Induction heating process monitoring method and system and storage medium
By setting multiple chamber wall temperature control points inside the quenching cavity, collecting temperature data in real time and calculating confidence intervals, and generating a thermal map to evaluate the temperature gradient, the problem of insufficient temperature monitoring in the quenching heating process in the prior art is solved, and more accurate temperature control and more stable product quality are achieved.
Patent Information
- Application Number
- CN202411925965.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-25
- Publication Date
- 2025-03-28
AI Technical Summary
In the prior art, the temperature monitoring of the quenching heating process is insufficient, especially when dealing with complex temperature change curves or high-precision quenching processes, it is difficult for fuzzy rules to accurately describe the relationship between temperature and heating power, resulting in the workpiece temperature exceeding the optimal range.
By setting multiple uniformly distributed chamber wall temperature control points inside the quenching cavity, temperature data is collected in real time, confidence intervals of temperature distribution are calculated, and thermal maps are generated to evaluate the significance of the temperature gradient and identify the temperature distribution characteristics, so as to achieve accurate temperature control.
It improves the accuracy of the quenching process and the accuracy of the evaluation of temperature gradients, ensures that the workpiece temperature is always within the optimal range, and improves the stability and consistency of product quality.
Smart Images
Figure CN119710216A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of heat treatment technology, and more particularly to an induction heating process monitoring method, system and storage medium. Background Art
[0002] At present, the heating furnaces used for heat treatment of wire rods in China are still mainly muffle furnaces, pit furnaces, box furnaces, and trolley furnaces. These heating furnaces use coal burning or resistance heating as heating means, which have the disadvantages of poor sealing conditions, large heat storage, and slow heating speed, resulting in large heat loss in the furnace body and a large amount of energy waste. Test data show that the power consumption of traditional resistance furnace heat treatment is 1000-1200 kWh / ton of material. Using coal as a heating means will cause greater pollution, and the heating temperature curve is not well controlled, which affects the quality of wire rod heat treatment.
[0003] With the development of artificial intelligence technology, some intelligent algorithms such as fuzzy control and neural network control have also begun to be applied to the field of quenching and heating monitoring. These intelligent algorithms can analyze and process a large amount of data collected by sensors, automatically adjust control parameters to adapt to different workpiece materials, shapes and quenching requirements, and further improve the control accuracy and stability of quenching and heating. For example, the fuzzy control system can automatically adjust the heating power according to the fuzzy information fed back by the temperature sensor, so that the workpiece temperature is always kept within the optimal quenching range. However, there are still various problems in the prior art. For example, the rules of the fuzzy control system are based on experience and expert knowledge. These rules may not be accurate enough. For example, when dealing with complex temperature change curves or quenching processes with high precision requirements, fuzzy rules may not accurately describe the relationship between temperature and heating power. For example, for the quenching of some special alloy materials, the optimal quenching temperature range may be very narrow, and the temperature change is very sensitive to the material properties. Fuzzy rules may not be detailed enough, resulting in inappropriate step size for heating power adjustment, causing the workpiece temperature to exceed the optimal range.
[0004] Therefore, how to solve the technical problems existing in the prior art and make temperature monitoring more accurate still requires further research by those skilled in the art. Summary of the invention
[0005] In view of this, the present invention provides an induction heating process monitoring method, system and storage medium, which improve the accuracy of the quenching process and optimize the temperature gradient evaluation.
[0006] In order to achieve the above object, the present invention adopts the following technical solution:
[0007] A method for monitoring an induction heating process comprises the following steps:
[0008] A plurality of cavity wall temperature control points are set inside the quenching cavity, and the cavity wall temperature control points correspond to the internal structure of the cavity to meet the uniform distribution, and the temperature mean and standard deviation inside the quenching cavity are collected in real time, and the confidence interval of the temperature distribution inside the quenching cavity is calculated;
[0009] Generate a thermodynamic map based on the temperature distribution inside the quenching chamber, determine the temperature gradient inside the quenching chamber based on the appearance of the thermodynamic map, evaluate the significance of the temperature gradient in combination with the confidence interval, and identify the temperature distribution characteristics inside the quenching chamber;
[0010] Obtain the equipment technical parameters of the quenching chamber, quenching heating assembly and quenching cooling mechanism, control the temperature of the quenching chamber according to actual needs, control the temperature in combination with the confidence interval of the internal temperature distribution, and obtain the temperature control sequence;
[0011] The temperature monitoring results are obtained by conducting a joint analysis based on the impact of equipment technical parameters on temperature parameters, temperature distribution characteristics, and temperature distribution characteristics.
[0012] Optionally, the temperature mean and standard deviation inside the quenching chamber are collected in real time, and the confidence interval of the temperature distribution inside the quenching chamber is calculated. Specifically, the real-time temperatures of the temperature control points on the quenching chamber wall are obtained multiple times, and the real-time temperatures of different temperature control points on the chamber wall are plotted into curves, and correlation analysis is performed on changes in different temperature curves. Abnormal temperature curves are screened according to the results of the correlation analysis, and the abnormal temperature curves are smoothed based on changes in the temperature curves; the temperature mean and standard deviation are obtained for different temperature curves, and then the confidence interval is calculated.
[0013] Optionally, generating a thermal map based on the temperature distribution inside the quenching chamber specifically includes the following steps:
[0014] Obtain the structural characteristics inside the quenching chamber, the temperature control points of the chamber wall, and the temperatures corresponding to the temperature control points of the chamber wall;
[0015] Draw the corresponding grid structure based on the structural characteristics inside the quenching chamber, and adjust the size of the grid structure according to the temperature control points on the chamber wall and the temperatures corresponding to the temperature control points on the chamber wall;
[0016] The temperatures corresponding to the temperature control points on the cavity wall are superimposed or averaged to complete the assignment of the grid structure. Based on the assigned features, color mapping is completed to obtain a thermal map.
[0017] Optionally, the temperature control points of the cavity wall are obtained as follows: based on the internal space cross-section of the quenching cavity, the quenching cavity is proportionally reduced into four groups of regional spaces, and then based on the center point of the innermost regional space and the corner points of the quenching cavity, relevant connecting lines are constructed to divide the regional space into several designated spaces, and sensors are evenly arranged in the designated spaces.
[0018] Optionally, the temperature control includes the following nodes: brazing node, annealing node, quenching node, tempering node and solution node.
[0019] Optionally, the numerical value of each grid or data point is mapped to a corresponding color on the color gradient by an interpolation algorithm to ensure smoothness of color transition.
[0020] An induction heating process monitoring system, comprising:
[0021] Temperature distribution acquisition module: used to set multiple cavity wall temperature control points inside the quenching cavity. The cavity wall temperature control points correspond to the internal structure of the cavity to meet the uniform distribution. The temperature mean and standard deviation inside the quenching cavity are collected in real time, and the confidence interval of the temperature distribution inside the quenching cavity is calculated.
[0022] Temperature distribution feature generation module: used to generate a thermogram based on the temperature distribution inside the quenching chamber, determine the temperature gradient inside the quenching chamber according to the appearance of the thermogram, evaluate the significance of the temperature gradient in combination with the confidence interval, and identify the temperature distribution features inside the quenching chamber;
[0023] Temperature control sequence acquisition module: obtains the equipment technical parameters of the quenching chamber, quenching heating components and quenching cooling mechanism, controls the temperature of the quenching chamber according to actual needs, controls the temperature in combination with the confidence interval of the internal temperature distribution, and obtains the temperature control sequence;
[0024] Temperature monitoring result output module: used to perform joint analysis based on the impact of equipment technical parameters on temperature parameters, temperature distribution characteristics, and temperature distribution characteristics to obtain temperature monitoring results.
[0025] A computer storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of any one of the methods for monitoring an induction heating process.
[0026] It can be seen from the above technical solutions that, compared with the prior art, the present invention provides an induction heating process monitoring method, system and storage medium, which have the following beneficial effects:
[0027] 1. Improve the accuracy of the quenching process: By setting multiple evenly distributed cavity wall temperature control points inside the quenching cavity, the temperature data inside the quenching cavity can be collected in real time and accurately. This includes not only the temperature mean, but also the standard deviation, so that a more comprehensive understanding of the temperature distribution can be achieved. This helps to accurately control the temperature during the quenching process and ensure the stability and consistency of product quality.
[0028] 2. Optimize temperature gradient evaluation: The thermal map generated based on the temperature distribution inside the quenching chamber can intuitively display the temperature gradient. Combined with the confidence interval to evaluate the significance of the temperature gradient, the temperature distribution characteristics inside the quenching chamber can be more accurately identified. This helps to promptly discover and solve the problem of uneven temperature distribution and avoid product defects due to excessive temperature gradients.
[0029] 3. Improve the flexibility of temperature control: The temperature of the quenching chamber is controlled according to actual needs, and the temperature is dynamically adjusted in combination with the confidence interval of the internal temperature distribution, so that a temperature control sequence that better meets actual needs can be obtained. This flexible temperature control method helps to improve the adaptability and stability of the quenching process and meet the production needs of different products. BRIEF DESCRIPTION OF THE DRAWINGS
[0030] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.
[0031] Figure 1 It is a schematic diagram of the method flow of the present invention;
[0032] Figure 2 It is a schematic diagram of the system structure of the present invention. DETAILED DESCRIPTION
[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions 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 are within the scope of protection of the present invention.
[0034] Example 1
[0035] The embodiment of the present invention discloses a method for monitoring an induction heating process. Figure 1 As shown, the following steps are included:
[0036] Step 1: multiple cavity wall temperature control points are set inside the quenching cavity, and the cavity wall temperature control points correspond to the internal structure of the cavity to meet the uniform distribution, and the temperature mean and standard deviation inside the quenching cavity are collected in real time, and the confidence interval of the temperature distribution inside the quenching cavity is calculated;
[0037] Step 2: Generate a thermodynamic map based on the temperature distribution inside the quenching chamber, determine the temperature gradient inside the quenching chamber according to the appearance of the thermodynamic map, evaluate the significance of the temperature gradient in combination with the confidence interval, and identify the temperature distribution characteristics inside the quenching chamber;
[0038] Step 3: Obtain the equipment technical parameters of the quenching chamber, the quenching heating component, and the quenching cooling mechanism, control the temperature of the quenching chamber according to actual needs, and control the temperature in combination with the confidence interval of the internal temperature distribution to obtain a temperature control sequence;
[0039] Step 4: Perform a joint analysis based on the impact of equipment technical parameters on temperature parameters, temperature distribution characteristics, and temperature distribution characteristics to obtain temperature monitoring results.
[0040] Furthermore, in step one, the temperature mean and standard deviation inside the quenching chamber are collected in real time, and the confidence interval of the temperature distribution inside the quenching chamber is calculated. Specifically, the real-time temperatures of the temperature control points on the quenching chamber wall are obtained multiple times, and the real-time temperatures of different temperature control points on the chamber wall are plotted as curves, and correlation analysis is performed on changes in different temperature curves. Abnormal temperature curves are screened according to the results of the correlation analysis, and the abnormal temperature curves are smoothed based on changes in the temperature curves; the temperature mean and standard deviation are obtained for different temperature curves, and then the confidence interval is calculated.
[0041] Calculating Confidence Intervals Confidence intervals are calculated using statistical methods. For normally distributed data, the confidence interval can be calculated using the properties of the standard normal distribution.
[0042] The confidence interval is calculated as:
[0043]
[0044] Where Z is the critical value of the standard normal distribution corresponding to the confidence level, and n is the number of samples.
[0045] Furthermore, multiple thermocouples are placed at different locations inside the quenching chamber to ensure that the temperature distribution can be fully captured. The number and location of thermocouples should be determined according to the shape and size of the quenching chamber, and they are usually installed at key locations such as the top, bottom, side, and center.
[0046] Connect the thermocouple to a data acquisition system that can record temperature data at various locations in real time. The data acquisition system should have high precision and stability to ensure that the collected temperature data is accurate and reliable.
[0047] Set the appropriate sampling frequency as needed to ensure that the details of temperature changes can be captured. The sampling frequency should be determined according to the characteristics of the quenching process and actual needs.
[0048] Furthermore, in step 2, a thermal map is generated based on the temperature distribution inside the quenching chamber, which specifically includes the following steps:
[0049] Step 2.1, obtaining the structural characteristics inside the quenching chamber, the temperature control points of the chamber wall and the temperatures corresponding to the temperature control points of the chamber wall;
[0050] Step 2.2, drawing a corresponding grid structure based on the structural features inside the quenching chamber, and adjusting the size of the grid structure according to the temperature control points on the chamber wall and the temperatures corresponding to the temperature control points on the chamber wall;
[0051] Step 2.3: Superimpose or average the temperatures corresponding to the temperature control points on the cavity wall to complete the assignment of the grid structure. Based on the assigned features, complete the color mapping to obtain the thermal map.
[0052] Optionally, the temperature control includes the following nodes: brazing node, annealing node, quenching node, tempering node and solution node.
[0053] Furthermore, in Bad Walk 2.3, the value of each grid or data point is mapped to the corresponding color on the color gradient through an interpolation algorithm to ensure the smoothness of the color transition.
[0054] Furthermore, in step 4,
[0055] Analyze the impact of equipment technical parameters on temperature distribution characteristics. For example, changes in cooling rate may lead to changes in temperature gradients; cavity size and material thermal conductivity may affect temperature uniformity. Use correlation analysis, cluster analysis and other methods to study the correlation between different temperature distribution characteristics. For example, there may be a certain correlation between temperature gradient and hot spot location. Combine multiple temperature distribution characteristics to comprehensively evaluate the temperature conditions inside the quenching chamber. This helps to have a more comprehensive understanding of the temperature distribution and provide a basis for subsequent temperature control.
[0056] and Figure 1 Corresponding to the method shown, the present invention also discloses an induction heating process monitoring system for Figure 1 The implementation of the method, the specific structure is as follows Figure 2 As shown, including:
[0057] Temperature distribution acquisition module: used to set multiple cavity wall temperature control points inside the quenching cavity. The cavity wall temperature control points correspond to the internal structure of the cavity to meet the uniform distribution. The temperature mean and standard deviation inside the quenching cavity are collected in real time, and the confidence interval of the temperature distribution inside the quenching cavity is calculated.
[0058] Temperature distribution feature generation module: used to generate a thermogram based on the temperature distribution inside the quenching chamber, determine the temperature gradient inside the quenching chamber according to the appearance of the thermogram, evaluate the significance of the temperature gradient in combination with the confidence interval, and identify the temperature distribution features inside the quenching chamber;
[0059] Temperature control sequence acquisition module: obtains the equipment technical parameters of the quenching chamber, quenching heating components and quenching cooling mechanism, controls the temperature of the quenching chamber according to actual needs, controls the temperature in combination with the confidence interval of the internal temperature distribution, and obtains the temperature control sequence;
[0060] Temperature monitoring result output module: used to perform joint analysis based on the impact of equipment technical parameters on temperature parameters, temperature distribution characteristics, and temperature distribution characteristics to obtain temperature monitoring results.
[0061] This embodiment discloses a computer storage medium, on which a computer program is stored. When the computer program is executed by a processor, the steps of any one of the methods for monitoring an induction heating process are implemented.
[0062] Example 2
[0063] The only difference between this embodiment and Embodiment 1 is that, in step one, the temperature control point of the cavity wall is obtained as follows: based on the internal space cross-section of the quenching cavity, the quenching cavity is proportionally reduced into four groups of regional spaces, and then based on the center point of the innermost regional space and the corner points of the quenching cavity, relevant connecting lines are constructed to divide the regional space into several designated spaces, and sensors are evenly arranged in the designated spaces.
[0064] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.
[0065] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A method for monitoring an induction heating process, characterized in that: The following steps are involved: A plurality of cavity wall temperature control points are set inside the quenching cavity, and the cavity wall temperature control points correspond to the internal structure of the cavity to meet the uniform distribution, and the temperature mean and standard deviation inside the quenching cavity are collected in real time, and the confidence interval of the temperature distribution inside the quenching cavity is calculated; Generate a thermodynamic map based on the temperature distribution inside the quenching chamber, determine the temperature gradient inside the quenching chamber based on the appearance of the thermodynamic map, evaluate the significance of the temperature gradient in combination with the confidence interval, and identify the temperature distribution characteristics inside the quenching chamber; Obtain the equipment technical parameters of the quenching chamber, quenching heating assembly and quenching cooling mechanism, control the temperature of the quenching chamber according to actual needs, control the temperature in combination with the confidence interval of the internal temperature distribution, and obtain the temperature control sequence; The temperature monitoring results are obtained by conducting a joint analysis based on the impact of equipment technical parameters on temperature parameters, temperature distribution characteristics, and temperature distribution characteristics.
2. The induction heating process monitoring method according to claim 1, characterized in that: The temperature mean and standard deviation inside the quenching chamber are collected in real time, and the confidence interval of the temperature distribution inside the quenching chamber is calculated. Specifically, the real-time temperatures of the temperature control points on the quenching chamber wall are obtained multiple times, and the real-time temperatures of different temperature control points on the chamber wall are plotted into curves, and the changes of different temperature curves are analyzed for correlation, and the abnormal temperature curves are screened according to the results of the correlation analysis, and the abnormal temperature curves are smoothed based on the changes of the temperature curves; the temperature mean and standard deviation are obtained for different temperature curves, and then the confidence interval is calculated.
3. The induction heating process monitoring method according to claim 1, characterized in that: Generating a thermal map based on the temperature distribution inside the quenching chamber includes the following steps: Obtain the structural characteristics inside the quenching chamber, the temperature control points of the chamber wall, and the temperatures corresponding to the temperature control points of the chamber wall; Draw the corresponding grid structure based on the structural characteristics inside the quenching chamber, and adjust the size of the grid structure according to the temperature control points on the chamber wall and the temperatures corresponding to the temperature control points on the chamber wall; The temperatures corresponding to the temperature control points on the cavity wall are superimposed or averaged to complete the assignment of the grid structure. Based on the assigned features, color mapping is completed to obtain a thermal map.
4. The induction heating process monitoring method according to claim 1, characterized in that: The method for obtaining the temperature control points of the cavity wall is as follows: based on the internal space cross-section of the quenching cavity, the quenching cavity is proportionally reduced into four groups of regional spaces, and then based on the center point of the innermost regional space and the corner points of the quenching cavity, relevant connecting lines are constructed to divide the regional space into several designated spaces, and sensors are evenly arranged in the designated spaces.
5. The induction heating process monitoring method according to claim 1, characterized in that: Temperature control includes the following nodes: brazing node, annealing node, quenching node, tempering node and solution node.
6. The induction heating process monitoring method according to claim 3, characterized in that: The value of each grid or data point is mapped to the corresponding color on the color gradient through an interpolation algorithm to ensure smooth color transition.
7. An induction heating process monitoring system, characterized in that: include: Temperature distribution acquisition module: used to set multiple cavity wall temperature control points inside the quenching cavity. The cavity wall temperature control points correspond to the internal structure of the cavity to meet the uniform distribution. The temperature mean and standard deviation inside the quenching cavity are collected in real time, and the confidence interval of the temperature distribution inside the quenching cavity is calculated. Temperature distribution feature generation module: used to generate a thermogram based on the temperature distribution inside the quenching chamber, determine the temperature gradient inside the quenching chamber according to the appearance of the thermogram, evaluate the significance of the temperature gradient in combination with the confidence interval, and identify the temperature distribution features inside the quenching chamber; Temperature control sequence acquisition module: obtains the equipment technical parameters of the quenching chamber, quenching heating components and quenching cooling mechanism, controls the temperature of the quenching chamber according to actual needs, controls the temperature in combination with the confidence interval of the internal temperature distribution, and obtains the temperature control sequence; Temperature monitoring result output module: used to perform joint analysis based on the impact of equipment technical parameters on temperature parameters, temperature distribution characteristics, and temperature distribution characteristics to obtain temperature monitoring results.
8. A computer storage medium, characterized in that: The computer storage medium stores a computer program, and when the computer program is executed by the processor, the steps of the induction heating process monitoring method according to any one of claims 1 to 6 are implemented.