A microcontroller-based power allocation method and system based on real-time feedback

Abstract

This invention discloses a microcontroller-controlled power allocation method and system based on real-time feedback, relating to the field of medium-frequency induction melting technology. The system includes a host computer, potentiometers, a transformer, a main controller, and a main control board. The microcontroller-controlled power allocation method specifically includes the following steps: acquiring the power signal of each furnace in the medium-frequency furnace; outputting a power setpoint signal based on the sum of the real-time power signals and the total system power; uniformly adjusting the power allocation according to the power setpoint signal; when the actual power signal of a certain path is detected to be less than the power setpoint signal of a certain path on the main control board, the unused power is obtained and centrally allocated. This invention effectively solves the problems of insufficient utilization of the rated power capacity of the transformer and long melting time in existing medium-frequency furnace systems by real-time monitoring of the actual output power of the medium-frequency furnace and using closed-loop feedback adjustment to centrally and evenly distribute unused power to other normally operating medium-frequency furnaces.

Description

Technical Field

[0001] This invention relates to the field of medium-frequency induction melting technology, and in particular to a microcontroller-controlled power distribution method and system based on real-time feedback. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] Most medium-frequency furnace melting systems on the market currently use one power supply to power multiple medium-frequency furnaces, a practice known as "one power supply, multiple furnaces." Figure 1 As shown, the rated power capacity of the transformer (total system power) is P. 总 The rated power of other equipment is P. s The maximum output power (power limit) of each intermediate frequency furnace is P. Under normal circumstances, P 总 <nP+P s Because other devices in the system consume some power, and the transformer's rated power P also needs to be considered. 总 If the capacity is limited, then when the rated power capacity of the transformer is fully utilized, P 总 =P1+P2+···+P n +P s P1~P n P represents the rated power of each intermediate frequency furnace during operation. The rated power of each intermediate frequency furnace is less than its maximum output power (power limit value), i.e., P i <P(i=1,2,3,···,n-1,n).

[0004] However, the inventors discovered that the potentiometers in existing power distribution systems can only adjust the given power of the intermediate frequency furnace, but cannot monitor and adjust the actual output power of the intermediate frequency furnace, resulting in the rated power P of the transformer in the intermediate frequency furnace system being affected. 总 Insufficient capacity utilization and prolonged smelting time are mainly due to the following problems during the smelting process: Medium-frequency furnaces with the capacity to output power are unable to do so due to limitations in the total system power; some medium-frequency furnaces are unable to output the given power due to various limitations such as capacitor voltage, coil current, medium-frequency voltage, and chopper output current. Therefore, the actual output power is less than the rated power value P allocated to them by the system. i (i = 1, 2, 3, ..., n-1, n), resulting in insufficient utilization of the transformer's rated power capacity; furthermore, other equipment is often connected to the transformer, and the current method is to reserve transformer capacity based on the rated power of these other devices. However, these devices often do not operate simultaneously with the induction furnace, thus also causing a waste of transformer capacity. The unused power resulting from the above reasons is denoted as ΔP, ΔP = P 总 -P 实 P 实This represents the total actual output power of each medium-frequency furnace. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide a single-chip microcomputer-controlled power distribution method and system based on real-time feedback. By monitoring the actual output power of the intermediate frequency furnace and the real-time power of other equipment under the transformer in real time, the unused power is concentrated and evenly distributed to other normally operating intermediate frequency furnaces using closed-loop feedback regulation. This overcomes the limitation that potentiometers can only adjust the given power of the intermediate frequency furnace but cannot monitor and adjust the actual output power of the intermediate frequency furnace. It can effectively solve the problems of insufficient utilization of the rated power capacity of the transformer and long melting time in existing intermediate frequency furnace systems.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0007] The first aspect of this invention provides a microcontroller-controlled power allocation method based on real-time feedback, comprising:

[0008] 1. Collect the power command signal for each furnace in the intermediate frequency furnace;

[0009] 2. When the sum of the multiple given signals is less than the total power given value of the system, the power is adjusted according to the original voltage value of each signal, and the signals do not interfere with each other.

[0010] 3. When the sum of multiple given signals is greater than the total system power given value, the adjustment is allocated according to the proportion of each original voltage value in the total system power given value.

[0011] 4. Collect the power signal of each furnace in the medium frequency furnace, and at the same time collect the real-time power of other equipment under the transformer, and sum the real-time power signal of the medium frequency furnace with the real-time power of other equipment.

[0012] 5. Compare the sum of the real-time power signals with the given total power of the system to calculate the remaining capacity of the system.

[0013] 6. Unused power is redistributed. For intermediate frequency furnaces whose actual power reaches the given power and whose given power is less than the power limit, their given power is increased. At the same time, intermediate frequency furnaces whose actual power does not reach the given power are detected and their given power is decreased. Finally, the power of all intermediate frequency furnaces is dynamically optimized and allocated as long as the sum of the given power of all intermediate frequency furnaces does not exceed the total power of the system.

[0014] A second aspect of the present invention provides a microcontroller-controlled power distribution system based on real-time feedback, comprising:

[0015] The system includes a host computer, potentiometers, a transformer, a main controller, and a main control board. The host computer is used to monitor the input and output parameters of the power distribution system and modify the setting value of the total power limit of the medium frequency furnace system online. The main controller is used to automatically adjust the power distribution based on the power signals collected by the multi-channel potentiometers and convert the adjusted multi-channel power signals into given voltages and send them to the main control board.

[0016] Furthermore, the main controller includes a microcontroller and its signal output circuit. The microcontroller is used to automatically adjust the power distribution of multiple power signals and unused power signals, and the signal output circuit is used to convert the adjusted power signals into a given voltage.

[0017] Furthermore, the signal output circuit includes a D / A conversion chip and a controllable precision voltage regulator. The D / A conversion chip is used to simultaneously output multiple analog signals with different voltage ranges, and the controllable precision voltage regulator is used to provide a voltage reference for the D / A conversion chip.

[0018] Furthermore, there are several main control boards, and each furnace is equipped with a main control board. Each main control board receives a given voltage signal.

[0019] A third aspect of the present invention provides a medium having a program stored thereon, which, when executed by a processor, implements the steps in the microcontroller-controlled power allocation method based on real-time feedback as described in the first aspect of the present invention.

[0020] A fourth aspect of the present invention provides an apparatus including a memory, a processor, and a program stored in the memory and executable on the processor, wherein the processor executes the program to implement the steps of the microcontroller-controlled power allocation method based on real-time feedback as described in the first aspect of the present invention.

[0021] The above one or more technical solutions have the following beneficial effects:

[0022] This invention integrates a microcontroller-controlled power distribution system into the existing medium-frequency furnace melting system. The given power of the medium-frequency furnace is adjusted by a potentiometer knob connected to the microcontroller-controlled power distribution system. The microcontroller-controlled power distribution system performs comprehensive scheduling and allocation based on the transformer's rated power capacity, the given power of each device, the actual output power of each device, and the actual power of other devices in the system.

[0023] This invention discloses a single-chip microcomputer-controlled power allocation method and system based on real-time feedback. By monitoring the actual output power of the intermediate frequency furnace in real time, the unused power is concentrated and evenly distributed to other normally operating intermediate frequency furnaces using closed-loop feedback adjustment. This makes up for the deficiency that potentiometers can only adjust the given power of the intermediate frequency furnace, but cannot monitor and adjust the actual output power of the intermediate frequency furnace. It can effectively solve the problems of insufficient utilization of the rated power capacity of the transformer and long melting time in existing intermediate frequency furnace systems.

[0024] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0025] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0026] Figure 1 This is an overall structural diagram of an existing medium-frequency furnace melting system;

[0027] Figure 2 This is a flowchart of the microcontroller-controlled power allocation method based on real-time feedback in Embodiment 1 of the present invention;

[0028] Figure 3 This is an overall structural diagram of the microcontroller-controlled power distribution system based on real-time feedback in Embodiment 2 of the present invention;

[0029] Figure 4 This is a flowchart of the microcontroller-controlled power allocation method based on real-time feedback in Embodiment 3 of the present invention. Detailed Implementation

[0030] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0031] This invention discloses a microcontroller-controlled power allocation method and system based on real-time feedback. By monitoring the actual output power of each medium-frequency furnace and the actual power of other equipment in the system in real time, the unused power is concentrated and evenly distributed to the normally operating medium-frequency furnaces using closed-loop feedback adjustment, that is, the medium-frequency furnaces whose actual power reaches the given power.

[0032] Firstly, when the medium-frequency furnace is started, due to the low temperature of the molten metal and its influence on the inductance of the heating coils inside the furnace, the actual output power of some furnaces cannot immediately reach the given power value. As the heating time increases and the temperature of the molten metal rises, the actual output power of the furnaces that have not yet reached the given power value can be increased. At this point, a microcontroller-controlled power distribution system is needed to monitor and adjust the actual output power of this portion of the furnace in real time, using power distribution to gradually increase the actual output power of the furnace to the given power value over time.

[0033] During the process of adjusting the actual output power of each intermediate frequency furnace to the given power value by the microcontroller-controlled power distribution system, some intermediate frequency furnaces may be unable to output the given power due to various limitations such as capacitor voltage, coil current, intermediate frequency voltage, and chopper output current. Other devices in the system may not all be operating, thus generating some unused power ΔP. Based on the actual output power feedback, the microcontroller-controlled power distribution system will concentrate and evenly distribute the unused power ΔP to the intermediate frequency furnaces whose actual output power has reached the given power, thereby increasing the given value of the intermediate frequency furnaces and ensuring that the transformer capacity is fully utilized.

[0034] In addition, when some intermediate frequency furnaces are shut down, a large amount of unused power is generated. In order to ensure that the rated power capacity of the transformer is fully utilized and that no individual intermediate frequency furnace is damaged, the microcontroller-controlled power distribution system will control the actual maximum output power of each intermediate frequency furnace to not exceed the power limit value P when distributing power.

[0035] The microcontroller-controlled power distribution system of this invention also has a transformer rated power protection function:

[0036] 1. When the system performs power distribution, the actual output power of the system is compared with the total power of the system simultaneously to ensure that the actual output power is always within the total power of the system during the power distribution process.

[0037] 2. The total system power includes the sum of the rated power of each transformer and the rated power of other equipment. During operation, if the power of any transformer reaches its rated power P... i (i=1,2,3,···,n-1,n), then the power distribution system will lock the total power limit to the current state to avoid transformer protection or damage caused by uneven current distribution in parallel transformers.

[0038] 3. Before starting the medium-frequency furnace, adjust the setpoint power of the furnace using a potentiometer. If the total setpoint power of the medium-frequency furnace (including the rated power P of other equipment) is... sIf the total power exceeds the system's total power, the microcontroller-controlled power distribution system will allocate the transformer's rated power capacity according to the ratio of the given power of each intermediate frequency furnace to the total given power, ensuring that the total actual output power does not exceed the system's total power. Even if the total given power displayed on the control panel exceeds the system's total power, the system will control the actual output power within the total system power. This avoids errors caused by manual adjustment of the given power, which could lead to the total output power exceeding the system's power limit and causing the transformer to operate under overload.

[0039] The specific implementation plan is as follows:

[0040] Example 1:

[0041] Embodiment 1 of the present invention provides a microcontroller-controlled power allocation method based on real-time feedback, such as... Figure 2 As shown, it includes:

[0042] Step 1: Collect the power signal of each furnace in the medium frequency furnace system, and sum the real-time power signals of each furnace in the system.

[0043] Step 2: Compare the sum of the real-time power signals with the given total power signal of the system.

[0044] Step 3: Adjust the power distribution according to the power command signal and convert the adjusted power into the command voltage.

[0045] Step 4: When the actual power signal of a certain channel is detected to be less than the power setpoint signal of a certain main control board, the unused power is obtained and the unused power is centrally allocated.

[0046] In step 1, the actual power signals of multiple medium-frequency furnaces, multiple transformer power signals, and other equipment are collected centrally.

[0047] In step 3, when sampling signals from multiple field potentiometers, the power allocation formula is:

[0048]

[0049] Among them, V total V is the total power signal of the system. other The actual power signal from other devices in the system is used to embed this parameter into the CPU of the power distribution system via a host computer. (V) in1 ~V inn V is the original voltage signal given by the field potentiometer. out1 This is the power input voltage signal that is actually output to a certain main control board.

[0050] The specific steps for adjusting the power allocation, derived from the power allocation formula, are as follows:

[0051] When the sum of the original voltage values ​​from multiple channels is less than the total system power signal, the microcontroller adjusts the power based on the individual original voltage values, and the channels do not interfere with each other; at this time, the voltage signal V in =V out .

[0052] When the sum of the multiple original voltage values ​​exceeds the total system power signal, the microcontroller allocates and adjusts the power based on the weight of each original voltage value within the total system power signal. Specifically, it first allocates the power to each furnace voltage signal according to its proportion. The next step is to send the voltage signal to the intermediate frequency furnace, which then operates at the corresponding power based on the voltage signal. This automatically limits the total system power. At this time, the voltage signal V... in >V out .

[0053] In step 4, the intermediate frequency furnace operates stably, and the power set by the main control board is equal to the total system power, i.e., V. out1 +V out2 +V out3 +…+V outn +V other =V total When the actual power signal of a certain channel is less than the power setpoint signal of a certain main control board, i.e., V0 < V out0 In this situation, the actual power of a certain medium-frequency furnace cannot reach the given power of the main control board.

[0054] The formula for comparing the actual power signals acquired from multiple channels with the total power signal of the system is as follows:

[0055] V0+V out1 +V out2 +V out3 +…+V out(n-1) +V other <V total

[0056] Where V0 represents the power generated by the medium-frequency furnace that is malfunctioning, and the subscripts of the other normally operating medium-frequency furnaces are 1, 2, 3, ... n-1, so the total number is still n.

[0057] At this point, the system generates a portion of unused power ΔP. This unused power can be centrally allocated to the remaining normally operating intermediate frequency furnaces. The power allocation formula for the unused power is:

[0058]

[0059] V out_1 This is the power command signal actually output to a specific main control board after unused power allocation; V out1 This refers to the actual power command signal output to a specific main control board before power distribution; VΔP This represents the unused power of the system.

[0060] The specific steps for centralized allocation of unused power are as follows: when the actual output power of multiple channels is less than the total power of the system, the microcontroller allocates and adjusts the power according to the weight of each voltage value in the total power setpoint.

[0061] The total allowable power of the system is calculated based on the collected power signals from each transformer. The formula for the total system power is:

[0062]

[0063] The maximum power signal of each transformer is V P During normal system operation and power distribution, the main controller actually outputs the power command signal to a specific transformer. It must be within the maximum power signal range of the transformer, that is

[0064] Example 2:

[0065] Embodiment 2 of the present invention provides a microcontroller-controlled power distribution system based on real-time feedback, such as... Figure 3 As shown, it includes:

[0066] The system includes a host computer, potentiometers, transformers, a main controller, and a main control board; the potentiometers are multi-channel potentiometers, each of which is individually connected to the main controller; the transformers are multi-channel transformers, each of which is individually connected to the main controller; other devices are also included, each individually connected to the main controller.

[0067] The host computer monitors the input and output parameters of the power distribution system and modifies the total power limit setting online. The main controller automatically adjusts the power distribution based on the power signals collected by the multi-channel potentiometers and converts the adjusted multi-channel power signals into given voltages, which are then sent to the main control board. There are several main control boards, with one main control board for each furnace, and each main control board receives one given voltage signal.

[0068] The main controller includes a microcontroller and its signal output circuit. The microcontroller is an AVR series mega8 microcontroller with built-in 8-channel A / D sampling. Depending on the operational requirements, it can sample up to 4 channels of 0-5V signals from field potentiometers. The microcontroller is used to automatically perform power distribution adjustment on multiple power signals and unused power signals. The signal output circuit is used to convert the multi-channel power signals after distribution adjustment into a given voltage.

[0069] The signal output circuit includes a D / A converter chip and a controllable precision voltage regulator. The D / A converter chip is used to simultaneously output multiple analog signals with different voltage ranges, and the controllable precision voltage regulator is used to provide a voltage reference for the D / A converter chip.

[0070] Example 3:

[0071] Embodiment 3 of the present invention provides a medium on which a program is stored. When executed by a processor, this program implements the steps in the microcontroller-based power allocation method based on real-time feedback as described in Embodiment 1 of the present invention. Figure 4 As shown, the steps are as follows:

[0072] 1) Initialize the device;

[0073] 2) Analog acquisition of multiple power signals, followed by summation calculation;

[0074] 3) Determine if the sum of the multiple power signals is less than the total system power. If yes, proceed to step 4); otherwise, proceed to step 5.

[0075] 4) Adjust power independently based on each power signal;

[0076] 5) The power signals are allocated and adjusted according to their respective weights in the total power of the system;

[0077] 6) Communicate with the host computer once every 0.2 seconds.

[0078] The detailed steps are the same as those in the microcontroller-controlled power allocation method based on real-time feedback provided in Example 1, and will not be repeated here.

[0079] Example 4:

[0080] Embodiment 4 of the present invention provides a device, including a memory, a processor, and a program stored in the memory and executable on the processor. When the processor executes the program, it implements the steps in the microcontroller-controlled power allocation method based on real-time feedback as described in Embodiment 1 of the present invention.

[0081] The detailed steps are the same as those of the power demand response method based on data matching algorithm provided in Example 1, and will not be repeated here.

[0082] The steps and methods involved in Embodiments 2, 3, and 4 above correspond to those in Embodiment 1. For specific implementation details, please refer to the relevant description section of Embodiment 1. The term "computer-readable storage medium" should be understood as a single medium or multiple media including one or more instruction sets; it should also be understood as including any medium capable of storing, encoding, or carrying an instruction set for execution by a processor and enabling the processor to perform any of the methods in this invention.

[0083] Those skilled in the art will understand that the modules or steps of the present invention described above can be implemented using general-purpose computer devices. Optionally, they can be implemented using computer-executable program code, thereby allowing them to be stored in a storage device for execution by a computer device, or they can be fabricated as separate integrated circuit modules, or multiple modules or steps can be fabricated as a single integrated circuit module. The present invention is not limited to any particular combination of hardware and software.

[0084] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A microcontroller-controlled power allocation method based on real-time feedback, characterized in that, include: The power signal of each furnace in the intermediate frequency furnace is collected, and the real-time power signal of the intermediate frequency furnace is summed and calculated. The sum of the real-time power signals is compared with the value of the system's total power given signal; Power allocation is adjusted uniformly based on the power command signal, and the adjusted power is converted into a command voltage. When the actual power signal of a certain channel is detected to be less than the power setpoint signal of a certain main control board, the unused power is acquired and centrally allocated. The microcontroller-controlled power distribution method based on real-time feedback centrally collects actual power signals from multiple medium-frequency furnaces, multiple transformers, and other equipment. The specific steps of the microcontroller-controlled power allocation method based on real-time feedback for centralized allocation of unused power are as follows: when the actual output power given signals of multiple channels are less than the total power of the system, the microcontroller allocates and adjusts the power according to the proportion of each voltage value in the total power given value. The power allocation formula for the unused power is as follows: This is the power command signal actually output to a certain main control board after unused power allocation. This refers to the power command signal actually output to a certain main control board before power distribution. This represents unused power in the system. When some of the intermediate frequency furnaces are shut down, a significant amount of unused power is generated. To ensure full utilization of the transformer's rated power capacity and to prevent damage to individual intermediate frequency furnaces, the microcontroller-controlled power distribution system will control the actual maximum output power of each intermediate frequency furnace to not exceed the power limit value during power distribution. ; The total system power includes the sum of the rated power of each transformer and the rated power of other equipment. During operation, if any transformer reaches its rated power... , If this happens, the power distribution system will lock the total power limit to the current state to avoid transformer protection or damage caused by uneven current distribution in parallel transformers.

2. The microcontroller-based power allocation method based on real-time feedback as described in claim 1, characterized in that, The specific steps for uniformly adjusting power allocation based on the power command signal are as follows: When the sum of the original voltage values ​​of multiple channels is less than the given total power of the system, the power is adjusted according to the original voltage values ​​of each channel, and the channels do not interfere with each other. When the sum of the original voltage values ​​of multiple channels is greater than the total power setpoint of the system, the adjustment is allocated according to the proportion of each original voltage value in the total power setpoint.

3. The microcontroller-based power allocation method based on real-time feedback as described in claim 1, characterized in that, Based on the collected power signals from each transformer, the maximum allowable power of the system is calculated.

4. A microcontroller-controlled power distribution system based on real-time feedback, employing the microcontroller-controlled power distribution method based on real-time feedback as described in any one of claims 1-3, characterized in that, include: The system includes a host computer, potentiometer, transformer, main controller, and main control board. The host computer is used to monitor the input and output parameters of the power distribution system and modify the total power limit setting value online. The main controller is used to automatically adjust the power distribution based on the power signals collected by the multi-channel potentiometers, and convert the adjusted multi-channel power signals into given voltages and send them to the main control board.

5. The microcontroller-controlled power distribution system based on real-time feedback as described in claim 4, characterized in that, The main controller includes a microcontroller and its signal output circuit. The microcontroller is used to automatically adjust the power distribution of multiple power signals and unused power signals. The signal output circuit is used to convert the adjusted power signals into a given voltage.

6. The microcontroller-controlled power distribution system based on real-time feedback as described in claim 4, characterized in that, The signal output circuit includes a D / A converter chip and a controllable precision voltage regulator. The D / A converter chip is used to simultaneously output multiple analog signals with different voltage ranges, and the controllable precision voltage regulator is used to provide a voltage reference for the D / A converter chip.

7. The microcontroller-controlled power distribution system based on real-time feedback as described in claim 4, characterized in that, There are several main control boards, and each furnace is equipped with a main control board. Each main control board receives a given voltage signal.

8. A computer-readable storage medium, characterized in that, It stores multiple instructions, which are adapted to be loaded and executed by the processor of the terminal device according to any one of claims 1-3, the single-chip microcomputer-controlled power allocation method based on real-time feedback.

9. A terminal device, characterized in that, The device includes a processor and a computer-readable storage medium, wherein the processor is used to implement various instructions; and the computer-readable storage medium is used to store multiple instructions adapted to be loaded by the processor and executed by the processor according to any one of claims 1-3, which describes a microcontroller-based power allocation method for real-time feedback.

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