Systems and Methods for Controlling Current During Electrochemical Processes

A method for controlling current during electrochemical processes, the method comprising:

• providing a system for controlling current during electrochemical processes, including:
• an electrochemical cell, the cell comprising:
• a tank, the tank including a suitable electrolyte solution;
• an anode and a cathode, said anode and cathode in electrical communication with said electrolyte solution;
• and
• a power supply;
• a current sensor for measuring the current in the system;
• one or more semiconductor arrays;
• and
• a microcontroller system;
• said microcontroller system setting a target system operating current;
• said microcontroller system comparing said measured current to said target system operating current;
• said microcontroller system identifying a deviation between said measured current and said target operating current;
• said microcontroller adjusting the bias of said semiconductor arrays to modulate the measured current to maintain the modulated current generally at said target system operating current;
• and
• adjusting the frequency of said system for resonance with relation to said cell.

A method of AC electrolytic anodizing, the method comprising:

• providing a system for controlling current during electrochemical processes, including:
• an electrochemical cell, the cell comprising:
• a tank, the tank including a suitable electrolyte solution;
• an anode and a cathode, said anode and cathode in electrical communication with said electrolyte solution;
• and
• a power supply;
• a current sensor for measuring the current in the system;
• a microcontroller system;
• a positive DC voltage rail;
• a negative DC voltage rail;
• at least one means of controlling said positive DC voltage rail and said negative DC voltage rail;
• one or more semiconductor arrays on said positive DC voltage rail;
• and
• one or more semiconductor arrays on said negative DC voltage rail;
• said means generating a positive half of a waveform on said positive DC voltage rail and a negative half of said waveform on said negative DC voltage rail;
• said positive half of the waveform being combined with said negative half of the waveform to create a synthesized AC waveform;
• said microcontroller system setting a target system operating current;
• said microcontroller system comparing said measured current to said target system operating current;
• said microcontroller system identifying a deviation between said measured current and said target operating current;
• said microcontroller system adjusting the bias of said semiconductor arrays on said positive DC voltage rail and said semiconductor arrays on said negative DC voltage rail to modulate the measured current to maintain the modulated current generally at said target system operating current;
• and
• said microcontroller system electrically communicating with said semiconductor arrays on said positive DC voltage rail and said semiconductor arrays on said negative DC voltage rail to control the frequency of the synthesized AC waveform.

A method of continuous coil anodizing, the method comprising:

• providing a system for controlling current during electrochemical processes, including:
• an electrochemical cell, the cell comprising:
• a tank, the tank including a suitable electrolyte solution;
• a coil;
• a plurality of cathodes, wherein the plurality of cathodes includes cathodes of varying resistive values;
• and
• a power supply;
• a current sensor for measuring the current in the system;
• a voltage sensor for measuring the voltage in the system;
• one or more semiconductor arrays;
• and
• a microcontroller system;
• placing each cathode of said plurality of cathodes in order of decreasing resistive value in said electrolyte solution;
• submerging said coil in said electrolyte solution at the location of the highest resistive value cathode;
• applying a steady voltage to said system;
• said microcontroller system monitoring said measured voltage and adjusting the bias of said semiconductor arrays to maintain said system at a steady voltage;
• and
• simulating a ramp profile of slowly increasing current by moving said coil past each said cathode and through said electrolyte solution.