Intelligent temperature control system for field heat treatment

Abstract

The invention provides an on-site heat treatment intelligent temperature control system, which comprises a temperature acquisition module, an analog-to-digital conversion module, a control processing module, a power output module, an interaction module and an early warning module, and is characterized in that the temperature acquisition module comprises a thermocouple and a signal amplifier; the analog-to-digital conversion module comprises an AD analog-to-digital converter. The control processing module comprises a single-chip microcomputer, a memory, a communication interface and a computer. The computer can control other modules through operations such as current measurement and control, data storage, data modification and the like. The power output module comprises a silicon controlled rectifier, a trigger controller and a heater; the interaction module comprises a display and a keyboard; the early warning module comprises a temperature sensor, a current sensor and a single-chip microcomputer. Output modes can be converted according to different requirements, adaptability is high, multiple functional modules are independently packaged, a reasonable arrangement method and a reliable heat dissipation method are added, the size and weight of equipment are reduced, and convenience and mobility are improved.

Description

Technical Field

[0001] The invention relates to the field of heat treatment, and in particular to an intelligent temperature control system for on-site heat treatment. Background Art

[0002] Heat treatment is one of the indispensable and important processes in industrial production. It involves the heating, insulation and cooling of metal materials, aiming to change the internal structure and performance of the material to meet specific usage requirements. With the development of modern industry, the requirements for material performance are getting higher and higher, and heat treatment technology plays a vital role in metal processing, material modification and other fields. With the continuous emergence of new materials, more precise and optimized heat treatment processes are needed to meet their performance requirements. Temperature control during the heat treatment process directly affects the performance and quality of the product. Therefore, the development of efficient and accurate temperature control systems has become an urgent need in the industry.

[0003] Temperature control systems are of vital importance in the field of heat treatment. Accurate temperature control can ensure uniform structure and stable performance of materials during heat treatment, thereby improving product quality and reliability. Intelligent temperature control systems can also achieve automated production, reduce the impact of human factors, improve production efficiency, and reduce production costs.

[0004] However, there are still some problems with the current heat treatment temperature control technology: First, the accuracy and stability of temperature measurement need to be improved. In complex field environments, thermocouples may be disturbed, resulting in measurement errors, which in turn affect the accuracy of temperature control; second, early temperature control systems mostly adopted simple switch control or proportional control strategies, which could not be accurately adjusted according to real-time temperature changes, resulting in large temperature fluctuations and affecting product quality; traditional system components are mostly designed independently, lacking a unified data exchange and control platform, making it difficult to achieve automation and intelligent management, and the system integration is not enough, the temperature control equipment is large and heavy, and it is not convenient to move; and traditional systems often have a single output voltage mode. When facing larger heating objects, using larger heaters multiple times will cause the heaters to be unusable, and more smaller heaters need to be connected in parallel, resulting in increased costs; in addition, the traditional system operation interface is complex, parameter settings are cumbersome, and lacks intuitive monitoring and early warning functions, which increases the difficulty of operation and maintenance costs. Summary of the invention

[0005] In order to solve the above problems, the present invention proposes an on-site heat treatment intelligent temperature control system.

[0006] In order to achieve the above purpose, the following technical solutions are adopted: The on-site heat treatment intelligent temperature control system includes a temperature acquisition module, an analog-to-digital conversion module, a control processing module, a power output module, an interactive module and an early warning module. The temperature acquisition module includes a thermocouple and a signal amplifier; the analog-to-digital conversion module includes an AD analog-to-digital converter; the control processing module includes a single-chip microcomputer, a memory, a communication interface, and a computer. The computer can control other modules through current measurement and control, data storage, data modification and other operations; the power output module includes a thyristor, a trigger controller, and a heater; the interactive module includes a display and a keyboard; the early warning module includes a temperature sensor, a current sensor, and a single-chip microcomputer.

[0007] Among them, the thermocouple, the signal amplifier and the AD analog-to-digital converter are electrically connected in series, the trigger controller and the current sensor are electrically connected in parallel between the thyristor and the single-chip microcomputer, the single-chip microcomputer is connected to the display and the keyboard respectively, the computer and the single-chip microcomputer are connected through a communication interface, the thyristor is connected to the heater, and several heaters can be connected in series at the same time to cope with different on-site conditions.

[0008] Preferably, the temperature acquisition module comprises a thermocouple and a signal amplifier, wherein the signal amplifier integrates a filter and an amplifier, and the signal amplifier is electrically connected to the output end of the thermocouple.

[0009] Preferably, the analog-to-digital conversion module includes an AD analog-to-digital converter, the input end of the AD analog-to-digital converter is electrically connected to the output end of the signal amplifier, and the output end of the AD analog-to-digital converter is electrically connected to the single-chip computer.

[0010] Preferably, the control processing module includes a single-chip microcomputer, a memory, a communication interface and a computer, the single-chip microcomputer is electrically connected to the memory, and the single-chip microcomputer is connected to the computer via the communication interface.

[0011] Preferably, the computer can utilize current measurement and control, data storage, data modification and other operations to transmit digital signals to the single-chip microcomputer through the communication interface, and the single-chip microcomputer controls other components, thereby controlling the operation of other functional modules.

[0012] Preferably, the power output module includes a thyristor, a trigger controller and a heater, the output end of the thyristor is connected to the heater, the trigger controller is electrically connected to the input end of the thyristor, and the trigger controller is electrically connected to the single-chip computer.

[0013] Preferably, when facing a stable sinusoidal power supply with a frequency of 50Hz or 60Hz, the on or off time of the components in the circuit can be accurately controlled by triggering the controller, the layout of different components in the circuit can be changed, and the function of the voltage output range can be further expanded by delay time correction, thereby switching the voltage output mode.

[0014] Preferably, the voltage-dropping resistor includes two resistors, the voltage-dropping resistor is electrically connected to the input end of the 817B optocoupler, the 817B optocoupler is electrically connected to the single-chip computer, the MOC3041 optocoupler is electrically connected to the thyristor, the thyristor is electrically connected to the heating circuit, the heating circuit constitutes a heater, the 817B optocoupler is an opto-isolator, the 817B optocoupler includes a diode and a transistor, the MOC3041 optocoupler is a photoelectric coupler, and the MOC3041 optocoupler includes a diode and a thyristor.

[0015] Preferably, the interactive module includes a display and a keyboard, the display screen is connected to the single-chip microcomputer via a parallel or serial interface, and the keyboard is connected to an input terminal of the single-chip microcomputer.

[0016] Preferably, the early warning module includes a temperature sensor, a current sensor and a single-chip microcomputer, the temperature sensor is connected to the input end of the signal amplifier, the current sensor is electrically connected to the thyristor, the current sensor is electrically connected to the single-chip microcomputer, and the temperature sensor is a thermocouple.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: a high-precision thermocouple is used as a temperature sensor, combined with a low-noise amplifier, a filter and a high-precision AD analog-to-digital converter, to achieve accurate collection and conversion of temperature signals and improve measurement accuracy; an advanced control algorithm is introduced to dynamically adjust the control amount according to the real-time temperature difference, to achieve accurate control of the heater power output, reduce temperature fluctuations and improve product quality; the various components of the system are connected through standardized interfaces to achieve rapid data transmission and sharing, and at the same time, a local touch screen operation interface and a remote computer connection function are provided to achieve centralized monitoring and remote management of the system, greatly reducing the volume and weight, and facilitating transportation and storage; two output voltage modes are invented, and a larger heater can be used for heating, saving material costs; an intuitive operation interface and detailed operation guide are provided to reduce the difficulty of operation; at the same time, the system has fault diagnosis and early warning functions, which can promptly detect and deal with potential problems and reduce maintenance costs and time. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a structural schematic diagram of an on-site heat treatment intelligent temperature control system according to Example 1 of the present invention; Figure 2This is a circuit diagram of an intelligent temperature control system for on-site heat treatment according to Example 1 of the present invention; DETAILED DESCRIPTION

[0019] Hereinafter, the on-site heat treatment intelligent temperature control system of the present invention will be described in detail with reference to the accompanying drawings.

[0020] like Figure 1 As shown, an on-site heat treatment intelligent temperature control system according to an embodiment of the present invention includes a temperature acquisition module, an analog-to-digital conversion module, a control processing module, a power output module, an interaction module and an early warning module.

[0021] Furthermore, the temperature acquisition module includes a thermocouple 1 and a signal amplifier 2, wherein the signal amplifier 2 integrates an amplifier and a filter, and is electrically connected to the output end of the thermocouple 1. The thermocouple 1 converts the temperature into a weak potential difference (millivolt level) through the thermoelectric effect. The signal amplifier 2 amplifies the weak signal transmitted by the thermocouple 1 until it is suitable for the processing range of the AD analog-to-digital converter 3, and then filters the amplified signal to remove high-frequency noise and interference, thereby improving the signal-to-noise ratio of the signal, making the signal clearer, and improving the temperature acquisition accuracy.

[0022] Furthermore, the analog-to-digital conversion module includes an AD analog-to-digital converter 3, the input end of the AD analog-to-digital converter 3 is electrically connected to the output end of the signal amplifier 2, and the output end of the AD analog-to-digital converter 3 is electrically connected to the single-chip computer 4. The AD analog-to-digital converter 3 receives the amplified and filtered analog voltage signal, converts the analog voltage signal into a digital signal that can be processed by the single-chip computer 5 and the computer, and then transmits the converted digital signal to the single-chip 4.

[0023] Furthermore, the control processing module includes a single-chip microcomputer 4, a memory 5, a communication interface 6 and a computer 7. The single-chip microcomputer 4 is electrically connected to the memory 5, and the single-chip microcomputer 4 is connected to the computer 7 through the communication interface 6. The single-chip microcomputer 4 receives the digital signal from the AD analog-to-digital converter 3, and calculates the control quantity according to a preset control algorithm. The obtained control quantity will be sent to the power output module and the memory 5 at the same time. After the computer 7 is connected to the communication interface 6, the single-chip microcomputer 4 can exchange data with the computer 7 through the communication interface 6.

[0024] Furthermore, the computer 7 can utilize current measurement and control, data storage, data modification and other operations to transmit digital signals to the single-chip microcomputer 4 through the communication interface 6, and the single-chip microcomputer 4 transmits the digital signals to other response elements, thereby controlling the operation of other functional modules.

[0025] Furthermore, the power output module includes a thyristor 8, a trigger controller 9 and a heater 10, the output end of the thyristor 8 is connected to the heater 10, the trigger controller 9 is electrically connected to the input end of the thyristor 8, and the trigger controller 9 is electrically connected to the single-chip computer 4, wherein the conduction and shutdown of the thyristor 8 are controlled by the single-chip computer 4 through the trigger controller 9, the single-chip computer 4 sends a control signal to the trigger controller 9, and the trigger controller 9 converts the received control signal into a driving signal required by the thyristor 8. After receiving the driving signal, the thyristor 8 is turned on and outputs current to the heater 10, and then the heater 10 that receives the current is heated.

[0026] Furthermore, the interactive module includes a display 11 and a keyboard 12. The display 11 is connected to the single-chip computer 4 via a parallel or serial interface, and the keyboard 12 is connected to the input end of the single-chip computer 4. The display 11 is used to display information such as the current temperature, set temperature, and system status, and displays the display data sent by the single-chip computer 4 by receiving it; the keyboard 12 serves as an input device, and the user inputs operation instructions by touching the buttons. The user's touch operation is recognized and converted into a corresponding electrical signal input to the single-chip computer 4 for processing.

[0027] Furthermore, the early warning module includes a temperature sensor 1, a current sensor 13 and a single-chip computer 4. The temperature sensor 1 is connected to the input end of the signal amplifier 2, the current sensor 13 is electrically connected to the thyristor 8, and the current sensor 13 is electrically connected to the single-chip computer 4. The temperature sensor 1 and the current sensor 13 convert the monitored physical quantities into electrical signals and output them to the single-chip computer 4 of the control processing module. The single-chip computer 4 processes and judges the electrical signals output by the sensors to determine whether the system is in a normal state.

[0028] Furthermore, the temperature sensor 1 is a thermocouple, which amplifies and filters the weak signal through the signal amplifier 2 and transmits it to the AD analog-to-digital converter 3, converts it into a digital signal and transmits it to the single-chip microcomputer 4. The single-chip microcomputer 4 processes the received signal and transmits it backward while comparing it with the signal transmitted by the current sensor 13 to ensure that the system is in a normal state.

[0029] like Figure 2As shown, the positive half cycle of the alternating current is stepped down by the step-down resistor 14 and then transmitted to the diode 15. The diode 15 rectifies the stepped-down alternating current, and the rectified voltage signal is sent to the input end of the 817B optocoupler 16. The 817B optocoupler 16 converts the electrical signal into an optical signal, and receives the optical signal through the internal triode and converts it into an electrical signal to drive the output end of the 817B optocoupler 16. While outputting a synchronization signal to the single-chip microcomputer 4, the 817B optocoupler 16 can isolate the electrical interference between the circuits at both ends. After receiving the synchronization signal, the single-chip microcomputer 4 processes the signal. According to the calculated time control value, the single-chip microcomputer 4 sends a control signal to the MOC3041 optocoupler 17 at the appropriate time. The MOC3041 optocoupler 17 also converts the optical signal into an electrical signal and transmits the drive signal to the thyristor 8. The thyristor starts to conduct after receiving the drive signal, and the heating circuit 18 starts heating by virtue of the current passing therethrough.

[0030] The connection method of the control line will affect the size of the output voltage. When connected to the neutral line (N), the output can be controlled at 0 to 210V, and when connected to the phase line (L), the output can be controlled at 0 to 370V. This output is mainly used to control the current of the heating circuit 18, and the current range is 0 to 90A. The control principle is achieved by cutting the sine wave. By adjusting the moment when the thyristor 8 is triggered to turn on, the part of the sine wave that is turned on in each cycle can be determined, thereby achieving control of the output voltage. For example, if the sine wave is only output 0.1 milliseconds later, the output voltage will be very low. Therefore, even if the phase line voltage is very high, the output will be limited due to this cutting control. The components in the circuit together constitute this circuit that can achieve voltage and current control.

[0031] Furthermore, when faced with a stable sinusoidal power supply, the on or off time of the thyristor 8 can be accurately controlled by triggering the controller 9, changing the layout of different components in the circuit and the current size, and then further expanding the voltage output range function through delay time correction, thereby switching the voltage output mode.

[0032] Furthermore, the voltage-dropping resistor 14 includes two resistors, the voltage-dropping resistor 14 is electrically connected to the input end of the 817B optocoupler 15, the 817B optocoupler 15 is electrically connected to the microcontroller 4, the MOC3041 optocoupler 16 is electrically connected to the thyristor 8, the thyristor 8 is electrically connected to the heating circuit 18, and the heating circuit 18 constitutes the heater 10.

[0033] Among them, the 817B optocoupler 15 is a photoelectric isolator, which includes a diode and a triode, and the MOC3041 optocoupler 16 is a photoelectric coupler, which includes a diode and a thyristor. Both optocouplers can convert optical signals into electrical signals. The 817B optocoupler 15 can achieve electrical isolation between the input circuit and the output circuit, thereby improving the stability of the system. The MOC3041 optocoupler 16 can directly drive the gate of the thyristor, thereby controlling the conduction of the thyristor.

[0034] The present invention can perform startup detection and temperature detection during normal operation.

[0035] Power-on detection: When the power of the device is turned on and the power indicator light comes on, the single-chip microcomputer 4 starts to execute the power-on initialization program and waits to receive the self-test instruction. After receiving the self-test signal, the single-chip microcomputer 4 sends test signals to each module of the system in turn. The system will first check whether the connection status of the thermocouple 1 is normal, and then the single-chip microcomputer 4 sends a test signal to the signal amplifier 2 to check whether its amplification and filtering functions are normal. The signal amplifier 2 returns the test result to the single-chip microcomputer 4. The single-chip microcomputer 4 sends a test voltage signal to the AD converter 3 and reads the conversion result. By comparing the actual conversion value with the theoretical value, the accuracy and stability of the AD converter 3 are judged. The single-chip microcomputer 4 executes the self-test program to check whether the internal memory 5, the communication interface 6, the control algorithm, etc. are working properly. At the same time, the single-chip microcomputer 4 will also check whether the communication with the computer 7 is normal. The system checks whether the input function of the keyboard 12 is normal. By simulating user input, it checks whether the system can correctly receive and process the input signal. The system sends a test image or text to the display screen 11 to check whether its display effect and communication are normal. During the self-test phase, the system checks whether the signal transmission between the trigger controller 9 and the thyristor 8 is normal, and also checks whether the connection status and communication of the sensor are normal. Finally, the system displays the self-test results on the display screen, including success, failure or specific error information.

[0036] Normal operation: The user sets the target temperature, heating time and other parameters through the human-computer interaction module and starts the system. After receiving the user's setting instructions, the single-chip microcomputer 4 or computer 7 performs parameter verification and prepares to enter the temperature control cycle. The thermocouple 1 senses the temperature of the heat treatment area in real time and converts it into a weak potential difference signal. The potential difference signal is amplified and filtered by the signal amplifier 2 and then received by the AD analog-to-digital converter 3. The AD analog-to-digital converter 3 converts the analog signal into a digital signal and transmits the digital signal to the single-chip microcomputer 4. The single-chip microcomputer 4 reads the digital signal and compares it with the preset target temperature. According to the comparison result, the single-chip microcomputer 4 executes the control algorithm to calculate the control amount. Then the single-chip microcomputer 4 transmits the control amount to the memory 5 and the computer 7 respectively. At this time, the display screen 11 displays the current temperature, target temperature, heating time and other key information. Then, the temperature control operation can be performed through the single-chip microcomputer 4 or computer 7. The single-chip microcomputer 4 controls the conduction angle of the thyristor by driving the trigger controller 9, thereby adjusting the power output of the heater 10. When the actual temperature is lower than the target temperature, the power of the heater 10 is increased; when the actual temperature is higher than the target temperature, the power of the heater 10 is reduced to keep the temperature within the target range. At the same time, the temperature sensor 1 and the current sensor 13 monitor the operating status and environmental parameters of the system in real time, and feed back the parameters to the single-chip microcomputer 4 or the computer 7 in real time. The single-chip microcomputer 4 stores key information such as temperature data and control parameters in the memory 5 for subsequent query and analysis, and interacts with the computer 7 through the communication interface 6. When the heat treatment process is completed, the user stops the system operation through the human-computer interaction module.

[0037] In the present invention, the millivolt signal generated by the thermocouple 1 is relatively weak. After being amplified by the signal amplifier 2, it will also undergo filtering processing. The filtering processing can remove noise and interference components in the signal to ensure the purity of the signal; the processed signal will be transmitted to the AD analog-to-digital converter 3, and the AD converter 3 converts the analog signal into a digital signal; the converted digital signal is transmitted to the single-chip microcomputer 4 or the computer 7, and the single-chip microcomputer 4 or the computer 7 determines the corresponding temperature data by looking up the table according to the thermocouple's graduation number. After obtaining the preliminary temperature data, the temperature data needs to be corrected by the environmental compensation algorithm to obtain more accurate actual measured temperature data. Then, the measured temperature is calculated with the actual set temperature to obtain the control amount. This calculation process is based on a specific control algorithm and is intended to determine the adjustment amount required to reach the set temperature; the control amount will be partitioned according to the sine wave waveform and form a uniformly distributed power table; finally, the current required power size and timing time are output according to the table lookup. The present invention can provide a voltage of 0-210V or 0-370V according to the output requirements. For stable sine wave 50Hz or 60Hz stable frequency power supply, it can also be corrected by delay time to meet the output requirements of 0 - 220V or 0 - 380V.

[0038] The above description is only a preferred example of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have other optimization schemes and additional functions. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. On-site heat treatment intelligent temperature control system, characterized by: The invention comprises a temperature acquisition module, an analog-to-digital conversion module, a control processing module, a power output module, an interaction module and an early warning module. The temperature acquisition module comprises a thermocouple (1) and a signal amplifier (2); the analog-to-digital conversion module comprises an AD analog-to-digital converter (3); the control processing module comprises a single-chip microcomputer (4), a memory (5), a communication interface (6) and a computer (7); the computer (7) can control other modules through operations such as current measurement and control, data storage and data modification; the power output module comprises a thyristor (8), a trigger controller (9) and a heater (10); the interaction module comprises a display (11) and a keyboard (12); the early warning module comprises a temperature A sensor (1), a current sensor (13), and a single-chip computer (4); wherein the thermocouple (1), the signal amplifier (2), and the AD converter (3) are electrically connected in series, the trigger controller (9) and the current sensor (13) are electrically connected in parallel between the thyristor (8) and the single-chip computer (4), the single-chip computer (4) is connected to the display (11) and the keyboard (12) respectively, the computer (7) and the single-chip computer (4) are connected via the communication interface (6), the thyristor (8) is connected to the heater (10), and a plurality of the heaters (10) can be connected in series at the same time to cope with different on-site conditions.

2. The on-site heat treatment intelligent temperature control system according to claim 1, characterized in that: The temperature acquisition module comprises a thermocouple (1) and the signal amplifier (2), wherein the signal amplifier (2) is integrated with a filter and an amplifier, and the signal amplifier (2) is electrically connected to the output end of the thermocouple (1).

3. The on-site heat treatment intelligent temperature control system according to claim 1, characterized in that: The analog-to-digital conversion module comprises an AD analog-to-digital converter (3), the input end of the AD analog-to-digital converter (3) being electrically connected to the output end of the signal amplifier (2), and the output end of the AD analog-to-digital converter (3) being electrically connected to the single-chip computer (4).

4. The on-site heat treatment intelligent temperature control system according to claim 1, characterized in that: The control processing module comprises a single-chip microcomputer (4), a memory (5), a communication interface (6) and a computer (7); the single-chip microcomputer (4) is electrically connected to the memory (5), and the single-chip microcomputer (4) is connected to the computer (7) via the communication interface (6).

5. The on-site heat treatment intelligent temperature control system according to claim 4, characterized in that: The computer (7) can utilize operations such as current measurement and control, data storage, and data modification to transmit digital signals to the single-chip microcomputer (4) through the communication interface (6), and the single-chip microcomputer (4) can control other components, thereby controlling the operation of other functional modules.

6. The on-site heat treatment intelligent temperature control system according to claim 1, characterized in that: The power output module comprises a thyristor (8), a trigger controller (9) and a heater (10), wherein the output end of the thyristor (8) is connected to the heater (10), the trigger controller (9) is electrically connected to the input end of the thyristor (8), and the trigger controller (9) is electrically connected to the single-chip computer (4).

7. The on-site heat treatment intelligent temperature control system according to claim 6, characterized in that: When facing a stable sinusoidal power supply with a frequency of 50 Hz or 60 Hz, the trigger controller (9) can accurately control the on or off time of the thyristor (8), change the layout of different components in the circuit and the current size, and then further expand the voltage output range through delay time correction, thereby switching the voltage output mode.

8. The on-site heat treatment intelligent temperature control system according to claim 7, characterized in that: The voltage-dropping resistor (14) comprises two resistors. The voltage-dropping resistor (14) is electrically connected to the diode (15). The diode (15) is electrically connected to the input end of the 817B optocoupler (16). The output end of the 817B optocoupler (16) is electrically connected to the single-chip computer (4). The MOC3041 optocoupler (17) is electrically connected to the thyristor (8). The thyristor (8) is electrically connected to the heating circuit (18). The heating circuit (18) together constitutes the heater (10). The 817B optocoupler (16) is a photoelectric isolator. The 817B optocoupler (16) comprises a diode and a triode. The MOC3041 optocoupler (17) is a photoelectric coupler. The MOC3041 optocoupler (17) comprises a diode and a thyristor.

9. The on-site heat treatment intelligent temperature control system according to claim 1, characterized in that: The interactive module comprises a display (11) and a keyboard (12); the display (11) is connected to the single-chip computer (4) via a parallel or serial interface; and the keyboard (12) is connected to an input terminal of the single-chip computer (4).

10. The on-site heat treatment intelligent temperature control system according to claim 1, characterized in that: The early warning module comprises a temperature sensor (1), a current sensor (13) and a single-chip computer (4); the temperature sensor (1) is connected to the input end of the signal amplifier (2); the current sensor (13) is electrically connected to the thyristor (8); the current sensor (13) is electrically connected to the single-chip computer (4); and the temperature sensor (1) is a thermocouple.

Images