冲孔钢带镀镍流程工艺指标稳定控制方法研究

Punching steel strip nickel plating is a continuous long production process, the key technical index are difficult to detect on-line and process is coupled to each other, stable optimization control of the whole process in the multi-species flexible production is one of the important technical problems faced by green production enterprises. The existing production process control accuracy is low, the operating parameters adjustment is the lack of integrity and coordination, easy to lead to nickel-plated product quality is not stable. The project will analyze the process mechanism, study the detection method of the key parameters, propose the time and space registration method of the associated process data and construct the process index correlation forecasting model based on the fusion mechanism, the multi-process production data and the knowledge. The distribution trend of process index is proposed, and the optimal local process parameter setting method under multi-variety flexible production condition is put forward. The sub-process decentralized control strategy for the decomposition of process index and the multi-operation parameter optimization method are studied, which can reduce the consumption of the product while ensuring the quality of the product. The effectiveness of the proposed method is verified in actual industrial process. At the same time, it provides theoretical support for the efficient green punching steel strip nickel plating，which is of great significance for both industrial application and scientific research.

冲孔钢带镀镍是一个连续长流程生产过程，其关键工艺参数难以在线检测，工序关联耦合，多品种柔性生产中全流程稳定优化运行困难，是企业实现绿色生产所亟需解决的关键技术难题。现有生产过程控制精度低，操作参数调整系统性和协调性差，易导致镀镍成品质量不稳定。为确保镀镍成品的质量，往往以能源和药剂的过量消耗为代价。本项目在镀镍过程工艺机理分析基础上，研究关键工艺参数在线检测方法，提出关联工序数据的时空配准方法，构建融合机理、多工序生产数据和知识的工艺指标关联预估模型；研究各工序工艺指标的分布变化趋势，提出多品种柔性生产条件下的各工序工艺指标优化方法；研究面向工艺指标分解的子工序分散控制策略和面向多品种的多操作参数协调优化方法。将所提方法在实际工业过程进行应用验证，为冲孔钢带镀镍高效绿色生产提供理论方法，具有重要的工业应用价值和科学价值。

项目组深入冲孔钢带镀镍生产现场调研，针对多品种冲孔钢带镀镍柔性生产中工艺指标的稳定控制问题，提出以分层协调优化为核心，以过程对象建模和子工序闭环分散控制为基础的总体研究思路；设计了冲孔钢带电镀过程溶液浓度的光学检测装置和冲孔镀镍钢带表面缺陷的在线视觉检测装置。针对冲孔钢带镀镍流程多工艺参数难以在线检测问题，提出一种基于光学干涉技术和平衡探测器的电镀液浓度在线检测方法，提出一种基于差分进化的在线支持向量回归(OSVR)电镀液pH值预测控制策略；针对溶液浓度测量时，相位测量系统中投影仪输出与CCD输入变形条纹光强之间的非线性导致频谱混叠影响测量精度的问题，提出了一种基于系统非线性校正与滤波的相位测量方法。针对电镀过程多工序关联耦合，多品种柔性生产中全流程优化运行困难，提出一种面向多品种柔性生产的基于多目标优化的电流密度分层协调优化方法；提出一种基于案例推理和光学干涉技术的电镀溶液浓度协调优化控制策略。针对冲孔镀镍钢带成品质量检测复杂，设计了冲孔镀镍钢带表面缺陷在线视觉检测系统，提出了与收卷机同步的图像采集方法；针对在线高精度检测大幅面钢带总宽的需要，提出一种基于CCD和直线电机测量方法；针对人工检测冲孔镀镍钢带表面缺陷存在的误检和漏检等问题，提出基于时频多尺度的MB-LBP缺陷特征提取和检测方法，提出基于改进最小二乘法的冲孔镀镍钢带表面缺陷识别方法。项目研究形成了系统的冲孔钢带镀镍过程稳定控制方法，通过工业数据仿真和实际过程验证了方法的有效性，为实现冲孔钢带镀镍的精细化稳定控制提供理论指导和方法支撑。