Safety detection system and method for microwire annealing tinning machine production line

Abstract

The invention relates to the technical field of industrial intelligent production, and provides a safety detection system and method for a microwire annealing tinning machine production line, and the system comprises a data collection module, a safety monitoring module and an emergency protection module. The problems existing in the operation process of the production line are intelligently regulated, controlled and solved through the intelligent temperature control system, the temperature condition is monitored and managed in real time through a feedback control algorithm, output of the control device is adjusted according to the error between the current temperature and the set temperature, and the temperature control efficiency is improved. Therefore, the temperature can rapidly and stably reach a set value, overshoot and oscillation conditions are reduced, the production quality and performance of products are improved, the equipment damage probability is reduced, and potential safety hazards are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial intelligent production, and in particular to a safety detection system and method for a production line of a fine wire annealing tinning machine. Background Art

[0002] Fine wire annealing and tinning machine is a kind of equipment used to process fine wires. Usually in the process of manufacturing, intelligent control is used to realize the overall process supervision and regulation of the production line, and automatic operation is realized by computer control or programmed control. However, in the production process, the temperature change of the equipment is irregular, and the heating and cooling systems of the existing devices are faulty or improperly adjusted, and cannot match the temperature change patterns. This will cause annealing and tinning temperature fluctuations. Unstable temperature may affect the quality and performance of the product, and even damage the equipment or cause safety hazards.

[0003] Therefore, in order to solve the above problems, a safety detection system and method for a fine wire annealing tinning machine production line is now developed. Summary of the invention

[0004] In order to overcome the shortcomings of annealing and tinning temperature fluctuations caused by failures or improper adjustments in the heating and cooling systems of existing devices, the present invention provides a safety detection system and method for a fine wire annealing and tinning machine production line.

[0005] The technical solution of the present invention is: a safety detection system and method for a fine wire annealing tinning machine production line, comprising:

[0006] A data collection module, wherein the data collection module is used to uniformly process the collected machine operation data;

[0007] Safety monitoring module, which is configured to place sensors at key positions of the production line, comprehensively monitor the temperature, pressure, current, gas and operating status of the production line during operation, and transmit the collected data information to the main control system through the data acquisition module;

[0008] The emergency protection module is used to start up urgently when a safety accident risk occurs, quickly cut off the power supply of the equipment, and protect the operator from equipment risk damage.

[0009] As a preferred embodiment of the present invention, the safety monitoring module includes a temperature monitoring module, and the temperature monitoring module is configured to install thermistors in the heating furnace, annealing furnace, tinning tank, etc., to monitor temperature change data in real time, and synchronously transmit the data information to the data acquisition module, and the data acquisition module sends the information to the main control system.

[0010] As a preferred embodiment of the present invention, the temperature monitoring module also includes an intelligent temperature control system, which is configured to intelligently control and adjust the temperature when the heating and cooling systems may fail or are improperly adjusted, resulting in fluctuations in annealing and tinning temperatures. The intelligent temperature control system mainly includes an intelligent control algorithm and a safety warning mechanism. The intelligent control algorithm is configured to automatically adjust the operating status of the heating and cooling systems according to real-time collected temperature data and set production parameters to achieve stable temperature control. The safety warning mechanism is configured to implement safety protection logic, such as automatically cutting off power or stopping critical operations when the temperature is too high or too low, to avoid equipment damage or safety accidents.

[0011] As a preferred embodiment of the present invention, the intelligent control algorithm uses a feedback control algorithm to monitor and manage the temperature in real time, and adjusts the output of the control device according to the error between the current temperature and the set temperature, so that the temperature reaches the set value quickly and stably, reducing overshoot and oscillation. The specific calculation formula is as follows:

[0012] First, calculate the output state of the controller at time t, relying on u(t) = K p ·e(t) is calculated, where u(t) is the output state of the controller at time t, K p is the proportional gain value under the set state, and e(t) is the current error value

[0013] Then, the static error data is removed according to the accumulation of error over time, relying on Calculate, where K i is the integral gain, is the time integral under the error state;

[0014] Finally, the rate of change is predicted and calculated, and the calculation formula is: Where K d is the differential gain term, It is the time derivative value of the error. The response characteristics of the controller are adjusted according to the gain state of the corresponding number of items, so as to provide intelligent temperature control guarantee under production operation.

[0015] As a preferred embodiment of the present invention, the safety warning mechanism provides a real-time changing threshold for temperature monitoring. The threshold is set by the operator, and the change adjustment is adjusted according to the current operating status of the production line. The specific method is as follows:

[0016] Step 1: Design a parameterized system that allows operators to set different temperature thresholds based on different stages or states of the production line. These parameters can be entered and adjusted on the system’s user interface or control panel.

[0017] Step 2: Combining real-time data and production line status information, the system can automatically adjust the temperature threshold. If the production line is running at high capacity, the system can set a lower temperature threshold to ensure that the equipment operates within a safe range. Otherwise, a higher temperature threshold will be set.

[0018] Step 3: The system automatically adjusts the threshold to keep the device within the optimal operating temperature range by monitoring the device's response and temperature changes;

[0019] As a preferred embodiment of the present invention, the safety warning mechanism also includes a preset plan unit, which is configured to formulate preset plans and strategies under different production line conditions in advance. These preset plans can include a preset temperature threshold set, and a suitable threshold combination is selected according to needs.

[0020] As a preferred embodiment of the present invention, the safety monitoring module also includes a pressure monitoring module, an electrical safety module, an operation status monitoring module and a gas monitoring and processing module. The pressure monitoring module is configured to install a pressure sensor on a system component or pipeline involving pressure, such as a gas pipeline or a hydraulic system. The electrical safety module is configured to install a voltage and current monitoring device at a key circuit and power input to monitor circuit parameters such as voltage and current, and is provided with a circuit breaker and a protective switch. The operation status monitoring module is configured to monitor the overall operation of the equipment by means of a rotor position sensor and a transmission system sensor. The gas monitoring and processing module is configured to install a gas sensor on a system component involving gas use or generation, so as to monitor gas concentration and promptly detect gas leakage.

[0021] As a preferred embodiment of the present invention, the emergency protection module includes an automatic planning intervention unit and a manual intervention unit. The automatic intervention unit is used to automatically cut off the power supply to prevent the equipment from further operation or damage. The manual intervention unit is configured so that when the automated measures cannot completely solve the problem or human judgment is required, the operator can receive an alarm and take appropriate manual control measures.

[0022] By adopting the above technical solution, the beneficial effects of the present invention are:

[0023] 1. The present invention uses an intelligent temperature control system to intelligently regulate and solve problems existing in the operation of the production line, adopts a feedback control algorithm to monitor and manage the temperature conditions in real time, and adjusts the output of the control device according to the error between the current temperature and the set temperature, so that the temperature reaches the set value quickly and stably, reduces overshoot and oscillation, improves product production quality and energy, reduces the probability of equipment damage, and reduces safety hazards.

[0024] 2. The present invention adopts a two-way combination of automatic planning intervention and manual intervention to provide double insurance for emergency situations under production conditions, which can respond quickly to emergencies. When the automatic planning intervention is judged abnormal, the operator can receive an alarm and take appropriate manual control measures. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the structure of the present invention.

[0026] Figure 2 It is a structural schematic diagram of the temperature monitoring module of the present invention.

[0027] Figure 3 It is a structural schematic diagram of the emergency protection module of the present invention. DETAILED DESCRIPTION

[0028] The technical solution of the present invention is further described below in conjunction with the accompanying drawings.

[0029] Example 1

[0030] A safety detection system and method for a fine wire annealing tinning machine production line, such as Figure 1 As shown, it includes a data acquisition module, a safety monitoring module and an emergency protection module. The data acquisition module is used to uniformly process the collected machine operation data. The safety monitoring module is configured at the key position of the production line to place sensors, and comprehensively monitors the temperature, pressure, current, gas and operating status during the operation of the production line, and transmits the collected data information to the main control system through the data acquisition module. The emergency protection module is used to start up urgently when a safety accident risk occurs, quickly cut off the power supply of the equipment, and protect the operator from equipment risk damage.

[0031] like Figure 1As shown, the safety monitoring module includes a temperature monitoring module. The temperature monitoring module is configured to install thermistors in the heating furnace, annealing furnace, tinning tank, etc., monitor the temperature change data in real time, and synchronously transmit the data information to the data acquisition module. The data acquisition module sends the information to the main control system. The safety monitoring module also includes a pressure monitoring module, an electrical safety module, an operation status monitoring module and a gas monitoring processing module. The pressure monitoring module is configured to install the pressure sensor on the system components or pipelines involving pressure, such as gas pipelines and hydraulic systems. The electrical safety module is configured to install the voltage and current monitoring device at the key circuit and power input, monitor the circuit voltage, current and other parameters, and is provided with a circuit breaker and a protective switch. The operation status monitoring module is configured to rely on the rotor position sensor and the transmission system sensor to monitor the overall operation of the equipment. The gas monitoring processing module is configured to install the gas sensor on the system components involving the use or generation of gas, which is used to monitor the gas concentration and timely detect gas leakage.

[0032] like Figure 2 As shown, the temperature monitoring module also includes an intelligent temperature control system. The intelligent temperature control system is configured to intelligently control and adjust the temperature when the heating and cooling systems may fail or are improperly adjusted, resulting in fluctuations in annealing and tinning temperatures. The intelligent temperature control system mainly includes an intelligent control algorithm and a safety warning mechanism. The intelligent control algorithm is configured to automatically adjust the operating status of the heating and cooling systems based on real-time collected temperature data and set production parameters to achieve stable temperature control. The safety warning mechanism is configured to implement safety protection logic, such as automatically cutting off power or stopping key operations when the temperature is too high or too low, to avoid equipment damage or safety accidents.

[0033] The intelligent control algorithm uses a feedback control algorithm to monitor and manage the temperature in real time. According to the error between the current temperature and the set temperature, the output of the control device is adjusted so that the temperature reaches the set value quickly and stably, reducing overshoot and oscillation. The specific calculation formula is as follows:

[0034] First, calculate the output state of the controller at time t, relying on u(t) = K p ·e(t) is calculated, where u(t) is the output state of the controller at time t, K p is the proportional gain value under the set state, and e(t) is the current error value

[0035] Then, the static error data is removed according to the accumulation of error over time, relying on Calculate, where K i is the integral gain, is the time integral in the error state;

[0036] Finally, the rate of change is predicted and calculated, and the calculation formula is: Where K d is the differential gain term, It is the time derivative value of the error. The response characteristics of the controller are adjusted according to the gain state of the corresponding number of items, so as to provide intelligent temperature control guarantee under production operation.

[0037] The safety warning mechanism will provide a real-time threshold for temperature monitoring. This threshold is set by the operator and the change adjustment is adjusted according to the current operating status of the production line. The specific method is as follows:

[0038] Step 1: Design a parameterized system that allows operators to set different temperature thresholds based on different stages or states of the production line. These parameters can be entered and adjusted on the system’s user interface or control panel.

[0039] Step 2: Combining real-time data and production line status information, the system can automatically adjust the temperature threshold. If the production line is running at high capacity, the system can set a lower temperature threshold to ensure that the equipment operates within a safe range. Otherwise, a higher temperature threshold will be set.

[0040] Step 3: The system automatically adjusts the threshold to keep the device within the optimal operating temperature range by monitoring the device's response and temperature changes;

[0041] The safety warning mechanism also includes a preset plan unit, which is configured to formulate preset plans and strategies under different production line conditions in advance. These preset plans can include a pre-set temperature threshold set, and the appropriate threshold combination can be selected according to needs.

[0042] To sum up, the intelligent temperature control system is used to intelligently regulate and solve the problems existing in the operation of the production line, and the feedback control algorithm is used to monitor and manage the temperature conditions in real time. According to the error between the current temperature and the set temperature, the output of the control device is adjusted so that the temperature reaches the set value quickly and stably, reducing overshoot and oscillation, improving product production quality and energy, reducing the probability of equipment damage, and reducing safety hazards.

[0043] Example 2

[0044] like Figure 3 As shown, the emergency protection module includes an automatic planning intervention unit and a manual intervention unit. The automatic intervention unit is used to automatically cut off the power supply to prevent the equipment from further operation or damage. The manual intervention unit is configured so that when the automatic measures cannot completely solve the problem or human judgment is required, the operator can receive an alarm and take appropriate manual control measures.

[0045] In summary, the two-way combination of automatic planning intervention and manual intervention is used to provide double insurance for emergency situations under production conditions, which can respond quickly to emergencies. When the automatic planning intervention is judged abnormally, the operator can receive an alarm and take appropriate manual control measures.

[0046] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A safety detection system and method for a fine wire annealing tinning machine production line, characterized in that: It includes: a data acquisition module, which is used to uniformly process the collected machine operation data; Safety monitoring module, which is configured to place sensors at key positions of the production line, comprehensively monitor the temperature, pressure, current, gas and operating status of the production line during operation, and transmit the collected data information to the main control system through the data acquisition module; The emergency protection module is used to start up urgently when a safety accident risk occurs, quickly cut off the power supply of the equipment, and protect the operator from equipment risk damage.

2. A safety detection system and method for a fine wire annealing tinning machine production line according to claim 1, characterized in that: The safety monitoring module includes a temperature monitoring module, which is configured to install thermistors in the heating furnace, annealing furnace, tinning tank, etc., to monitor temperature change data in real time and synchronously transmit the data information to the data acquisition module, and the data acquisition module sends the information to the main control system.

3. A safety detection system and method for a fine wire annealing tinning machine production line according to claim 2, characterized in that: The temperature monitoring module also includes an intelligent temperature control system, which is configured to intelligently control and adjust the temperature when the heating and cooling systems may fail or are improperly adjusted, resulting in fluctuations in annealing and tinning temperatures. The intelligent temperature control system mainly includes an intelligent control algorithm and a safety warning mechanism. The intelligent control algorithm is configured to automatically adjust the operating status of the heating and cooling systems based on real-time collected temperature data and set production parameters to achieve stable temperature control. The safety warning mechanism is configured to implement safety protection logic, such as automatically cutting off power or stopping critical operations when the temperature is too high or too low, to avoid equipment damage or safety accidents.

4. A safety detection system and method for a fine wire annealing tinning machine production line according to claim 3, characterized in that: The intelligent control algorithm uses a feedback control algorithm to monitor and manage the temperature in real time. According to the error between the current temperature and the set temperature, the output of the control device is adjusted so that the temperature reaches the set value quickly and stably, reducing overshoot and oscillation. The specific calculation formula is as follows: First, calculate the output state of the controller at time t, relying on u(t) = K p ·e(t) is calculated, where u(t) is the output state of the controller at time t, K p is the proportional gain value under the set state, and e(t) is the current error value; Then, the static error data is removed according to the accumulation of error over time, relying on Calculate, where K i is the integral gain, is the time integral under the error state; Finally, the rate of change is predicted and calculated, and the calculation formula is: Where K d is the differential gain term, It is the time derivative value of the error. The response characteristics of the controller are adjusted according to the gain state of the corresponding number of items, so as to provide intelligent temperature control guarantee under production operation.

5. A safety detection system and method for a fine wire annealing tinning machine production line according to claim 3, characterized in that: The safety warning mechanism will provide a real-time threshold for temperature monitoring. This threshold is set by the operator and the change adjustment is adjusted according to the current operating status of the production line. The specific method is as follows: Step 1: Design a parameterized system that allows operators to set different temperature thresholds based on different stages or states of the production line. These parameters can be entered and adjusted on the system’s user interface or control panel. Step 2: Combining real-time data and production line status information, the system can automatically adjust the temperature threshold. If the production line is running at high capacity, the system can set a lower temperature threshold to ensure that the equipment operates within a safe range. Otherwise, a higher temperature threshold will be set. Step 3: The system automatically adjusts the threshold to keep the device within the optimal operating temperature range by monitoring the device's response and temperature changes.

6. A safety detection system and method for a fine wire annealing tinning machine production line according to claim 5, characterized in that: The safety warning mechanism also includes a preset plan unit, which is configured to formulate preset plans and strategies under different production line conditions in advance. These preset plans can include a preset temperature threshold set, and a suitable threshold combination can be selected according to needs.

7. A safety detection system and method for a fine wire annealing tinning machine production line according to claim 2, characterized in that: The safety monitoring module also includes a pressure monitoring module, an electrical safety module, an operation status monitoring module and a gas monitoring and processing module. The pressure monitoring module is configured to install a pressure sensor on a system component or pipeline involving pressure, such as a gas pipeline or a hydraulic system. The electrical safety module is configured to install a voltage and current monitoring device at a key circuit and power input to monitor circuit parameters such as voltage and current, and is provided with a circuit breaker and a protective switch. The operation status monitoring module is configured to monitor the overall operation of the equipment by means of a rotor position sensor and a transmission system sensor. The gas monitoring and processing module is configured to install a gas sensor on a system component involving gas use or generation, so as to monitor gas concentration and promptly detect gas leaks.

8. A safety detection system and method for a fine wire annealing tinning machine production line according to claim 1, characterized in that: The emergency protection module includes an automatic planning intervention unit and a manual intervention unit. The automatic intervention unit is used to automatically cut off the power supply to prevent the equipment from further operation or damage. The manual intervention unit is configured so that when the automatic measures cannot completely solve the problem or human judgment is required, the operator can receive an alarm and take appropriate manual control measures.

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