An intelligent control method for nickel electrode atmosphere tunnel furnace

Abstract

The present invention relates to the field of furnace control technology, specifically to an intelligent control method for a nickel electrode atmosphere tunnel furnace, comprising the following steps: through full-automatic PLC control, using PID technology to independently control the temperature of the temperature zone, real-time acquisition of regional temperature data and setting of preliminary temperature control parameters in the furnace, confirmation of stable operation of the basic temperature control, and generation of temperature control baseline data. 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, energy distribution in the furnace is optimized, energy efficiency is improved, and energy output is adjusted through the integration of infrared and microwave technologies, directly responding to changes in the furnace environment, improving material processing quality, and precise control of chemical reactions. By adjusting the gas flow rate and ratio, the accuracy and balance of the chemical reaction are ensured, energy consumption and operational complexity are significantly reduced, and the control strategy is dynamically adjusted. According to the comparison between the actual output and the target value, the production process is optimized to ensure high efficiency and high-quality output.

Description

Technical Field

[0001] The present 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 of heating equipment in industrial applications. Its primary goal is to ensure the stability, efficiency, and safety of the heating process, while optimizing energy utilization and reducing operating costs. Specifically for industrial furnaces (such as tunnel furnaces and rotary kilns), the control system encompasses, but is not limited to, temperature control, atmosphere control, and monitoring and adjusting furnace pressure and heat distribution. By utilizing hardware such as sensors, controllers, and actuators, along with supporting software algorithms, furnace control technology enables precise control of the furnace environment, ensuring that the quality and properties of materials processed meet production requirements.

[0003] The intelligent control method for nickel electrode atmosphere tunnel furnaces is a control solution specifically designed for atmosphere tunnel furnaces containing nickel electrodes. A tunnel furnace is a continuously operating industrial furnace used for heating, baking, or melting materials. Atmosphere control refers to creating a specific gas environment within the furnace to influence or control the chemical and physical properties of the material during the heating process. The control process involves automatic adjustment of temperature, pressure, and gas composition to optimize the processing and improve product quality. It is primarily used to improve processing efficiency and material handling quality while reducing energy consumption and operational difficulty.

[0004] Existing technologies often lack immediate response and precise management in temperature control and energy distribution adjustments, resulting in low energy efficiency and unstable product quality. Especially in the handling 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, existing technologies are unable to adjust temperature or gas ratios in a timely manner to rapidly changing production conditions, increasing scrap rates and production costs. Furthermore, existing control systems are highly complex and require extensive manual intervention, increasing the likelihood of operational errors and reducing 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 solution: an intelligent control method for a nickel electrode atmosphere tunnel furnace, comprising the following steps:

[0007] S1: Through fully automatic PLC control, PID technology is used to independently control the temperature of each temperature zone, collect regional temperature data in real time, set preliminary furnace temperature control parameters, confirm the stable operation of basic temperature control, and generate temperature control baseline data;

[0008] S2: Using the temperature control baseline data, the temperature, pressure, and gas composition in the furnace are monitored in real time. The data is collected and compared with the set control standards. Based on 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;

[0009] 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 requirements 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;

[0010] 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 based on the adjustment results, dynamically evaluate and adjust the control strategy, and generate a continuously optimized tunnel furnace control plan.

[0011] As a further solution of the present invention, the step of obtaining the temperature control baseline data is:

[0012] S111: Monitor the temperature of the temperature zones in real time through the fully automatic PLC, record sensor data, and output the real-time temperature data set of the temperature zones in the furnace;

[0013] S112: Based on the real-time temperature data set of the temperature zones in the furnace, PID control technology is applied to adjust parameters to ensure that the temperature of each temperature zone reaches a preset target, and an adjusted control parameter data set is generated;

[0014] S113: Continuous monitoring is performed based on the adjusted control parameter data set to verify the stability of the temperature control process and output temperature control baseline data.

[0015] As a further embodiment of the present invention, the steps of collecting data and setting control standards are as follows:

[0016] S211: Deploy sensors to collect real-time temperature, pressure, and gas composition data in the furnace and generate real-time monitoring data;

[0017] S212: Compare the real-time monitoring data with the temperature control baseline data using the formula:

[0018]

[0019] Calculate the deviation value , and obtain the deviation analysis results, where Indicates real-time temperature, air pressure and gas composition data. represents baseline data, Represent the standard deviations of temperature, pressure and gas composition content respectively;

[0020] 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.

[0021] As a further solution of the present invention, the step of obtaining the dynamic energy adjustment record is:

[0022] S221: Based on the deviation analysis result, determining the adjustment requirements for infrared and microwave, determining the corresponding output intensities by evaluating the deviation values, and obtaining infrared and microwave output intensity analysis records;

[0023] S222: Executing infrared and microwave output intensity adjustment based on the infrared and microwave output intensity analysis record, adjusting the infrared and microwave outputs in real time, monitoring the adjusted furnace temperature and energy distribution data, and obtaining adjusted output data;

[0024] S223: Based on the adjusted output data, record all adjustment actions and results, including energy output data before and after adjustment, construct a temperature distribution graph, and generate a dynamic energy adjustment record.

[0025] As a further embodiment of the present invention, the step of adjusting the proportional flow rate of the input gas is as follows:

[0026] 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;

[0027] S312: Analyze the chemical reaction monitoring data, using the formula:

[0028]

[0029] 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;

[0030] S313: Based on the adjusted input parameters, optimize the energy output, match the chemical reaction requirements in the furnace, and output an adjustment plan.

[0031] As a further solution of the present invention, the step of obtaining the chemical control state balance result is:

[0032] S321: Applying the adjustment scheme, continuously acquiring real-time change data of chemical reaction rate and concentration in the furnace, and recording and outputting analysis records of the current chemical reaction state;

[0033] 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.

[0034]

[0035] 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;

[0036] S323: Implementing the adjusted energy output parameters, performing dynamic regulation, confirming the dynamic equilibrium of the chemical reaction and the stable equilibrium of the chemical control state, and generating a chemical control state equilibrium result.

[0037] As a further embodiment of the present invention, the temperature control and gas flow parameter adjustment steps are as follows:

[0038] 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;

[0039] S412: Evaluate whether production conditions are met based on the dynamic monitoring data set by comparing it with preset standards, and generate an environmental adjustment need assessment result;

[0040] 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.

[0041] As a further solution of the present invention, the step of obtaining the continuously optimized tunnel furnace control solution is:

[0042] 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,

[0043]

[0044] 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 measurement value of each measurement point, represents the corresponding target measurement value, Represents the total number of measurement points;

[0045] S422: 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;

[0046] 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 needs are matched, and a continuously optimized tunnel furnace control plan is generated.

[0047] Compared with the prior art, the advantages and positive effects of the present invention are:

[0048] In the present invention, by real-time monitoring of the temperature in the temperature zones and precise adjustment, fine-grained management of temperature control is achieved, 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, thereby improving material processing quality. Precise control of chemical reactions is achieved by adjusting gas flow rates and ratios to ensure the accuracy and balance of chemical reactions, significantly reducing energy consumption and operational complexity. The control strategy is dynamically adjusted to optimize the production process based on the comparison between actual output and target values, thereby ensuring high-efficiency and high-quality output. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 It is a flow chart of the main steps of the present invention;

[0050] Figure 2 This is a flow chart for obtaining temperature control baseline data of the present invention;

[0051] Figure 3 Flowchart for collecting data and setting control standards for the present invention;

[0052] Figure 4 A flowchart for obtaining dynamic energy adjustment records of the present invention;

[0053] Figure 5 This is a flow chart for adjusting the proportional flow rate of input gas according to the present invention;

[0054] Figure 6 The flowchart of obtaining the chemical control state equilibrium result of the present invention is as follows;

[0055] Figure 7 This is a flow chart of the temperature control and gas flow parameter adjustment of the present invention;

[0056] Figure 8 This is a flow chart for obtaining the tunnel furnace control solution that is continuously optimized in the present invention. DETAILED DESCRIPTION

[0057] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to 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.

[0058] 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, indicating positions or relationships, are based on the positions or relationships shown in the accompanying drawings and are intended only to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limiting the present invention. Furthermore, in the description of the present invention, "plurality" means two or more, unless otherwise expressly and specifically defined.

[0059] See also Figure 1 , an intelligent control method for a nickel electrode atmosphere tunnel furnace, comprising the following steps:

[0060] S1: Through fully automatic PLC control, PID technology is used to independently control the temperature of each temperature zone, collect regional temperature data in real time, set preliminary furnace temperature control parameters, confirm the stable operation of basic temperature control, and generate temperature control baseline data;

[0061] S2: Monitor the temperature, pressure, and gas composition in the furnace in real time using temperature control baseline data. The collected data is compared with the set control standards. Based on the comparison results, the infrared and microwave output intensities are adjusted to match the energy output to the furnace requirements, optimizing the temperature and energy distribution uniformity in the furnace and generating dynamic energy adjustment records.

[0062] S3: Based on dynamic energy adjustment records, monitor the concentration changes and reaction rates of chemical substances in the furnace, adjust the proportional flow rate of input gas, and adjust the energy output according to the adjustment results to match the needs of the chemical reaction, ensuring the balance of chemical reaction and generating the chemical control state balance result;

[0063] 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 based on the adjustment results, dynamically evaluate and adjust the control strategy, and generate a continuously optimized tunnel furnace control plan.

[0064] Temperature control baseline data includes regional control difference data, control loop stability records and baseline adjustment records; dynamic energy adjustment records include energy adjustment reaction time, output power records and temperature response speed records; 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 plan includes parameter optimization history, control efficiency indicators and adjustment strategy records.

[0065] See also Figure 2 ,The steps for obtaining temperature control baseline data are as follows,

[0066] S111: Monitor the temperature of the temperature zones in real time through the fully automatic PLC, record sensor data, and output the real-time temperature data set of the temperature zones in the furnace;

[0067] Based on the real-time monitoring capability of the fully automatic PLC system, the system collects temperature data from each temperature zone through multiple sensors. The output signal of each sensor is first amplified and filtered by the signal conditioning module to optimize the signal quality and accuracy. The adjusted signal is collected, converted into a digital signal to ensure digital processing of the 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 settings immediately or trigger an alarm. During this process, all temperature data is recorded and forms a real-time temperature zone temperature data set, providing a reliable foundation for subsequent control and adjustment.

[0068] S112: Based on the real-time temperature data set of the temperature zones in the furnace, PID control technology is applied to adjust parameters to ensure that the temperature of each temperature zone reaches the preset target, and an adjusted control parameter data set is generated;

[0069] Applying PID control technology, we first extract the current temperature value of each temperature zone from the real-time temperature zone temperature data set in the furnace obtained above, compare it with the set target temperature, and calculate the temperature adjustment required for each temperature zone (the current temperature value of each temperature zone minus the set target temperature, and take the absolute value). This includes error determination, proportional (P), integral (I), and differential (D) control calculations. 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 are synthesized into adjustment signals through the control algorithm and sent to the actuators, such as heaters or coolers, to adjust the temperature zones in real time, ultimately generating an adjusted control parameter data set for further temperature control verification.

[0070] 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;

[0071] 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 from 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, the temperature control baseline data is formed, which provides a key reference for evaluating the performance of the tunnel furnace.

[0072] See also Figure 3 The steps for collecting data and setting control standards are:

[0073] S211: Deploy sensors to collect real-time temperature, pressure, and gas composition data in the furnace and generate real-time monitoring data;

[0074] During sensor deployment, the first step is to select high-precision sensors suitable for high-temperature environments. 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 adjusting temperature deviations, calibrating the sensitivity of air pressure sensing, and testing the accuracy 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.

[0075] S212: Compare the real-time monitoring data with the temperature control baseline data using the formula,

[0076]

[0077] Calculate the deviation value , and obtain the deviation analysis results, where Indicates real-time temperature, air pressure and gas composition data. represents baseline data, Represent the standard deviations of temperature, pressure and gas composition content respectively;

[0078] Through data collection, ℃ represents the real-time measured temperature, ℃ is the baseline temperature, °C is the standard deviation of the temperature data, and are real-time and baseline air pressure, is the standard deviation of air pressure, 、 and .

[0079] The calculation process is:

[0080]

[0081]

[0082] The results showed significant deviations between the real-time and baseline data, indicating that the furnace environment may need to be adjusted to maintain process stability.

[0083] S213: Based on the deviation analysis results, 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. A control standard adjustment decision record is generated.

[0084] The process of making decisions based on the deviation analysis results involves evaluating the deviation value and comparing it with the standard threshold. First, the acceptable threshold of the deviation is set to 1.5 (the threshold is determined based on historical data analysis and safety standards). With a threshold of 1.5, because A value above 1.5 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 settings, gas pressure regulation, and gas ratio optimization to ensure product quality and production safety. The adjusted settings will be recorded in the system's operation log for future reference and audit use.

[0085] See also Figure 4 ,The steps for obtaining dynamic energy adjustment records are,

[0086] S221: Based on the deviation analysis results, determining the adjustment requirements for infrared and microwaves, determining the corresponding output intensities by evaluating the deviation values, and obtaining infrared and microwave output intensity analysis records;

[0087] Based on the deviation analysis results, in the process of determining the adjustment requirements for infrared and microwave power systems, we first conduct an in-depth statistical analysis of the deviation data, including calculating the mean, variance, and frequency distribution of the deviations. Based on the size and distribution characteristics of the deviation values, we develop an adjustment strategy, which covers different levels of adjustment, from minor adjustments 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 for infrared and microwave power systems. Ultimately, a detailed adjustment strategy document is generated, which will serve as a guide for the next step of actual adjustment operations.

[0088] S222: Execute infrared and microwave output intensity adjustment based on the infrared and microwave output intensity analysis records, adjust the infrared and microwave outputs in real time, monitor the adjusted furnace temperature and energy distribution data, and obtain adjusted output data;

[0089] 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 adjusting 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 adjustment command execution, for subsequent effect analysis and system optimization. The final output data will be recorded in detail in the system database for future analysis and backtracking.

[0090] S223: Based on the adjusted output data, record all adjustment actions and results, including energy output data before and after adjustment, construct a temperature distribution map, and generate a dynamic energy adjustment record;

[0091] The process of recording all adjustment actions and results is a key part of data management and analysis. First, each adjustment action and corresponding results are automatically recorded by the system in the dynamic energy adjustment record, including the specific parameters of the adjustment, the time when the adjustment was performed, and the system status before and after the adjustment, such as temperature and energy output data. In addition, 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 form an important data foundation for optimizing adjustment strategies and improving system performance.

[0092] See also Figure 5 , the adjustment steps of the proportional flow rate of the input gas are,

[0093] S311: Using dynamic energy adjustment records, the concentration and reaction rate of chemical substances in the furnace are measured by sensors to generate chemical reaction monitoring data;

[0094] The existing dynamic energy adjustment records are used for monitoring, and the chemical concentration and reaction rate are measured in real time by the high-precision sensor system in the furnace. The collected data is transmitted to the central processing unit in real time via 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 measurement data, any changes that exceed 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 sensors are checked regularly to maintain the optimal performance of the tunnel furnace.

[0095] S312: Analyze chemical reaction monitoring data using the formula,

[0096]

[0097] 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;

[0098] In a specific monitoring period, the concentration change of chemical substances obtained by chemical sensors 10 mg / m 3 , measuring time interval For 30 seconds, the initial gas ratio The adjusted gas ratio is 0.2 is 0.3, and we can calculate it by substituting it into the formula:

[0099] Calculate the absolute value of the concentration change and get:

[0100]

[0101] Taking the square root of the absolute value, we get:

[0102]

[0103] Calculate the ratio of the gas proportions and get:

[0104]

[0105] Substituting the above results into the formula, we can get:

[0106]

[0107] 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.

[0108] S313: Based on the adjusted input parameters, optimize the energy output, match the chemical reaction requirements in the furnace, and output an adjustment plan;

[0109] Energy output is optimized based on the adjusted input parameters. The degree of match 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. The energy output setting is adjusted according to the analysis results to ensure the balance of chemical reaction. In addition, by implementing a dynamic energy adjustment strategy, the system can automatically respond to any unforeseen changes in the chemical reaction, thereby adjusting the 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 rate is achieved, ensuring the efficiency of the production process and the stability of product quality.

[0110] See also Figure 6 , the steps to obtain the chemical control state balance result are,

[0111] S321: Apply the adjustment plan to continuously obtain real-time change data of chemical reaction rate and concentration in the furnace, and record and output the current chemical reaction status analysis record;

[0112] Through real-time data monitoring, real-time changes in the chemical reaction rate and concentration in the furnace are obtained. Analysis shows that the reaction speed is closely related to the required energy output. The relevant data is further processed through data analysis to identify key change points and potential adjustment needs. Statistical analysis is used to evaluate data quality to ensure the accuracy and reliability of the collected data. The data is then 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, a detailed report on the current chemical reaction status is generated, which provides a scientific basis for subsequent energy output adjustments and ensures the efficiency and safety of the chemical reaction process.

[0113] S322: Based on the analysis and record of the current chemical reaction state and the actual energy output demand in the furnace, the formula is used.

[0114]

[0115] 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;

[0116] The reaction rate is monitored by the sensor. is 0.75 mol / s, and the concentration changes is 0.1mol / L, and the time constant is adjusted For 50s, substitute into the formula for calculation:

[0117] calculate The product of , we get:

[0118] mol 2 / Ls

[0119] Divide the above result by the time constant ,have to:

[0120] mol / Ls

[0121] 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. This ensures that the energy output accurately matches the needs of the actual chemical reaction and provides the possibility of continuous optimization of the chemical reaction process.

[0122] S323: Implementing the adjusted energy output parameters, performing dynamic regulation, confirming the dynamic equilibrium of the chemical reaction and the stable equilibrium of the chemical control state, and generating a chemical control state equilibrium result;

[0123] By precisely adjusting the energy output parameters and implementing dynamic adjustments, the monitoring system continuously tracks changes in reaction conditions within 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 reaction. 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. This not only ensures the continuity of the chemical production process, but also optimizes energy utilization efficiency, ensuring product quality and environmental safety.

[0124] See also Figure 7 , the steps for adjusting temperature control and gas flow parameters are,

[0125] 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;

[0126] Based on the chemical control state balance results, sensors are used to continuously monitor the temperature and chemical composition of the furnace environment, which can collect data on furnace temperature and chemical changes 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 the monitoring data is transmitted 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 and use to generate a dynamic monitoring data set.

[0127] S412: Based on the dynamic monitoring data set, by comparing with the preset standards, evaluate whether the production conditions are met and generate the environmental adjustment need assessment results;

[0128] Based on 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, including but 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.

[0129] S413: Adjusting the furnace temperature and gas flow parameters based on the environmental adjustment need assessment results, dynamically optimizing the furnace environment, and generating dynamically adjusted control parameters;

[0130] According to the evaluation results of the environmental adjustment needs, the temperature and gas flow parameters in the furnace are dynamically adjusted, 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.

[0131] See also Figure 8 ,The steps to obtain the continuously optimized tunnel furnace control solution are,

[0132] 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,

[0133]

[0134] 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 measurement value of each measurement point, represents the corresponding target measurement value, Represents the total number of measurement points;

[0135] In a certain actual operation, the furnace temperatures were measured to be 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.

[0136] get , The calculation process is as follows:

[0137] Calculate the absolute value of the difference between each actual value and the target value to obtain:

[0138]

[0139]

[0140]

[0141] Compute the mean of the differences:

[0142]

[0143] Calculate the root mean square deviation:

[0144]

[0145] 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.

[0146] S422: Based on the comparison results between actual and target, analyze the deviation trend and evaluate the degree of deviation, analyze whether there is a persistent deviation trend, and generate evaluation and adjustment suggestions;

[0147] 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, its difference from 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.

[0148] 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;

[0149] Based on the evaluation and adjustment suggestions provided, the furnace temperature control strategy was updated. This involved adjusting multiple parameters, such as the set points of the temperature controller and the mixing ratio of the chemical components. Through precise adjustments, a more stable furnace environment was ensured, thereby improving product quality and production efficiency. The updated control strategy was verified with actual operating data to ensure that its effectiveness met production requirements. In addition, the adjustments will be continuously optimized based on new production data, forming a dynamically updated cycle, thereby generating a continuously optimized tunnel furnace control solution.

[0150] The above are merely preferred embodiments of the present invention and do not limit the present invention in any other form. Any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall still fall within the scope of protection 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 independently control the temperature of each temperature zone, collect regional temperature data in real time, set preliminary furnace temperature control parameters, confirm the stable operation of basic temperature control, and generate temperature control baseline data; The temperature, pressure and gas composition in the furnace are monitored in real time using the temperature control baseline data. The data is collected and compared with the set control standards. Based on 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 requirements of the chemical reaction, thereby ensuring the balance of the chemical reaction and generating a chemical control state balance result; Based on the chemical control state balance results, 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 based on the adjustment results, the control strategy is dynamically evaluated and adjusted, and a continuously optimized tunnel furnace control plan is generated; The steps of collecting data and comparing it with the set control standards are: Deploy sensors to collect real-time temperature, pressure, and gas composition data inside the furnace and generate real-time monitoring data; The real-time monitoring data is compared with the temperature control baseline data, and the formula is used Calculate the deviation value , and obtain the deviation analysis results, where Indicates real-time temperature, air pressure and gas composition data. represents baseline data, Represent the standard deviations of temperature, pressure and gas composition content respectively; Based on the deviation analysis results, 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; The steps for generating the dynamic energy adjustment record are: Based on the deviation analysis results, determining the adjustment requirements for infrared and microwaves, determining the corresponding output intensities by evaluating the deviation values, and obtaining infrared and microwave output intensity analysis records; According to the infrared and microwave output intensity analysis records, performing infrared and microwave output intensity adjustment, adjusting the infrared and microwave outputs in real time, monitoring the adjusted furnace temperature and energy distribution data, and obtaining adjusted output data; Based on the adjusted output data, record all adjustment actions and results, including energy output data before and after adjustment, construct a temperature distribution map, and generate a dynamic energy adjustment record; The steps for adjusting the proportional flow rate of the input gas are as follows: 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 and use 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 to match the chemical reaction requirements in the furnace and an adjustment plan is output; The steps for generating the chemical control state balance result are: Applying the adjustment scheme, continuously acquiring real-time change data of chemical reaction rate and concentration in the furnace, and recording and outputting analysis records of the current chemical reaction state; According to the analysis record of the current chemical reaction state, combined with the actual energy output demand in the furnace, the formula 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; Implementing the adjusted energy output parameters, performing dynamic adjustments, confirming the dynamic equilibrium of the chemical reaction and the stable equilibrium of the chemical control state, and generating a chemical control state equilibrium result; The steps for generating the temperature control baseline data are as follows: 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, PID control technology is applied to adjust parameters to ensure that the temperature of each temperature zone reaches a preset target, and an adjusted control parameter data set is generated; Performing continuous monitoring based on the adjusted control parameter data set to verify the stability of the temperature control process and outputting temperature control baseline data; The steps for adjusting the temperature control and gas flow parameters are as follows: Based on the chemical control state balance result, 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 dynamic monitoring data set, by comparing with preset standards, evaluating whether production conditions are met and generating an assessment result of the need for environmental adjustment; According to the evaluation results 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; The steps for generating the continuously optimized tunnel furnace control scheme are as follows: 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 measurement value of each measurement 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, and the production needs are matched to generate a continuously optimized tunnel furnace control plan; By real-time monitoring of the temperature in each temperature zone and precise adjustment, fine-grained management of temperature control is achieved, 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, improving material processing quality. Precise control of chemical reactions is achieved by adjusting gas flow rates and ratios to ensure the accuracy and balance of chemical reactions, significantly reducing energy consumption and operational complexity. Dynamic adjustment of control strategies is carried out based on the comparison between actual output and target values ​​to optimize the production process and ensure high-efficiency and high-quality output.

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