CN117105536B - Intelligent management system for glass online coating process based on big data - Google Patents
Intelligent management system for glass online coating process based on big data Download PDFInfo
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- CN117105536B CN117105536B CN202311368823.5A CN202311368823A CN117105536B CN 117105536 B CN117105536 B CN 117105536B CN 202311368823 A CN202311368823 A CN 202311368823A CN 117105536 B CN117105536 B CN 117105536B
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- 238000000576 coating method Methods 0.000 title claims abstract description 229
- 239000011521 glass Substances 0.000 title claims abstract description 104
- 239000011248 coating agent Substances 0.000 claims abstract description 209
- 239000012535 impurity Substances 0.000 claims abstract description 110
- 238000012937 correction Methods 0.000 claims abstract description 49
- 238000007664 blowing Methods 0.000 claims abstract description 33
- 238000011156 evaluation Methods 0.000 claims abstract description 27
- 238000012790 confirmation Methods 0.000 claims abstract 2
- 238000010926 purge Methods 0.000 claims description 300
- 238000012544 monitoring process Methods 0.000 claims description 135
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 118
- 229910052757 nitrogen Inorganic materials 0.000 claims description 60
- 238000007747 plating Methods 0.000 claims description 38
- 238000000034 method Methods 0.000 claims description 20
- 239000007789 gas Substances 0.000 claims description 17
- 239000000428 dust Substances 0.000 claims description 16
- 230000003749 cleanliness Effects 0.000 claims description 13
- 239000007888 film coating Substances 0.000 claims description 12
- 238000009501 film coating Methods 0.000 claims description 12
- 238000000605 extraction Methods 0.000 claims description 10
- 238000009825 accumulation Methods 0.000 claims description 9
- 238000004364 calculation method Methods 0.000 claims description 6
- 238000012216 screening Methods 0.000 claims description 6
- 230000003044 adaptive effect Effects 0.000 claims description 3
- 230000001174 ascending effect Effects 0.000 claims description 3
- 239000003086 colorant Substances 0.000 claims description 3
- 239000006185 dispersion Substances 0.000 claims description 3
- 230000007613 environmental effect Effects 0.000 claims description 3
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen(.) Chemical compound [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 claims description 2
- 238000010408 sweeping Methods 0.000 claims description 2
- 239000010408 film Substances 0.000 description 29
- 238000002372 labelling Methods 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- 230000007547 defect Effects 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000009977 dual effect Effects 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000007792 addition Methods 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B9/00—Cleaning hollow articles by methods or apparatus specially adapted thereto
- B08B9/08—Cleaning containers, e.g. tanks
- B08B9/093—Cleaning containers, e.g. tanks by the force of jets or sprays
Abstract
The invention belongs to the technical field of glass coating process management, and particularly discloses an intelligent management system for a glass online coating process based on big data. The invention solves the limitation existing in the current coating blowing control management by carrying out blowing parameter correction evaluation and proper blowing parameter confirmation by combining the reactive impurities, the coating environment, the coating state and the actual blowing state in the coating process, realizes the multi-dimensional evaluation of the coating blowing, improves the flexibility and pertinence of the current coating blowing control management, ensures the effectiveness of the current coating blowing control management, and also ensures the timeliness of the current coating blowing control correction.
Description
Technical Field
The invention belongs to the technical field of glass coating process management, and relates to an intelligent management system for a glass online coating process based on big data.
Background
Glass coating is a process of coating a thin film on the surface of glass to change its optical, thermal or chemical properties. Along with the progress of science and technology and the increase of demands, glass coating is gradually expanded to various fields such as buildings, automobiles, electronics, energy sources and the like, and in order to ensure the quality and effect of glass coating, the glass online coating process needs to be managed.
Glass coating is usually carried out in a coating reactor consisting of a closed reaction chamber and a feed end, an exhaust end and a control end connected to the reaction chamber. In a film plating reactor, purging is a common operation step for removing impurities in the reactor or replacing the atmosphere in the reactor, and the effect of current film plating purging control management has certain limitations, which are specifically expressed in the following aspects: 1. at present, the flow of the purging airflow is mainly controlled according to the conditions of residues and impurities in the reaction chamber, the condition of film plating of glass in the reaction chamber, the atmosphere state and the like are not combined for comprehensive control evaluation, the reliability and the suitability of the purging control cannot be ensured, the occurrence probability of film plating falling plates cannot be reduced, and the stability and the yield of film plating of the glass cannot be ensured.
2. At present, the blowing precision of the unbonded blowing device is comprehensively set, so that the blowing effect is difficult to achieve the expected value, and meanwhile, the defects of film coating are easily caused, such as bubbles or uneven and local too thick and too thin phenomena, the stability of film coating quality cannot be ensured, the follow-up requirement is frequently corrected, the unnecessary shutdown and switching time is increased, and the operation efficiency of glass film coating cannot be improved.
3. At present, fixed purging frequency is mainly adopted, pertinence and flexibility regulation and control are not carried out according to the specific state of the coating film in the reaction chamber, the timeliness of atmosphere replacement in the reaction chamber cannot be improved, the stability and the balance of the reaction environment in the reaction chamber cannot be improved, and the interference of oxygen on the reaction cannot be timely reduced or the introduction of impurities cannot be timely avoided.
Disclosure of Invention
In view of this, in order to solve the problems set forth in the background art, an intelligent management system for an online glass coating process based on big data is provided.
The aim of the invention can be achieved by the following technical scheme: the invention provides an intelligent management system for a glass online coating process based on big data, which comprises the following components: the basic information extraction module is used for extracting the area, the planned coating thickness and the planned coating duration of the glass to be coated currently, and extracting currently set purging parameters, wherein the purging parameters are purging nitrogen flow, purging modes and purging frequency.
And the reaction impurity information monitoring module is used for monitoring the dust concentration and VOC concentration of each impurity monitoring area in the glass coating reaction chamber in each monitoring time period and extracting the position of each impurity monitoring area.
The film coating environment information monitoring module is used for monitoring the temperature of each environment monitoring area in the glass film coating reaction chamber at each monitoring time point and monitoring the concentration of each process gas in each environment monitoring area.
And the coating state information monitoring module is used for monitoring the state of the current glass coating to obtain coating state information.
The actual purging information extraction module is used for extracting the actual purging nitrogen flow of each purging corresponding to each purging time point in the current glass coating reaction chamber.
The purging setting correction evaluation module is used for performing purging parameter correction evaluation, and when the evaluation result is corrected, the current proper purging nitrogen flow, purging mode and purging frequency are confirmed according to the current set purging nitrogen flow, purging mode and purging frequency.
And the purging control management terminal is used for feeding back the current proper flow rate, purging mode and purging frequency of the purging nitrogen to the purging control terminal and carrying out purging control correction.
Preferably, the purging modes are single-point nozzle purging and annular purging.
The filming state information comprises filming time, filming area, the number of color types existing in the filming area, the filming area occupied by each color type and the thickness of each filming monitoring point in the filming area.
Preferably, the performing a purge parameter correction assessment includes: positioning the dust accumulation concentration and the VOC concentration of the current time period from the dust accumulation concentration and the VOC concentration of each impurity monitoring area in the glass coating reaction chamber in each monitoring time period, and counting the interference degree of the current coating impurities。
The temperature of each environment monitoring area in the glass coating reaction chamber at each monitoring time point is recorded as，/>Indicating the number of the environment monitoring area,/->，/>Indicating the monitoring time point number,/->Counting deviation degree of the current coating reaction temperature>。
According to the concentration of each process gas in each environment monitoring area, counting the deviation degree of the reaction atmosphere of the current coating。
Counting the trend degree of the purging parameter correction requirement in the glass coating reaction chamber，，/>、/>、/>Respectively setting the coating impurity removal requirement degree, the coating reaction temperature deviation degree and the coating reaction atmosphere deviation degree which are correspondingly referred by the currently set purging parameters, and +.>To round down the symbol.
If it isThen correct as blowingAnd the sweep parameter is used for correcting the evaluation result, otherwise, the sweep parameter is not corrected to be used as the purge parameter correction evaluation result.
Preferably, the counting the interference degree of the current coating impurities includes: the dust concentration and VOC concentration of each impurity monitoring area in the current time period are respectively recorded asAnd->，/>Indicates the impurity monitoring region number, < > and->The cleanliness of each impurity monitoring region was counted +.>，/>，/>And->The allowable dust concentration and VOC concentration in the reaction chamber are respectively set.
Will beProper cleanliness in the reference film-plating reactor is set>In contrast, statistics are less than +.>Impurity monitoring region number->。
Extracting a minimum value from the cleanliness of each impurity monitoring regionCounting interference degree of current coating impurity>，N is the number of impurity monitoring regions, +.>Impurity profile dispersion for the set reference.
Preferably, the counting the deviation degree of the current coating reaction temperature includes: and constructing a temperature change curve of each environment monitoring area by taking the monitoring time point as an abscissa and the temperature as an ordinate.
Dividing the temperature change curve into temperature change curve segments according to the peak point positions in the temperature change curve, extracting the slope of each temperature change curve segment, further extracting the maximum value and the minimum value from the slope of each temperature change curve segment, and respectively taking the maximum value and the minimum value as the temperature rise rate of each environment monitoring areaAnd the rate of temperature decrease->Counting temperature variation deviation degree of each environment monitoring area>，/>，/>Respectively the proper temperature rise rate, the proper temperature drop rate and the proper temperature change rate difference in the set coating reaction chamber.
Counting the deviation degree of the current coating reaction temperature，，/>To set the permissible degree of deviation of the temperature change +.>For the temperature of the jth environmental monitoring area in the glass coating reaction chamber at the t monitoring time point,/>Indicating the number of monitoring time points, +.>And m is the number of environment monitoring areas for the set allowable temperature difference in the glass coating reaction chamber.
Preferably, said confirming the currently appropriate purge nitrogen flow comprises: extracting the number of color types existing in the coated area, the area of the coated area occupied by each type of color and the thickness of each coated monitoring point of the coated area from the coated state information, and counting the uniformity of the coated film of the current glass。
The currently set flow rate of the purging nitrogenThe actual purging nitrogen flow corresponding to each purging time point in the current glass coating reaction chamber is subjected to difference, the purging flow difference is obtained, and a purging nitrogen flow correction compensation factor is set according to the purging flow difference>。
Positioning the coated time length from the coating state informationAnd has already beenArea of coating area->Simultaneously, the area of the glass to be coated and the planned coating time length are respectively recorded as +.>And->。
Statistics is carried out on current proper flow of nitrogen purging in glass coating reaction chamber，，/>The deviation degree of the set unit comprehensive coating state and the increased purging nitrogen flow corresponding to the unit purging nitrogen flow correction compensation factor are respectively +.>For a set allowable film coating rate difference +.>The uniformity of the glass coating film and the sweeping parameter of the set reference are respectively corrected to the trend degree of demand +.>And the deviation degree of the current comprehensive coating state in the glass coating reaction chamber is represented.
Preferably, the counting the uniformity of the current glass coating includes: the thickness of the current glass to be coated is calculated according to the planned coating thickness and the thickness of each coating monitoring point in the coated area, the thickness difference of each coating monitoring point is obtained, and the maximum thickness difference is extracted from the thickness differenceAnd minimum thickness difference>。
The number of color types existing in the coated area is recorded asExtracting the highest occupied plating area from the plating area occupied by each color>And the area of the lowest occupied coating area->。
Statistics and statistics of uniformity of coating film of current glass，，/>To permit the thickness deviation of the coating film, < > of>The areas of the areas which are set and suitable for different colors and the areas of the allowable variegated coating areas are respectively different.
Preferably, the setting the purge nitrogen flow correction compensation factor includes: if the purge flow difference of a certain purge corresponding to a certain purge time point is larger than the set allowable purge flow differenceThe purge was designated as a deviation purge, the purge time was designated as a deviation purge time, and the number of deviation purges was counted +.>And the number of offset purge time points for each offset purge was counted.
Each non-deviated purge time point in each deviated purge time point corresponding to each purge time point is recorded as each normal purge time point.
Marking the deviation purging time points and the normal purging time points corresponding to the deviation purging time points on a time number axis to obtain deviation marking points and normal marking points.
Extracting the number of normal labeling points corresponding to the intervals between the deviation labeling points in each deviation purging, and screening the number of normal labeling points corresponding to the minimum intervals in each deviation purging.
If the ratio of the number of the deviation blowing time points of a certain deviation blowing to the number of the blowing time points is greater thanOr the number of the minimum interval normal marking points of the deviation purging is smaller than 2, marking the deviation purging as serious deviation purging, and counting the number of the serious deviation purging>。
Extracting the maximum purging flow difference of each purging from the purging flow differences of each purging corresponding to each purging time point, and obtaining the average purging flow difference through average value calculation。
Setting a purge nitrogen flow correction compensation factor，，/>Is the number of purges.
Preferably, confirming the currently appropriate purge mode includes: will have a cleanliness of less thanThe impurity monitoring regions of (2) are marked as important impurity regions, the positions of the important impurity regions are extracted, and the important impurity regions are respectively identifiedLabeling the domain positions to obtain impurity labeling points, and connecting the impurity labeling points in sequence to obtain an impurity distribution path.
And performing superposition comparison on the impurity distribution path and an adaptive purge impurity path purged by a set single-point nozzle to obtain superposition path length.
If it isAnd (3) taking the single-point nozzle blowing as a current proper blowing mode, and otherwise taking the annular blowing as the current proper blowing mode.
Preferably, identifying the currently appropriate purge frequency comprises: according toAnd (3) obtaining the interference degree of the coating impurity in each monitoring time period by means of the same statistics, and constructing a change curve of the interference degree of the coating impurity by taking the monitoring time period as an abscissa and taking the interference degree of the coating impurity as an ordinate.
Dividing the coating impurity disturbance degree change curve into disturbance change curve sections according to the positions of peak points in the coating impurity disturbance degree change curve, screening out disturbance change curve sections with the curve trend as the ascending direction from the disturbance change curve sections, marking the disturbance change curve sections as target curve sections, extracting the slope of each target curve section, taking the slope as the coating impurity disturbance growth rate, and obtaining the average coating impurity disturbance growth rate through mean value calculation。
The currently set purge frequency is recorded asStatistics of currently suitable purge frequency +.>，，/>The conventional coating impurity interference growth rate is set.
Compared with the prior art, the invention has the following beneficial effects: (1) The invention carries out correction evaluation of the purging parameters by combining the reactive impurities, the coating environment, the coating state and the actual purging state in the coating process, effectively solves the limitation of the current coating purging control management, realizes the multidimensional evaluation of the coating purging, further ensures the control and management effects of the coating purging flow, improves the flexibility and pertinence of the current coating purging control management, simultaneously ensures the effectiveness of the current coating purging control management, and also ensures the timeliness of the correction of the current coating purging control.
(2) According to the invention, by counting the interference degree of the current coating impurities in the glass coating reaction chamber, the deviation degree of the current coating reaction temperature and the deviation degree of the current coating reaction atmosphere, and confirming the current proper flow of the purging nitrogen in combination with the coating state information of the coated area, the dual analysis of the coating finished product and the coating environment is realized, the defect that the factors such as the coating condition and the atmosphere state of the glass in the reaction chamber are subjected to comprehensive control evaluation is effectively avoided, the reliability and the suitability of the control of the flow of the purging nitrogen in the glass coating reaction chamber are ensured, the occurrence probability of the falling plate of the coating is effectively reduced, and the stability and the yield of the glass coating are ensured.
(3) According to the invention, the actual purging nitrogen flow and the set purging nitrogen flow corresponding to each purging time point are compared and analyzed, and the purging nitrogen flow correction compensation factor is set accordingly, so that the accurate condition and the stable condition of each purging are intuitively displayed, the influence of the purging precision of the purging device on the setting of the purging nitrogen flow is fully considered, the subsequent purging effect is further ensured, meanwhile, the occurrence probability of bad film plating phenomena such as film plating bubbles, uneven film plating and uneven film plating thickness is also reduced, the stability of film plating quality is further ensured, the frequency of subsequent correction requirements is further avoided, the unnecessary shutdown and switching time is further reduced, and the operation efficiency of glass film plating is ensured.
(4) According to the invention, the current proper purging frequency is confirmed by analyzing the increasing condition of coating impurities and the current uniform condition of glass coating, the defects of the current fixed purging frequency are effectively overcome, the pertinence and flexibility control of the current purging frequency are realized, the timeliness of atmosphere replacement in the glass coating reaction chamber is ensured, the stability and balance of the reaction environment in the glass coating reaction chamber are also improved, the interference of oxygen on the coating reaction is also timely reduced, and the introduction of impurities is further avoided.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed for the description of the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of the connection of the modules of the system of the present invention.
FIG. 2 is a schematic diagram of the interval between the deviation mark point and the normal mark point according to the invention.
Reference numerals: 1. and (2) marking points in a deviation way, and marking points in a normal way.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention provides an intelligent management system for a glass online coating process based on big data, which comprises the following components: the device comprises a coating basic information extraction module, a reaction impurity information monitoring module, a coating environment information monitoring module, a coating state information monitoring module, an actual purging information extraction module, a purging setting correction evaluation module and a purging control management terminal.
As shown in fig. 1, in the foregoing description, the purge setting correction evaluation module is respectively connected to the plating film basic information extraction module, the reactive impurity information monitoring module, the plating film environment information monitoring module, the plating film state information monitoring module, the actual purge information extraction module, and the purge control management terminal.
The basic information extraction module is used for extracting the area, the planned coating thickness and the planned coating duration of the glass to be coated currently, and extracting currently set purging parameters, wherein the purging parameters are purging nitrogen flow, purging modes and purging frequency.
Specifically, the purging modes are single-point nozzle purging and annular purging.
The reaction impurity information monitoring module is used for monitoring the dust accumulation concentration and the VOC concentration of each impurity monitoring area in the glass coating reaction chamber in each monitoring time period, and extracting the position of each impurity monitoring area.
In one embodiment, the dust concentration is monitored by a particle counter and the VOC concentration is monitored by an optical sensor.
The film coating environment information monitoring module is used for monitoring the temperature of each environment monitoring area in the glass film coating reaction chamber at each monitoring time point and the concentration of each process gas in each environment monitoring area currently.
In one embodiment, each process gas includes, but is not limited to, ammonia, formaldehyde, and silica and nitrogen, wherein the temperature is monitored by a temperature sensor disposed within the glass coating reaction chamber and the concentration of each process gas is monitored by a gas sensor disposed within the glass coating reaction chamber.
And the coating state information monitoring module is used for monitoring the state of the current glass coating and obtaining coating state information.
Specifically, the filming state information comprises filming time, filming area, the number of color types existing in the filming area, the filming area occupied by each color type and the thickness of each filming monitoring point in the filming area.
In a specific embodiment, the thickness of each coating monitoring point is obtained by monitoring through a laser thickness detector arranged in the glass coating reaction chamber, the coated time is obtained by monitoring through a glass coating reaction chamber management background, and the coated area, the number of color types existing in the coated area and the coated area occupied by each color type are obtained by monitoring through a high-definition camera arranged in the glass coating reaction chamber.
The actual purging information extraction module is used for extracting the actual purging nitrogen flow of each purging corresponding to each purging time point in the current glass coating reaction chamber.
In one embodiment, the actual purge nitrogen flow is monitored by a flow meter positioned within the purge line.
And the purging setting correction evaluation module is used for performing purging parameter correction evaluation, and when the evaluation result is corrected, the current proper purging nitrogen flow, purging mode and purging frequency are confirmed according to the current set purging nitrogen flow, purging mode and purging frequency.
Illustratively, making a purge parameter correction assessment includes: a1, locating the dust accumulation concentration and the VOC concentration of the current time period from the dust accumulation concentration and the VOC concentration of each impurity monitoring area in the glass coating reaction chamber in each monitoring time period, and counting the interference degree of the current coating impurities。
Understandably, counting the current coating impurity interference degree comprises the following steps: a1-1, respectively recording the dust accumulation concentration and VOC concentration of each impurity monitoring area in the current time period asAnd->，/>Indicates the impurity monitoring region number, < > and->The cleanliness of each impurity monitoring region was counted +.>，/>，/>And->The allowable dust concentration and VOC concentration in the reaction chamber are respectively set.
A1-2, willProper cleanliness in the reference film-plating reactor is set>In contrast, statistics are less than +.>Impurity monitoring region number->。
A1-3, extracting the minimum value from the cleanliness of each impurity monitoring regionCounting the interference degree of the impurities of the current coating film，/>N is the number of impurity monitoring regions, +.>Impurity profile dispersion for the set reference.
A2, coating the glass reverselyThe temperature of each environment monitoring area in the room at each monitoring time point is recorded as，/>Indicating the number of the environment monitoring area,/->，/>Indicating the monitoring time point number,/->Counting deviation degree of the current coating reaction temperature>。
Understandably, counting the deviation degree of the reaction temperature of the current coating comprises the following steps: a2-1, constructing a temperature change curve of each environment monitoring area by taking a monitoring time point as an abscissa and taking temperature as an ordinate.
A2-2, dividing the temperature change curve into temperature change curve segments according to the peak point positions in the temperature change curve, extracting the slope of each temperature change curve segment, further extracting the maximum value and the minimum value from the slope of each temperature change curve segment, and respectively taking the maximum value and the minimum value as the temperature rise rate of each environment monitoring areaAnd the rate of temperature decrease->Counting temperature variation deviation degree of each environment monitoring area>，/>，Respectively the proper temperature rise rate, the proper temperature drop rate and the proper temperature change rate difference in the set coating reaction chamber.
A2-3, counting the deviation degree of the current coating reaction temperature，，/>In order to set the allowable degree of deviation of the temperature change,for the temperature of the jth environmental monitoring area in the glass coating reaction chamber at the t monitoring time point,/>Indicating the number of monitoring time points, +.>And m is the number of environment monitoring areas for the set allowable temperature difference in the glass coating reaction chamber.
A3, counting the deviation degree of the current coating reaction atmosphere according to the concentration of each current process gas in each environment monitoring area。
Understandably, counting the deviation degree of the reaction atmosphere of the current coating comprises: comparing the concentration of each process gas in each environment monitoring area with the sum of the concentrations of each process gas in each environment monitoring area in the glass coating reaction chamber to obtain the concentration ratio of each process gas in each environment monitoring areaR represents a process gas number, < > and->Counting the current coating reactionAtmosphere deviation degree->，/>，/>For the number of process gases>For the set appropriate concentration ratio of the (r) th process gas, (-) th process gas>The concentration difference is allowed for the set process gas.
A4, counting the trend degree of the purging parameter correction requirement in the glass coating reaction chamber，，/>、/>、/>Respectively setting the coating impurity removal requirement degree, the coating reaction temperature deviation degree and the coating reaction atmosphere deviation degree which are correspondingly referred by the currently set purging parameters,to round down the symbol.
A5, ifAnd if not, taking the correction as the purge parameter correction evaluation result, otherwise taking the non-correction as the purge parameter correction evaluation result.
The embodiment of the invention carries out correction evaluation of the purging parameters by combining the reactive impurities, the plating environment, the plating state and the actual purging state in the plating process, effectively solves the limitation of the current plating purging control management, realizes the multidimensional evaluation of the plating purging, further ensures the control and management effects of the plating purging flow, improves the flexibility and pertinence of the current plating purging control management, simultaneously ensures the effectiveness of the current plating purging control management, and also ensures the timeliness of the correction of the current plating purging control.
Still another exemplary procedure for confirming the currently appropriate purge nitrogen flow, purge mode, and purge frequency, respectively, is: 1) Confirming the currently appropriate purge nitrogen flow, including: u1, extracting the number of color types existing in the coated area, the area of the coated area occupied by each type of color and the thickness of each coated monitoring point in the coated area from the coated state information, and counting the uniformity of the coated film of the current glass。
Understandably, counting the uniformity of the current glass coating comprises: u1-1, the thickness of the current glass to be coated corresponding to the planned coating thickness and the thickness of each coating monitoring point in the coated area are subjected to difference making to obtain the thickness difference of each coating monitoring point, and the maximum thickness difference is extracted from the thickness differenceAnd minimum thickness difference>。
U1-2, the number of color types existing in the coated area is recorded asExtracting the highest occupied plating area from the plating area occupied by each color>And the area of the lowest occupied coating area->。
U1-3, and statistics of uniformity of coating film of current glass，，/>To permit the thickness deviation of the coating film, < > of>The areas of the areas which are set and suitable for different colors and the areas of the allowable variegated coating areas are respectively different.
U2, the currently set flow of the nitrogen purgingThe actual purging nitrogen flow corresponding to each purging time point in the current glass coating reaction chamber is subjected to difference, the purging flow difference is obtained, and a purging nitrogen flow correction compensation factor is set according to the purging flow difference>。
Understandably, setting the purge nitrogen flow correction compensation factor includes: u2-1, if the purge flow difference corresponding to a certain purge time point of a certain purge is larger than the set allowable purge flow differenceThe purge was designated as a deviation purge, the purge time was designated as a deviation purge time, and the number of deviation purges was counted +.>And the number of offset purge time points for each offset purge was counted.
U2-2, and recording each non-deviation purging time point in each purging time point corresponding to each deviation purging as each normal purging time point.
And U2-3, marking the deviation purging time points corresponding to each deviation purging time point and each normal purging time point on a time number axis to obtain each deviation marking point and each normal marking point, wherein 1 is the deviation marking point and 2 is the normal marking point as shown in fig. 2.
U2-4, extracting the number of normal labeling points corresponding to the intervals between the deviation labeling points in each deviation purging, and screening the number of normal labeling points corresponding to the minimum intervals in each deviation purging.
U2-5, if the ratio of the number of the deviation purge time points of a certain deviation purge to the number of the purge time points is greater thanOr the number of the minimum interval normal marking points of the deviation purging is smaller than 2, marking the deviation purging as serious deviation purging, and counting the number of the serious deviation purging>。
U2-6, extracting the maximum purging flow difference of each purging from the purging flow differences of each purging corresponding to each purging time point, and obtaining the average purging flow difference through average value calculation。
U2-7, and setting a purge nitrogen flow correction compensation factor，，/>Is the number of purges.
According to the embodiment of the invention, the actual purging nitrogen flow and the set purging nitrogen flow corresponding to each purging time point are compared and analyzed, and the purging nitrogen flow correction compensation factor is set according to the actual purging nitrogen flow and the set purging nitrogen flow, so that the accurate condition and the stable condition of each purging are intuitively displayed, the influence of the purging precision of the purging device on the setting of the purging nitrogen flow is fully considered, the subsequent purging effect is further ensured, meanwhile, the occurrence probability of bad film plating phenomena such as film plating bubbles, uneven film plating thickness and the like is also reduced, the stability of film plating quality is further ensured, the frequency of subsequent correction requirements is further avoided, the unnecessary shutdown and switching time is further reduced, and the operation efficiency of glass film plating is ensured.
U3, locating the coated time length from the coating state informationAnd the area of the coated area->Simultaneously, the area of the glass to be coated and the planned coating time length are respectively recorded as +.>And->。
U4, counting the current proper flow of nitrogen purging in the glass coating reaction chamber，/>，/>Respectively increasing the purging nitrogen flow corresponding to the set unit comprehensive coating state deviation degree and the unit purging nitrogen flow correction compensation factor,for a set allowable film coating rate difference +.>Respectively set reference glass coating film uniformityDegree, purge parameter correction demand trend, +.>And the deviation degree of the current comprehensive coating state in the glass coating reaction chamber is represented.
According to the embodiment of the invention, the current coating impurity interference degree, the current coating reaction temperature deviation degree and the current coating reaction atmosphere deviation degree in the glass coating reaction chamber are counted, and the current proper blowing nitrogen flow is confirmed by combining the coating state information of the coated area, so that the dual analysis of a coating finished product and a coating environment is realized, the defect that factors such as the coating condition and the atmosphere state of the glass in the reaction chamber are not combined at present to carry out comprehensive control evaluation is effectively avoided, the reliability and the suitability of the blowing nitrogen flow control in the glass coating reaction chamber are ensured, the occurrence probability of coating falling plates is effectively reduced, and the stability and the yield of glass coating are ensured.
2) Confirming the currently suitable purging mode comprises the following steps: will have a cleanliness of less thanThe impurity monitoring areas of the device are marked as key impurity areas, the positions of the key impurity areas are extracted, the positions of the key impurity areas are marked to obtain impurity marking points, and the impurity marking points are sequentially connected to obtain impurity distribution paths.
And performing superposition comparison on the impurity distribution path and an adaptive purge impurity path purged by a set single-point nozzle to obtain superposition path length.
If it isAnd (3) taking the single-point nozzle blowing as a current proper blowing mode, and otherwise taking the annular blowing as the current proper blowing mode.
According to the embodiment of the invention, through the analysis of the purging mode, not only is the cleanliness of purging ensured, but also the coverage of purging is ensured, so that the occurrence possibility of incomplete purging is further reduced, the waste of nitrogen is prevented, and meanwhile, the optimization of a coating process can be facilitated, and the quality of a coating finished product and the yield of the coating finished product are promoted.
3) Confirming the currently appropriate purge frequency includes: according toAnd (3) obtaining the interference degree of the coating impurity in each monitoring time period by means of the same statistics, and constructing a change curve of the interference degree of the coating impurity by taking the monitoring time period as an abscissa and taking the interference degree of the coating impurity as an ordinate.
Dividing the coating impurity disturbance degree change curve into disturbance change curve sections according to the positions of peak points in the coating impurity disturbance degree change curve, screening out disturbance change curve sections with the curve trend as the ascending direction from the disturbance change curve sections, marking the disturbance change curve sections as target curve sections, extracting the slope of each target curve section, taking the slope as the coating impurity disturbance growth rate, and obtaining the average coating impurity disturbance growth rate through mean value calculation。
The currently set purge frequency is recorded asStatistics of currently suitable purge frequency +.>，，/>The conventional coating impurity interference growth rate is set.
According to the embodiment of the invention, the current proper purging frequency is confirmed by analyzing the increasing condition of the coating impurities and the current uniform condition of the glass coating, the defect of the current fixed purging frequency is effectively overcome, the pertinence and flexibility control of the current purging frequency are realized, the timeliness of atmosphere replacement in the glass coating reaction chamber is ensured, the stability and balance of the reaction environment in the glass coating reaction chamber are also improved, the interference of oxygen on the coating reaction is also timely reduced, and the introduction of impurities is further avoided.
And the purging control management terminal is used for feeding back the current proper purging nitrogen flow, purging mode and purging frequency to the purging control terminal and carrying out purging control correction.
The foregoing is merely illustrative and explanatory of the principles of this invention, as various modifications and additions may be made to the specific embodiments described, or similar arrangements may be substituted by those skilled in the art, without departing from the principles of this invention or beyond the scope of this invention as defined in the claims.
Claims (7)
1. An intelligent management system for a glass online coating process based on big data is characterized in that: the system comprises:
the basic information extraction module is used for extracting the area, the planned coating thickness and the planned coating duration of the glass to be coated at present, and extracting currently set purging parameters, wherein the purging parameters are purging nitrogen flow, purging modes and purging frequency;
the reaction impurity information monitoring module is used for monitoring the dust accumulation concentration and the VOC concentration of each impurity monitoring area in the glass coating reaction chamber in each monitoring time period and extracting the position of each impurity monitoring area;
the film coating environment information monitoring module is used for monitoring the temperature of each environment monitoring area in the glass film coating reaction chamber at each monitoring time point and monitoring the concentration of each process gas in each environment monitoring area;
the coating state information monitoring module is used for monitoring the state of the current glass coating to obtain coating state information;
the actual purging information extraction module is used for extracting the actual purging nitrogen flow corresponding to each purging time point in the current glass coating reaction chamber;
the purging setting correction evaluation module is used for performing purging parameter correction evaluation, and when the evaluation result is corrected, the current proper purging nitrogen flow, purging mode and purging frequency are confirmed according to the current set purging nitrogen flow, purging mode and purging frequency;
the purging control management terminal is used for feeding back the current proper purging nitrogen flow, purging mode and purging frequency to the purging control terminal and carrying out purging control correction;
the purge parameter correction evaluation comprises the following steps:
positioning the dust accumulation concentration and the VOC concentration of the current time period from the dust accumulation concentration and the VOC concentration of each impurity monitoring area in the glass coating reaction chamber in each monitoring time period, and counting the interference degree of the current coating impurities；
The temperature of each environment monitoring area in the glass coating reaction chamber at each monitoring time point is recorded as，/>Indicating the number of the environment monitoring area,/->，/>Indicating the monitoring time point number,/->Counting deviation degree of the current coating reaction temperature>；
According to the concentration of each process gas in each environment monitoring area, counting the deviation degree of the reaction atmosphere of the current coating；
Counting the trend degree of the purging parameter correction requirement in the glass coating reaction chamber，，/>、/>、/>Respectively setting the coating impurity removal requirement degree, the coating reaction temperature deviation degree and the coating reaction atmosphere deviation degree which are correspondingly referred by the currently set purging parameters,rounding down the symbol;
if it isTaking the correction as a purge parameter correction evaluation result, otherwise taking the non-correction as a purge parameter correction evaluation result;
the statistics of the interference degree of the current coating impurities comprises the following steps:
the dust concentration and VOC concentration of each impurity monitoring area in the current time period are respectively recorded asAnd->，/>Indicates the impurity monitoring region number, < > and->The cleanliness of each impurity monitoring region was counted +.>，，/>And->Respectively setting the allowable dust concentration and VOC concentration in the reaction chamber;
will beProper cleanliness in the reference film-plating reactor is set>In contrast, statistics are less than +.>Impurity monitoring region number->；
Extracting a minimum value from the cleanliness of each impurity monitoring regionCounting interference degree of current coating impurity>，N is the number of impurity monitoring regions, +.>Impurity distribution dispersion for setting reference;
the step of counting the deviation degree of the current coating reaction temperature comprises the following steps:
constructing a temperature change curve of each environment monitoring area by taking a monitoring time point as an abscissa and taking temperature as an ordinate;
dividing the temperature change curve into temperature change curve segments according to the peak point positions in the temperature change curve, extracting the slope of each temperature change curve segment, further extracting the maximum value and the minimum value from the slope of each temperature change curve segment, and respectively taking the maximum value and the minimum value as the temperature rise rate of each environment monitoring areaAnd the rate of temperature decrease->Counting temperature variation deviation degree of each environment monitoring area>，/>，/>Respectively setting proper temperature rise rate, temperature drop rate and temperature change rate difference in the coating reaction chamber;
counting the deviation degree of the current coating reaction temperature，，/>In order to set the allowable degree of deviation of the temperature change,for the temperature of the jth environmental monitoring area in the glass coating reaction chamber at the t monitoring time point,/>Indicating the number of monitoring time points, +.>And m is the number of environment monitoring areas for the set allowable temperature difference in the glass coating reaction chamber.
2. The intelligent management system for the glass online coating process based on big data as claimed in claim 1, wherein: the purging modes are single-point nozzle purging and annular purging;
the filming state information comprises filming time, filming area, the number of color types existing in the filming area, the filming area occupied by each color type and the thickness of each filming monitoring point in the filming area.
3. The intelligent management system for the glass online coating process based on big data as claimed in claim 1, wherein: the confirmation of the currently suitable purge nitrogen flow includes:
extracting the number of color types existing in the coated area, the area of the coated area occupied by each type of color and the thickness of each coated monitoring point of the coated area from the coated state information, and counting the uniformity of the coated film of the current glass；
The currently set flow rate of the purging nitrogenThe actual purging nitrogen flow corresponding to each purging time point in the current glass coating reaction chamber is subjected to difference to obtain a purging flow difference, and accordinglySetting a purge nitrogen flow correction compensation factor；
Positioning the coated time length from the coating state informationAnd the area of the coated area->Simultaneously, the area of the glass to be coated and the planned coating time length are respectively recorded as +.>And->；
Statistics is carried out on current proper flow of nitrogen purging in glass coating reaction chamber，，/>The deviation degree of the set unit comprehensive coating state and the increased purging nitrogen flow corresponding to the unit purging nitrogen flow correction compensation factor are respectively +.>For a set allowable film coating rate difference +.>The uniformity of the glass coating film and the sweeping parameter of the set reference are respectively corrected to the trend degree of demand +.>And the deviation degree of the current comprehensive coating state in the glass coating reaction chamber is represented.
4. The intelligent management system for the glass online coating process based on big data according to claim 3, wherein: the statistics of the uniformity of the current glass coating comprises the following steps:
the thickness of the current glass to be coated is calculated according to the planned coating thickness and the thickness of each coating monitoring point in the coated area, the thickness difference of each coating monitoring point is obtained, and the maximum thickness difference is extracted from the thickness differenceAnd minimum thickness difference>；
The number of color types existing in the coated area is recorded asExtracting the highest occupied plating area from the plating area occupied by each color>And the area of the lowest occupied coating area->；
Statistics and statistics of uniformity of coating film of current glass，，/>In order to permit the deviation of the thickness of the plating film,the areas of the areas which are set and suitable for different colors and the areas of the allowable variegated coating areas are respectively different.
5. The intelligent management system for the glass online coating process based on big data according to claim 3, wherein: the setting purge nitrogen flow correction compensation factor comprises:
if the purge flow difference of a certain purge corresponding to a certain purge time point is larger than the set allowable purge flow differenceThe purge was designated as a deviation purge, the purge time was designated as a deviation purge time, and the number of deviation purges was counted +.>Counting the number of deviation purging time points of each deviation purging;
recording each non-deviation purging time point in each purging time point corresponding to each deviation purging as each normal purging time point;
marking the deviation purging time points and the normal purging time points corresponding to the deviation purging time points on a time number axis to obtain deviation marking points and normal marking points;
extracting the number of normal marking points of intervals between the deviation marking points corresponding to each deviation blowing, and screening the number of normal marking points of the minimum intervals corresponding to each deviation blowing;
if the ratio of the number of the deviation blowing time points of a certain deviation blowing to the number of the blowing time points is greater thanOr the number of the minimum interval normal marking points of the deviation purging is smaller than 2, marking the deviation purging as serious deviation purging, and counting the number of the serious deviation purging>；
Extracting the maximum purging flow difference of each purging from the purging flow differences of each purging corresponding to each purging time point, and obtaining the average purging flow difference through average value calculation；
Setting a purge nitrogen flow correction compensation factor，/>，Is the number of purges.
6. The intelligent management system for the glass online coating process based on big data as claimed in claim 1, wherein: confirming the currently suitable purging mode comprises the following steps:
will have a cleanliness of less thanThe impurity monitoring areas of the device are marked as key impurity areas, the positions of the key impurity areas are extracted, the positions of the key impurity areas are marked to obtain impurity marking points, and the impurity marking points are sequentially connected to obtain impurity distribution paths;
overlapping and comparing the impurity distribution path with an adaptive purge impurity path purged by a set single-point nozzle to obtain an overlapping path length;
if it isAnd (3) taking the single-point nozzle blowing as a current proper blowing mode, and otherwise taking the annular blowing as the current proper blowing mode.
7. The intelligent management system for the glass online coating process based on big data according to claim 3, wherein: confirming the currently appropriate purge frequency includes:
according toThe method comprises the steps of (1) carrying out statistics in the same way to obtain the interference degree of the coating impurity in each monitoring time period, and constructing a variation curve of the interference degree of the coating impurity by taking the monitoring time period as an abscissa and taking the interference degree of the coating impurity as an ordinate;
dividing the coating impurity disturbance degree change curve into disturbance change curve sections according to the positions of peak points in the coating impurity disturbance degree change curve, screening out disturbance change curve sections with the curve trend as the ascending direction from the disturbance change curve sections, marking the disturbance change curve sections as target curve sections, extracting the slope of each target curve section, taking the slope as the coating impurity disturbance growth rate, and obtaining the average coating impurity disturbance growth rate through mean value calculation；
The currently set purge frequency is recorded asStatistics of currently suitable purge frequency +.>，，/>The conventional coating impurity interference growth rate is set.
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