Intelligent control system and method for soldering station temperature

Abstract

The present invention relates to the field of soldering station temperature control technology, specifically to a soldering station temperature intelligent control system and method, comprising a setting module, a sensing module, an analysis module, an adjustment module and a fault maintenance module; the present invention optimizes the control algorithm of soldering station temperature regulation, comprehensively considers temperature deviation, cumulative temperature deviation and temperature deviation change rate, analyzes the temperature regulation effect from three aspects of real-time temperature, cumulative temperature change and temperature change rate, and meets the demand for precise temperature control; by setting a control signal and a signal output judgment mechanism in the adjustment module, the temperature deviation, cumulative temperature deviation and temperature deviation change rate data are comprehensively analyzed, and the efficient execution of temperature precision control operation is achieved; by analyzing the harmonic current in the soldering station circuit through the fault maintenance module, the current waveform distortion is sensed, the equipment is prevented from overheating or even damage, and the stable operation of the power system is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of soldering station temperature control, and in particular to a soldering station temperature intelligent control system and method. Background Art

[0002] Soldering station temperature control technology is a key part of the electronic welding process, which is directly related to the welding quality and production efficiency. Soldering station temperature control technology is widely used in electronic appliance repair, electronic integrated circuit and chip manufacturing, PCB circuit board soldering in electronic factories and other fields. In industrial production, soldering station temperature control technology plays an important role in improving welding quality and production efficiency. Modern soldering station temperature control technology usually has high precision and can ensure stable temperature during the welding process.

[0003] However, the existing soldering station temperature control technology has significant deficiencies and limitations in many aspects. First, most soldering stations currently use PID control algorithms for temperature control. Although this algorithm is simple and effective, it may not fully meet the needs of precise control in the face of complex and changeable soldering environments.

[0004] In addition, the soldering station needs regular maintenance during use, such as cleaning dust, replacing worn parts, etc. If the maintenance is not done properly, the performance of the soldering station may decline and the temperature control effect may be affected.

[0005] Therefore, it is necessary to propose a soldering station temperature intelligent control system and method to solve the above problems. Summary of the invention

[0006] The purpose of the present invention is to solve the problems existing in the background technology and to provide a soldering station temperature intelligent control system and method;

[0007] The purpose of the present invention can be achieved through the following technical solutions:

[0008] On the one hand, the present invention provides a soldering station temperature intelligent control system, including a setting module, a sensing module, an analysis module, an adjustment module and a fault maintenance module;

[0009] The setting module obtains the temperature setting value T(t) through the display screen and the knob every preset time △t, that is, the expected value of the soldering iron tip temperature set by the user at a certain time t, where t is time.

[0010] As a preferred embodiment of the present invention, the sensing module senses the real-time temperature r(t) of the soldering iron tip based on the change of electromotive force generated by the thermoelectric effect of the thermocouple at a preset time interval △t, where t is time. The real-time temperature deviation e1(t) is calculated by the formula e1(t)=T(t)-r(t).

[0011] Furthermore, the real-time temperature deviation e1(t) is visualized and function-fitted, and a real-time temperature deviation-time change graph is dynamically generated with time as the horizontal axis and the real-time temperature deviation e1(t) as the vertical axis. By continuously adding newly calculated time and real-time temperature deviation data points (t, e1(t)) to the image and connecting all data points with a smooth curve, it is ensured that the image presents a trend of dynamic extension and that the image intuitively reflects the changing trend of the real-time temperature deviation of the soldering iron tip over time.

[0012] As a preferred embodiment of the present invention, by formula Calculate the cumulative temperature deviation e2(t) by the formula Calculate the temperature deviation change rate e3(t).

[0013] Furthermore, the sensing module senses fault data based on the soldering station circuit, obtains the current I(t) in the soldering station circuit through an oscilloscope, and plots the current-time variation graph with time as the horizontal axis and current as the vertical axis. The current-time variation graph is transformed from the time domain to the frequency domain through fast Fourier transform to obtain a current spectrum. In the current spectrum, the effective value of the third harmonic current I(n=3), the effective value of the fifth harmonic current I(n=5), and the effective value of the seventh harmonic current I(n=7) are extracted, and the frequency n(5) corresponding to the third harmonic current, the frequency n(3) corresponding to the fifth harmonic current, and the frequency n(7) corresponding to the seventh harmonic current are obtained.

[0014] As a preferred embodiment of the present invention, the analysis module presets a set of control signals, specifically: five temperature increase control signals P1-P5, five temperature decrease control signals M1-M5 and one maintenance control signal H, respectively;

[0015] The temperature rise control signals P1-P5 are respectively = P1 = +0000; P2 = ++000; P3 = +++00; P4 = ++++0; P5 = +++++;

[0016] The cooling control signals M1-M5 are respectively = M1:-0000; M2=--000; M3=---00; M4=----0; M5=-----;

[0017] The control signal H is maintained at H=00000.

[0018] It should be noted that in the control signal, the adjustment symbols "+", "-" and "0" each accurately map a specific control operation. Among them, the "+" symbol represents the connection of the thyristor used for the heating element to perform the heating operation; the "-" symbol indicates the connection of the thyristor used for the cooling element to achieve cooling control; and the "0" symbol means that the thyristors connected to the heating and cooling elements are cut off at the same time to maintain the current temperature state, that is, to maintain the operation. In addition, each control signal encodes five adjustment symbols, which together define five independent adjustment actions that are performed continuously and orderly within a single adjustment cycle △t. The time distribution of these five adjustment actions is equal, that is, the execution time of each operation is strictly controlled at △t / 5. At the same time, the arrangement order of the five adjustment symbols determines the execution order of these adjustment actions, thereby realizing the fine management and control of temperature changes.

[0019] As a preferred embodiment of the present invention, the temperature increase control signals P1 to P5 realize a temperature increase power output that increases step by step from low to high by setting the number of thyristor conduction times of different temperature increase components within a single adjustment time; correspondingly, the temperature reduction control signals M1 to M5 realize a temperature reduction power output that increases step by step from low to high by setting the number of thyristor conduction times of different temperature reduction components within a single adjustment time; the maintenance control signal H aims to minimize the unnecessary intervention of the soldering station on the temperature of the soldering iron tip by setting the continuous disconnection of the thyristors that control the temperature increase components and the temperature reduction components within a single adjustment time, thereby maintaining a relatively stable temperature state.

[0020] As a preferred embodiment of the present invention, a signal output judgment mechanism is established, specifically: obtaining the real-time temperature deviation e1(t), the accumulated temperature deviation e2(t) and the temperature deviation change rate e3(t).

[0021] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) > λ, a temperature increase control signal P5 is generated;

[0022] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) ≤ λ, a temperature increase control signal P4 is generated;

[0023] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is greater than λ, a temperature increase control signal P3 is generated;

[0024] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is less than or equal to λ, a temperature increase control signal P2 is generated;

[0025] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)>0, a temperature increase control signal P1 is generated;

[0026] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)=0, a maintenance control signal H is generated;

[0027] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)<0, a temperature reduction control signal M1 is generated;

[0028] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)≤λ, a cooling control signal M2 is generated;

[0029] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)>λ, a cooling control signal M3 is generated;

[0030] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)≤λ, a temperature reduction control signal M4 is generated;

[0031] When the real-time temperature deviation e1 (t)>0, the accumulated temperature deviation e2 (t)>δ, and the temperature deviation change rate e3 (t)>λ, the temperature reduction control signal M5 is generated.

[0032] Wherein δ and λ are preset judgment parameters.

[0033] Analyze the values ​​of real-time temperature deviation e1(t), cumulative temperature deviation e2(t) and temperature deviation change rate e3(t), and generate and output corresponding control signals in strict accordance with the established signal output judgment mechanism.

[0034] The regulation module obtains the control signal generated by the analysis module and strictly executes the regulation operation it points to.

[0035] As a preferred embodiment of the present invention, the fault maintenance module obtains the effective value of the 3rd harmonic current I (n=3), the effective value of the 5th harmonic current I (n=5), and the effective value of the 7th harmonic current I (n=7) extracted by the perception module, and obtains the frequency n (5) corresponding to the 3rd harmonic current, the frequency n (3) corresponding to the 5th harmonic current, and the frequency n (7) corresponding to the 7th harmonic current. By formula Calculate the fault characteristic index M, where k is the harmonic current order, k=3, 5, 7; where γk is a set of preset influence factors, γk=γ3, γ5, γ7; where μk is a set of preset bias factors, μk=μ3, μ5, μ7. When the fault characteristic index is M, obtain the control signal history of the analysis module. If it contains R consecutive temperature increase control signals P5 or R consecutive temperature reduction control signals M5, a fault alarm is issued through the display screen. Where R is a preset fault judgment parameter.

[0036] On the other hand, the present invention provides a method for intelligently controlling the temperature of a soldering station, which specifically comprises the following steps:

[0037] Step 1: Set the desired temperature value;

[0038] The temperature setting value T(t) is obtained through the display screen and the knob at every preset time △t, that is, the expected value of the soldering iron tip temperature set by the user at a certain time t, where t is time.

[0039] Step 2: Temperature data perception;

[0040] The real-time temperature r(t) of the soldering iron tip is sensed based on the change in electromotive force generated by the thermoelectric effect of the thermocouple at preset time intervals △t, where t is time. The real-time temperature deviation e1(t) is calculated using the formula e1(t)=T(t)-r(t).

[0041] The real-time temperature deviation e1(t) is visualized and function-fitted, and a real-time temperature deviation-time change graph is dynamically generated with time as the horizontal axis and the real-time temperature deviation e1(t) as the vertical axis. Newly calculated time and real-time temperature deviation data points (t, e1(t)) are continuously added to the image and all data points are connected with a smooth curve to ensure that the image presents a trend of dynamic extension and that the image intuitively reflects the trend of the real-time temperature deviation of the soldering iron tip over time.

[0042] By formula Calculate the cumulative temperature deviation e2(t) by the formula Calculate the temperature deviation change rate e3(t).

[0043] Step 3: Temperature data analysis;

[0044] A set of control signals is preset, specifically: five temperature increase control signals P1-P5, five temperature decrease control signals M1-M5 and one maintenance control signal H, respectively;

[0045] The temperature rise control signals P1-P5 are respectively = P1 = +0000; P2 = ++000; P3 = +++00; P4 = ++++0; P5 = +++++;

[0046] The cooling control signals M1-M5 are respectively = M1:-0000; M2=--000; M3=---00; M4=----0; M5=-----;

[0047] The control signal H is maintained at H=00000.

[0048] A signal output judgment mechanism is established, specifically: obtaining the real-time temperature deviation e1(t), the accumulated temperature deviation e2(t) and the temperature deviation change rate e3(t).

[0049] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) > λ, a temperature increase control signal P5 is generated;

[0050] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) ≤ λ, a temperature increase control signal P4 is generated;

[0051] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is greater than λ, a temperature increase control signal P3 is generated;

[0052] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is less than or equal to λ, a temperature increase control signal P2 is generated;

[0053] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)>0, a temperature increase control signal P1 is generated;

[0054] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)=0, a maintenance control signal H is generated;

[0055] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)<0, a temperature reduction control signal M1 is generated;

[0056] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)≤λ, a cooling control signal M2 is generated;

[0057] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)>λ, a cooling control signal M3 is generated;

[0058] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)≤λ, a temperature reduction control signal M4 is generated;

[0059] When the real-time temperature deviation e1 (t)>0, the accumulated temperature deviation e2 (t)>δ, and the temperature deviation change rate e3 (t)>λ, the temperature reduction control signal M5 is generated.

[0060] Wherein δ and λ are preset judgment parameters.

[0061] Analyze the values ​​of real-time temperature deviation e1(t), cumulative temperature deviation e2(t) and temperature deviation change rate e3(t), and generate and output corresponding control signals in strict accordance with the established signal output judgment mechanism.

[0062] Step 4: Signal response;

[0063] The acquisition and analysis module generates control signals and strictly executes the regulatory operations it points to.

[0064] Step 5: Fault perception and maintenance;

[0065] The current I(t) is obtained in the soldering station circuit by an oscilloscope and a current-time variation diagram is drawn with time as the horizontal axis and current as the vertical axis. The current-time variation diagram is transformed from the time domain to the frequency domain by fast Fourier transform to obtain a current spectrum. The effective value of the third harmonic current I(n=3), the effective value of the fifth harmonic current I(n=5) and the effective value of the seventh harmonic current I(n=7) are extracted from the current spectrum, and the frequency n(5) corresponding to the third harmonic current, the frequency n(3) corresponding to the fifth harmonic current and the frequency n(7) corresponding to the seventh harmonic current are obtained.

[0066] By formula Calculate the fault characteristic index M, where k is the harmonic current order, k=3, 5, 7; where γk is a set of preset influence factors, γk=γ3, γ5, γ7; where μk is a set of preset bias factors, μk=μ3, μ5, μ7. When the fault characteristic index is M, obtain the control signal history of the analysis module. If it contains R consecutive temperature increase control signals P5 or R consecutive temperature reduction control signals M5, a fault alarm is issued through the display screen. Where R is a preset fault judgment parameter.

[0067] Compared with the prior art, the present invention has the following beneficial effects:

[0068] (1) The present invention optimizes the control algorithm of soldering station temperature regulation through the perception module and the analysis module, comprehensively considers the temperature deviation, the cumulative temperature deviation and the temperature deviation change rate, analyzes the temperature regulation effect from three aspects: real-time temperature, cumulative temperature change and temperature change rate, and meets the demand for precise temperature control;

[0069] (2) The present invention realizes efficient execution of temperature precision control operation by setting control signals and signal output judgment mechanisms in the adjustment module to comprehensively analyze temperature deviation, cumulative temperature deviation and temperature deviation change rate data. At the same time, the execution sequence of these adjustment actions is determined by the arrangement sequence of the five adjustment symbols, thereby realizing fine management and control of temperature changes;

[0070] (3) The present invention analyzes the harmonic current in the welding station circuit through the fault maintenance module. The harmonic current may cause resonance in the power system, resulting in voltage waveform distortion, equipment overheating and even damage. Harmonic current analysis helps to prevent these problems and ensure the stable operation of the power system. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] In order to facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0072] Figure 1 is a system block diagram of the present invention;

[0073] Figure 2 It is a schematic diagram of the signal output judgment mechanism of the present invention;

[0074] Figure 3 The present invention is a flow chart of the method. DETAILED DESCRIPTION

[0075] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0076] See also Figure 1 As shown, a soldering station temperature intelligent control system includes a setting module, a sensing module, an analysis module, an adjustment module and a fault maintenance module;

[0077] The setting module obtains the temperature setting value T(t) through the display screen and the knob every preset time △t, that is, the expected value of the soldering iron tip temperature set by the user at a certain time t, where t is time.

[0078] The sensing module senses the real-time temperature r(t) of the soldering iron tip based on the change in electromotive force generated by the thermoelectric effect of the thermocouple at preset intervals △t, where t is time. The real-time temperature deviation e1(t) is calculated using the formula e1(t)=T(t)-r(t).

[0079] Furthermore, the real-time temperature deviation e1(t) is visualized and function-fitted, and a real-time temperature deviation-time change graph is dynamically generated with time as the horizontal axis and the real-time temperature deviation e1(t) as the vertical axis. By continuously adding newly calculated time and real-time temperature deviation data points (t, e1(t)) to the image and connecting all data points with a smooth curve, it is ensured that the image presents a trend of dynamic extension and that the image intuitively reflects the changing trend of the real-time temperature deviation of the soldering iron tip over time.

[0080] By formula Calculate the cumulative temperature deviation e2(t) by the formula Calculate the temperature deviation change rate e3(t).

[0081] Furthermore, the sensing module senses fault data based on the soldering station circuit, obtains the current I(t) in the soldering station circuit through an oscilloscope, and plots the current-time variation graph with time as the horizontal axis and current as the vertical axis. The current-time variation graph is transformed from the time domain to the frequency domain through fast Fourier transform to obtain a current spectrum. In the current spectrum, the effective value of the third harmonic current I(n=3), the effective value of the fifth harmonic current I(n=5), and the effective value of the seventh harmonic current I(n=7) are extracted, and the frequency n(5) corresponding to the third harmonic current, the frequency n(3) corresponding to the fifth harmonic current, and the frequency n(7) corresponding to the seventh harmonic current are obtained.

[0082] The analysis module presets a set of control signals, specifically: five temperature increase control signals P1-P5, five temperature decrease control signals M1-M5 and one maintenance control signal H, respectively;

[0083] The temperature rise control signals P1-P5 are respectively = P1 = +0000; P2 = ++000; P3 = +++00; P4 = ++++0; P5 = +++++;

[0084] The cooling control signals M1-M5 are respectively = M1:-0000; M2=--000; M3=---00; M4=----0; M5=-----;

[0085] The control signal H is maintained at H=00000.

[0086] It should be noted that in the control signal, the adjustment symbols "+", "-" and "0" each accurately map a specific control operation. Among them, the "+" symbol represents the connection of the thyristor used for the heating element to perform the heating operation; the "-" symbol indicates the connection of the thyristor used for the cooling element to achieve cooling control; and the "0" symbol means that the thyristors connected to the heating and cooling elements are cut off at the same time to maintain the current temperature state, that is, to maintain the operation. In addition, each control signal encodes five adjustment symbols, which together define five independent adjustment actions that are performed continuously and orderly within a single adjustment cycle △t. The time distribution of these five adjustment actions is equal, that is, the execution time of each operation is strictly controlled at △t / 5. At the same time, the arrangement order of the five adjustment symbols determines the execution order of these adjustment actions, thereby realizing the fine management and control of temperature changes.

[0087] It should be further explained that the temperature increase control signals P1 to P5 achieve a temperature increase power output that increases step by step from low to high by setting the number of thyristor conduction times of different temperature increase components within a single adjustment time; correspondingly, the temperature reduction control signals M1 to M5 achieve a temperature reduction power output that increases step by step from low to high by setting the number of thyristor conduction times of different temperature reduction components within a single adjustment time; the maintenance control signal H aims to minimize the unnecessary intervention of the soldering station on the temperature of the soldering iron tip by setting the continuous disconnection of the thyristors that control the temperature increase components and the temperature reduction components within a single adjustment time, thereby maintaining a relatively stable temperature state.

[0088] For example, the preset adjustment time △t=5 seconds, then the adjustment operation corresponding to the temperature increase control signal P1=+0000 is as follows: the operation is performed in the first second: turn on the thyristor that controls the temperature increase component; the operation is performed in the second, third, fourth, and fifth seconds: simultaneously turn off the thyristors that control the temperature increase component and the temperature reduction component.

[0089] See also Figure 2 As shown, a signal output judgment mechanism is established, specifically: obtaining the real-time temperature deviation e1(t), the accumulated temperature deviation e2(t) and the temperature deviation change rate e3(t).

[0090] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) > λ, a temperature increase control signal P5 is generated;

[0091] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) ≤ λ, a temperature increase control signal P4 is generated;

[0092] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is greater than λ, a temperature increase control signal P3 is generated;

[0093] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is less than or equal to λ, a temperature increase control signal P2 is generated;

[0094] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)>0, a temperature increase control signal P1 is generated;

[0095] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)=0, a maintenance control signal H is generated;

[0096] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)<0, a temperature reduction control signal M1 is generated;

[0097] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)≤λ, a cooling control signal M2 is generated;

[0098] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)>λ, a cooling control signal M3 is generated;

[0099] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)≤λ, a temperature reduction control signal M4 is generated;

[0100] When the real-time temperature deviation e1 (t)>0, the accumulated temperature deviation e2 (t)>δ, and the temperature deviation change rate e3 (t)>λ, the temperature reduction control signal M5 is generated.

[0101] Wherein δ and λ are preset judgment parameters.

[0102] Analyze the values ​​of real-time temperature deviation e1(t), cumulative temperature deviation e2(t) and temperature deviation change rate e3(t), and generate and output corresponding control signals in strict accordance with the established signal output judgment mechanism.

[0103] The regulation module obtains the control signal generated by the analysis module and strictly executes the regulation operation it points to.

[0104] The fault maintenance module obtains the effective value of the 3rd harmonic current I (n=3), the effective value of the 5th harmonic current I (n=5), and the effective value of the 7th harmonic current I (n=7) extracted by the perception module, and obtains the frequency n (5) corresponding to the 3rd harmonic current, the frequency n (3) corresponding to the 5th harmonic current, and the frequency n (7) corresponding to the 7th harmonic current. Calculate the fault characteristic index M, where k is the harmonic current order, k=3, 5, 7; where γk is a set of preset influence factors, γk=γ3, γ5, γ7; where μk is a set of preset bias factors, μk=μ3, μ5, μ7. When the fault characteristic index is M, obtain the control signal history of the analysis module. If it contains R consecutive temperature increase control signals P5 or R consecutive temperature reduction control signals M5, a fault alarm is issued through the display screen. Where R is a preset fault judgment parameter.

[0105] It should be noted that the control signal history record refers specifically to the control signal output data record of the analysis module, which includes the types and generation times of all output control signals.

[0106] See also Figure 3 As shown, a method for intelligently controlling the temperature of a soldering station comprises the following steps:

[0107] Step 1: Set the desired temperature value;

[0108] The temperature setting value T(t) is obtained through the display screen and the knob at every preset time △t, that is, the expected value of the soldering iron tip temperature set by the user at a certain time t, where t is time.

[0109] Step 2: Temperature data perception;

[0110] The real-time temperature r(t) of the soldering iron tip is sensed based on the change in electromotive force generated by the thermoelectric effect of the thermocouple at preset time intervals △t, where t is time. The real-time temperature deviation e1(t) is calculated using the formula e1(t)=T(t)-r(t).

[0111] The real-time temperature deviation e1(t) is visualized and function-fitted, and a real-time temperature deviation-time change graph is dynamically generated with time as the horizontal axis and the real-time temperature deviation e1(t) as the vertical axis. Newly calculated time and real-time temperature deviation data points (t, e1(t)) are continuously added to the image and all data points are connected with a smooth curve to ensure that the image presents a trend of dynamic extension and that the image intuitively reflects the trend of the real-time temperature deviation of the soldering iron tip over time.

[0112] By formula Calculate the cumulative temperature deviation e2(t) by the formula Calculate the temperature deviation change rate e3(t).

[0113] Step 3: Temperature data analysis;

[0114] A set of control signals is preset, specifically: five temperature increase control signals P1-P5, five temperature decrease control signals M1-M5 and one maintenance control signal H, respectively;

[0115] The temperature rise control signals P1-P5 are respectively = P1 = +0000; P2 = ++000; P3 = +++00; P4 = ++++0; P5 = +++++;

[0116] The cooling control signals M1-M5 are respectively = M1:-0000; M2=--000; M3=---00; M4=----0; M5=-----;

[0117] The control signal H is maintained at H=00000.

[0118] A signal output judgment mechanism is established, specifically: obtaining the real-time temperature deviation e1(t), the accumulated temperature deviation e2(t) and the temperature deviation change rate e3(t).

[0119] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) > λ, a temperature increase control signal P5 is generated;

[0120] When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) ≤ λ, a temperature increase control signal P4 is generated;

[0121] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is greater than λ, a temperature increase control signal P3 is generated;

[0122] When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is less than or equal to λ, a temperature increase control signal P2 is generated;

[0123] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)>0, a temperature increase control signal P1 is generated;

[0124] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)=0, a maintenance control signal H is generated;

[0125] When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)<0, a temperature reduction control signal M1 is generated;

[0126] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)≤λ, a cooling control signal M2 is generated;

[0127] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)>λ, a cooling control signal M3 is generated;

[0128] When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)≤λ, a temperature reduction control signal M4 is generated;

[0129] When the real-time temperature deviation e1 (t)>0, the accumulated temperature deviation e2 (t)>δ, and the temperature deviation change rate e3 (t)>λ, the temperature reduction control signal M5 is generated.

[0130] Wherein δ and λ are preset judgment parameters.

[0131] Analyze the values ​​of real-time temperature deviation e1(t), cumulative temperature deviation e2(t) and temperature deviation change rate e3(t), and generate and output corresponding control signals in strict accordance with the established signal output judgment mechanism.

[0132] Step 4: Signal response;

[0133] The acquisition and analysis module generates control signals and strictly executes the regulatory operations it points to.

[0134] Step 5: Fault perception and maintenance;

[0135] The current I(t) is obtained in the soldering station circuit by an oscilloscope and a current-time variation diagram is drawn with time as the horizontal axis and current as the vertical axis. The current-time variation diagram is transformed from the time domain to the frequency domain by fast Fourier transform to obtain a current spectrum. The effective value of the third harmonic current I(n=3), the effective value of the fifth harmonic current I(n=5) and the effective value of the seventh harmonic current I(n=7) are extracted from the current spectrum, and the frequency n(5) corresponding to the third harmonic current, the frequency n(3) corresponding to the fifth harmonic current and the frequency n(7) corresponding to the seventh harmonic current are obtained.

[0136] By formula Calculate the fault characteristic index M, where k is the harmonic current order, k=3, 5, 7; where γk is a set of preset influence factors, γk=γ3, γ5, γ7; where μk is a set of preset bias factors, μk=μ3, μ5, μ7. When the fault characteristic index is M, obtain the control signal history of the analysis module. If it contains R consecutive temperature increase control signals P5 or R consecutive temperature reduction control signals M5, a fault alarm is issued through the display screen. Where R is a preset fault judgment parameter.

[0137] It should be understood that the terms "include" and "comprising" used in the specification and claims of the present disclosure indicate the presence of described features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or collections thereof.

[0138] It should also be understood that the terms used in this disclosure are only for the purpose of describing specific embodiments and are not intended to limit the disclosure. As used in this disclosure and claims, the singular forms "a", "an", and "the" are intended to include plural forms unless the context clearly indicates otherwise. It should also be further understood that the term "and / or" used in this disclosure and claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes these combinations;

[0139] The preferred embodiments of the present invention disclosed above are only used to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to only specific implementation methods. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A soldering station temperature intelligent control system, comprising an analysis module, an adjustment module and a fault maintenance module, characterized in that: The analysis module presets a set of control signals, including five temperature increase control signals P1-P5, five temperature decrease control signals M1-M5 and one maintenance control signal H. The temperature increase control signals P1-P5 are respectively P1=+0000; P2=++00; P3=+++00; P4=++++0; P5=+++++; the temperature decrease control signals M1-M5 are respectively M1=-0000; M2=--000; M3=---00; M4=----0; M5=-----; the maintenance control signal H is H=00000; wherein the adjustment symbols "+", "-" and "0" each accurately map a specific control operation; The "+" symbol indicates that the thyristor used for the heating element is turned on to perform the heating operation; the "-" symbol indicates that the thyristor used for the cooling element is turned on to perform the cooling control; and the "0" symbol indicates that the thyristors connected to the heating and cooling elements are cut off at the same time to maintain the current temperature state, that is, to maintain the operation; in addition, each control signal encodes five adjustment symbols, which together define five independent adjustment actions that are continuously and orderly executed within a single adjustment cycle △t; the time distribution of these five independent adjustment actions is equal, that is, the execution time of each operation is strictly controlled within △t / 5; The temperature increase control signals P1 to P5 are configured by setting the thyristor conduction times of different temperature increase components in a single adjustment time; correspondingly, the temperature decrease control signals M1 to M5 are configured by setting the thyristor conduction times of different temperature decrease components in a single adjustment time; the maintenance control signal H is configured by setting the continuous disconnection of the thyristors of the temperature increase components and the temperature decrease components in a single adjustment time; Comprehensively analyze the values ​​of real-time temperature deviation e1(t), cumulative temperature deviation e2(t) and temperature deviation change rate e3(t), and strictly generate and output corresponding control signals according to the established signal output judgment mechanism; The signal output judgment mechanism is specifically as follows: When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) > λ, a temperature increase control signal P5 is generated; When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) ≤ λ, a temperature increase control signal P4 is generated; When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is greater than λ, a temperature increase control signal P3 is generated; When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is less than or equal to λ, a temperature increase control signal P2 is generated; When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)>0, a temperature increase control signal P1 is generated; When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)=0, a maintenance control signal H is generated; When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)<0, a temperature reduction control signal M1 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)≤λ, a cooling control signal M2 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)>λ, a cooling control signal M3 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)≤λ, a temperature reduction control signal M4 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)>λ, a temperature reduction control signal M5 is generated; Among them, δ and λ are preset judgment parameters; The regulation module obtains the control signal generated by the analysis module and strictly executes the regulation operation it points to; The fault maintenance module obtains the effective value of the 3rd harmonic current I (n=3), the effective value of the 5th harmonic current I (n=5), and the effective value of the 7th harmonic current I (n=7) extracted by the perception module, and obtains the frequency n (3) corresponding to the 3rd harmonic current, the frequency n (5) corresponding to the 5th harmonic current, and the frequency n (7) corresponding to the 7th harmonic current; through the formula Calculate the fault characteristic index M, where k is the harmonic current order, k=3, 5, 7; where γk is a set of preset influencing factors, γk=γ3, γ5, γ7; where μk is a set of preset bias factors, μk=μ3, μ5, μ7; when the fault characteristic index M is greater than the preset threshold, obtain the control signal history of the analysis module, and if it contains R consecutive temperature increase control signals P5 or R consecutive temperature reduction control signals M5, a fault alarm is issued through the display screen; where R is a preset fault judgment parameter.

2. According to claim 1, a soldering station temperature intelligent control system is characterized in that: It also includes a setting module and a perception module; The setting module obtains the temperature setting value T(t) through the display screen and the knob every preset time △t, that is, the expected value of the soldering iron tip temperature set by the user at a certain time t, where t is time; The sensing module senses the real-time temperature r(t) of the soldering iron tip based on the change of electromotive force generated by the thermoelectric effect of the thermocouple at a preset time interval △t, where t is time; The real-time temperature deviation e1(t) is calculated by the formula e1(t)=T(t)-r(t); The real-time temperature deviation e1(t) is visualized and function-fitted, with time as the horizontal axis and the real-time temperature deviation e1(t) as the vertical axis, to dynamically generate a real-time temperature deviation-time change graph, by continuously adding newly calculated time and real-time temperature deviation data points (t, e1(t)) to the real-time temperature deviation-time change graph and connecting all data points with a smooth curve; by formula Calculate the cumulative temperature deviation e2(t) by the formula Calculate the temperature deviation change rate e3(t); perform fault data perception based on the soldering station circuit, obtain the current I(t) in the soldering station circuit through an oscilloscope and draw a current-time variation graph with time as the horizontal axis and current as the vertical axis; transform the current-time variation graph from the time domain to the frequency domain through fast Fourier transform to obtain a current spectrum; In the current spectrum, the effective value of the third harmonic current I (n=3), the effective value of the fifth harmonic current I (n=5), and the effective value of the seventh harmonic current I (n=7) are extracted to obtain the frequency n (3) corresponding to the third harmonic current, the frequency n (5) corresponding to the fifth harmonic current, and the frequency n (7) corresponding to the seventh harmonic current.

3. A soldering station temperature intelligent control method, characterized in that: The following steps are involved: Step 1: Set the desired temperature value; The temperature setting value T(t) is obtained through the display screen and the knob at every preset time △t, that is, the expected value of the soldering iron tip temperature set by the user at a certain time t, where t is the time; Step 2: Temperature data perception; The real-time temperature r(t) of the soldering iron tip is sensed based on the change of electromotive force generated by the thermoelectric effect of the thermocouple at a preset time interval △t, where t is time; The real-time temperature deviation e1(t) is calculated by the formula e1(t)=T(t)-r(t); The real-time temperature deviation e1(t) is visualized and function-fitted, with time as the horizontal axis and the real-time temperature deviation e1(t) as the vertical axis, a real-time temperature deviation-time change graph is dynamically generated, by continuously adding newly calculated time and real-time temperature deviation data points (t, e1(t)) to the real-time temperature deviation-time change graph and connecting all data points with a smooth curve; By formula Calculate the cumulative temperature deviation e2(t) by the formula Calculate the temperature deviation change rate e3(t); Step 3: Temperature data analysis; A set of control signals is preset, specifically: five temperature increase control signals P1-P5, five temperature decrease control signals M1-M5 and one maintenance control signal H, respectively; The temperature rise control signals P1-P5 are P1=+0000; P2=++000; P3=+++00; P4=++++0; P5=+++++; The cooling control signals M1-M5 are M1=-0000; M2=--000; M3=---00; M4=----0; M5=-----; Maintain control signal H to H=00000; The "+" symbol indicates that the thyristor used for the heating element is turned on to perform the heating operation; the "-" symbol indicates that the thyristor used for the cooling element is turned on to perform the cooling control; and the "0" symbol indicates that the thyristors connected to the heating and cooling elements are cut off at the same time to maintain the current temperature state, that is, to maintain the operation; in addition, each control signal encodes five adjustment symbols, which together define five independent adjustment actions that are continuously and orderly executed within a single adjustment cycle △t; the time distribution of these five independent adjustment actions is equal, that is, the execution time of each operation is strictly controlled within △t / 5; The temperature increase control signals P1 to P5 are configured by setting the thyristor conduction times of different temperature increase components in a single adjustment time; correspondingly, the temperature decrease control signals M1 to M5 are configured by setting the thyristor conduction times of different temperature decrease components in a single adjustment time; the maintenance control signal H is configured by setting the continuous disconnection of the thyristors of the temperature increase components and the temperature decrease components in a single adjustment time; Establish a signal output judgment mechanism, specifically: obtain the real-time temperature deviation e1(t), the accumulated temperature deviation e2(t) and the temperature deviation change rate e3(t); When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) > λ, a temperature increase control signal P5 is generated; When the real-time temperature deviation e1(t) < 0 and the accumulated temperature deviation e2(t) > δ and the temperature deviation change rate e3(t) ≤ λ, a temperature increase control signal P4 is generated; When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is greater than λ, a temperature increase control signal P3 is generated; When the real-time temperature deviation e1(t) is less than 0 and the accumulated temperature deviation e2(t) is less than or equal to δ and the temperature deviation change rate e3(t) is less than or equal to λ, a temperature increase control signal P2 is generated; When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)>0, a temperature increase control signal P1 is generated; When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)=0, a maintenance control signal H is generated; When the real-time temperature deviation e1(t)=0 and the temperature deviation change rate e3(t)<0, a temperature reduction control signal M1 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)≤λ, a cooling control signal M2 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)≤δ and the temperature deviation change rate e3(t)>λ, a cooling control signal M3 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)≤λ, a temperature reduction control signal M4 is generated; When the real-time temperature deviation e1(t)>0 and the accumulated temperature deviation e2(t)>δ and the temperature deviation change rate e3(t)>λ, a temperature reduction control signal M5 is generated; Among them, δ and λ are preset judgment parameters; Analyze the values ​​of real-time temperature deviation e1(t), cumulative temperature deviation e2(t) and temperature deviation change rate e3(t), and generate and output corresponding control signals in strict accordance with the established signal output judgment mechanism; Step 4: Signal response; The acquisition and analysis module generates control signals and strictly executes the regulation operations it points to; Step 5: Fault perception and maintenance; The current I(t) is obtained in the soldering station circuit through an oscilloscope and a current-time variation diagram is drawn with time as the horizontal axis and current as the vertical axis; the current-time variation diagram is converted from the time domain to the frequency domain through fast Fourier transform to obtain a current spectrum diagram; Extracting the effective value of the third harmonic current I (n=3), the effective value of the fifth harmonic current I (n=5), and the effective value of the seventh harmonic current I (n=7) from the current spectrum, and obtaining the frequency n (3) corresponding to the third harmonic current, the frequency n (5) corresponding to the fifth harmonic current, and the frequency n (7) corresponding to the seventh harmonic current; By formula Calculate the fault characteristic index M, where k is the harmonic current order, k=3, 5, 7; where γk is a set of preset influencing factors, γk=γ3, γ5, γ7; where μk is a set of preset bias factors, μk=μ3, μ5, μ7; when the fault characteristic index M is greater than the preset threshold, obtain the control signal history of the analysis module, and if it contains R consecutive temperature increase control signals P5 or R consecutive temperature reduction control signals M5, a fault alarm is issued through the display screen; where R is a preset fault judgment parameter.

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