Wireless temperature monitoring management system for factory quenching bath

Abstract

The invention relates to the technical field of factory intellectualization, in particular to a factory quenching bath wireless temperature monitoring management system which comprises a database used for storing temperature change data of quenching liquid, a wireless transmission module used for wireless transmission connection of data signals, and an early warning module used for conducting acousto-optic early warning after receiving early warning signals. The temperature acquisition module is used for acquiring and analyzing temperature data, the intelligent recommendation terminal is used for performing data analysis to obtain a target quenching frequency, the quenching rate monitoring module is used for performing data analysis to obtain a quenching frequency I, and the data processing unit is used for performing data processing to obtain a quenching frequency II. The device is beneficial to reminding when the quenching liquid reaches the early warning value so as to cool and replace the quenching liquid, meanwhile, the real-time temperature of the quenching liquid is monitored and analyzed, a worker can be warned to adjust the temperature in time according to the abnormal temperature condition, the quenching quality is guaranteed, and the quenching stability is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of factory intelligence, and in particular to a wireless temperature monitoring and management system for a factory quenching pool. Background Art

[0002] The quenching tank is a heat treatment equipment, whose main function is to carry out the quenching process in metal processing, so as to improve the surface hardness, strength and other properties of the metal. The quenching liquid temperature is an important parameter in the heat treatment production process, which directly determines the product quality. Therefore, the quenching liquid temperature needs to be monitored.

[0003] Existing quenching liquid temperature monitoring mainly relies on manual feel and the use of a temperature measuring gun. The liquid temperature can only be sampled during the production process. The production team relies on experience and cannot detect liquid temperature changes in real time. Product quality is unstable, resulting in batch rework and affecting production efficiency.

[0004] Based on this, a wireless temperature monitoring and management system for factory quenching pool is proposed. Summary of the invention

[0005] The main purpose of the present invention is to provide a wireless temperature monitoring and management system for a factory quenching pool to overcome the problems mentioned in the above background technology.

[0006] To achieve the above-mentioned purpose, the present invention provides a wireless temperature monitoring and management system for a factory quenching pool, comprising a database, a wireless transmission module, an early warning module, a temperature acquisition module and an intelligent recommendation terminal, and also comprising a quenching rate monitoring module and a data processing unit;

[0007] A quenching rate monitoring module is used to obtain the quenching times and total duration data of the quenching pool within a limited time period, to form a total quenching rate index within the limited time period of the quenching pool, to average the total quenching rate index to obtain a quenching rate average index, to set a quenching rate total threshold index, to process and analyze the quenching rate total threshold index and the quenching rate average index to obtain a quenching frequency one, and to transmit it to a data processing unit;

[0008] The data processing unit is used to parse the temperature data, obtain the initial temperature value and the final temperature value of the quenching liquid within a limited time period, process and analyze the initial temperature value and the final temperature value to obtain a total temperature increase index, average the total temperature increase index to obtain an average temperature increase index, perform a comprehensive analysis based on the average temperature increase index and the initial temperature value to obtain an average temperature rise, set a quenching liquid temperature threshold, process and analyze the quenching liquid temperature threshold and the average temperature rise to obtain a quenching frequency 2, and mark it as a reference quenching frequency for transmission to the intelligent recommendation terminal.

[0009] As a further improvement of the present invention, the specific processing process of quenching frequency 1 is: through the formula The quenching rate average index CHJ is obtained, CS and SC represent the number of quenching times and the total duration respectively, where β1 and β2 represent the set weight factors, and the quenching rate total index threshold CHZ is set. The quenching frequency PL1 is obtained, where β3 and β4 represent the set weight factors.

[0010] As a further improvement of the present invention, the specific processing process of quenching frequency 2 is: through the formula The average temperature increase index JZF is obtained, CW and ZW represent the initial temperature value and the end temperature value respectively, where δ1 represents the set proportional coefficient factor, the average temperature increase index JZF and the initial temperature value CW are substituted into the formula WSJ = JZF × CW to obtain the average temperature rise WSJ, the quenching liquid temperature threshold WY is set, and the formula is substituted The quenching frequency 2 PL2 is obtained, where β5, β6, and β7 represent the set weight factors.

[0011] As a further improvement of the present invention, the intelligent recommendation terminal performs processing and analysis based on the received quenching frequency 2 PL2, and the specific process is as follows:

[0012] Set the quenching liquid temperature threshold WY, which means that when the real-time temperature of the quenching liquid approaches the temperature threshold WY, it needs to be cooled and replaced. Set the preset quenching time SC', and substitute the formula CS'=(PL2×δ2)×(SC'×δ3) to obtain the preset quenching times CS', where δ2 and δ3 represent the set proportional coefficient factors;

[0013] The real-time temperature SW of the quenching liquid after the preset number of quenching times CS' is obtained by the formula SW = (CW + WY) · CS' / 2, the minimum value within the influence range of the temperature threshold WY is selected to construct the temperature threshold interval (-WY, WY), and the real-time temperature SW is compared with the temperature threshold interval (-WY, WY). If SW∈(-WY, WY) and <WY, it indicates that the real-time temperature of the quenching liquid after the preset number of quenching times is within the temperature threshold interval, and the current preset number of quenching times is marked as the target number. If It indicates that the real-time temperature of the quenching liquid after the preset number of quenching exceeds the temperature threshold range, the current preset number of quenching is marked as an abnormal number, and the preset number of quenching is reduced in sequence to recalculate the screening target number;

[0014] The preset number of quenching times marked as the target number is set as the warning threshold and transmitted to the warning module.

[0015] As a further improvement of the present invention, the temperature acquisition module is used to collect the real-time temperature of the quenching liquid, and the specific analysis is as follows:

[0016] Set several depth ranges, match the quenching pool depth with the depth range, obtain several temperature collection areas, and divide them into surface, middle and bottom areas according to the depth range. Collect the temperature of each area and mark the surface temperature as temperature 1, the middle temperature as temperature 2, and the bottom temperature as temperature 3. Substitute into the formula The temperature differences are obtained as WC1, WC2 and WC3, WD1, WD2 and WD3 are respectively represented as temperatures one, two and three, where γ1, γ2 and γ3 are respectively represented as the set proportional coefficient factors;

[0017] Set the temperature difference thresholds WC1', WC2' and WC3', select the maximum value to the minimum value in the influence range to form the temperature difference threshold interval 1 (-WC1', WC1', +WC1'), the temperature difference threshold interval 2 (-WC2', WC2', +WC2'), and the temperature difference threshold interval 3 (-WC3', WC3', +WC3'), respectively, and match the temperature differences 1, 2 and 3 with the threshold intervals. If This indicates that the match is successful and a normal quenching liquid temperature signal is generated. This indicates that the matching has failed, and a quenching liquid temperature abnormality signal is generated, and an early warning signal is generated and transmitted to the early warning module.

[0018] As a further improvement of the present invention, it also includes:

[0019] A database for storing the temperature variation data of the quenching liquid and forming a queryable historical database;

[0020] Wireless transmission module, used for wireless transmission connection of data signals;

[0021] The early warning module is used to issue an audible and visual early warning after receiving the early warning signal. At the same time, based on the early warning threshold, an early warning is issued when the quenching times of the quenching liquid reach the target times, reminding the staff to cool and replace the quenching liquid.

[0022] Beneficial effects of the present invention:

[0023] The present invention analyzes the quenching data to obtain the usable range of the quenching liquid within a limited time, thereby setting a threshold warning, which is conducive to reminding when the quenching liquid reaches the warning value, so as to cool and replace the quenching liquid, avoiding the problem that the quenching liquid affects the quenching quality with continuous use, which is conducive to reasonable organization of production, and at the same time provides certain parameter support for liquid replenishment and cooling, which is conducive to further improving product quality, reducing the defective product rate, and allowing the operating team to perform production operations more intuitively;

[0024] The present invention monitors and analyzes the real-time temperature of the quenching liquid and sets a threshold warning. When there is an error between the real-time temperature and the threshold, an early warning can be given in time to terminate the quenching operation and adjust the temperature of the quenching liquid, which is beneficial to ensuring the quenching quality, improving the quenching stability, reducing product quality problems and thus reducing the probability of product rework. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the accompanying drawings:

[0026] Figure 1 is a system schematic diagram of the present invention;

[0027] Figure 2 It is a schematic diagram of data changes of the present invention. DETAILED DESCRIPTION

[0028] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0029] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0030] It should be noted that the terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so as to describe the embodiments of the present invention described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0031] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0032] See also Figure 1-Figure 2 As shown, a wireless temperature monitoring and management system for a factory quenching pool includes a database, a wireless transmission module, an early warning module, a temperature acquisition module and an intelligent recommendation terminal, and also includes a quenching rate monitoring module and a data processing unit;

[0033] A database for storing the temperature variation data of the quenching liquid and forming a queryable historical database;

[0034] The specific analysis is as follows: several quenching pools are numbered and set, and the temperature acquisition module monitors and collects the quenching liquid temperature data of quenching pools with different numbers in real time for storage, including the surface, middle and bottom temperature data of the quenching liquid. The collected data are sorted in the order of collection, and connected with a smooth curve to obtain a temperature data change curve diagram, forming a searchable historical database.

[0035] Wireless transmission module, used for wireless transmission connection of data signals;

[0036] The wireless network transmission connection realizes the simultaneous transmission and reception of multiple data signals, and by adjusting the transmission frequency to match the quenching frequency, the normal transmission of data signals is guaranteed while reducing power consumption.

[0037] A quenching rate monitoring module is used to obtain the quenching times and total duration data of the quenching pool within a limited time period, to form a total quenching rate index within the limited time period of the quenching pool, to average the total quenching rate index to obtain a quenching rate average index, to set a quenching rate total threshold index, to process and analyze the quenching rate total threshold index and the quenching rate average index to obtain a quenching frequency one, and to transmit it to a data processing unit;

[0038] The specific processing process for quenching frequency 1 is: through the formula The quenching rate average index CHJ is obtained, CS and SC represent the number of quenching times and the total duration respectively, where β1 and β2 represent the set weight factors, and the quenching rate total index threshold CHZ is set. The quenching frequency is obtained as PL1, where β3 and β4 represent the set weight factors;

[0039] A data processing unit is used to analyze the temperature data, obtain the initial temperature value and the end temperature value of the quenching liquid within a limited time period, process and analyze the initial temperature value and the end temperature value to obtain a total temperature increase index, average the total temperature increase index to obtain an average temperature increase index, perform a comprehensive analysis based on the average temperature increase index and the initial temperature value to obtain a temperature rise average, set a quenching liquid temperature threshold, process and analyze the quenching liquid temperature threshold and the temperature rise average to obtain a second quenching frequency, and mark it as a reference quenching frequency for transmission to the intelligent recommendation terminal;

[0040] The specific processing process for quenching frequency 2 is: through the formula The average temperature increase index JZF is obtained, CW and ZW represent the initial temperature value and the end temperature value respectively, where δ1 represents the set proportional coefficient factor, the average temperature increase index JZF and the initial temperature value CW are substituted into the formula WSJ = JZF × CW to obtain the average temperature rise WSJ, the quenching liquid temperature threshold WY is set, and the formula is substituted The quenching frequency 2 PL2 is obtained, where β5, β6, and β7 represent the set weight factors.

[0041] The intelligent recommendation terminal performs processing and analysis based on the received quenching frequency 2 PL2. The specific process is as follows:

[0042] Set the quenching liquid temperature threshold WY, which means that when the real-time temperature of the quenching liquid approaches the temperature threshold WY, it needs to be cooled and replaced. Set the preset quenching time SC', and substitute the formula CS'=(PL2×δ2)×(SC'×δ3) to obtain the preset quenching times CS', where δ2 and δ3 represent the set proportional coefficient factors;

[0043] The real-time temperature SW of the quenching liquid after the preset number of quenching times CS' is obtained by the formula SW = (CW + WY) · CS' / 2, the minimum value within the influence range of the temperature threshold WY is selected to construct the temperature threshold interval (-WY, WY), and the real-time temperature SW is compared with the temperature threshold interval (-WY, WY). If SW∈(-WY, WY) and <WY, it indicates that the real-time temperature of the quenching liquid after the preset number of quenching times is within the temperature threshold interval, and the current preset number of quenching times is marked as the target number. If It indicates that the real-time temperature of the quenching liquid after the preset number of quenching exceeds the temperature threshold range, the current preset number of quenching is marked as an abnormal number, and the preset number of quenching is reduced in sequence to recalculate the screening target number;

[0044] If the current preset quenching times are marked as abnormal times, substitute the formula CS'1=CS'-1 to reduce the preset quenching times in sequence to obtain the preset quenching times CS'1, substitute the preset quenching times SW1=(CW+WY)·CS'1 / 2 to obtain the real-time temperature SW1, compare the real-time temperature with the temperature threshold interval, and determine whether the preset quenching times meet the target times based on the comparison result. If so, mark the preset quenching times as the target times. If not, continue to reduce and recalculate the screening target times.

[0045] The preset number of quenching times marked as the target number is set as the warning threshold and transmitted to the warning module.

[0046] The temperature acquisition module is used to collect the real-time temperature of the quenching liquid. The specific analysis is as follows:

[0047] The quenching pools are numbered and arranged in order of numbering: A, B, C, ... The temperature collection areas are divided according to the depth of the quenching pool, including the surface, middle and bottom collection areas. The corresponding quenching pool numbers are marked as A1, A2, A3, B1, B2, B3, C1, C2, C3, ... In each temperature collection area, a number of high-temperature waterproof digital temperature sensor water temperature probes are arranged to monitor and collect the corresponding quenching liquid temperature in the temperature collection areas in different quenching pools;

[0048] Set several depth ranges, match the quenching pool depth with the depth range, obtain several temperature collection areas, and divide them into surface, middle and bottom areas according to the depth range. Collect the temperature of each area and mark the surface temperature as temperature 1, the middle temperature as temperature 2, and the bottom temperature as temperature 3. Substitute into the formula The temperature differences are obtained as WC1, WC2 and WC3, WD1, WD2 and WD3 are respectively represented as temperatures one, two and three, where γ1, γ2 and γ3 are respectively represented as the set proportional coefficient factors;

[0049] Set the temperature difference thresholds WC1', WC2' and WC3', select the maximum value to the minimum value in the influence range to form the temperature difference threshold interval 1 (-WC1', WC1', +WC1'), the temperature difference threshold interval 2 (-WC2', WC2', +WC2'), and the temperature difference threshold interval 3 (-WC3', WC3', +WC3'), respectively, and match the temperature differences 1, 2 and 3 with the threshold intervals. If This indicates that the match is successful and a normal quenching liquid temperature signal is generated. This indicates that the matching has failed, and a quenching liquid temperature abnormality signal is generated, and an early warning signal is generated and transmitted to the early warning module.

[0050] The early warning module is used to issue an audible and visual early warning after receiving the early warning signal. At the same time, based on the early warning threshold, an early warning is issued when the quenching times of the quenching liquid reach the target times, reminding the staff to cool and replace the quenching liquid;

[0051] The specific analysis is as follows: the quenching liquid temperature is abnormal after analyzing the warning signal. Since the quenching pool and the temperature collection area are marked with corresponding numbers, the abnormal temperature area corresponding to the abnormal quenching pool can be found by numbering;

[0052] For example, the temperature data collected by the quenching pool numbered A are: AWD1, AWD2, and AWD3 represent the temperature data of the surface, middle, and bottom areas of the quenching pool numbered A. Substitute the temperature data into the formula The temperature differences of quenching pool A are obtained as AWC1, AWC2 and AWC3;

[0053] Set the temperature difference thresholds AWC1', AWC2', and AWC3', and select the maximum value to the minimum value in the influence range to form the temperature difference threshold interval 1 (-AWC1', AWC1', +AWC1'), the temperature difference threshold interval 2 (-AWC2', AWC2', +AWC2'), and the temperature difference threshold interval 3 (-AWC3', AWC3', +AWC3'). Match the temperature differences 1, 2, and 3 with the threshold intervals respectively. If This indicates that the match is successful and the quenching liquid temperature in quenching pool A is normal. It indicates that the matching fails, and a signal of abnormal quenching liquid temperature in quenching pool A is obtained, and a signal of abnormal quenching liquid temperature in the surface, middle and bottom temperature collection areas of quenching pool A is obtained, and an early warning is issued based on this signal;

[0054] The warning threshold is analyzed to obtain the preset number of quenching times, the actual number of quenching times is monitored, and a warning is issued when the actual number of quenching times reaches the preset number of quenching times;

[0055] For example: if the preset number of acceptable quenching times ACS' for the quenching liquid in the quenching pool numbered A is 12, then the warning threshold of the quenching liquid is 12. The actual number of quenching times of the quenching liquid in the quenching pool A is monitored by the intelligent monitoring probe. When the actual number of quenching times reaches 12, that is, the actual number of quenching times matches the preset number of quenching times and reaches the warning threshold, a warning signal is generated to warn the staff to cool and replace the quenching liquid.

[0056] The above are only embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention should be included in the scope of the claims of the present invention.

Claims

1. A wireless temperature monitoring and management system for a factory quenching pool, comprising a database, a wireless transmission module, an early warning module, a temperature acquisition module and an intelligent recommendation terminal, characterized in that: It also includes a quenching rate monitoring module and a data processing unit; The quenching rate monitoring module is used to obtain the quenching times and total duration data of the quenching pool within a limited time period, to form a total quenching rate index within a limited time period of the quenching pool, to calculate the average of the total quenching rate index to obtain a quenching rate average index, to set a quenching rate total threshold index, to process and analyze the quenching rate total threshold index and the quenching rate average index to obtain a quenching frequency one, and to transmit it to the data processing unit; The data processing unit is used to parse the temperature data, obtain the initial temperature value and the final temperature value of the quenching liquid within a limited time period, process and analyze the initial temperature value and the final temperature value to obtain a total temperature increase index, average the total temperature increase index to obtain an average temperature increase index, perform a comprehensive analysis based on the average temperature increase index and the initial temperature value to obtain an average temperature rise, set a quenching liquid temperature threshold, process and analyze the quenching liquid temperature threshold and the average temperature rise to obtain a quenching frequency two, and mark it as a reference quenching frequency for transmission to the intelligent recommendation terminal.

2. A factory quenching pool wireless temperature monitoring and management system according to claim 1, characterized in that: The specific processing process for quenching frequency 1 is: through the formula The quenching rate average index CHJ is obtained, CS and SC represent the number of quenching times and the total duration respectively, where β1 and β2 represent the set weight factors, and the quenching rate total index threshold CHZ is set. The quenching frequency PL1 is obtained, where β3 and β4 represent the set weight factors.

3. A factory quenching pool wireless temperature monitoring and management system according to claim 1, characterized in that: The specific processing process for quenching frequency 2 is: through the formula The average temperature increase index JZF is obtained, CW and ZW represent the initial temperature value and the end temperature value respectively, where δ1 represents the set proportional coefficient factor, the average temperature increase index JZF and the initial temperature value CW are substituted into the formula WSJ = JZF × CW to obtain the average temperature rise WSJ, the quenching liquid temperature threshold WY is set, and the formula is substituted The quenching frequency 2 PL2 is obtained, where β5, β6, and β7 represent the set weight factors.

4. A factory quenching pool wireless temperature monitoring and management system according to claim 1, characterized in that: The intelligent recommendation terminal performs processing and analysis based on the received quenching frequency 2 PL2. The specific process is as follows: Set the quenching liquid temperature threshold WY, which means that when the real-time temperature of the quenching liquid approaches the temperature threshold WY, it needs to be cooled and replaced. Set the preset quenching time SC', and substitute the formula CS'=(PL2×δ2)×(SC'×δ3) to obtain the preset quenching times CS', where δ2 and δ3 represent the set proportional coefficient factors; The real-time temperature SW of the quenching liquid after the preset number of quenching times CS' is obtained by the formula SW = (CW + WY) · CS' / 2, the minimum value within the influence range of the temperature threshold WY is selected to construct the temperature threshold interval (-WY, WY), and the real-time temperature SW is compared with the temperature threshold interval (-WY, WY). If SW∈(-WY, WY) and <WY, it indicates that the real-time temperature of the quenching liquid after the preset number of quenching times is within the temperature threshold interval, and the current preset number of quenching times is marked as the target number. If And>WY, it indicates that the real-time temperature of the quenching liquid after the preset number of quenching exceeds the temperature threshold range, the current preset number of quenching is marked as abnormal, and the preset number of quenching is reduced in sequence to recalculate the screening target number; The preset number of quenching times marked as the target number is set as the warning threshold and transmitted to the warning module.

5. A factory quenching pool wireless temperature monitoring and management system according to claim 1, characterized in that: The temperature acquisition module is used to collect the real-time temperature of the quenching liquid. The specific analysis is as follows: Set several depth ranges, match the quenching pool depth with the depth range, obtain several temperature collection areas, and divide them into surface, middle and bottom areas according to the depth range. Collect the temperature of each area and mark the surface temperature as temperature 1, the middle temperature as temperature 2, and the bottom temperature as temperature 3. Substitute into the formula The temperature differences are obtained as WC1, WC2 and WC3, WD1, WD2 and WD3 are respectively represented as temperatures one, two and three, where γ1, γ2 and γ3 are respectively represented as the set proportional coefficient factors; Set the temperature difference thresholds WC1', WC2' and WC3', select the maximum value to the minimum value in the influence range to form the temperature difference threshold interval 1 (-WC1', WC1', +WC1'), the temperature difference threshold interval 2 (-WC2', WC2', +WC2'), and the temperature difference threshold interval 3 (-WC3', WC3', +WC3'), respectively, and match the temperature differences 1, 2 and 3 with the threshold intervals. If This indicates that the match is successful and a normal quenching liquid temperature signal is generated. This indicates that the matching has failed, and a quenching liquid temperature abnormality signal is generated, and an early warning signal is generated and transmitted to the early warning module.

6. A factory quenching pool wireless temperature monitoring and management system according to claim 1, characterized in that: Also includes: A database for storing the temperature variation data of the quenching liquid and forming a queryable historical database; Wireless transmission module, used for wireless transmission connection of data signals; The early warning module is used to issue an audible and visual early warning after receiving the early warning signal. At the same time, based on the early warning threshold, an early warning is issued when the quenching times of the quenching liquid reach the target times, reminding the staff to cool and replace the quenching liquid.

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