Intelligent water temperature monitoring and alarming system for electric furnace
Through the intelligent water temperature monitoring and alarm system, cooling pipeline data is obtained in real time, water demand is calculated and status is analyzed, and alarm signals are generated, which solves the problems of blockage and leakage of electric furnace cooling water circuits, and improves monitoring response speed and equipment safety.
Patent Information
- Application Number
- CN202411228804.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-03
- Publication Date
- 2025-01-07
- Estimated Expiration
- Not applicable · inactive patent
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Figure CN119268374A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of electric furnace temperature control, and in particular to an intelligent water temperature monitoring and alarm system for an electric furnace. Background Art
[0002] In the process of metal heat treatment, medium frequency heating induction furnaces are often used to heat the workpiece. During the operation of the electric furnace, various components inside it (such as thyristors, reactors, capacitors, busbars, water-cooled cables, and induction coils, etc.) will generate a lot of heat. When the furnace is working, when any cooling water channel is blocked or the water flow is reduced, the local water temperature will rise, which will not only affect the cooling effect, causing the local temperature of the induction coil to be too high, but also easily damage the cooling system, thus creating a safety hazard.
[0003] In the existing cooling water circuit, due to long-term exposure to high temperature, the pipeline is prone to rupture and leakage or internal acid salt deposition leading to blockage, but the production personnel cannot quickly identify the fault point, and thus cannot quickly repair the pipeline, affecting production efficiency and reducing the life of various components; in addition, the existing water temperature monitoring device is passive, and its response has a time lag, and it is impossible to provide early active warning, resulting in damage to related components or reduced life. To this end, we provide an intelligent water temperature monitoring and alarm system for electric furnaces. Summary of the invention
[0004] The object of the present invention is to provide an intelligent water temperature monitoring and alarm system for an electric furnace.
[0005] The technical problems solved by the present invention are:
[0006] (1) How to accurately calculate the actual water demand in the cooling pipeline under certain production environment conditions based on theoretical analysis and calculation, solving the problem of resource waste caused by excessive flow in the cooling pipeline and poor cooling effect caused by small flow in the prior art;
[0007] (2) How to determine the working status of the cooling pipe by analyzing the status of the cooling pipe, monitor and determine the adverse conditions before the water temperature alarm, and solve the problem of time lag caused by passive water temperature alarm in the prior art, which may cause equipment damage or shortened life.
[0008] The present invention can be implemented by the following technical scheme: An intelligent water temperature monitoring and alarm system for an electric furnace, comprising:
[0009] Data acquisition module, used to obtain real-time data on pipe pressure at the water inlet and outlet, water temperature, flow rate, current passing through the induction coil, molten metal temperature, outer wall temperature of the insulation layer, and specification data of the electric furnace and cooling pipeline;
[0010] The water demand analysis module accurately calculates the actual water demand of cooling water in the cooling pipeline according to the working status of the electric furnace and induction coil in actual production;
[0011] The status analysis module analyzes the leakage status and blockage status in the cooling pipeline. When leakage or blockage occurs, it generates a pipeline leakage alarm signal and determines the leakage location or a pipeline blockage alarm signal and determines the deadline for cleaning;
[0012] The alarm display module is used to receive and display the alarm signal and related location data and time data generated by the status analysis module, and send it to the staff's mobile phone for prompting.
[0013] A further technical improvement of the present invention is that the steps of the water demand analysis module for accurately analyzing and calculating the actual water demand include:
[0014] Step 1: Determine the total heat that needs to be taken away by cooling water, that is, the heat generated by the resistor and the heat conducted by the metal liquid;
[0015] Step 2: Calculate the resistance heat and the metal liquid conduction heat within a certain period of time respectively;
[0016] Step 3: Based on the law of energy conservation, according to the maximum temperature rise of the inlet and outlet of the cooling pipeline, the heat absorption of water and the total heat within a certain period of time are balanced, and then the required flow rate of cooling water per unit time is obtained;
[0017] Step 4: On the basis of the above required flow rate, reserve redundancy for the cooling pipeline, multiply it by the cooling redundancy coefficient, and obtain the value range of the actual water demand.
[0018] A further technical improvement of the present invention is that the calculation process of the resistance heating amount includes:
[0019] Calculate the equivalent DC current corresponding to the sine wave AC, that is, Among them I d is the equivalent direct current, I m is the peak value of the alternating current,
[0020] The heat generated by the resistor within a certain period of time Δt is
[0021] Among them, R R represents the resistance of the induction coil, ρ represents the resistivity of the induction coil, l represents the wire length of the induction coil, and A represents the cross-sectional area of the induction coil wire.
[0022] A further technical improvement of the present invention is that the calculation process of the heat conducted by the molten metal includes:
[0023] Calculate the thermal resistance R of the furnace lining C1 and thermal insulation resistance RC2 :
[0024]
[0025] Wherein, d1, d2, d3 represent the inner diameter of the furnace lining, the outer diameter of the furnace lining and the outer diameter of the thermal insulation layer respectively; λ1, λ2 represent the thermal conductivity of the furnace lining material and the thermal conductivity of the thermal insulation layer material respectively; H represents the liquid level of the molten metal in the furnace;
[0026] The heat conducted by the molten metal within a certain period of time Δt is
[0027] Among them, W 液 , W 隔 They represent the molten metal temperature and the external temperature of the insulation layer respectively.
[0028] The further technical improvement of the present invention is that the equilibrium equation for the heat absorbed by water and the total heat in a certain period of time in step 3 is: 水 cq0Δt·(W 出 -W 进 )=E;
[0029] Among them, ρ 水 represents the density of cooling water; c represents the specific heat capacity of cooling water; q0 represents the required flow rate of cooling water per unit time, i.e., flow rate; W 进 , W 出 They represent the water temperature of the coolant at the water inlet and outlet of the pipeline respectively, and E is the total heat.
[0030] A further technical improvement of the present invention is that the specific process of the state analysis module determining the leakage state and leakage location includes:
[0031] Based on the pipeline pressure at the inlet and outlet of the cooling pipeline, a pressure wave change curve with time series is constructed respectively; the initial time t when the two pressure waves suddenly change is recorded 11 ,t 21 and the time t when the pressure wave peak decays to half 12 ,t 22 ;
[0032] Set a decay time limit t0 and construct the following comparison judgment:
[0033] when When the negative pressure wave is determined to be caused by the bursting of bubbles in the water, it is directly ignored;
[0034] when When the negative pressure wave is generated, it is determined that the cooling pipeline leaks and a pipeline leak alarm signal is generated;
[0035] The distance between the leak location and the pipeline pressure sensor at the water inlet end along the pipeline trajectory is calculated based on the following formula:
[0036] Where S is the distance between the two pipeline pressure sensors along the pipeline trajectory, v 波 is the pressure wave velocity, ρ 水 is the density of cooling water, E 水 is the elastic modulus of water, E 管 is the elastic modulus of the cooling pipe, e is the wall thickness of the cooling pipe, d is the diameter of the cooling pipe, and ξ is the gas influence coefficient.
[0037] A further technical improvement of the present invention is that the specific process of the state analysis module determining the congestion state and deriving the deadline time includes:
[0038] When the water pressure at the outlet of the water pump and the water temperature of the cooling management are on an upward trend, it is determined that the cooling pipeline is blocked and a pipeline blockage alarm signal is generated;
[0039] Construct a time-series water temperature change curve and set a water temperature threshold line, calculate the average water temperature of each working cycle in the last N working cycles, and calculate the water temperature change rate of adjacent working cycles;
[0040] The fitting function relationship between the water temperature change rate and the working cycle is constructed to predict the average water temperature of the subsequent working cycle, and the number of working cycles when the average water temperature reaches the water temperature threshold line is obtained, thereby obtaining the absolute time, and the absolute time is calculated and updated in each current working cycle.
[0041] A further technical improvement of the present invention is that the state analysis module also sets a time window with a certain step length in the water temperature change curve, and coincides the right endpoint of the time window with the updated data time point, calculates the temperature rise rate in the current time window, compares the temperature rise rate with the set value, and when it exceeds the set value, generates an alarm signal for excessive temperature rise, and records the continuous over-temperature time.
[0042] Compared with the prior art, the present invention has the following beneficial effects:
[0043] 1. The present invention accurately calculates the actual water demand in the cooling pipeline under certain production environment conditions based on theoretical analysis, so as to control the water delivery volume and water pump power, and provide data support for its operation within a reasonable range, avoiding the problem of excessive resource loss due to excessive flow, and also preventing the phenomenon of poor cooling effect due to too small flow.
[0044] 2. By analyzing the status of the cooling pipe, the working status of the cooling pipe can be determined, and the leakage location or the deadline for clearing the blockage can be accurately determined, providing guidance for the staff to take remedial measures; it can respond quickly at the early stage of the adverse condition, avoiding the time lag caused by the passive water temperature alarm, improving the response sensitivity of the monitoring system, and protecting the safety of equipment and personnel. BRIEF DESCRIPTION OF THE DRAWINGS
[0045] In order to facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.
[0046] Figure 1 It is a system block diagram of the present invention. DETAILED DESCRIPTION
[0047] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the specific implementation methods, structures, features and effects of the present invention are described in detail below in conjunction with the accompanying drawings and preferred embodiments.
[0048] See also Figure 1 As shown, an intelligent water temperature monitoring and alarm system for an electric furnace includes a data acquisition module, a memory, a water demand analysis module, a state analysis module and an alarm display module.
[0049] The data acquisition module monitors the real-time current passing through the induction coil, the temperature of the molten metal in the furnace, and the temperature of the outer wall of the insulation layer in real time, and uses a flow meter to obtain the flow rate in the cooling pipeline in real time; at the same time, the data acquisition module also installs pipeline pressure sensors near both ends of the cooling pipeline to monitor the pipeline pressure at the corresponding position in real time and measure the water temperature at the inlet and outlet ends of the cooling pipeline; in addition, the data acquisition module provides a data entry interface for the staff to enter parameters such as the inner and outer diameters of the furnace lining, the outer diameter of the insulation layer, the resistivity-temperature relationship curve of the induction coil, and the length of the induction coil. The data acquisition module sends the collected data to the memory for storage;
[0050] The heat of the induction coil comes from two sources: (1) the heat generated by the resistance of the current passing through the metal induction coil; (2) the heat caused by the liquid metal in the furnace transferring heat to the induction coil;
[0051] The water demand analysis module is used to analyze the water demand for cooling the induction coil in a certain temperature environment, including:
[0052] S11: Assume that the heat generated by the resistor within a certain period of time Δt is E R , the heat conducted by the metal liquid is E C , the total heat that needs to be removed by cooling water is E = E R +E C;
[0053] S12: Solve the heat generated by the resistor
[0054] In a cycle T, the heat generated by AC is equal to the heat generated by DC, and the current value of this equivalent DC is the effective value of AC. Let the equivalent DC be I d , the peak value of the alternating current is I m , then
[0055] The AC we use daily is a sinusoidal AC, so I(t) = I m sin(ωt);
[0056] Combining the above two equations, we have
[0057] but
[0058] Among them, R R represents the resistance of the induction coil, ρ represents the resistivity of the induction coil, l represents the length of the wire of the induction coil, and A represents the cross-sectional area of the wire of the induction coil;
[0059] S13: Solving the heat transfer of molten metal
[0060] First, calculate the thermal resistance of the furnace lining and the insulation layer according to the following formula:
[0061]
[0062] Among them, R C1 , R C2 They represent the thermal resistance of the furnace lining and the thermal resistance of the thermal insulation layer, respectively; d1, d2, d3 represent the inner diameter of the furnace lining, the outer diameter of the furnace lining and the outer diameter of the thermal insulation layer, respectively; λ1, λ2 represent the thermal conductivity of the furnace lining material (generally neutral corundum material) and the thermal conductivity of the thermal insulation layer material (generally asbestos cloth), respectively; H represents the liquid level of the molten metal in the furnace;
[0063] The heat transferred from the metal liquid to the induction coil
[0064] Among them, W 液 , W 隔 Respectively represent the temperature of the molten metal and the temperature outside the insulation layer;
[0065] S14: Calculate water demand based on the maximum temperature rise of cooling water
[0066] According to the law of conservation of energy, in order to ensure the temperature stability of the induction coil itself, all the heat within the time Δt must be taken away by the cooling water, so:
[0067] ρ水 cq0Δt·(W 出 -W 进 )=E(*)
[0068] Among them, ρ 水 represents the density of cooling water; c represents the specific heat capacity of cooling water; q0 represents the required flow rate of cooling water per unit time, i.e., flow rate; W 进 , W 出 Respectively represent the water temperature of the coolant at the water inlet and outlet of the pipeline. Generally speaking, W 进 The value is between 5℃~25℃, W 出 The value is not greater than 55℃;
[0069] According to formula (*), the minimum required flow rate q0 of cooling water can be obtained. Due to the "skin effect" of alternating current on the surface of the induction coil and the redundancy reserved for the cooling system, the actual water demand q≥εq0, where ε is the cooling redundancy coefficient, and ε can take any value in the interval [1.56, 2.5). The larger the ratio of the length of the cooling pipeline to the cross-sectional area, the larger the value.
[0070] The cooling pipeline supplies water according to the actual water demand per unit time obtained from the water demand analysis module. The state analysis unit obtains the real-time data obtained by each instrument from the memory for analysis to accurately determine the current working state of the cooling pipeline. Specifically:
[0071] S21: constructing a water temperature variation curve with the water temperature at the water outlet as the ordinate and time as the abscissa, and constructing a pressure wave variation curve with the monitoring value of the pipeline pressure sensor as the ordinate and time as the abscissa;
[0072] S22: When a leak occurs in the cooling pipeline, the leaking part immediately loses cooling water, which causes the fluid density and pressure to decrease. Due to the continuity of the fluid in the pipeline, the fluid in the pipeline will not change its flow rate immediately, resulting in a pressure difference between the leak point and the adjacent areas on both sides, causing the fluid to fill the leak point from the upstream and downstream areas, thereby causing the density and pressure of the area adjacent to the leak area to decrease. This phenomenon spreads to the upstream and downstream of the leak point in turn, forming a negative pressure wave, and the propagation speed of the negative pressure wave is close to the propagation speed of the sound wave in the pipeline fluid.
[0073] When both pressure wave change curves undergo a sudden change, record the initial time t 11 ,t 21 , that is, the moment when the pipeline pressure sensor receives the pressure wave, and simultaneously records the peaks of the two pressure waves decay to The time t 12 ,t 22 , set a decay time limit t0, then when When the negative pressure wave is generated, it is determined that the generation of the negative pressure wave is caused by the bursting of bubbles in the water;
[0074] when When the negative pressure wave is generated, it is determined that the cooling pipeline leaks;
[0075] If it is caused by bubble bursting, ignore the sudden change of pressure wave;
[0076] If the cooling pipeline leaks, a pipeline leakage alarm signal is directly generated;
[0077] S23: After determining that a leak has occurred, it is necessary to further determine the location of the leak, specifically;
[0078] Assume that the distance between the two pipeline pressure sensors along the pipeline trajectory is S, and the pressure wave velocity is v 波 , the distance between the leakage position and the pipeline pressure sensor at the water inlet end along the pipeline trajectory is S 上 , then: It should be noted that, since the pressure wave velocity is much greater than the flow velocity of cooling water, the effect of the water flow velocity on the pressure wave velocity is omitted here.
[0079] Pressure wave velocity v 波 The density of cooling water ρ 水 , elastic modulus of water E 水 , Elastic modulus E of cooling pipe 管 , the wall thickness of the cooling pipe is e and the diameter of the cooling pipe is d, and the calculation formula is: Among them, ξ is the gas influence coefficient, and its value range is 0.86~0.95. The gas cannot be completely eliminated in the pipeline. When gas exists, the density of water will decrease and the pressure wave velocity will also decrease relatively. Therefore, the length of the pipeline relative to the cooling water inlet end of the leakage point can be accurately determined.
[0080] S24: Keep the flow rate at the water inlet stable and continuously monitor the water pressure at the water outlet of the water pump. When the water pressure at the water outlet of the water pump shows an upward trend and the water temperature at the water outlet of the pipeline is also on an upward trend, it is determined that the cooling pipeline is blocked and a pipeline blockage alarm signal is generated;
[0081] At this time, according to the water temperature change curve, the water temperature threshold line is set, and the average water temperature when each working cycle reaches the working temperature in the last N working cycles (each time the electric furnace is turned on and off is a working cycle) is calculated. Calculate the water temperature change rate μ for every two adjacent working cycles i,i+1 , where 1≤i≤N-1, and N is generally in the range of 14 to 30;
[0082] A functional equation with a power function as the basic model is constructed to fit the relationship between the above water temperature change rate and the working cycle, and the functional relationship of μ = G(x) is obtained, so as to predict the average water temperature in the subsequent working cycle.
[0083] When the average water temperature of a certain cycle reaches the water temperature threshold, the corresponding number of working cycles can be solved, that is, the absolute time when the cooling pipeline needs to be cleaned. The absolute time is updated and calculated again in the above manner in each working cycle;
[0084] S25: a time window with a certain step length is set to move along with the data update of the water temperature change curve, and the right end point of the time window is kept consistent with the updated data point, and the temperature rise rate within the time window is calculated. When the temperature rise rate exceeds the set temperature rise rate, an alarm signal of excessive temperature rise is generated;
[0085] Of course, when the water temperature reaches the water temperature threshold line, an over-temperature alarm signal will be automatically generated and a timer will be started to record the over-temperature time.
[0086] The status analysis unit transmits the generated pipeline leakage alarm signal, pipeline blockage alarm signal, leakage point location, blockage clearing deadline time, excessive temperature rise alarm signal, over-temperature alarm signal and over-temperature time to the alarm display module.
[0087] The alarm display module is connected to the staff's mobile phone through network communication, and displays the received alarm signal and the corresponding location data and time data, reminding the staff to take remedial measures. It should be noted that the location of the leak point is convenient for the staff to quickly locate the leak point for emergency treatment to prevent coil damage; the blockage cleaning deadline provides the staff with a time node reference for replacing or cleaning the cooling pipeline; the over-temperature time is used for the staff to estimate the impact on the life of the induction coil and increase the number of operations and maintenance.
[0088] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technical personnel in this field can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the technical solution of the present invention.
Claims
1. An intelligent water temperature monitoring and alarm system for an electric furnace, characterized in that: include: Data acquisition module, used to obtain real-time data on pipe pressure at the water inlet and outlet, water temperature, flow rate, current passing through the induction coil, molten metal temperature, outer wall temperature of the insulation layer, and specification data of the electric furnace and cooling pipeline; The water demand analysis module accurately calculates the actual water demand of cooling water in the cooling pipeline according to the working status of the electric furnace and induction coil in actual production; The status analysis module analyzes the leakage status and blockage status in the cooling pipeline. When leakage or blockage occurs, it generates a pipeline leakage alarm signal and determines the leakage location or a pipeline blockage alarm signal and determines the deadline for cleaning; The alarm display module is used to receive and display the alarm signal and related location data and time data generated by the status analysis module, and send it to the staff's mobile phone for prompting.
2. The intelligent water temperature monitoring and alarm system for an electric furnace according to claim 1, characterized in that: The steps of the water demand analysis module accurately analyzing and calculating the actual water demand include: Step 1: Determine the total heat that needs to be taken away by cooling water, that is, the heat generated by the resistor and the heat conducted by the metal liquid; Step 2: Calculate the resistance heat and the metal liquid conduction heat within a certain period of time respectively; Step 3: Based on the law of energy conservation, according to the maximum temperature rise of the inlet and outlet of the cooling pipeline, the heat absorption of water and the total heat within a certain period of time are balanced, and then the required flow rate of cooling water per unit time is obtained; Step 4: On the basis of the above required flow rate, reserve redundancy for the cooling pipeline, multiply it by the cooling redundancy coefficient, and obtain the value range of the actual water demand.
3. The intelligent water temperature monitoring and alarm system for an electric furnace according to claim 2, characterized in that: The calculation process of the resistance heating amount includes: Calculate the equivalent DC current corresponding to the sine wave AC, that is, Among them I d is the equivalent direct current, I m is the peak value of the alternating current, The heat generated by the resistor within a certain period of time Δt is Among them, R R represents the resistance of the induction coil, ρ represents the resistivity of the induction coil, l represents the wire length of the induction coil, and A represents the cross-sectional area of the induction coil wire.
4. The intelligent water temperature monitoring and alarm system for an electric furnace according to claim 2, characterized in that: The calculation process of the heat transfer of the molten metal includes: Calculate the thermal resistance R of the furnace lining C1 and thermal insulation resistance R C2 : Wherein, d1, d2, d3 represent the inner diameter of the furnace lining, the outer diameter of the furnace lining and the outer diameter of the thermal insulation layer respectively; λ1, λ2 represent the thermal conductivity of the furnace lining material and the thermal conductivity of the thermal insulation layer material respectively; H represents the liquid level of the molten metal in the furnace; The heat conducted by the molten metal within a certain period of time Δt is Among them, W 液 , W 隔 They represent the molten metal temperature and the external temperature of the insulation layer respectively.
5. The intelligent water temperature monitoring and alarm system for an electric furnace according to claim 2, characterized in that: In step 3, the equilibrium equation for the heat absorbed by water and the total heat within a certain period of time to reach equilibrium is: 水 cq0Δt·(W 出 -W 进 )=E; Among them, ρ 水 represents the density of cooling water; c represents the specific heat capacity of cooling water; q0 represents the required flow rate of cooling water per unit time, i.e., flow rate; W 进 , W 出 They represent the water temperature of the coolant at the water inlet and outlet of the pipeline respectively, and E is the total heat.
6. The intelligent water temperature monitoring and alarm system for an electric furnace according to claim 1, characterized in that: The specific process of the state analysis module determining the leakage state and leakage location includes: Based on the pipeline pressure at the inlet and outlet of the cooling pipeline, a pressure wave change curve with time series is constructed respectively; the initial time t when the two pressure waves suddenly change is recorded 11 ,t 21 and the time t when the pressure wave peak decays to half 12 ,t 22 ; Set a decay time limit t0 and construct the following comparison judgment: when When the negative pressure wave is determined to be caused by the bursting of bubbles in the water, it is directly ignored; when When the negative pressure wave is determined to be caused by a cooling pipeline leakage, a pipeline leakage alarm signal is generated; The distance S between the leak location and the pipeline pressure sensor at the water inlet end along the pipeline trajectory is calculated based on the following formula: 上 : Where S is the distance between the two pipeline pressure sensors along the pipeline trajectory, v 波 is the pressure wave velocity, ρ 水 is the density of cooling water, E 水 is the elastic modulus of water, E 管 is the elastic modulus of the cooling pipe, e is the wall thickness of the cooling pipe, d is the diameter of the cooling pipe, and ξ is the gas influence coefficient.
7. The intelligent water temperature monitoring and alarm system for an electric furnace according to claim 1, characterized in that: The specific process of the state analysis module determining the congestion state and deriving the deadline time includes: When the water pressure at the outlet of the water pump and the water temperature of the cooling management are on an upward trend, it is determined that the cooling pipeline is blocked and a pipeline blockage alarm signal is generated; Construct a time-series water temperature change curve and set a water temperature threshold line, calculate the average water temperature of each working cycle in the last N working cycles, and calculate the water temperature change rate of adjacent working cycles; The fitting function relationship between the water temperature change rate and the working cycle is constructed to predict the average water temperature of the subsequent working cycle, and the number of working cycles when the average water temperature reaches the water temperature threshold line is obtained, thereby obtaining the absolute time, and the absolute time is calculated and updated in each current working cycle.
8. The intelligent water temperature monitoring and alarm system for an electric furnace according to claim 7, characterized in that: The state analysis module also sets a time window of a certain step length in the water temperature change curve, and overlaps the right endpoint of the time window with the updated data time point, calculates the temperature rise rate in the current time window, compares the temperature rise rate with the set value, and generates an alarm signal for excessive temperature rise when it exceeds the set value, and records the continuous over-temperature time.
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