Intelligent control method of nickel electrode atmosphere tunnel furnace

Abstract

The invention relates to the technical field of furnace control, in particular to an intelligent control method for a nickel electrode atmosphere tunnel furnace, which comprises the following steps of: independently controlling the temperature of a temperature area by adopting a PID (Proportion Integration Differentiation) technology through full-automatic PLC (Programmable Logic Controller) control, acquiring the temperature data of the area in real time, setting primary temperature control parameters in the furnace, confirming the stable operation of basic temperature control, and generating temperature control baseline data. According to the invention, the temperature of the temperature zone is monitored in real time and accurately adjusted, so that fine granularity management of temperature control is realized, energy distribution in the furnace is optimized, energy efficiency is improved, and through integration of infrared and microwave technologies, energy output is adjusted, changes of the environment in the furnace are directly responded, material processing quality is improved, and chemical reaction is accurately controlled. By adjusting the gas flow rate and proportion, the accuracy and balance of chemical reaction are ensured, the energy consumption and the operation complexity are obviously reduced, the control strategy is dynamically adjusted, the production process is optimized according to the comparison between the actual output and the target value, and the high-efficiency and high-quality output is ensured.

Description

Technical Field

[0001] The invention relates to the technical field of furnace control, and in particular to an intelligent control method for a nickel electrode atmosphere tunnel furnace. Background Art

[0002] Furnace control involves the automation and intelligent control technology of heating equipment in industrial applications. The main purpose is to ensure the stability, efficiency and safety of the heating process, while optimizing energy utilization and reducing operating costs. Specific to the control system of industrial furnaces (such as tunnel furnaces, rotary furnaces, etc.), including but not limited to temperature control, atmosphere control, monitoring and adjustment of furnace pressure and heat distribution. By using hardware such as sensors, controllers and actuators and supporting software algorithms, furnace control technology can achieve precise control of the furnace environment, thereby ensuring that the quality and characteristics of the materials during the processing meet the production requirements.

[0003] Among them, the intelligent control method of the nickel electrode atmosphere tunnel furnace is a control scheme specially designed for atmosphere tunnel furnaces containing nickel electrodes. The tunnel furnace is a continuously operated industrial furnace used for heating, baking or melting materials, and atmosphere control refers to creating a specific gas environment in the furnace to affect or control the chemical and physical properties of the material during the heating process. The control process includes automatic adjustment of temperature, air pressure, gas composition, etc. to optimize the processing process and improve product quality. It is mainly used to improve processing efficiency and material handling quality, while reducing energy consumption and operating difficulty.

[0004] Existing technologies often lack immediate response and fine management in temperature control and energy distribution adjustment, resulting in low energy utilization and unstable product quality. Especially in the processing of chemical substances and the adjustment of gas composition, traditional technologies often cannot accurately adapt to rapidly changing production needs, affecting the efficiency and quality of chemical reactions. For example, for rapidly changing production conditions, existing technologies cannot adjust the temperature or gas ratio in time, increasing scrap rate and production costs. In addition, the existing control system has high operational complexity and requires a lot of manual intervention, which increases the possibility of operational errors and reduces overall production efficiency. Summary of the invention

[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose an intelligent control method for a nickel electrode atmosphere tunnel furnace.

[0006] In order to achieve the above object, the present invention adopts the following technical scheme: an intelligent control method for a nickel electrode atmosphere tunnel furnace, comprising the following steps: S1: Through fully automatic PLC control, PID technology is used to control the temperature of each temperature zone individually, collect regional temperature data in real time and set preliminary furnace temperature control parameters, confirm the stable operation of basic temperature control, and generate temperature control baseline data; S2: The temperature, pressure and gas composition in the furnace are monitored in real time through the temperature control baseline data, and the data are collected and compared with the set control standards. According to the comparison results, the infrared and microwave output intensities are adjusted to adjust the energy output to match the furnace demand, optimize the temperature and energy distribution uniformity in the furnace, and generate dynamic energy adjustment records; S3: Based on the dynamic energy adjustment record, monitor the concentration change and reaction rate of the chemical substances in the furnace, adjust the proportional flow rate of the input gas, and synchronously adjust the energy output to match the needs of the chemical reaction according to the adjustment result to ensure the balance of the chemical reaction and generate a chemical control state balance result; S4: Based on the chemical control state balance result, continuously monitor the temperature and chemical changes in the furnace, dynamically adjust the temperature control and gas flow parameters according to the current conditions in the furnace, regularly compare the actual output with the target value according to the adjustment result, dynamically evaluate and adjust the control strategy, and generate a continuously optimized tunnel furnace control plan.

[0007] As a further solution of the present invention, the step of obtaining the temperature control baseline data is: S111: Monitor the temperature of the temperature zone in real time through the fully automatic PLC, record the sensor data, and output the real-time temperature data set of the temperature zone in the furnace; S112: Based on the real-time temperature data set of the temperature zones in the furnace, the PID control technology is applied to adjust the parameters, and the temperature of each temperature zone is determined to reach the preset target, and an adjusted control parameter data set is generated; S113: Perform continuous monitoring based on the adjusted control parameter data set to verify the stability of the temperature control process and output temperature control baseline data.

[0008] As a further embodiment of the present invention, the steps of collecting data and setting control standards are as follows: S211: deploy sensors to collect real-time temperature, air pressure and gas composition data in the furnace and generate real-time monitoring data; S212: Compare the real-time monitoring data with the temperature control baseline data, using the formula: Calculate the deviation value , and obtain the deviation analysis results, where Indicates real-time temperature, air pressure and gas composition data. represents the baseline data, Represent the standard deviations of temperature, air pressure and gas component content respectively; S213: Based on the deviation analysis result, determine whether the deviation exceeds a preset threshold. If so, it is considered that the furnace environment has deviated from the safe operating range, and the control standard needs to be adjusted, and a control standard adjustment decision record is generated.

[0009] As a further solution of the present invention, the step of acquiring the dynamic energy adjustment record is: S221: Based on the deviation analysis result, determining the adjustment requirements of infrared and microwave, determining the corresponding output intensity by evaluating the deviation value, and obtaining the infrared and microwave output intensity analysis record; S222: According to the infrared and microwave output intensity analysis record, perform infrared and microwave output intensity adjustment, adjust the infrared and microwave output in real time, monitor the adjusted furnace temperature and energy distribution data, and obtain adjusted output data; S223: According to the adjusted output data, record all adjustment actions and results, including energy output data before and after adjustment, construct a temperature distribution diagram, and generate a dynamic energy adjustment record.

[0010] As a further solution of the present invention, the step of adjusting the proportional flow rate of the input gas is: S311: Using the dynamic energy adjustment record, measuring the concentration and reaction rate of chemical substances in the furnace through sensors to generate chemical reaction monitoring data; S312: Analyze the chemical reaction monitoring data, using the formula: Calculate the adjusted gas flow rate , get the adjusted input parameters, where, represents the change in the concentration of a chemical substance, represents the measurement time interval, represents the initial input gas ratio, Represents the adjusted gas ratio; S313: Based on the adjusted input parameters, optimize the energy output, match the chemical reaction requirements in the furnace, and output an adjustment plan.

[0011] As a further solution of the present invention, the step of obtaining the chemical control state balance result is: S321: Apply the adjustment scheme to continuously obtain real-time change data of chemical reaction rate and concentration in the furnace, and record and output current chemical reaction state analysis records; S322: Based on the analysis record of the current chemical reaction state and the actual energy output demand in the furnace, the formula is used: Calculate the required energy output , adjust the energy output parameters to obtain the adjusted energy output parameters, where: represents the chemical reaction rate monitored in real time, represents the instantaneous concentration change, represents the adjustment time constant; S323: Implement the adjusted energy output parameters, perform dynamic adjustment, confirm the dynamic balance of the chemical reaction and the stable balance of the chemical control state, and generate a chemical control state balance result.

[0012] As a further solution of the present invention, the temperature control and gas flow parameter adjustment steps are: S411: Based on the chemical control state balance result, dynamically and continuously monitor the furnace environment, record the changing temperature and chemical composition data, and generate a dynamic monitoring data set; S412: According to the dynamic monitoring data set, by comparing with preset standards, evaluating whether the production conditions are met, and generating an environmental adjustment need evaluation result; S413: According to the evaluation result of the environmental adjustment needs, the temperature and gas flow parameters in the furnace are adjusted to dynamically optimize the environment in the furnace and generate dynamically adjusted control parameters.

[0013] As a further solution of the present invention, the step of obtaining the continuously optimized tunnel furnace control solution is: S421: Apply the dynamically adjusted control parameters and regularly compare them with the target values ​​set for product quality and production efficiency requirements, using the formula, Calculate the square root of the mean of the absolute deviations of all measurement points , generate actual and target comparison results, where Represents the actual measured value of each measuring point, represents the corresponding target measurement value, Represents the total number of measurement points; S422: Based on the actual and target comparison results, analyze the deviation trend and evaluate the deviation degree, analyze whether there is a continuous deviation trend, and generate evaluation and adjustment suggestions; S423: Based on the evaluation and adjustment suggestions, the control strategy is updated, the control parameters of temperature and chemical composition are optimized, the production process control is refined, the production demand is matched, and a continuously optimized tunnel furnace control solution is generated.

[0014] Compared with the prior art, the advantages and positive effects of the present invention are: In the present invention, by real-time monitoring of the temperature of the temperature zone and precise adjustment, fine-grained management of temperature control is achieved, the energy distribution in the furnace is optimized, and energy efficiency is improved. By integrating infrared and microwave technologies, energy output is adjusted to directly respond to changes in the furnace environment and improve material processing quality. Chemical reactions are precisely controlled by adjusting the gas flow rate and ratio to ensure the accuracy and balance of chemical reactions, significantly reduce energy consumption and operational complexity, dynamically adjust control strategies, and optimize the production process based on the comparison between actual output and target value to ensure high-efficiency and high-quality output. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a main step flow chart of the present invention; Figure 2 This is a flow chart for obtaining temperature control baseline data of the present invention; Figure 3 Flow chart for collecting data and setting control standards for the present invention; Figure 4 A flowchart for obtaining dynamic energy adjustment records of the present invention; Figure 5 The flow chart of adjusting the proportional flow rate of the input gas of the present invention is as follows; Figure 6 The flowchart of obtaining the chemical control state equilibrium result of the present invention; Figure 7 The figure is a flow chart of the temperature control and gas flow parameter adjustment of the present invention; Figure 8 A flow chart for obtaining the tunnel furnace control solution that is continuously optimized according to the present invention. DETAILED DESCRIPTION

[0016] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0017] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, in the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined.

[0018] See also Figure 1, an intelligent control method for a nickel electrode atmosphere tunnel furnace, comprising the following steps: S1: Through fully automatic PLC control, PID technology is used to control the temperature of each temperature zone individually, collect regional temperature data in real time and set preliminary furnace temperature control parameters, confirm the stable operation of basic temperature control, and generate temperature control baseline data; S2: Monitor the temperature, pressure and gas composition in the furnace in real time through the temperature control baseline data, collect data and compare it with the set control standards, adjust the infrared and microwave output intensity according to the comparison results, adjust the energy output to match the furnace demand, optimize the temperature and energy distribution uniformity in the furnace, and generate dynamic energy adjustment records; S3: Based on the dynamic energy adjustment record, monitor the concentration change and reaction rate of the chemical substances in the furnace, adjust the proportional flow rate of the input gas, and adjust the energy output to match the needs of the chemical reaction according to the adjustment results to ensure the balance of the chemical reaction and generate the balance result of the chemical control state; S4: Based on the chemical control state balance results, continuously monitor the temperature and chemical changes in the furnace, dynamically adjust the temperature control and gas flow parameters according to the current conditions in the furnace, regularly compare the actual output with the target value according to the adjustment results, dynamically evaluate and adjust the control strategy, and generate a continuously optimized tunnel furnace control plan.

[0019] The temperature control baseline data includes regional control difference data, control loop stability records and baseline adjustment records; the dynamic energy adjustment records include energy adjustment reaction time, output power records and temperature response speed records; the chemical control state balance results include reaction rate adjustment records, chemical balance data and input gas ratio adjustment records; the continuously optimized tunnel furnace control scheme includes parameter optimization history, control efficiency indicators and adjustment strategy records.

[0020] See also Figure 2 , the steps to obtain the temperature control baseline data are: S111: Monitor the temperature of the temperature zone in real time through the fully automatic PLC, record the sensor data, and output the real-time temperature data set of the temperature zone in the furnace; Based on the real-time monitoring capability of the fully automatic PLC system, the system collects temperature data of each temperature zone through multi-point sensors. The output signal of each sensor is first amplified and filtered by the signal conditioning module to optimize the quality and accuracy of the signal. The adjusted signal is collected, the analog signal is converted into a digital signal to ensure the digital processing of information, and the digital signal is sent to the central processing unit. The CPU performs preliminary logical judgment and critical value comparison on the data to determine whether it is necessary to adjust the temperature zone setting immediately or trigger an alarm. In this process, all temperature data are recorded and form a real-time temperature zone temperature data set, providing a reliable basis for subsequent control and adjustment.

[0021] S112: Based on the real-time temperature data set of the temperature zones in the furnace, the PID control technology is applied to adjust the parameters, and the temperature of each temperature zone is determined to reach the preset target, and an adjusted control parameter data set is generated; Applying PID control technology, firstly, the current temperature value of each temperature zone is extracted from the real-time temperature data set of the temperature zones in the furnace obtained above, and compared with the set target temperature, and the temperature adjustment required for each temperature zone is calculated (the current temperature value of each temperature zone minus the set target temperature, and the absolute value is taken), including the determination of error, the calculation of proportional (P), integral (I), and differential (D) control. Among them, proportional control considers the current error, integral control focuses on the cumulative error, and differential control predicts the future error change trend. These three control actions synthesize adjustment signals through the control algorithm and send them to the actuators, such as heaters or coolers, to adjust the temperature zones in real time, and finally generate the adjusted control parameter data set for further temperature control verification.

[0022] S113: Perform continuous monitoring based on the adjusted control parameter data set to verify the stability of the temperature control process and output the temperature control baseline data; Based on the adjusted control parameter data set, continuous system monitoring is carried out. During the monitoring process, the system will regularly collect temperature data of the current temperature zone and compare the data with the adjusted control parameters to check whether the temperature of each temperature zone meets the range set by the control parameters. In addition, the system will analyze temperature fluctuations and evaluate the stability of temperature control. This evaluation is based on statistical analysis of historical data and real-time data to ensure that the temperature control system not only responds promptly but also remains stable under various working conditions, ultimately forming temperature control baseline data to provide a key reference for evaluating tunnel furnace performance.

[0023] See also Figure 3 The steps for collecting data and setting control standards are: S211: deploy sensors to collect real-time temperature, air pressure and gas composition data in the furnace and generate real-time monitoring data; During the deployment of sensors, first select sensors that are suitable for high-temperature environments and have high precision. The sensors must be able to withstand continuous high temperatures and chemical corrosion. Secondly, the installation location must ensure that it can cover every corner of the furnace to ensure the comprehensiveness and representativeness of the data. After installation, the system is calibrated. The calibration process includes the adjustment of temperature deviation, sensitivity calibration of air pressure sensing, and accuracy testing of gas composition detection. This process ensures the accuracy and reliability of data collection. Finally, the generated real-time monitoring data will be directly transmitted to the central monitoring system for subsequent data analysis and processing.

[0024] S212: Compare the real-time monitoring data with the temperature control baseline data, using the formula, Calculate the deviation value , and obtain the deviation analysis results, where Indicates real-time temperature, air pressure and gas composition data. represents the baseline data, Represent the standard deviations of temperature, air pressure and gas component content respectively; Through data collection, ℃ represents the temperature measured in real time, ℃ is the baseline temperature, ℃ is the standard deviation of the temperature data, and are real-time and baseline air pressure, is the standard deviation of air pressure, , and .

[0025] The calculation process is: The results showed significant deviations between the real-time data and the baseline data, indicating that the furnace environment may need to be adjusted to maintain the stability of the production process.

[0026] S213: judging whether the deviation exceeds a preset threshold value according to the deviation analysis result; if so, it is considered that the furnace environment has deviated from the safe operating range, and the control standard needs to be adjusted, and a control standard adjustment decision record is generated; The process of making decisions based on the results of deviation analysis involves evaluating the deviation value and comparing it with the standard threshold. First, the acceptable threshold of deviation is set, and the threshold is set to 1.5 (the threshold is determined based on historical data analysis and safety standards). With a threshold of 1.5, because If it is higher than 1.5, it indicates that the current furnace environment has deviated from the optimal operating range. Finally, this judgment basis will be used to adjust the control parameters, including but not limited to temperature setting, gas pressure regulation and gas ratio optimization, so as to ensure product quality and production safety. The adjusted settings will be recorded in the system's operation log for future reference and auditing.

[0027] See also Figure 4 ,The steps to obtain the dynamic energy adjustment record are, S221: Based on the deviation analysis result, determining the adjustment requirements of infrared and microwave, determining the corresponding output intensity by evaluating the deviation value, and obtaining the infrared and microwave output intensity analysis record; In the process of determining the adjustment requirements for infrared and microwave based on the deviation analysis results, we first conduct an in-depth statistical analysis of the deviation data, including calculating the mean, variance and frequency distribution of the deviation. According to the size and distribution characteristics of the deviation values, we develop an adjustment strategy, which covers different levels from fine-tuning to major adjustments. Each level of adjustment strategy has specific parameter settings and expected effects. These parameter settings include but are not limited to the power adjustment range, adjustment frequency and expected deviation range after adjustment of infrared and microwave. Finally, a detailed adjustment strategy document is generated, which will serve as a guide for the next step of actual adjustment operations.

[0028] S222: According to the infrared and microwave output intensity analysis records, the infrared and microwave output intensities are adjusted, the infrared and microwave outputs are adjusted in real time, the adjusted furnace temperature and energy distribution data are monitored, and the adjusted output data is obtained; The process of adjusting the infrared and microwave output intensities is as follows: first, the adjustment command is issued by the central control system. After that, the infrared and microwave output devices receive the adjustment command and start to adjust the output intensity. The process is carried out through closed-loop control. According to the preset feedback adjustment algorithm, the adjustment effect is monitored in real time, and the output intensity is fine-tuned to ensure that the optimal temperature and energy distribution state is achieved. At the same time, data from the adjustment process is collected in real time, including temperature data before and after adjustment, energy output data, and the timestamp of the execution of the adjustment command, which are used for subsequent effect analysis and system optimization. The output data finally generated will be recorded in detail in the system database for future analysis and backtracking.

[0029] S223: recording all adjustment actions and results according to the adjusted output data, including the energy output data before and after the adjustment, constructing a temperature distribution diagram, and generating a dynamic energy adjustment record; The process of recording all adjustment actions and results is a key part of data management and analysis. First, each adjustment action and the corresponding results are automatically recorded by the system in the dynamic energy adjustment record, including the specific parameters of the adjustment, the time of adjustment execution, and the system status before and after the adjustment, such as temperature and energy output data; In addition, in order to ensure the integrity and traceability of the data, the record also includes the operator information, operation time and specific operation commands of each adjustment, ensuring that the adjustment actions and results can be traced back and verified at any time. Ultimately, these detailed records are not only used for daily production management, but also an important data basis for optimizing adjustment strategies and improving system performance.

[0030] See also Figure 5 , the adjustment steps of the input gas proportional flow rate are, S311: using dynamic energy adjustment records, measuring chemical concentrations and reaction rates in the furnace through sensors, and generating chemical reaction monitoring data; The existing dynamic energy adjustment records are used for monitoring, and the chemical concentration and reaction rate are measured in real time through the high-precision sensor system in the furnace. The collected data is transmitted to the central processing unit in real time through the wireless network. The real-time data is used for preliminary data cleaning and verification to eliminate any possible data deviation caused by erroneous readings or equipment failures, ensuring the accuracy and real-time nature of the data. At the same time, through real-time monitoring of the measured data, any changes exceeding the preset threshold can be immediately identified so that the working conditions in the furnace can be adjusted in time to ensure the stable progress of the chemical reaction. The function and calibration status of the sensor are checked regularly to maintain the optimal performance of the tunnel furnace.

[0031] S312: Analyze chemical reaction monitoring data using the formula, Calculate the adjusted gas flow rate , get the adjusted input parameters, where, represents the change in the concentration of a chemical substance, represents the measurement time interval, represents the initial input gas ratio, Represents the adjusted gas ratio; The concentration change of chemical substances obtained by chemical sensors during a specific monitoring period 10 mg / m 3 , measuring time interval For 30 seconds, the initial gas ratio is 0.2, the adjusted gas ratio is 0.3, and we can get the following result by substituting it into the formula: Calculate the absolute value of the concentration change and get: Taking the square root of the absolute value, we get: Calculate the ratio of the gas proportions and get: Substituting the above results into the formula, we can get: The results show that the adjusted flow rate About 0.070m 3 / s, the adjusted gas flow rate obtained based on actual measurement data, represents the actual gas flow rate after adjusting the original ratio, which is crucial for gas flow rate adjustment and energy output optimization during chemical reactions.

[0032] S313: Based on the adjusted input parameters, optimize the energy output, match the chemical reaction requirements in the furnace, and output an adjustment plan; Energy output is optimized based on the adjusted input parameters. The matching degree between energy output and chemical reaction is evaluated through real-time monitoring. Difference analysis is performed by comparing real-time data with preset energy output. Energy output settings are adjusted according to the analysis results to ensure the balance of chemical reaction. In addition, by implementing dynamic energy adjustment strategies, the system can automatically respond to any unforeseen changes in chemical reactions, so as to adjust energy input in time. The final optimization results are verified by advanced data analysis tools. The verification results show that the optimal match between energy input and reaction speed is achieved, ensuring the efficiency of the production process and the stability of product quality.

[0033] See also Figure 6 , the steps to obtain the chemical control state equilibrium result are: S321: Apply the adjustment scheme to continuously obtain the real-time change data of the chemical reaction rate and concentration in the furnace, and record and output the current chemical reaction state analysis record; Through real-time data monitoring, we can obtain real-time change data of chemical reaction rate and concentration in the furnace. Analysis shows that the reaction speed is closely related to the required energy output. We further process the relevant data through data analysis to identify key change points and potential adjustment needs. We use statistical analysis to evaluate data quality to ensure the accuracy and reliability of the collected data. Then, the data is presented in a visual form, and the operating parameters are adjusted according to the data analysis results to optimize the energy distribution in the furnace and the reaction environment of the chemical substances. Through a series of operations, we generate a detailed report on the current chemical reaction status, which provides a scientific basis for subsequent energy output adjustments and ensures the efficiency and safety of the chemical reaction process.

[0034] S322: Based on the current chemical reaction state analysis record and the actual energy output demand in the furnace, the formula is used. Calculate the required energy output , adjust the energy output parameters to obtain the adjusted energy output parameters, where: represents the chemical reaction rate monitored in real time, represents the instantaneous concentration change, represents the adjustment time constant; The reaction rate is monitored by the sensor. is 0.75 mol / s, and the concentration changes is 0.1mol / L, adjust the time constant is 50s, substitute it into the formula for calculation: calculate The product of , we get: mol 2 / Ls Divide the above result by the time constant ,have to: mol / Ls result mol / Ls represents the energy output that needs to be adjusted per second to maintain the balance between the chemical reaction rate and the concentration change, ensuring that the energy output accurately matches the needs of the actual chemical reaction and providing the possibility of continuous optimization of the chemical reaction process.

[0035] S323: Implement the adjusted energy output parameters, perform dynamic adjustment, confirm the dynamic balance of the chemical reaction and the stable balance of the chemical control state, and generate a chemical control state balance result; By precisely adjusting the energy output parameters and implementing dynamic adjustments, the monitoring system continuously tracks the changes in reaction conditions in the furnace. At the same time, the system automatically adjusts the energy output to respond to the immediate needs of the chemical substances, and regularly evaluates the adjustment effects to ensure that the implemented parameter adjustments can effectively match the dynamic changes of the chemical reactions. In addition, the energy output strategy is continuously optimized through feedback data, and through precise control logic, energy waste is minimized, production efficiency is improved, and ultimately a stable balance of the chemical control state is achieved, which not only ensures the continuity of the chemical production process, but also optimizes energy utilization efficiency and ensures product quality and environmental safety.

[0036] See also Figure 7 , the steps for adjusting temperature control and gas flow parameters are, S411: Based on the chemical control state balance results, the furnace environment is dynamically and continuously monitored, the changing temperature and chemical composition data are recorded, and a dynamic monitoring data set is generated; Based on the balance results of the chemical control state, sensors are used to continuously monitor the temperature and chemical composition of the furnace environment. Data on the temperature and chemical changes in the furnace can be collected in real time to ensure real-time updating and accuracy of the data. The sensors are connected to the data processing center through the electronic interface of the detection equipment and transmit the monitoring data to the central server in real time. The server will perform preliminary filtering and preprocessing on the collected data to remove obvious erroneous readings or abnormal data to ensure the accuracy of subsequent analysis. The processed data is stored in the central database for further analysis to generate a dynamic monitoring data set.

[0037] S412: Based on the dynamic monitoring data set, by comparing with the preset standard, evaluating whether the production conditions are met, and generating the evaluation result of the need for environmental adjustment; According to the dynamic monitoring data set, the processing in the system includes comparison with the preset production standards. The process needs to call the standard parameters stored in the database. The parameters include but are not limited to the optimal temperature range, chemical component ratio, etc. The monitored data is compared with these standard parameters to determine whether the current furnace environment meets the production requirements. The system will output an environmental adjustment signal based on the comparison result. The signal will be used for subsequent control parameter adjustments to generate an evaluation result of the environmental adjustment needs.

[0038] S413: According to the evaluation result of the environmental adjustment needs, the temperature and gas flow parameters in the furnace are adjusted to dynamically optimize the environment in the furnace and generate dynamically adjusted control parameters; According to the evaluation results of the environmental adjustment needs, the temperature and gas flow parameters in the furnace are adjusted dynamically, and the temperature controller and gas flow meter in the control system are adjusted. The control system converts the received adjustment signals into specific control commands and programs the temperature controller to achieve precise temperature regulation. At the same time, the settings of the gas flow meter are adjusted to optimize the flow and distribution of the gas. Through refined management, it can ensure that the furnace environment operates according to the optimized parameters to achieve the best production effect and generate dynamically adjusted control parameters.

[0039] See also Figure 8 ,The steps to obtain the continuously optimized tunnel furnace control solution are, S421: Apply dynamically adjusted control parameters and regularly compare them with the target values ​​set for product quality and production efficiency requirements, using the formula, Calculate the square root of the mean of the absolute deviations of all measurement points , generate actual and target comparison results, where Represents the actual measured value of each measuring point, represents the corresponding target measurement value, Represents the total number of measurement points; In a certain actual operation, the furnace temperatures measured were 1050 degrees Celsius, 1075 degrees Celsius, and 1060 degrees Celsius; is the target measurement value, and the target furnace temperature is set to 1060 degrees Celsius; Represents the total number of measurement points, which is 3.

[0040] get , The calculation process is as follows: Calculate the absolute value of the difference between each actual value and the target value to get: Compute the mean of the differences: Calculate the RMS deviation: The results showed that the average deviation was 2.89 degrees Celsius, indicating that the furnace temperature control had slight fluctuations relative to the target value and that the control strategy needed to be further adjusted to reduce the deviation.

[0041] S422: Based on the comparison results between the actual and target, analyze the deviation trend and evaluate the degree of deviation, analyze whether there is a continuous deviation trend, and generate evaluation and adjustment suggestions; After comparing the actual measurement results with the target values, data analysis is performed to determine whether the control system needs to be adjusted. By analyzing the trend of the deviation, it is determined whether there is a persistent deviation or an accidental event. For each measurement point, the difference between it and the set target is evaluated, and trend analysis is performed based on the data. This can help understand the cause of the deviation and make appropriate adjustments to the control strategy to ensure production efficiency and product quality. Based on the analysis results, a detailed evaluation and adjustment proposal is generated to provide decision support for technical personnel.

[0042] S423: Based on the evaluation and adjustment suggestions, update the control strategy, optimize the control parameters of temperature and chemical composition, refine the production process control, match the production needs, and generate a continuously optimized tunnel furnace control plan; Based on the evaluation and adjustment suggestions provided, the furnace temperature control strategy was updated, involving the adjustment of multiple parameters, such as the set value of the temperature controller and the mixing ratio of the chemical components. Through precise adjustments, a more stable furnace environment is ensured, thereby improving product quality and production efficiency. The updated control strategy is verified through actual operating data to ensure that its effect meets production requirements. In addition, the adjustments will be continuously optimized according to new production data, forming a dynamically updated cycle, thereby generating a continuously optimized tunnel furnace control solution.

[0043] The above are only preferred embodiments of the present invention and are not intended to limit the present invention in other forms. Any technician familiar with the profession may use the technical contents disclosed above to change or modify them into equivalent embodiments with equivalent changes and apply them to other fields. However, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the technical solution of the present invention still falls within the protection scope of the technical solution of the present invention.

Claims

1. An intelligent control method for a nickel electrode atmosphere tunnel furnace, characterized in that: The following steps are involved: Through fully automatic PLC control, PID technology is used to control the temperature of each temperature zone individually, real-time regional temperature data is collected and preliminary furnace temperature control parameters are set to confirm the stable operation of basic temperature control and generate temperature control baseline data; Through the temperature control baseline data, the temperature, air pressure and gas composition in the furnace are monitored in real time, the data are collected and compared with the set control standards, and according to the comparison results, the infrared and microwave output intensities are adjusted to adjust the energy output to match the furnace demand, optimize the temperature and energy distribution uniformity in the furnace, and generate dynamic energy adjustment records; Based on the dynamic energy adjustment record, the concentration change and reaction rate of the chemical substances in the furnace are monitored, the proportional flow rate of the input gas is adjusted, and the energy output is synchronously adjusted according to the adjustment result to match the needs of the chemical reaction, so as to ensure the balance of the chemical reaction and generate the balance result of the chemical control state; Based on the chemical control state balance result, the temperature and chemical changes in the furnace are continuously monitored, the temperature control and gas flow parameters are dynamically adjusted according to the current conditions in the furnace, the actual output is regularly compared with the target value according to the adjustment result, the control strategy is dynamically evaluated and adjusted, and a continuously optimized tunnel furnace control solution is generated.

2. The intelligent control method for the nickel electrode atmosphere tunnel furnace according to claim 1, characterized in that: The steps for obtaining the temperature control baseline data are: The temperature of the temperature zone is monitored in real time through the fully automatic PLC, the sensor data is recorded, and the real-time temperature data set of the temperature zone in the furnace is output; Based on the real-time temperature data set of the temperature zones in the furnace, the PID control technology is applied to adjust the parameters, determine that the temperature of each temperature zone reaches the preset target, and generate an adjusted control parameter data set; Based on the adjusted control parameter data set, continuous monitoring is performed to verify the stability of the temperature control process and output temperature control baseline data.

3. The intelligent control method for the nickel electrode atmosphere tunnel furnace according to claim 2, characterized in that: The steps of collecting data and setting control standards are: Deploy sensors to collect real-time temperature, pressure and gas composition data in the furnace and generate real-time monitoring data; The real-time monitoring data is compared with the temperature control baseline data, using the formula, Calculate the deviation value , and obtain the deviation analysis results, where Indicates real-time temperature, air pressure and gas composition data. represents the baseline data, Represent the standard deviations of temperature, air pressure and gas component content respectively; Based on the deviation analysis results, determine whether the deviation exceeds the preset threshold. If so, it is considered that the furnace environment has deviated from the safe operating range, and the control standard needs to be adjusted to generate a control standard adjustment decision record.

4. The intelligent control method for the nickel electrode atmosphere tunnel furnace according to claim 3, characterized in that: The steps of obtaining the dynamic energy adjustment record are: Based on the deviation analysis results, determining the adjustment requirements of infrared and microwave, determining the corresponding output intensity by evaluating the deviation value, and obtaining the infrared and microwave output intensity analysis records; According to the infrared and microwave output intensity analysis records, infrared and microwave output intensity adjustments are performed, infrared and microwave outputs are adjusted in real time, and the adjusted furnace temperature and energy distribution data are monitored to obtain adjusted output data; According to the adjusted output data, all adjustment actions and results are recorded, including energy output data before and after the adjustment, a temperature distribution diagram is constructed, and a dynamic energy adjustment record is generated.

5. The intelligent control method for the nickel electrode atmosphere tunnel furnace according to claim 4, characterized in that: The step of adjusting the proportional flow rate of the input gas is: Using the dynamic energy adjustment record, the concentration and reaction rate of chemical substances in the furnace are measured by sensors to generate chemical reaction monitoring data; Analyze the chemical reaction monitoring data, using the formula, Calculate the adjusted gas flow rate , get the adjusted input parameters, where, represents the change in the concentration of a chemical substance, represents the measurement time interval, represents the initial input gas ratio, Represents the adjusted gas ratio; Based on the adjusted input parameters, the energy output is optimized, the chemical reaction requirements in the furnace are matched, and an adjustment plan is output.

6. The intelligent control method for the nickel electrode atmosphere tunnel furnace according to claim 5, characterized in that: The steps for obtaining the chemical control state balance result are: Apply the adjustment scheme to continuously obtain real-time change data of chemical reaction rate and concentration in the furnace, and record and output the current chemical reaction state analysis record; According to the analysis record of the current chemical reaction state, combined with the actual energy output demand in the furnace, the formula is used: Calculate the required energy output , adjust the energy output parameters to obtain the adjusted energy output parameters, where: represents the chemical reaction rate monitored in real time, represents the instantaneous concentration change, represents the adjustment time constant; The adjusted energy output parameters are implemented to perform dynamic adjustments, confirm the dynamic equilibrium of the chemical reaction and the stable equilibrium of the chemical control state, and generate a chemical control state equilibrium result.

7. The intelligent control method for the nickel electrode atmosphere tunnel furnace according to claim 6, characterized in that: The temperature control and gas flow parameter adjustment steps are: Based on the chemical control state balance result, dynamically and continuously monitor the furnace environment, record the changing temperature and chemical composition data, and generate a dynamic monitoring data set; According to the dynamic monitoring data set, by comparing with preset standards, evaluating whether the production conditions are met, and generating an evaluation result of the need for environmental adjustment; According to the evaluation result of the environmental adjustment needs, the temperature and gas flow parameters in the furnace are adjusted, the environment in the furnace is dynamically optimized, and the control parameters for dynamic adjustment are generated.

8. The intelligent control method for the nickel electrode atmosphere tunnel furnace according to claim 7, characterized in that: The steps for obtaining the continuously optimized tunnel furnace control solution are: Apply the dynamically adjusted control parameters and regularly compare them with the target values ​​set for product quality and production efficiency requirements, using the formula, Calculate the square root of the mean of the absolute deviations of all measurement points , generate actual and target comparison results, where Represents the actual measured value of each measuring point, represents the corresponding target measurement value, Represents the total number of measurement points; Based on the actual and target comparison results, analyze the deviation trend and evaluate the degree of deviation, analyze whether there is a persistent deviation trend, and generate evaluation and adjustment suggestions; Based on the evaluation and adjustment suggestions, the control strategy is updated, the control parameters of temperature and chemical composition are optimized, the production process control is refined, the production needs are matched, and a continuously optimized tunnel furnace control solution is generated.

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