CN115390527A - Intelligent control system for crystal growth - Google Patents
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- 239000013078 crystal Substances 0.000 title claims abstract description 123
- 238000004519 manufacturing process Methods 0.000 claims abstract description 59
- 238000012795 verification Methods 0.000 claims abstract description 51
- 238000004891 communication Methods 0.000 claims abstract description 36
- 238000010438 heat treatment Methods 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 32
- 238000010899 nucleation Methods 0.000 claims abstract description 25
- 230000008569 process Effects 0.000 claims abstract description 23
- 238000005457 optimization Methods 0.000 claims abstract description 21
- 238000011156 evaluation Methods 0.000 claims abstract description 16
- 238000013433 optimization analysis Methods 0.000 claims abstract description 4
- 238000012549 training Methods 0.000 claims description 12
- MGRWKWACZDFZJT-UHFFFAOYSA-N molybdenum tungsten Chemical compound [Mo].[W] MGRWKWACZDFZJT-UHFFFAOYSA-N 0.000 claims description 10
- 230000001360 synchronised effect Effects 0.000 claims description 10
- 230000004044 response Effects 0.000 claims description 6
- 230000002159 abnormal effect Effects 0.000 claims description 5
- 238000002425 crystallisation Methods 0.000 claims description 5
- 230000008025 crystallization Effects 0.000 claims description 5
- 238000010801 machine learning Methods 0.000 claims description 5
- 230000008859 change Effects 0.000 claims description 4
- 238000003860 storage Methods 0.000 claims description 4
- 238000012544 monitoring process Methods 0.000 claims description 3
- 238000004364 calculation method Methods 0.000 claims description 2
- 239000000047 product Substances 0.000 description 29
- 229910052594 sapphire Inorganic materials 0.000 description 5
- 239000010980 sapphire Substances 0.000 description 5
- 238000013479 data entry Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 230000003287 optical effect Effects 0.000 description 4
- 239000000155 melt Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000002109 crystal growth method Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B17/00—Single-crystal growth onto a seed which remains in the melt during growth, e.g. Nacken-Kyropoulos method
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- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
- C30B29/10—Inorganic compounds or compositions
- C30B29/16—Oxides
- C30B29/20—Aluminium oxides
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32252—Scheduling production, machining, job shop
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses an intelligent control system for crystal growth, which relates to the technical field of crystal growth control and comprises a crystal production module, a signal verification module, a production optimization module and a personnel evaluation module; the crystal production module comprises a crystal production furnace, an execution control unit and a signal transceiving unit; the execution control unit is used for receiving the signals of the signal receiving and sending unit and controlling the crystal production furnace; the signal verification module is used for verifying the communication state of the signal receiving and transmitting unit in real time and ensuring the control precision; the production optimization module is used for carrying out optimization analysis on the heating power and the pulling speed in the seeding process; when the Pzt exceeds a preset proportion of a quality coefficient threshold value, marking the pulling speed corresponding to the maximum value of the quality coefficient Pzt as an optimized pulling speed; and the personnel evaluation module is used for evaluating the operation state of an operator according to the quality coefficient of the finished crystal product, judging whether the operator needs to be alternated or not, and improving the crystal growth efficiency.
Description
Technical Field
The invention relates to the technical field of crystal growth control, in particular to an intelligent control system for crystal growth.
Background
Because the sapphire crystal has excellent optical property, mechanical property, thermal property, chemical stability and the like, the sapphire crystal is widely applied to civil fields such as optical systems, window materials, LED substrate materials, intelligent watches and the like, and the demand on the sapphire crystal in the international market is more and more increased.
The sapphire crystal growth method mainly comprises a pulling method, a kyropoulos method and the like. Among them, the kyropoulos method is recognized as a growth method having the best crystal quality, and particularly, optical characteristics are significantly superior to those of other methods. The kyropoulos method is similar to the pulling method, a seed crystal is arranged on a pulling rod, raw materials in a tungsten-molybdenum crucible are heated to be above a melting point by a resistor, the seed crystal is descended to contact with a melt for seeding when the melt flows stably, and then the melt grows along the crystal direction of the seed crystal. Then, the heating power is reduced by a certain gradient, and the lifting rod is lifted slowly at the same time, so that the crystal grows gradually. However, the low yield of large-size sapphire crystals has been a significant factor affecting the yield improvement. Kyropoulos seeding operations often require the field operation of an experienced craftsman, and the quality of the crystals is closely related to the operating level of the seeding personnel. Based on the defects, the invention provides an intelligent control system for crystal growth.
Disclosure of Invention
The present invention is directed to solving at least one of the problems of the prior art. Therefore, the invention provides an intelligent control system for crystal growth.
In order to achieve the above object, an embodiment according to a first aspect of the present invention provides an intelligent control system for crystal growth, including a data auditing module, a crystal production module, a signal verification module, a production optimization module, and a personnel evaluation module;
the data auditing module is used for auditing the acquired original growth data, converting the original growth data which are approved into dominant growth data and storing the dominant growth data in a database; the original growth data comprises heating power, pulling speed and quality coefficient Pz of a corresponding crystal finished product in the seeding process;
the crystal production module is used for realizing crystal growth and comprises a crystal production furnace, an execution control unit and a signal transceiving unit; the crystal production furnace comprises a tungsten-molybdenum crucible and a pulling motor; the execution control unit is used for receiving the signal of the signal receiving and sending unit and controlling the crystal production furnace; the signal verification module is connected with the signal transceiving unit and is used for verifying the communication state of the signal transceiving unit in real time;
the production optimization module is connected with the crystal production module and is used for optimizing and analyzing the heating power and the pulling speed in the seeding process; acquiring a quality coefficient of a finished crystal product and marking the quality coefficient as Pzt, marking a pulling speed corresponding to the maximum value of the quality coefficient Pzt as an optimized pulling speed when the Pzt exceeds a preset proportion of a quality coefficient threshold, and sending the optimized pulling speed to a database for storage;
and the personnel evaluation module is connected with the crystal production module and used for evaluating the operation state of an operator according to the quality coefficient of the finished crystal product and judging whether the operator needs to be alternated.
Further, the data source analyzed by the production optimization module is data stored in a database, and specifically includes:
acquiring a quality coefficient Pz of a finished crystal product in a period time, and heating power and a pulling speed of the finished crystal product in a crystallization process, and respectively marking the quality coefficient Pz as Pt and Vt; wherein t represents the acquisition time; establishing a curve graph of the change of the heating power along with the time by taking the acquisition time as an abscissa;
constructing a parameter optimization training sample according to the curve graph, training based on a machine learning method, and obtaining a relation model of time and heating power;
sending the relation model of the time and the heating power obtained by training to an execution control unit; the execution control unit gives corresponding heating power of the tungsten-molybdenum crucible according to time and adjusts the pulling speed of the pulling motor according to the speed adjusting range; the source of the speed regulation range is a database, namely the corresponding pulling speed range under the corresponding heating power condition.
Further, the specific evaluation steps of the personnel evaluation module are as follows:
in a working cycle of a crystal production module, after a crystal finished product is generated, if the quality coefficient Pzt is smaller than a quality coefficient threshold value, indicating that a seeding operator is unqualified to generate an unqualified signal;
when an unqualified signal is monitored, automatically counting down, wherein the count down is R1, and R1 is a preset value; continuously monitoring unqualified signals in a countdown stage, automatically returning countdown to an original value if a new unqualified signal is monitored, and carrying out countdown again according to R1; otherwise, the countdown is returned to zero, and the countdown is stopped;
in the back counting stage, if the occurrence frequency of unqualified signals reaches a preset first number or a preset first proportion or the occurrence frequency of continuous unqualified signals reaches a preset second number, indicating that the state of a corresponding seeding operator is not good, and generating a scheduling signal at the moment;
the personnel evaluation module is used for feeding back the dispatching signals to the controller, and the controller is used for receiving the dispatching signals and then arranging the dispatching personnel to rotate with the operators.
Furthermore, the data auditing module is provided with a quality coefficient threshold, and when the quality coefficient Pz of the finished crystal product is smaller than the quality coefficient threshold, the corresponding original growth data auditing is not passed.
Further, the specific verification steps of the signal verification module are as follows:
the signal verification module sends a verification configuration message to an FPGA main control of the signal transceiving unit according to a preset verification period, wherein the verification configuration message comprises a first signal quality threshold;
responding to the received verification configuration message sent by the signal verification module, and sending a second synchronization signal to the signal verification module by the FPGA main control; in response to the second synchronous signal being monitored, the signal verification module determines the signal quality of the second synchronous signal, and compares the signal quality of the second synchronous signal with the first signal quality threshold to obtain a corresponding quality difference value Z1;
calculating the time difference between the moment when the signal verification module sends the verification configuration message and the moment when the signal verification module monitors the second synchronous signal again to obtain a response time length XT; calculating by using a formula SH = Z1 × a1+ XT × a2 to obtain a signal loss index SH, wherein a1 and a2 are coefficient factors;
establishing a time-varying curve graph of the signal loss index SH, comparing the signal loss index SH with a loss threshold value, and calculating to obtain a communication deviation coefficient Cy; and if the Cy is more than or equal to the preset deviation threshold, judging that the signal interference is serious and the communication state is abnormal, and generating a communication early warning instruction.
Further, the signal verification module is used for transmitting the communication early warning instruction to the execution control unit through the controller, and the execution control unit controls the crystal production furnace to stop after receiving the communication early warning instruction; and meanwhile, the controller is used for driving the alarm module to give an alarm so as to remind a manager to process as soon as possible.
Further, the specific calculation process of the communication deviation coefficient Cy is as follows:
if SH is larger than or equal to the loss threshold value, intercepting a corresponding curve segment from a corresponding curve graph for marking, and marking as a loss curve segment; counting the number of the loss curve segments as L1 in a preset time period, and integrating all the loss curve segments with time to obtain loss reference energy L2; the communication deviation coefficient Cy is calculated by using Cy = L1 × a3+ L2 × a4, where a3 and a4 are both coefficient factors.
Compared with the prior art, the invention has the beneficial effects that:
1. the crystal production module is used for realizing crystal growth and comprises a crystal production furnace, an execution control unit and a signal transceiving unit; the signal verification module is connected with the signal transceiving unit and used for verifying the communication state of the signal transceiving unit in real time, if the communication deviation coefficient Cy is larger than or equal to a preset deviation threshold value, the signal interference is judged to be serious, the communication state is abnormal, and a communication early warning instruction is generated; the execution control unit controls the crystal production furnace to stop after receiving the communication early warning instruction; meanwhile, the controller is used for driving the alarm module to give an alarm so as to remind a manager to process as soon as possible and improve the control precision of crystal growth;
2. the production optimization module is used for carrying out optimization analysis on the heating power and the pulling speed in the seeding process; acquiring a quality coefficient Pz of a crystal finished product in a period time, and heating power and pulling speed of the crystal finished product in a crystallization process, constructing a parameter optimization training sample, and training based on a machine learning method to obtain a relation model of time and heating power; setting corresponding heating power of the tungsten-molybdenum crucible according to time by using an execution control unit, and adjusting the pulling speed of a pulling motor according to a speed adjusting range; obtaining a quality coefficient Pzt of a finished crystal product after the finished crystal product is generated; when the Pzt exceeds the quality coefficient threshold value preset proportion, marking the pulling speed corresponding to the maximum value of the quality coefficient Pzt as an optimized pulling speed, and feeding the optimized pulling speed back to the database to improve the crystal growth efficiency;
3. the personnel evaluation module is connected with the crystal production module and used for evaluating the operation state of an operator according to the quality coefficient of a finished crystal product; in a working cycle of the crystal production module, if the quality coefficient Pzt is smaller than the quality coefficient threshold value, indicating that the seeding operator is unqualified to generate an unqualified signal; in the countdown stage, if the occurrence frequency of unqualified signals reaches a preset first number or a preset first proportion or the occurrence frequency of continuous unqualified signals reaches a preset second number, indicating that the state of a corresponding seeding operator is not good, and generating a scheduling signal at the moment; after the controller receives the dispatching signals, corresponding dispatching personnel and operators are reasonably arranged to carry out rotation, and the crystal growth efficiency is improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a block diagram of an intelligent control system for crystal growth according to the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, an intelligent control system for crystal growth comprises a data entry module for acquiring original growth data, a data auditing module for auditing the original growth data acquired by the data entry module, a database, a crystal production module, a signal verification module, a controller, a production optimization module, a personnel evaluation module and an alarm module;
the data auditing module is used for auditing the acquired original growth data, converting the audited original growth data into dominant growth data and storing the dominant growth data in a database, wherein the database comprises a plurality of pieces of dominant growth data, and the dominant growth data comprises heating power, pulling speed and a quality coefficient Pz of a finished crystal product in the seeding process; when the quality coefficient Pz is calculated, the quality coefficient Pz is calculated from multiple dimensions, including the optical property, the mechanical property, the thermal property, the chemical stability and the like of the finished crystal product, and the quality coefficient which can represent the excellent quality of the finished crystal product is comprehensively obtained;
the mode of acquiring the original growth data by the data entry module comprises the following steps: employing an experienced authority expert to write a knowledge block, collecting partial knowledge from a network by using a web crawler, and extracting the knowledge from knowledge precipitates asked by a seeding operator and answered by the expert, wherein the knowledge refers to heating power and pulling speed in a seeding process; then the crystal production furnace heats the tungsten-molybdenum crucible according to the obtained heating power, the pulling motor performs seeding according to the obtained pulling speed, and the quality coefficient Pz of the finally obtained crystal finished product is fed back to the data entry module;
all the finished crystal products produced within the period time are not qualified, therefore, a quality coefficient threshold value is set by the data auditing module, and when the quality coefficient Pz of the finished crystal product is smaller than the quality coefficient threshold value, the corresponding original growth data is not referred;
the crystal production module is used for realizing crystal growth and comprises a crystal production furnace, an execution control unit and a signal transceiving unit; the crystal production furnace comprises a tungsten-molybdenum crucible, a pulling motor and the like; the execution control unit is used for receiving the signals of the signal receiving and sending unit and controlling the crystal production furnace; in order to ensure the control precision, the stable communication state of the signal transceiving unit is necessary; therefore, the communication state of the signal transceiving unit needs to be monitored;
the signal verification module is connected with the signal transceiving unit and used for verifying the communication state of the signal transceiving unit in real time, and the specific verification steps are as follows:
the signal verification module sends a verification configuration message to an FPGA main control of the signal transceiving unit according to a preset verification period, wherein the verification configuration message comprises a first signal quality threshold; responding to the received verification configuration message sent by the signal verification module, and sending a second synchronization signal to the signal verification module by the FPGA main control;
in response to the second synchronization signal being monitored, the signal verification module determines the signal quality of the second synchronization signal, and compares the signal quality of the second synchronization signal with the first signal quality threshold to obtain a corresponding quality difference value Z1; wherein any metric known in the art can be used to characterize signal quality, such as RSRQ, RSRP, RSSI, etc., as will be appreciated by those skilled in the art; the quality difference can reflect the attenuation of the signal in the transmission process;
calculating the time difference between the moment when the signal verification module sends the verification configuration message and the moment when the signal verification module monitors the second synchronous signal again to obtain a response time length XT; calculating by using a formula SH = Z1 × a1+ XT × a2 to obtain a signal loss index SH, wherein a1 and a2 are coefficient factors;
establishing a curve graph of the change of the signal loss index SH along with time, and comparing the signal loss index SH with a loss threshold value; if SH is larger than or equal to the loss threshold value, intercepting a corresponding curve segment from a corresponding curve graph for marking, and marking as a loss curve segment;
counting the number of the loss curve segments as L1 in a preset time period, and integrating all the loss curve segments with time to obtain loss reference energy L2; calculating a communication deviation coefficient Cy by using Cy = L1 × a3+ L2 × a4, wherein a3 and a4 are coefficient factors;
comparing the communication deviation coefficient Cy with a preset deviation threshold value; if the Cy is larger than or equal to a preset deviation threshold, judging that the signal interference is serious and the communication state is abnormal, and generating a communication early warning instruction;
the signal verification module is used for transmitting the communication early warning instruction to the execution control unit through the controller, and the execution control unit controls the crystal production furnace to stop after receiving the communication early warning instruction; meanwhile, the controller is used for driving the alarm module to give an alarm so as to remind a manager to process as soon as possible and improve the control precision of crystal growth;
the production optimization module is connected with the crystal production module and is used for performing optimization analysis on heating power and pulling speed in the seeding process, and the data analyzed by the production optimization module is data stored in a database;
in this embodiment, the specific analysis process of the production optimization module is as follows:
the method comprises the following steps: acquiring a quality coefficient Pz of a finished crystal product in a period time, and heating power and a pulling speed of the finished crystal product in a crystallization process, and respectively marking the quality coefficient Pz as Pt and Vt; wherein t represents the acquisition time, and Pt corresponds to Vt in a one-to-one manner;
step two: establishing a curve graph of the change of the heating power along with the time by taking the acquisition time as an abscissa; constructing a parameter optimization training sample according to the curve graph, and training based on a machine learning method to obtain a relation model of time and heating power;
step three: the production optimization module is used for sending the trained relation model of time and heating power to the execution control unit; the execution control unit gives corresponding heating power of the tungsten-molybdenum crucible according to time and adjusts the pulling speed of the pulling motor according to the speed adjusting range;
wherein, the source of the speed adjusting range is a database, namely, the corresponding pulling speed range under the condition of corresponding heating power;
step four: when a finished crystal product is generated, acquiring a quality coefficient of the finished crystal product and marking the quality coefficient as Pzt; when the quality coefficient Pzt exceeds the preset quality coefficient threshold ratio, the production optimization module is used for marking the pulling speed corresponding to the maximum quality coefficient Pzt as the optimized pulling speed and sending the optimized pulling speed to the database for storage; wherein the preset proportion range is 50% -80%;
the personnel evaluation module is connected with the crystal production module and used for evaluating the operation state of an operator according to the quality coefficient of a finished crystal product, and the specific evaluation steps are as follows:
in a working cycle of a crystal production module, after a crystal finished product is generated, if the quality coefficient Pzt is smaller than a quality coefficient threshold value, indicating that a seeding operator is unqualified to generate an unqualified signal; otherwise, generating a qualified signal;
when an unqualified signal is monitored, automatically counting down, wherein the count down is R1, the R1 is a preset value, and the count down is reduced by one when one signal is monitored; continuously monitoring unqualified signals in a countdown stage, automatically returning countdown to an original value if a new unqualified signal is monitored, and carrying out countdown again according to R1; otherwise, the countdown returns to zero, and the countdown is stopped;
in the countdown stage, if the occurrence frequency of unqualified signals reaches a preset first number or a preset first proportion or the occurrence frequency of continuous unqualified signals reaches a preset second number, indicating that the state of a corresponding seeding operator is not good, and generating a scheduling signal at the moment;
the personnel evaluation module is used for feeding back the scheduling signals to the controller, and the controller is used for reasonably arranging corresponding scheduling personnel to rotate with operators after receiving the scheduling signals, so that the crystal growth efficiency is improved.
The above formulas are all calculated by removing dimensions and taking numerical values thereof, the formula is a formula which is obtained by acquiring a large amount of data and performing software simulation to obtain the closest real situation, and the preset parameters and the preset threshold value in the formula are set by the technical personnel in the field according to the actual situation or obtained by simulating a large amount of data.
The working principle of the invention is as follows:
an intelligent control system for crystal growth is disclosed, wherein in operation, a data auditing module converts original growth data which are approved to be an explicit growth data and stores the explicit growth data in a database; the crystal production module is used for realizing crystal growth and comprises a crystal production furnace, an execution control unit and a signal transceiving unit; the signal verification module is connected with the signal transceiving unit and used for verifying the communication state of the signal transceiving unit in real time, if the communication deviation coefficient Cy is larger than or equal to a preset deviation threshold value, the signal interference is judged to be serious, the communication state is abnormal, and a communication early warning instruction is generated; the execution control unit controls the crystal production furnace to stop after receiving the communication early warning instruction; meanwhile, the controller is used for driving the alarm module to give an alarm to remind a manager to process as soon as possible, so that the control precision of crystal growth is improved;
the production optimization module is connected with the crystal production module and is used for optimizing and analyzing the heating power and the pulling speed in the seeding process; acquiring a quality coefficient Pz of a finished crystal product in a period time, and heating power and pulling speed of the finished crystal product in a crystallization process, constructing a parameter optimization training sample, and training a machine learning-based method to obtain a relation model of time and heating power; setting corresponding heating power of the tungsten-molybdenum crucible according to time by using an execution control unit, and adjusting the pulling speed of a pulling motor according to a speed adjusting range; obtaining a quality coefficient Pzt of a finished crystal product after the finished crystal product is generated; when the Pzt exceeds the preset proportion of the quality coefficient threshold, marking the pulling speed corresponding to the maximum value of the quality coefficient Pzt as an optimized pulling speed, and sending the optimized pulling speed to a database for storage;
the personnel evaluation module is connected with the crystal production module and is used for evaluating the operation state of an operator according to the quality coefficient of the finished crystal product; in a working cycle of the crystal production module, if the quality coefficient Pzt is smaller than the quality coefficient threshold value, indicating that the seeding operator is unqualified to generate an unqualified signal; in the back counting stage, if the occurrence frequency of unqualified signals reaches a preset first number or a preset first proportion or the occurrence frequency of continuous unqualified signals reaches a preset second number, indicating that the state of a corresponding seeding operator is not good, and generating a scheduling signal at the moment; after the controller receives the dispatching signals, corresponding dispatching personnel and operators are reasonably arranged to carry out rotation, and the crystal growth efficiency is improved.
In the description herein, references to the description of "one embodiment," "an example," "a specific example," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.
Claims (7)
1. An intelligent control system for crystal growth is characterized by comprising a data auditing module, a crystal production module, a signal verification module, a production optimization module and a personnel evaluation module;
the data auditing module is used for auditing the acquired original growth data, converting the original growth data which are approved into dominant growth data and storing the dominant growth data in a database; the original growth data comprises heating power, pulling speed and quality coefficient Pz of a corresponding crystal finished product in the seeding process;
the crystal production module is used for realizing crystal growth and comprises a crystal production furnace, an execution control unit and a signal transceiving unit; the crystal production furnace comprises a tungsten-molybdenum crucible and a pulling motor; the execution control unit is used for receiving the signal of the signal receiving and sending unit and controlling the crystal production furnace; the signal verification module is connected with the signal transceiving unit and used for verifying the communication state of the signal transceiving unit in real time;
the production optimization module is connected with the crystal production module and is used for carrying out optimization analysis on heating power and pulling speed in the seeding process; acquiring a quality coefficient of a finished crystal product and marking the quality coefficient as Pzt, marking a pulling speed corresponding to the maximum value of the quality coefficient Pzt as an optimized pulling speed when the Pzt exceeds a preset proportion of a quality coefficient threshold, and sending the optimized pulling speed to a database for storage;
and the personnel evaluation module is connected with the crystal production module and used for evaluating the operation state of an operator according to the quality coefficient of the finished crystal product and judging whether the operator needs to be alternated.
2. The intelligent control system for crystal growth according to claim 1, wherein the data analyzed by the production optimization module is derived from data stored in a database, and specifically comprises:
acquiring a quality coefficient Pz of a finished crystal product in a period time, and heating power and a pulling speed of the finished crystal product in a crystallization process, and respectively marking the quality coefficient Pz as Pt and Vt; wherein t represents the acquisition time; establishing a curve graph of the change of the heating power along with the time by taking the acquisition time as an abscissa;
constructing a parameter optimization training sample according to the curve graph, training based on a machine learning method, and obtaining a relation model of time and heating power;
sending the relation model of the time and the heating power obtained by training to an execution control unit; the execution control unit gives corresponding heating power of the tungsten-molybdenum crucible according to time and adjusts the pulling speed of the pulling motor according to the speed adjusting range; the source of the speed regulation range is a database, namely the corresponding pulling speed range under the corresponding heating power condition.
3. An intelligent control system for crystal growth as claimed in claim 2, wherein the personnel assessment module comprises the following specific assessment steps:
in a working cycle of a crystal production module, after a crystal finished product is generated, if the quality coefficient Pzt is smaller than a quality coefficient threshold value, indicating that a seeding operator is unqualified to generate an unqualified signal;
when an unqualified signal is monitored, automatically counting down, wherein the count down is R1, and R1 is a preset value; continuously monitoring unqualified signals in a countdown stage, automatically returning countdown to an original value if a new unqualified signal is monitored, and carrying out countdown again according to R1; otherwise, the countdown returns to zero, and the countdown is stopped;
in the back counting stage, if the occurrence frequency of unqualified signals reaches a preset first number or a preset first proportion or the occurrence frequency of continuous unqualified signals reaches a preset second number, indicating that the state of a corresponding seeding operator is not good, and generating a scheduling signal at the moment; the personnel evaluation module is used for feeding back the dispatching signals to the controller, and the controller is used for receiving the dispatching signals and then arranging the dispatching personnel to rotate with the operators.
4. The intelligent control system for crystal growth according to claim 1, wherein the data auditing module sets a quality coefficient threshold, and if the quality coefficient Pz of the finished crystal is smaller than the quality coefficient threshold, the corresponding original growth data auditing is not passed.
5. An intelligent control system for crystal growth according to claim 1, wherein the specific verification steps of the signal verification module are:
the signal verification module sends a verification configuration message to an FPGA main control of the signal receiving and sending unit according to a preset verification period, wherein the verification configuration message comprises a first signal quality threshold;
responding to the received verification configuration message sent by the signal verification module, and sending a second synchronous signal to the signal verification module by the FPGA main control; in response to the second synchronous signal being monitored, the signal verification module determines the signal quality of the second synchronous signal, and compares the signal quality of the second synchronous signal with the first signal quality threshold to obtain a corresponding quality difference value Z1;
calculating the time difference between the moment when the signal verification module sends the verification configuration message and the moment when the signal verification module monitors the second synchronous signal again to obtain a response time length XT; calculating by using a formula SH = Z1 × a1+ XT × a2 to obtain a signal loss index SH, wherein a1 and a2 are coefficient factors;
establishing a time-varying curve graph of the signal loss index SH, comparing the signal loss index SH with a loss threshold value, and calculating to obtain a communication deviation coefficient Cy; and if the Cy is more than or equal to the preset deviation threshold, judging that the signal interference is serious and the communication state is abnormal, and generating a communication early warning instruction.
6. The intelligent control system for crystal growth according to claim 5, wherein the signal verification module is configured to transmit the communication early warning command to the execution control unit via the controller, and the execution control unit controls the crystal production furnace to stop after receiving the communication early warning command; and meanwhile, the controller is used for driving the alarm module to give an alarm so as to remind a manager to process as soon as possible.
7. An intelligent control system for crystal growth as claimed in claim 5, wherein the specific calculation process of the communication deviation coefficient Cy is as follows:
if SH is more than or equal to the loss threshold, intercepting a corresponding curve segment from a corresponding curve graph for marking, and recording as a loss curve segment; counting the number of the loss curve segments as L1 within a preset time period, and integrating all the loss curve segments with time to obtain loss reference energy L2; the communication deviation coefficient Cy is calculated using Cy = L1 × a3+ L2 × a4, where a3 and a4 are both coefficient factors.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116148911A (en) * | 2023-02-21 | 2023-05-23 | 上海动力天成智能科技有限公司 | Comprehensive situation display system based on ship automatic identification |
| CN116483128A (en) * | 2023-06-19 | 2023-07-25 | 湖南林科达信息科技有限公司 | Unmanned aerial vehicle multitasking load device conversion method and system |
| CN117568940A (en) * | 2024-01-17 | 2024-02-20 | 天津伍嘉联创科技发展股份有限公司 | Continuous production method and system for crystals |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116148911A (en) * | 2023-02-21 | 2023-05-23 | 上海动力天成智能科技有限公司 | Comprehensive situation display system based on ship automatic identification |
| CN116483128A (en) * | 2023-06-19 | 2023-07-25 | 湖南林科达信息科技有限公司 | Unmanned aerial vehicle multitasking load device conversion method and system |
| CN116483128B (en) * | 2023-06-19 | 2023-10-27 | 湖南林科达信息科技有限公司 | Unmanned aerial vehicle multitasking load device conversion method and system |
| CN117568940A (en) * | 2024-01-17 | 2024-02-20 | 天津伍嘉联创科技发展股份有限公司 | Continuous production method and system for crystals |
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