Inert gas shielded alloy bar induction heating device, heating system and control method thereof

Abstract

The invention relates to the technical field of alloy heating, in particular to an inert gas shielded alloy bar induction heating device, a heating system and a control method thereof, which comprises a physical heating tank, a copper pipe positioned in the physical heating tank, a moving platform sliding along the axis of the copper pipe, and an inert gas filling cabinet arranged above the physical heating tank, the filling water pumps are arranged at the two ends of the copper pipe, the electric cabinet is electrically connected with the copper pipe, the pressure sensor is arranged at the bottom of the physical heating groove, and the electric control cabinet is electrically connected with the whole heating device. The heating effect can be reasonably and effectively achieved, electric energy loss is reduced, energy saving is achieved, the heating efficiency is improved, meanwhile, safety in the heating process is improved, the device has the advantages of being simple in structure, convenient to use, safe, reliable in performance, intelligent, energy-saving, environmentally friendly, low in power consumption and the like, a universal chip is adopted, cost is reduced, the circuit integration degree is high, the technology is mature, and popularization is easy. And plate manufacturing procedures are few, and production is easy.

Description

Technical Field

[0001] The invention relates to the technical field of alloy heating, in particular to an inert gas protected alloy bar induction heating device, a heating system and a control method thereof. Background Art

[0002] Induction heating is a powerful heat treatment technology that uses the resistive heating produced by an induced current within a conductive material to quickly heat a metal object. The basic principle of induction heating is based on three main effects, namely electromagnetic induction, skin effect and heat transfer, which work together to convert electrical energy into thermal energy, thereby rapidly heating the conductive material. Induction heating systems use coils to generate a high-frequency AC magnetic field, which generates an electric current within the material, thereby generating heat energy.

[0003] With the rapid development of my country's national economy, my country's industrialization level is changing with each passing day, especially the construction of high-pressure die-casting technology, which has been rapidly developed. However, the ever-changing equipment modernization and the relatively backward level of heating devices are not coordinated. Among them, the non-contact heating method of alloy metal bars and the conveying technology of alloy metal bars after heating are the basic technologies of alloy softening treatment process;

[0004] An electric induction heater for heating metal parts is disclosed in a Chinese patent document with publication number CN104185326A. The alternating current of the electric induction heater for heating metal parts generates an alternating magnetic field in the coil and is effectively guided to the metal part (ingot) by the iron core. Eddy current pairs are induced in the metal ingot to counteract the alternating magnetic field generated by each coil winding. The eddy current can effectively heat the metal ingot. However, since the coil itself is a conductor, the electric induction heater for heating metal parts will also generate eddy current effect, which will inevitably form a heat source, thereby quickly burning itself out and having no heating effect.

[0005] In the existing non-contact heating device for alloy bars, during the non-contact heating process of alloy bars, due to the surface effect and proximity effect of eddy current, the induced current is mainly concentrated on the surface of the workpiece, resulting in the surface temperature of the workpiece being higher than the core temperature, forming a temperature gradient. The temperature gradient may cause uneven stress distribution inside the workpiece, and then cause problems such as cracking. Therefore, accurate temperature measurement and monitoring are key links in the induction heating process. The technical problems to be solved by the present invention are: it is inconvenient for the mobile platform to carry the alloy bars and the temperature gradient formed by the alloy bars during the non-contact heating process affects the yield. Summary of the invention

[0006] In order to overcome the above-mentioned shortcomings of the prior art and effectively solve the deficiencies of the prior art, the present invention provides an induction heating device, a heating system and a control method thereof which can utilize an electronic system to perform temperature sensing and temperature control on an alloy bar.

[0007] The present invention is achieved through the following technical scheme: an inert gas protected alloy bar induction heating device, heating system and control method thereof, including a physical heating tank, a copper tube located inside the physical heating tank, and a movable platform sliding along the axis of the copper tube, characterized in that it also includes an inert gas filling cabinet arranged above the physical heating tank, a filling water pump arranged at both ends of the copper tube, an electrical cabinet electrically connected to the copper tube, a pressure sensor arranged at the bottom of the physical heating tank, and an electric control cabinet electrically connected to the heating device as a whole.

[0008] Optionally, the material of the physical heating tank is a heat-insulating material, the thickness of the heat-insulating material of the physical heating tank is in the range of 3-5 cm, and the upper opening of the physical heating tank is square or circular;

[0009] The copper tube is in a hollow spiral shape, a slide rail is arranged inside the physical heating tank, the mobile platform is slidably connected to the slide rail, the sliding track of the mobile platform coincides with the spiral axis of the copper tube, a linear motor is arranged at one end of the slide rail, the linear motor drives the mobile platform to slide on the slide rail, and both the mobile platform and the slide rail are made of high temperature resistant non-conductive materials;

[0010] A limit switch is arranged at one end of the slide rail, and the limit switch monitors the position of the mobile platform in real time.

[0011] The above technical solution is adopted: a mobile platform sliding on a slide rail is set inside the physical heating tank, the alloy rod is placed on the mobile platform, the mobile platform sends the alloy rod into the coil composed of copper tubes, and the large current output by the high-voltage frequency conversion control cabinet is induced to form an eddy current effect, thereby heating the alloy rod. After the heating of the alloy rod is completed, the mobile platform carries the alloy rod out of the copper tube coil, and the heated alloy rod is clamped by a robotic arm and placed in a die-casting machine for die-casting processing. At the same time, a new alloy rod is placed on the mobile platform for heating, thereby realizing automatic feeding during the heating process of the alloy rod and improving the heating efficiency of the alloy rod. The mobile platform and the slide rail are made of high-temperature resistant non-conductive materials.

[0012] Optionally, an inert gas bottle is provided at the gas outlet of the inert gas filling cabinet, inert gas filling holes are provided on both sides of the top of the physical heating tank, and the gas outlet of the inert gas bottle is connected to the gas filling hole.

[0013] The above technical solution is adopted: by setting an inert gas filling cabinet with an inert gas bottle above the physical heating tank, when the alloy rod is induction heated, the inert gas is added into the physical heating tank, and the added amount is controlled by the inert gas filling cabinet. The alloy materials including magnesium alloy are highly active and easily oxidized. The inert gas stops after reaching a certain height to ensure that the heated alloy rod is immersed in the inert gas to prevent the alloy rod from burning. While the alloy rod is fully and quickly heated, the alloy rod is prevented from contacting with the air to cause oxidation and combustion.

[0014] Optionally, the water filling pump is connected to both ends of the copper tube to form a circulation structure, and the water filling pump continuously delivers circulating pure water into the copper tube. A water filling valve is provided at the water filling connection between the water filling pump and the copper tube. A high-voltage frequency conversion control module is provided inside the electrical cabinet, and the positive and negative poles of the high-voltage frequency conversion control module are electrically connected to the two ends of the copper tube respectively.

[0015] The above technical solution is adopted: by setting a hollow copper tube and allowing flowing pure water to continuously flow through the copper tube, the flowing pure water can take away a large amount of heat generated by the copper tube itself during the induction heating process, ensuring that the temperature of the copper tube is maintained at a low level, and avoiding the copper tube from being deformed or affecting the heating effect due to the continuous increase in its own temperature during the induction heating of the alloy rod.

[0016] Optionally, the pressure sensor collects the pressure at the bottom of the physical heating tank, and calculates the amount of inert gas inside the physical heating tank based on the pressure. By setting a pressure sensor at the bottom of the physical heating tank, the density difference between the inert gas and the air is used to determine the inert gas content inside the physical heating tank. When the inert gas content inside the physical heating tank is insufficient, the inert gas filling cabinet is timely controlled to add inert gas to the physical heating tank, so that the inert gas in the physical heating tank can ensure that the alloy rod is covered, thereby preventing the alloy rod from coming into contact with oxygen and oxidation during the heating process.

[0017] An inert gas protected alloy bar induction heating system comprises a main control system, and a power subsystem, a display subsystem, a detection subsystem connected to the main control system, a system control subsystem connected via a drive circuit, and a data transmission subsystem connected via a large-capacity storage.

[0018] The main control system includes an MCU main control unit, a memory, a button and a power supply, which can receive the detection subsystem data and output control instructions according to the internal control algorithm; the power subsystem includes a charging module, a power control, and a battery to provide power for the system and ensure the normal operation of the equipment; the display subsystem includes a display screen, a drive circuit and an interface to display the equipment status and functions; the detection subsystem includes a temperature detection module, a pressure detection module, a limit detection module and a voltage and current detection module, which are respectively used to detect the temperature of the physical heating tank, the pressure of the inert gas at the bottom of the physical heating tank, and the movement position of the mobile platform; the data transmission subsystem includes data packaging and wireless transmission modules to achieve reliable data transmission. The system control subsystem includes a linear motor control module, a water pump control module, a high-voltage frequency conversion control module and an inert gas filling control module, which perform corresponding functions according to the instructions of the main control system.

[0019] The linear motor control module is connected to the linear motor, and the MCU main control unit controls the movement of the mobile platform on the slide rail through the linear motor control module;

[0020] The water pump control module is connected to the water filling valve and the water filling pump, and the MCU main control unit controls the flow rate of pure water in the copper tube through the water pump control module;

[0021] The high-voltage frequency conversion control module controls the magnitude of the current and voltage passing through the copper tube;

[0022] The inert gas filling control module is connected to the inert gas filling cabinet, and the MCU main control unit controls the volume of the inert gas in the physical heating tank through the inert gas filling control module.

[0023] Optionally, the mass storage is a flash mass storage module designed on a circuit board. The mass storage stores various data of the operation of various parts of the system in a local storage space, and the wireless transmission module transmits the data to a cloud server.

[0024] An inert gas protected alloy bar induction heating control method comprises the following steps:

[0025] Step 1: Place the alloy bar to be heated on the mobile platform, start the linear motor to send the alloy bar to the middle of the copper tube coil, add inert gas through the inert gas adding hole, and prepare for heating;

[0026] Step 2: The power is turned on, the main control system, power subsystem, display subsystem, detection subsystem, system control subsystem, large-capacity storage and data transmission subsystem are initialized, the inert gas filling control module starts the inert gas filling, and the pressure detection module determines whether the inert gas filling meets the requirements;

[0027] Step 3: The detection subsystem works. The limit detection module determines whether the alloy bar to be heated has entered the coil. The MCU main control unit calculates the moving position of the mobile platform, determines whether there are alloy bars, whether the alloy bars have reached the position, and whether the total bar temperature has reached the temperature required for heating. When the temperature of the alloy bar that has reached the predetermined position is lower than the preset temperature, proceed to the next step.

[0028] Step 4: The MCU main control unit starts a large current for heating through the high-voltage frequency conversion control module, and transmits the detection results of the temperature detection module and the voltage and current detection module to the MCU main control unit, calculates the fuzzy PID control parameters, and uses the fuzzy control algorithm to calculate the heating voltage and current, thereby controlling the heating speed. The heating is completed when the temperature of the alloy bar reaches the preset temperature.

[0029] Step 5: Start the linear motor control module to remove the heated alloy rod from the coil. After the robotic arm takes it out, start the mobile platform and repeat the third and fourth steps.

[0030] In the process of steps one to five, the MCU main control unit will save and preliminarily process the information including heating results, pressure, and water pump flow rate, and use the temperature heating status to feed back to the display subsystem to analyze the equipment operation status; and display the results. The data generated by the system operation is stored in the storage space of the large-capacity storage, and then the wireless transmission module of the data transmission subsystem is used to package the data and upload it to the cloud storage system.

[0031] Positive and beneficial effects: 1. The inert gas protected alloy bar induction heating device, heating system and control method thereof can collect information such as the heated alloy bar in real time, and upload the information to the background cloud server by using a wireless transmission module. The large-capacity storage records the result data of the heating process for storage and display. According to the currently collected working status data, the fuzzy classification control algorithm is used to calculate the heating current size, and the calculation result is output to achieve effective control. It can reasonably and effectively achieve the heating effect, reduce the loss of electric energy, achieve energy saving and improve the heating efficiency, and at the same time improve the safety during the heating process. The present invention has the advantages of simple structure, convenience, safety, reliable performance, intelligence, energy saving and environmental protection, low power consumption, etc. It uses general chips to reduce costs, has high circuit integration, mature technology, fewer plate making processes, and is easy to produce.

[0032] 2. The inert gas protected alloy bar induction heating device places the alloy bar on the mobile platform by arranging a mobile platform sliding on a slide rail inside the physical heating tank. The mobile platform feeds the alloy bar into the coil composed of copper tubes, and the large current output by the induction electrical cabinet forms an eddy current effect, thereby heating the alloy bar. After the heating of the alloy bar is completed, the mobile platform carries the alloy bar out of the copper tube coil, and the heated alloy bar is clamped by a mechanical arm and put into a die-casting machine for die-casting processing. At the same time, a new alloy bar is placed on the mobile platform for heating, thereby realizing automatic feeding during the heating process of the alloy bar and improving the alloy To improve the heating efficiency of the alloy rod, the mobile platform and the slide rail are made of high-temperature resistant non-conductive materials. An inert gas filling cabinet with an inert gas bottle is set above the physical heating tank. When the alloy rod is induction heated, the inert gas is added to the physical heating tank. The amount of addition is controlled by the inert gas filling cabinet. Alloy materials including magnesium alloys are highly active and easily oxidized. The inert gas stops after reaching a certain height to ensure that the heated alloy rod is immersed in the inert gas to prevent the alloy rod from burning. While the alloy rod is fully and quickly heated, the alloy rod is prevented from contacting with the air for oxidation and combustion.

[0033] 3. The inert gas protected alloy rod induction heating device, by setting a hollow copper tube and allowing flowing pure water to continuously flow through the copper tube, the flowing pure water can take away a large amount of heat generated by the copper tube itself during the induction heating process, ensuring that the temperature of the copper tube is maintained at a low level, avoiding the copper tube from deforming or affecting the heating effect due to the continuous increase in its own temperature during the induction heating of the alloy rod. By setting a pressure sensor at the bottom of the physical heating tank, the density difference between the inert gas and the air is used to determine the inert gas content inside the physical heating tank. When the inert gas content inside the physical heating tank is insufficient, the inert gas filling cabinet is controlled in time to add inert gas to the physical heating tank, so that the inert gas in the physical heating tank can ensure that the alloy rod is covered, avoiding the oxidation of the alloy rod when it comes into contact with oxygen during the heating process. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic diagram of the composition of the alloy bar induction heating device of the present invention;

[0035] Figure 2 It is a schematic diagram of the composition of the alloy bar induction heating system of the present invention;

[0036] Figure 3 It is a schematic diagram of the fuzzy PID control algorithm of the present invention;

[0037] Figure 4 It is a schematic diagram of the control relationship and control rules of the present invention;

[0038] Figure 5It is a schematic diagram of the matlab simulation processing of the present invention.

[0039] In the figure: 1-electric control cabinet, 2-electric cabinet, 3-gas filling hole, 4-inert gas bottle, 5-slide rail, 6-inert gas filling cabinet, 7-water filling pump, 8-copper pipe, 9-physical heating tank, 10-moving platform, 11-limit switch, 12-linear motor, 13-pressure sensor, 14-water filling valve. DETAILED DESCRIPTION

[0040] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0041] Example 1

[0042] like Figure 1 As shown, an inert gas protected alloy rod induction heating device, heating system and control method thereof, the heating device includes a physical heating tank 9, a copper tube 8 located inside the physical heating tank 9, a movable platform 10 sliding along the axis of the copper tube 8, and also includes an inert gas filling cabinet 6 arranged above the physical heating tank 9, a filling water pump 7 arranged at both ends of the copper tube 8, an electrical cabinet 2 electrically connected to the copper tube 8, a pressure sensor 13 arranged at the bottom of the physical heating tank 9, and an electric control cabinet 1 electrically connected to the heating device as a whole.

[0043] like Figure 1 As shown, the material of the physical heating groove 9 is a heat-insulating material, the thickness of the heat-insulating material of the physical heating groove 9 is in the range of 3-5 cm, and the upper end opening of the physical heating groove 9 is square or circular.

[0044] The copper tube 8 is a hollow spiral coil, a slide rail 5 is arranged inside the physical heating groove 9, the mobile platform 10 is slidably connected to the slide rail 5, the sliding track of the mobile platform 10 coincides with the spiral axis of the copper tube 8, a linear motor 12 is arranged at one end of the slide rail 5, the linear motor 12 drives the mobile platform 10 to slide on the slide rail 5, and both the mobile platform 10 and the slide rail 5 are made of high temperature resistant non-conductive materials.

[0045] A limit switch 11 is provided at one end of the slide rail 5, and the limit switch 11 monitors the position of the mobile platform 10 in real time. The heated alloy rod is placed on the mobile platform 10 by setting the mobile platform 10 sliding on the slide rail 5 inside the physical heating tank 9, and the mobile platform 10 feeds the alloy rod into the coil of the copper tube 8. The alloy rod can be fed into the coil in a horizontal or vertical manner, depending on the placement of the copper tube 8.

[0046] The alloy bar is heated by the eddy current effect caused by the large current output by the electrical cabinet 2. After the heating of the alloy bar is completed, the mobile platform 10 carries the alloy bar away from the copper tube coil, and the heated alloy bar is clamped by the mechanical arm and placed in the die-casting machine for die-casting. At the same time, the alloy bar to be heated is placed on the mobile platform 10 for the above-mentioned heating operation, so as to realize automatic feeding during the heating process of the alloy bar and improve the heating efficiency of the alloy bar. The mobile platform 10 and the slide rail 5 are made of high-temperature resistant non-conductive materials.

[0047] like Figure 1 As shown, in order to quickly and evenly add inert gas, inert gas filling holes 3 are opened on both sides of the top of the physical heating tank 9, and the gas outlet of the inert gas bottle 4 is connected to the gas filling hole 3. The filling cabinet 6 controls the filling amount by controlling the switch size of the two inert gas bottles 4. When performing induction heating of the alloy rod, inert gas is added to the physical heating tank 9, and the amount of addition is controlled by the inert gas filling cabinet 6. Since the alloy materials including magnesium alloys are highly active and easy to oxidize, while the alloy rod is fully and quickly heated, the alloy rod should be prevented from contacting with the air to cause oxidation and combustion. The inert gas filling cabinet 6 stops after the inert gas filled reaches a certain height to ensure that the heated alloy rod is immersed in the inert gas to prevent the alloy rod from burning.

[0048] like Figure 1 As shown, the pressure sensor 13 collects the pressure at the bottom of the physical heating tank 9, and calculates the amount of inert gas inside the physical heating tank 9 according to the pressure. Specifically, a pressure sensor 13 is set at the bottom of the physical heating tank 9, and the amount of inert gas inside the physical heating tank 9 is determined by using the characteristic that the density of the inert gas is greater than the density of the air. When the inert gas content inside the physical heating tank 9 is insufficient, the inert gas filling cabinet 6 is promptly controlled to replenish the inert gas into the physical heating tank 9, so that the inert gas in the physical heating tank 9 can ensure that the alloy rod is covered, and the alloy rod is prevented from being oxidized by contact with oxygen during the heating process.

[0049] like Figure 1 As shown, during heating, a high-voltage frequency conversion control module is provided inside the electrical cabinet 2, and the positive and negative electrodes of the high-voltage frequency conversion control module are electrically connected to the two ends of the copper tube 8 respectively, generating eddy currents on the surface of the alloy rod to heat the alloy rod.

[0050] like Figure 1 As shown, the filling water pump 7 is connected with both ends of the copper tube 8 to form a circulation structure. The filling water pump 7 continuously delivers circulating pure water into the copper tube 8. A water filling valve 14 is provided at the water filling connection between the filling water pump 7 and the copper tube 8.

[0051] In order to ensure that the temperature of the copper tube 8 is at a low temperature, the copper tube 8 is set to be hollow, and flowing pure water is allowed to flow continuously through the copper tube 8. The flowing pure water can take away a large amount of heat generated by the copper tube 8 itself during the induction heating process, ensuring that the temperature of the copper tube is maintained at a low level, thereby avoiding the copper tube from being deformed or affecting the heating effect due to the continuous increase in its own temperature during the induction heating of the alloy rod.

[0052] like Figure 2 The alloy bar induction heating system of the present invention is shown, including a main control system, a power subsystem connected to the main control system, a display subsystem, a detection subsystem, a system control subsystem connected through a drive circuit, and a data transmission subsystem connected through a large-capacity storage. The main control system includes an MCU main control unit, a memory, a button and a power supply to receive the detection subsystem data and output control instructions according to the internal control algorithm; the power subsystem includes a charging module, a power control, and a battery to provide power for the system to ensure the normal operation of the equipment; the display subsystem includes a display screen, a drive circuit and an interface to realize the display of the equipment status and function; the detection subsystem includes a temperature detection module, a pressure detection module, a limit detection module and a voltage and current detection module, which are respectively used to detect the temperature of the physical heating tank, the pressure of the inert gas at the bottom of the physical heating tank, and the motion position of the mobile platform; the data transmission subsystem includes data packaging and wireless transmission modules to realize reliable data transmission. The system control subsystem includes a linear motor control module, a water pump control module, a high-voltage frequency conversion control module and an inert gas filling control module, which perform corresponding functions according to the instructions of the main control system.

[0053] Specifically, if Figure 2 As shown, in the detection subsystem, the temperature detection module detects and collects information on the multi-point temperatures of the physical heating tank, the copper tube and the heated alloy rod through multiple temperature collection points; the pressure detection module uses the pressure sensor at the bottom of the physical heating tank to detect the pressure at the bottom of the physical heating tank, and uses the pressure and the density characteristics of the inert gas to calculate the inert gas content in the physical heating tank; the limit detection module uses the limit switch to determine the position of the mobile platform, and determines whether the mobile platform and the alloy rod are within the heating range of the copper tube. Heating can only be carried out when the mobile platform enters the inside of the copper tube; the current and voltage detection module uses the mutual inductor detection device to detect the output current and voltage of the high-voltage frequency conversion control module, and the high-voltage frequency conversion control module outputs a large current of a certain frequency.

[0054] like Figure 2As shown, the system control subsystem includes a linear motor control module, a water pump control module, a high-voltage frequency conversion control module and an inert gas filling control module. Among them, the linear motor control module is connected to the linear motor, and the MCU main control unit drives the linear motor through the drive circuit to control the movement of the mobile platform on the slide rail; the water pump control module is connected to the water filling valve and the filling water pump, and the MCU main control unit controls the flow of pure water in the copper tube through the drive circuit; the high-voltage frequency conversion control module controls the magnitude of the current and voltage passing through the copper tube; the inert gas filling control module is connected to the inert gas filling cabinet, and the MCU main control unit controls the amount of inert gas in the physical heating tank through the drive circuit.

[0055] like Figure 2 As shown, the large-capacity storage is a flash large-capacity storage module designed on the circuit board, which stores various types of information running in various parts of the system in the local storage space. The wireless transmission module transmits the information to the system background, such as the cloud server, so that it can be viewed at any time.

[0056] The power controller and battery are connected to the MCU main control unit, the power control is connected to the charging module, and the charging module is connected to the battery; the power subsystem is divided into a direct power supply subsystem and a backup power intelligent charging subsystem. The direct power supply subsystem adopts a DC power supply mode, including four voltage modes of 12V, 5V, 48V and 3.3V to cope with different voltage requirements. The backup power charging subsystem charges when not in use, enters a holding state when fully charged, and provides power to the outside when the main power is off or there is a power outage to ensure the normal operation of the system.

[0057] A control method for an alloy bar induction heating device protected by an inert gas comprises the following steps:

[0058] Step 1: Place the alloy bar to be heated on the mobile platform, start the linear motor to send the alloy bar to the middle of the copper tube coil, add inert gas through the inert gas adding hole, and prepare for heating;

[0059] Step 2: The power is turned on, the main control system, power subsystem, display subsystem, detection subsystem, system control subsystem, large-capacity storage and data transmission subsystem are initialized, the inert gas filling control module starts the inert gas filling, and the pressure detection module determines whether the inert gas filling meets the requirements;

[0060] Step 3: The detection subsystem works. The limit detection module determines whether the alloy bar to be heated has entered the coil. The MCU main control unit calculates the moving position of the mobile platform, determines whether there are alloy bars, whether the alloy bars have reached the position, and whether the total bar temperature has reached the temperature required for heating. When the temperature of the alloy bar that has reached the predetermined position is lower than the preset temperature, proceed to the next step.

[0061] Step 4: The MCU main control unit starts a large current for heating through the high-voltage frequency conversion control module, and transmits the detection results of the temperature detection module and the voltage and current detection module to the MCU main control unit, calculates the fuzzy PID control parameters, and uses the fuzzy control algorithm to calculate the heating voltage and current, thereby controlling the heating speed. The heating is completed when the temperature of the alloy bar reaches the preset temperature.

[0062] Step 5: Start the linear motor control module to remove the heated alloy rod from the coil. After the robotic arm takes it out, start the mobile platform and repeat the third and fourth steps.

[0063] In the process of steps one to five, the MCU main control unit will save and preliminarily process the information including heating results, pressure, and water pump flow rate, and use the temperature heating status to feed back to the display subsystem to analyze the equipment operation status; and display the results. The data generated by the system operation is stored in the storage space of the large-capacity storage, and then the wireless transmission module of the data transmission subsystem is used to package the data and upload it to the cloud storage system.

[0064] Example 2

[0065] The spiral copper tube 8 is installed vertically in the physical heating tank 9, and the slide rail 5 is also vertically arranged along the spiral axis of the copper tube 8, so that the mobile platform 10 and the placed alloy rods can be lifted and transported. After the heating treatment of the alloy rods is completed, the mobile platform 10 is directly raised along the slide rail so that the mobile platform 10 and the alloy rods are located above the physical heating tank 9, which is convenient for taking out the heated alloy rods and placing them in the die-casting machine for plastic processing. At the same time, new alloy rods are placed in the mobile platform 10. The vertically lifted mobile platform relative to the horizontally sliding mobile platform can make the alloy rods separate from the physical heating tank 9, which is convenient for clamping and placement.

[0066] Example 3

[0067] like Figure 2 As shown, the mass storage is used to save the core data and save the corresponding data offline in case of emergency. The mass storage is a flash mass storage module designed on the circuit board. The mass storage stores various data of the heating system operation in the local storage space, including various data of the detection. The wireless transmission module transmits the data to the cloud server.

[0068] The wireless transmission module can realize fast and convenient access to the Internet at any time and any place. It has the characteristics of high-speed data transmission, always online, and billing according to data traffic. It is widely used in mobile office, mobile business, mobile information services, mobile Internet, multimedia services, etc. The large-capacity storage includes an on-chip flash storage module and a background cloud server. The data transmitted by the wireless transmission module is stored in the background server in real time. When there is no wireless signal, it is directly saved in the large-capacity storage unit. The background server provides disaster recovery backup data and information servers.

[0069] Example 4

[0070] like Figures 3 to 5 As shown in the figure, the fuzzy PID control algorithm performs fuzzification according to the input current change error, defuzzifies according to the fuzzy reasoning rules, and outputs the control result. The temperature detection module measures the relationship between the heating effect and the current size. The temperature change and heating effect are divided into 5 levels (negative large (NB), negative small (NS), zero (O), positive small (PS) and positive large (PB)). X represents the fuzzy set of fuzzy input variable errors, Y represents the level of change, and Z represents the degree of membership. It is divided into 5 levels according to the empirical value combined with the degree of temperature change. The automation device of the heating system requires that the heating effect can be calculated in time and the temperature change can be responded to in time. If the control effect cannot be timely, overshoot and excessive temperature may occur, resulting in liquefaction of the bar and inability to enter the next step. Therefore, the system has high requirements for the real-time performance of the device. At the same time, according to the actual conditions, the heating device is started after the mobile platform enters the copper tube coil to achieve effective heating.

[0071] The following conclusions can be drawn through MATLAB simulation. In the initial state, as the current increase rate continues to increase, the MCU main control unit will gradually increase the duty cycle through PWM. When the heating speed reaches the maximum or the radius of the heated alloy bar reaches the maximum, the MCU main control unit starts the PWM maximum duty cycle, the heating speed is the maximum, and the temperature rise is the fastest.

Claims

1. An inert gas protected alloy rod induction heating device, comprising a physical heating tank (9), a copper tube (8) located inside the physical heating tank (9), and a moving platform (10) sliding along the axis of the copper tube (8), wherein the alloy rod is placed on the moving platform (10), and the moving platform (10) delivers the alloy rod into the coil of the copper tube (8), characterized in that: It also includes an inert gas filling cabinet (6) arranged above the physical heating tank (9), a filling water pump (7) arranged at both ends of the copper tube (8), an electrical cabinet (2) electrically connected to the copper tube (8), a pressure sensor (13) arranged at the bottom of the physical heating tank (9), and an electrical control cabinet (1) electrically connected to the heating device as a whole.

2. The inert gas protected alloy bar induction heating device according to claim 1, characterized in that: The material of the physical heating groove (9) is a heat-insulating material, the thickness of the heat-insulating material of the physical heating groove (9) is in the range of 3-5 cm, and the upper opening of the physical heating groove (9) is square or circular; The copper tube (8) is in a hollow spiral shape, a slide rail (5) is arranged inside the physical heating tank (9), the mobile platform (10) is slidably connected to the slide rail (5), the sliding track of the mobile platform (10) coincides with the spiral axis of the copper tube (8), a linear motor (12) is arranged at one end of the slide rail (5), the linear motor (12) drives the mobile platform (10) to slide on the slide rail (5), and the mobile platform (10) and the slide rail (5) are both made of high temperature resistant non-conductive materials; A limit switch (11) is provided at one end of the slide rail (5), and the limit switch (11) monitors the position of the mobile platform (10) in real time.

3. The inert gas protected alloy bar induction heating device according to claim 1, characterized in that: An inert gas bottle (4) is provided at the gas outlet of the inert gas filling cabinet (6), inert gas filling holes (3) are provided on both sides of the top of the physical heating tank (9), and the gas outlet of the inert gas bottle (4) is connected to the gas filling holes (3).

4. The inert gas protected alloy bar induction heating device according to claim 1, characterized in that: The filling water pump (7) is connected to both ends of the copper tube (8) to form a circulation structure. The filling water pump (7) continuously delivers circulating pure water into the copper tube (8). A water filling valve (14) is provided at the water filling connection between the filling water pump (7) and the copper tube (8). A high-voltage frequency conversion control module is provided inside the electrical cabinet (2). The positive and negative poles of the high-voltage frequency conversion control module are electrically connected to the two ends of the copper tube (8) respectively.

5. The inert gas protected alloy bar induction heating device according to claim 1, characterized in that: The pressure sensor (13) collects the pressure at the bottom of the physical heating tank (9), and calculates the amount of inert gas inside the physical heating tank (9) according to the pressure.

6. An inert gas protected alloy bar induction heating system according to any one of claims 1 to 5, characterized in that: It includes a main control system, and a power subsystem, a display subsystem, a detection subsystem connected to the main control system, a system control subsystem connected via a drive circuit, and a data transmission subsystem connected via a large-capacity storage.

7. The inert gas protected alloy bar induction heating system according to claim 6, characterized in that: The main control system includes an MCU main control unit, a memory, a button and a power supply, which can receive the detection subsystem data and output control instructions according to the internal control algorithm; the power subsystem includes a charging module, a power control, and a battery to provide power for the system and ensure the normal operation of the equipment; the display subsystem includes a display screen, a drive circuit and an interface to display the equipment status and functions; the detection subsystem includes a temperature detection module, a pressure detection module, a limit detection module and a voltage and current detection module, which are respectively used to detect the temperature of the physical heating tank, the pressure of the inert gas at the bottom of the physical heating tank, and the movement position of the mobile platform; the data transmission subsystem includes data packaging and wireless transmission modules to achieve reliable data transmission. The system control subsystem includes a linear motor control module, a water pump control module, a high-voltage frequency conversion control module and an inert gas filling control module, which perform corresponding functions according to the instructions of the main control system.

8. The inert gas protected alloy bar induction heating system according to claim 6, characterized in that: The system control subsystem includes a linear motor control module, a water pump control module, a high-voltage frequency conversion control module and an inert gas filling control module; The linear motor control module is connected to the linear motor (12), and the MCU main control unit controls the movement of the mobile platform (10) on the slide rail (5) through the linear motor control module; The water pump control module is connected to the water filling valve (14) and the water filling pump (7), and the MCU main control unit controls the flow rate of pure water in the copper tube (8) through the water pump control module; The high-voltage frequency conversion control module controls the magnitude of the current and voltage passing through the copper tube (8); The inert gas filling control module is connected to the inert gas filling cabinet (6), and the MCU main control unit controls the volume of the inert gas in the physical heating tank (9) through the inert gas filling control module.

9. The inert gas protected alloy bar induction heating system according to claim 6, characterized in that: The large-capacity storage is a flash large-capacity storage module designed on the circuit board. The large-capacity storage stores various types of data running in various parts of the system in the local storage space, and the wireless transmission module transmits the data to the cloud server.

10. A control method for an inert gas protected alloy bar induction heating device according to any one of claims 1 to 9, characterized in that: The following steps are involved: Step 1: Place the alloy bar to be heated on the mobile platform, start the linear motor to send the alloy bar to the middle of the copper tube coil, add inert gas through the inert gas adding hole, and prepare for heating; Step 2: The power is turned on, the main control system, power subsystem, display subsystem, detection subsystem, system control subsystem, large-capacity storage and data transmission subsystem are initialized, the inert gas filling control module starts the inert gas filling, and the pressure detection module determines whether the inert gas filling meets the requirements; Step 3: The detection subsystem works, the limit detection module determines whether the alloy bar to be heated has entered the coil, and the MCU main control unit calculates the moving position of the mobile platform, determines whether there is an alloy bar, whether the alloy bar has reached the position, and whether the total bar temperature has reached the temperature required for heating. When the temperature of the alloy bar that has reached the predetermined position is lower than the preset temperature, proceed to the next step; Step 4: The MCU main control unit starts a large current for heating through the high-voltage frequency conversion control module, and transmits the detection results of the temperature detection module and the voltage and current detection module to the MCU main control unit, calculates the fuzzy PID control parameters, and uses the fuzzy control algorithm to calculate the heating voltage and current, thereby controlling the heating speed. When the temperature of the alloy bar reaches the preset temperature, the heating is completed; Step 5: Start the linear motor control module to remove the heated alloy rod from the coil. After the robotic arm takes it out, start the mobile platform and repeat the third and fourth steps. During steps one to five, the MCU main control unit saves and preliminarily processes the information including the heating results, pressure, and water pump flow rate, and uses the temperature heating status to feed back to the display subsystem to analyze the equipment operation status; and displays the results. The data generated by the system operation is stored in the storage space of the large-capacity storage, and then uploaded to the cloud storage system after the data is packaged by the wireless transmission module of the data transmission subsystem.

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