials, wire diameters, preset thickness of a lacquer film and lacquer types, and the lacquering process parameters comprise temperatures of all partitions of a lacquering furnace, hot air circulation speed, wire conveying speed and lacquering duration; the first control module (202) is used for implementing wire rod baking finish according to baking finish technological parameters and collecting dynamic parameters in the baking finish process in real time, wherein the dynamic parameters comprise real-time temperature of each partition in a baking finish furnace, atmosphere humidity of each partition, real-time temperature of wire rod surface, curing progress of a paint film and real-time speed of wire rod transmission; The second control module (203) is used for inputting the basic parameters and the dynamic parameters into a baking finish quality pre-judging model and outputting a pre-judging result of the baking finish quality, wherein the pre-judging result comprises an adhesion level pre-judging value, a thickness uniformity pre-judging value and a corrosion resistance pre-judging value; The third control module (204) is used for analyzing the deviation between the prejudging result and a preset quality standard, and dynamically correcting the baking finish process parameters through an improved fuzzy PID algorithm, wherein the preset quality standard comprises an adhesive force grade standard value, a thickness uniformity standard value and a corrosion resistance standard value; The fourth control module (205) is used for collecting the cooling temperature of the surface of the solidified wire rod in real time and dynamically adjusting cooling parameters according to a preset cooling curve, wherein the cooling parameters comprise the flow and the temperature of a cooling medium; And a fifth control module (206) for detecting the baking finish quality qualification rate of the cooled finished product, storing data in a correlated way and updating a database when the qualification rate is 100%, and generating a process optimization suggestion and iterating a baking finish quality prejudging model when the qualification rate is less than 100%.

Description

Wire rod baking finish control method and system Technical Field The application relates to the technical field of control, in particular to a wire rod baking finish control method and system. Background In the processing of enameled wire metal wires, the procedures of coarse wire drawing, fine wire painting, baking varnish, coating liquid and wire winding exist, wire baking varnish is a key procedure in the production of products such as wires, cables, metal components and the like, and the adhesive force, thickness uniformity and corrosion resistance of a paint film directly determine the service performance and service life of the wires. The existing wire rod baking finish control method in the industry has the following defects: 1. the process parameter matching is extensive, namely, the baking finish process parameter is selected by relying on manual experience, and the basic parameters such as material quality, diameter and the like of the non-bonded wire material are accurately matched, so that the process is not matched with the wire material characteristics, and the quality fluctuation of a paint film is easy to occur; 2. The process correction lacks pertinence, namely, the parameter adjustment mostly adopts a single threshold strategy, the influence degree of dynamic parameters on quality deviation is not quantized, and the problems of excessive correction or insufficient correction are easy to occur; 3. The cooling process is unreasonable, and a single cooling medium and a fixed cooling rate are adopted, so that the stress concentration and cracking of a paint film are easily caused by improper cooling, and the adhesive force and the integrity are reduced. In view of the above problems, no effective technical solution is currently available. Disclosure of Invention The application aims to provide a wire rod baking finish control method and system, which have the advantages of accurately adapting to an initial process to reduce quality fluctuation, improving process control efficiency through grading risk management and grading correction, and guaranteeing quality integrity of a paint film by means of grading cooling and stress control. In a first aspect, the present application provides a wire rod varnish baking control method, the method comprising the steps of: The method comprises the steps of obtaining basic parameters of wires to be lacquered, calling a database to match to obtain lacquering process parameters, wherein the basic parameters comprise wire materials, wire diameters, preset thickness of a paint film and paint types, and the lacquering process parameters comprise temperatures of all partitions of a lacquering furnace, hot air circulation speed, wire conveying speed and lacquering duration; Carrying out wire rod baking finish according to baking finish technological parameters, and collecting dynamic parameters in the baking finish process in real time, wherein the dynamic parameters comprise real-time temperature of each partition in a baking finish furnace, atmosphere humidity of each partition, real-time temperature of wire rod surface, curing progress of a paint film and real-time speed of wire rod transmission; Inputting the basic parameters and the dynamic parameters into a baking finish quality pre-judging model, and outputting a pre-judging result of the baking finish quality, wherein the pre-judging result comprises an adhesion level pre-judging value, a thickness uniformity pre-judging value and a corrosion resistance pre-judging value; analyzing the deviation between the prejudging result and a preset quality standard, and dynamically correcting the baking finish process parameters through an improved fuzzy PID algorithm, wherein the preset quality standard comprises an adhesion level standard value, a thickness uniformity standard value and a corrosion resistance standard value; Collecting the cooling temperature of the surface of the solidified wire rod in real time, and dynamically adjusting cooling parameters according to a preset cooling curve, wherein the cooling parameters comprise the flow and the temperature of a cooling medium; and (3) detecting the baking finish quality qualification rate of the cooled finished product, when the qualification rate is 100%, associating and storing data and updating a database, and when the qualification rate is less than 100%, generating a process optimization suggestion and iterating a baking finish quality pre-judging model. Further, in the present application, after the step of obtaining the basic parameters of the wire to be lacquered, before the step of carrying out the wire lacquering according to the lacquering process parameters, further comprises: Detecting the painting uniformity of the surface of the wire rod before entering the oven and judging whether a preset uniformity threshold value is reached; when the painting uniformity does not reach a preset uniformity threshold, generating a painting correction signal an