Intelligent induction heating control method and system

Abstract

The invention discloses an intelligent induction heating control method and system, and belongs to the technical field of quenching induction heating. The method comprises the steps that S100, a target temperature is set, and a temperature control gear and a first punching temperature are determined; s200, the initial temperature is detected, and cold and hot machine judgment is conducted; s300, heating in a mode of combining sub-temperature sections and sub-pulse periods; s400, carrying out real-time monitoring and self-adaptive adjustment on the heating process; s500, optimizing the temperature gradient; s600, temperature fluctuation suppression is carried out; and S700, quenching cooling control is conducted, and the quenching process is completed. The precision and efficiency of the heating process are improved, the product quality is improved, energy consumption is reduced, and remarkable economic and social benefits are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of quenching induction heating, and more particularly to an intelligent induction heating control method and system thereof. Background Art

[0002] In industrial manufacturing, induction heating technology is widely used in processes such as metal hardening, welding, and melting due to its efficient, precise and fast heating characteristics.

[0003] However, traditional induction heating control methods often have problems such as slow response speed, insufficient temperature control accuracy, high energy consumption and large temperature fluctuations. These problems not only affect the heating quality and efficiency, but may also cause excessive wear of equipment and energy waste.

[0004] Therefore, how to provide an intelligent induction heating control method and system that can solve the above problems is an issue that technical personnel in this field need to solve urgently. Summary of the invention

[0005] In view of this, the present invention provides an intelligent induction heating control method and system thereof to achieve more efficient and accurate temperature control.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] An intelligent induction heating control method, comprising:

[0008] S100: setting the target temperature and determining the temperature control gear and the first flushing temperature;

[0009] S200: Detect the initial temperature and make a judgment on whether the machine is hot or cold;

[0010] S300: Heating in a combination of temperature sections and pulse cycles;

[0011] S400: Real-time monitoring and adaptive adjustment of the heating process;

[0012] S500: temperature gradient optimization;

[0013] S600: Temperature fluctuation suppression;

[0014] S700: Perform quenching cooling control to complete the quenching process.

[0015] Furthermore, the S100 includes:

[0016] S110: Obtain historical target temperatures and corresponding actual temperatures and environmental conditions, analyze temperature variation patterns during the heating process, and establish a dynamic model based on the temperature variation patterns during the heating process;

[0017] S120: Initialize the dynamic model, set the prediction time range, control time step, constraints and optimization target;

[0018] S120: setting a target temperature based on the temperature required for quenching;

[0019] S130: inputting the set target temperature into the dynamic model to obtain a prediction result, and determining the optimal temperature control gear according to the prediction result;

[0020] S140: According to the optimal temperature control gear, a preset temperature control gear and first flushing temperature comparison table is searched to determine the first flushing temperature.

[0021] Furthermore, the S200 includes:

[0022] S210: collecting initial temperature;

[0023] S220: Compare the initial temperature and the first impulse temperature, where:

[0024] If the initial temperature is less than or equal to the first-charge temperature, it is judged that the machine is in a cold state, the first-charge temperature is used as the starting temperature, and the machine is heated to the starting temperature at full power;

[0025] If the initial temperature is greater than the first-rush temperature, it is determined that the current state is a hot engine state, a temperature compensation difference is determined, the temperature compensation difference is used as the starting temperature, and full power is used to heat to the starting temperature.

[0026] Furthermore, the S300 includes:

[0027] S310: After reaching the starting temperature, dividing the starting temperature to the target temperature into multiple temperature sections;

[0028] S320: Divide each temperature segment into a plurality of pulse cycles;

[0029] S330: In each pulse cycle, the heating power is adjusted using the uninterrupted PDM pulse density.

[0030] Furthermore, the step S330: in each pulse cycle, using uninterrupted PDM pulse density to adjust the heating power includes:

[0031] S331: Calculation error:

[0032] e(t)=T set -T actual ;

[0033] Where e(t) is the calculated error, T set is the target temperature, T actual It is the actual temperature fed back from the system or equipment;

[0034] S332: Adjust the duty cycle D(t) of the PDM signal according to the error e(t):

[0035] D(t) = f(e(t));

[0036] Where f is the function used to convert the error into duty cycle;

[0037] S333: Adjust the heating power based on the duty cycle of the PDM signal.

[0038] Furthermore, the S400 includes:

[0039] If the device needs to stop M pulses within N pulse cycles, the M stopped pulses will be evenly distributed to the pulses of N pulse cycles. This cycle will be repeated over and over again, and the device will not reach a state of zero current.

[0040] Further, S500, including:

[0041] S510: In each temperature segment, calculate the temperature gradient:

[0042]

[0043] Where, T set is the target temperature, T current is the current temperature, T remaining for the remaining time;

[0044] S520: Dynamically adjust the heating rate according to the temperature gradient.

[0045] Further, S600, including:

[0046] S610: Real-time detection of temperature fluctuations and calculation of the temperature fluctuation amplitude:

[0047] ΔT fluctuation =max(T actual )-min(T actual );

[0048] In the formula, ΔT fluctuation is the temperature fluctuation amplitude, T actual It is the actual temperature fed back from the system or equipment;

[0049] S620: If the temperature fluctuation amplitude exceeds a preset threshold, fluctuation suppression is initiated.

[0050] Further, S700, including:

[0051] S710: When the actual temperature reaches the target temperature, the heating is stopped and the cooling system is started;

[0052] S720: Use PDM control to adjust the flow of cooling medium to ensure the temperature drops;

[0053] S730: Monitor the temperature change during the cooling process in real time. When the temperature drops to a predetermined cooling end temperature, stop cooling and complete the quenching process.

[0054] An intelligent induction heating control system, comprising:

[0055] Initialization module: set the target temperature and determine the temperature control gear and the first flushing temperature;

[0056] Detection module: detects the initial temperature and makes a judgment on whether the machine is hot or cold;

[0057] Segmented module: heating by combining temperature segments and pulse cycles;

[0058] Temperature control module: real-time monitoring and adaptive adjustment of the heating process;

[0059] Gradient optimization module: temperature gradient optimization;

[0060] Fluctuation suppression module: temperature fluctuation suppression;

[0061] Cooling module: performs quenching cooling control and completes the quenching process.

[0062] It can be seen from the above technical solutions that, compared with the prior art, the present invention discloses an intelligent induction heating control method and system thereof to achieve more efficient and more accurate temperature control, and the specific beneficial effects are as follows:

[0063] (1) By setting the target temperature, temperature control level and first-rush temperature, combined with the establishment of a dynamic model and real-time monitoring, the heating process can be precisely controlled to ensure product quality;

[0064] (2) Adaptive fuzzy logic and feedforward control can be used to self-adjust based on real-time temperature feedback to adapt to different heating conditions and environmental changes, thereby improving the flexibility and stability of the system;

[0065] (3) Dynamically adjust the heating rate in different temperature ranges to effectively control the temperature gradient, reduce material stress caused by temperature changes, and extend equipment life;

[0066] (4) In each pulse cycle, the heating power is adjusted using uninterrupted PDM pulse density to ensure that the power factor of the equipment remains unchanged and that the temperature gradually approaches the target temperature;

[0067] (5) Real-time monitoring of temperature fluctuations and suppression of fluctuations help maintain the stability of the heating process, reduce uncertainty in the production process, and improve production efficiency;

[0068] (6) During the quenching cooling process, the flow rate of the cooling medium is accurately controlled to ensure that the temperature drops quickly and evenly, thereby improving the quenching effect and reducing the risk of material deformation and cracking.

[0069] (6) By optimizing the heating and cooling processes, unnecessary energy consumption can be reduced, achieving energy-saving and consumption-reducing effects, which meets the requirements of modern manufacturing industry for sustainable development.

[0070] In summary, the present invention not only improves the accuracy and efficiency of the heating process, but also helps to improve product quality, reduce energy consumption, and has significant economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] 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.

[0072] Figure 1 It is a schematic diagram of the method flow of the present invention;

[0073] Figure 2 It is a schematic diagram of the system structure of the present invention;

[0074] Figure 3 When P / Pmax=6 / 30, the output voltage and output current waveforms under the simple pulse density power regulation control mode;

[0075] Figure 4 When P / Pmax=6 / 30, the output voltage and output current waveforms under the uninterrupted PDM control mode provided by the present invention. DETAILED DESCRIPTION

[0076] 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.

[0077] See also Figure 1 The embodiment of the present invention discloses an intelligent induction heating control method, comprising:

[0078] S100: setting the target temperature and determining the temperature control gear and the first flushing temperature;

[0079] S200: Detect the initial temperature and make a judgment on whether the machine is hot or cold;

[0080] S300: Heating in a combination of temperature sections and pulse cycles;

[0081] S400: Real-time monitoring and adaptive adjustment of the heating process;

[0082] S500: temperature gradient optimization;

[0083] S600: Temperature fluctuation suppression;

[0084] S700: Perform quenching cooling control to complete the quenching process.

[0085] In a specific embodiment, S100 includes:

[0086] S110: Obtain historical target temperatures and corresponding actual temperatures and environmental conditions, analyze temperature variation patterns during the heating process, and establish a dynamic model based on the temperature variation patterns during the heating process;

[0087] S120: Initialize the dynamic model, set the prediction time range, control time step, constraints and optimization target;

[0088] S120: setting a target temperature based on the temperature required for quenching;

[0089] S130: inputting the set target temperature into the dynamic model to obtain a prediction result, and determining the optimal temperature control gear according to the prediction result;

[0090] S140: According to the optimal temperature control gear, a preset temperature control gear and first flushing temperature comparison table is searched to determine the first flushing temperature.

[0091] In a specific embodiment, S200 includes:

[0092] S210: collecting initial temperature;

[0093] S220: Compare the initial temperature and the first impulse temperature, where:

[0094] If the initial temperature is less than or equal to the first-charge temperature, it is judged that the machine is in a cold state, the first-charge temperature is used as the starting temperature, and the machine is heated to the starting temperature at full power;

[0095] If the initial temperature is greater than the first-rush temperature, it is determined that the current state is a hot engine state, a temperature compensation difference is determined, the temperature compensation difference is used as the starting temperature, and full power is used to heat to the starting temperature.

[0096] In a specific embodiment, S300 includes:

[0097] S310: After reaching the starting temperature, the starting temperature to the target temperature is divided into multiple temperature sections, which are represented by: Tset ={[T0,T1],[T1,T2],...[T N -1,T set ]}, where T set is the target temperature;

[0098] S320: Divide each temperature segment into multiple pulse periods, such as the temperature [T0, T1], divided into pulse periods T 11 , T 12 , T 13 ...T m ;

[0099] S330: In each pulse cycle, the heating power is adjusted using uninterrupted PDM pulse density to ensure that the temperature gradually approaches the target temperature.

[0100] In a specific embodiment, S330: in each pulse cycle, using uninterrupted PDM pulse density to adjust the heating power includes:

[0101] S331: Calculation error:

[0102] e(t)=T set -T actual ;

[0103] Where e(t) is the calculated error, T set is the target temperature, T actual It is the actual temperature fed back from the system or equipment;

[0104] S332: Adjust the duty cycle D(t) of the PDM signal according to the error e(t):

[0105] D(t) = f(e(t));

[0106] Where f is the function used to convert the error to duty cycle; typically, this function can be linear or nonlinear, depending on the characteristics of the system and the control requirements.

[0107] S333: Adjust the heating power based on the duty cycle of the PDM signal.

[0108] In a specific embodiment, S400 includes: if the device needs to stop M pulses within N pulse cycles, then the M pulses to be stopped are evenly distributed to the pulses of N pulse cycles, and this cycle is repeated, and the device will not appear in a state of zero current.

[0109] In a specific embodiment, the uninterrupted PDM (pulse density) power modulation method specifically includes:

[0110] A series inverter is used to convert DC current into high-frequency AC current. A new uninterrupted PDM method is used to adjust the output power of the power supply to achieve output power regulation of the equipment, and to ensure that during the adjustment process, the power factor of the equipment is always maintained at almost 1, effectively utilizing the effective capacity of the equipment.

[0111] Specifically, the power regulation methods of the power transmission series inverter include rectifier side power regulation and inverter side power regulation. The rectifier side power regulation requires additional circuit structure, which not only increases the cost but also reduces the overall stability of the device. In the inverter side power regulation method, since other methods reduce the power factor of the device during power regulation, not only the effective capacity of the device is reduced, but also the power consumption of the device is increased. The PDM method power regulation of the present invention ensures that the power factor of the device remains unchanged.

[0112] The PDM power adjustment method of this embodiment is as follows:

[0113] When the actual output power of the device is greater than the set output power, the device stops outputting voltage pulses, and the load current oscillates naturally and decays continuously. When the current is small, the device re-outputs voltage pulses to gradually increase the current. When adjusting in PDM mode, the load current will not increase to the set requirements.

[0114] Specifically, when the power transmission PDM mode adjusts the output power, when the actual output power of the device is greater than the set output power, the device stops outputting voltage pulses. If the device needs to stop 24 pulses within 30 cycles, the device first outputs 6 voltage pulses and then stops 24 output pulses. The device outputs voltage pulses repeatedly in the PDM mode. This will cause a problem. Since the 24 stopped cycles are long, the load current may decay to 0, causing the device to stop working. In the traditional PDM power regulation, the output current of the device will be interrupted, and the power regulation is not accurate, which affects the normal use of the device. Based on the study of the traditional PDM mode, this embodiment changes the pulse regulation mode of the traditional PDM and adopts the uninterrupted PDM mode to realize the power regulation of the device. The difference between this method and the traditional method is that when the device needs to stop 24 pulses in 30 pulse cycles, this embodiment adopts the method of evenly distributing the stopped 24 pulses to 30 pulses, that is, the device outputs 1 pulse and then stops 4 pulses. In this way, the device will not have a current of 0 in a cycle. When P / Pmax=6 / 30, the output voltage and output current waveforms under the simple pulse density power control mode are as follows Figure 3 As shown, when P / Pmax=6 / 30, the output voltage and output current waveforms under the uninterrupted PDM control mode are as follows Figure 4 shown.

[0115] Specifically, the control circuit of traditional equipment is constructed with analog electronic components, which has the disadvantages of complex circuits, easy aging of components, zero drift, and narrow signal processing range. In the circuit composed of traditional analog circuits, the circuit has a certain range for processing the frequency signal of the load current. When it exceeds the range, the signal will have a certain deviation, which will eventually cause the phase deviation between the output voltage pulse of the equipment and the load current, reduce the power factor of the equipment, and increase the equipment loss.

[0116] This embodiment uses PLC to monitor the output voltage pulse and load current of the equipment in real time. When the output voltage pulse and the load current deviate, the PLC adjusts the control signal to reduce the phase deviation between the output voltage pulse and the load current, so that the power factor of the equipment is always controlled at 0.98.

[0117] When multiple inverter bridges of a series inverter power supply are connected in parallel, the problem of bias current restricts the development of high power. In addition to adopting a symmetrical layout of the main circuit, this power supply also strengthens the driving ability of the drive circuit. One driver board drives multiple IGBTs to ensure the dynamic and static current balance of the circuit; at the same time, each IGBT output stage is equipped with a sampling loop to detect the output current in time. When any one of the IGBTs reaches the rated current, it can promptly and effectively send a pulse to shut down the drive signal to ensure that the IGBT never overcurrents and avoid the tube explosion phenomenon.

[0118] Traditional induction heating equipment uses analog circuit control. Due to the fixed resonant capacitor and transformer, the frequency application range is narrow and can only be used within the range of 10K. One device can only be used for one application and cannot be used for multiple purposes.

[0119] This machine uses intelligent microcontrollers and advanced PWM synchronization technology, resonant frequency automatic tracking technology, etc. in frequency locking, which can achieve frequency tracking of 1KHz-100KHz. At the same time, our company has developed transformer adjustable ratio technology, which makes the output voltage of the transformer adjustable in stages; it has developed resonant capacitor dynamic adjustment technology, which makes the capacity of the resonant capacitor adjustable as needed, thus ensuring that the resonant frequency of the equipment can be adjusted arbitrarily in a large range (1KHZ~100KHZ). Due to the use of intelligent phase adjustment and wide range adjustment technology in inverter in control technology, the application range of the equipment has been greatly broadened. Customers can meet the needs of quenching, tempering or heat smelting of various workpieces by purchasing one power supply, truly realizing one machine for multiple uses.

[0120] In a specific embodiment, S500 includes:

[0121] S510: In each temperature segment, calculate the temperature gradient:

[0122]

[0123] Where, T set is the target temperature, T current is the current temperature, T remaining for the remaining time;

[0124] S520: Dynamically adjust the heating rate according to the temperature gradient.

[0125] In a specific embodiment, S600 includes:

[0126] S610: Real-time detection of temperature fluctuations and calculation of the temperature fluctuation amplitude:

[0127] ΔT fluctuation =max(T actual )-min(T actual );

[0128] Where, ΔT fluctuation is the temperature fluctuation amplitude, T actual It is the actual temperature fed back inside the system or equipment;

[0129] S620: If the temperature fluctuation amplitude exceeds a preset threshold, fluctuation suppression is initiated.

[0130] In a specific embodiment, S700 includes:

[0131] S710: When the actual temperature reaches the target temperature, the heating is stopped and the cooling system is started;

[0132] S720: Use PDM control to adjust the flow of cooling medium to ensure the temperature drops;

[0133] S730: Monitor the temperature change during the cooling process in real time. When the temperature drops to a predetermined cooling end temperature, stop cooling and complete the quenching process.

[0134] See also Figure 2 On the other hand, the embodiment of the present invention also discloses an intelligent induction heating control system, including:

[0135] Initialization module: set the target temperature and determine the temperature control gear and the first flushing temperature;

[0136] Detection module: detects the initial temperature and makes a judgment on whether the machine is hot or cold;

[0137] Segmented module: heating by combining temperature segments and pulse cycles;

[0138] Temperature control module: real-time monitoring and adaptive adjustment of the heating process;

[0139] Gradient optimization module: temperature gradient optimization;

[0140] Fluctuation suppression module: temperature fluctuation suppression;

[0141] Cooling module: performs quenching cooling control and completes the quenching process.

[0142] 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.

[0143] 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. An intelligent induction heating control method, characterized in that: include: S100: setting the target temperature and determining the temperature control gear and the first flushing temperature; S200: Detect the initial temperature and make a judgment on whether the machine is hot or cold; S300: Heating in a combination of temperature sections and pulse cycles; S400: Real-time monitoring and adaptive adjustment of the heating process; S500: temperature gradient optimization; S600: Temperature fluctuation suppression; S700: Perform quenching cooling control to complete the quenching process.

2. The intelligent induction heating control method according to claim 1, characterized in that: The S100 includes: S110: Obtain historical target temperatures and corresponding actual temperatures and environmental conditions, analyze temperature variation patterns during the heating process, and establish a dynamic model based on the temperature variation patterns during the heating process; S120: Initialize the dynamic model, set the prediction time range, control time step, constraints and optimization target; S120: setting a target temperature based on the temperature required for quenching; S130: inputting the set target temperature into the dynamic model to obtain a prediction result, and determining the optimal temperature control gear according to the prediction result; S140: According to the optimal temperature control gear, a preset temperature control gear and first flushing temperature comparison table is searched to determine the first flushing temperature.

3. The intelligent induction heating control method according to claim 1, characterized in that: The S200 includes: S210: collecting initial temperature; S220: Compare the initial temperature and the first impulse temperature, where: If the initial temperature is less than or equal to the first-charge temperature, it is judged that the machine is in a cold state, the first-charge temperature is used as the starting temperature, and the machine is heated to the starting temperature at full power; If the initial temperature is greater than the first-rush temperature, it is determined that the current state is a hot engine state, a temperature compensation difference is determined, the temperature compensation difference is used as the starting temperature, and full power is used to heat to the starting temperature.

4. The intelligent induction heating control method according to claim 1, characterized in that: The S300 includes: S310: After reaching the starting temperature, dividing the starting temperature to the target temperature into multiple temperature sections; S320: Divide each temperature segment into a plurality of pulse cycles; S330: In each pulse cycle, the heating power is adjusted using the uninterrupted PDM pulse density.

5. The intelligent induction heating control method according to claim 4, characterized in that: The step S330: in each pulse cycle, using uninterrupted PDM pulse density to adjust the heating power includes: S331: Calculation error: e(t)=T set -T actual ; Where e(t) is the calculated error, T set is the target temperature, T actual It is the actual temperature fed back from the system or equipment; S332: Adjust the duty cycle D(t) of the PDM signal according to the error e(t): D(t) = f(e(t)); Where f is the function used to convert the error into duty cycle; S333: Adjust the heating power based on the duty cycle of the PDM signal.

6. The intelligent induction heating control method according to claim 1, characterized in that: The S400 includes: If the device needs to stop M pulses within N pulse cycles, the M stopped pulses will be evenly distributed to the pulses of N pulse cycles. This cycle will be repeated over and over again, and the device will not reach a state of zero current.

7. The intelligent induction heating control method according to claim 1, characterized in that: S500, including: S510: In each temperature segment, calculate the temperature gradient: Where, T set is the target temperature, T current is the current temperature, T remaining for the remaining time; S520: Dynamically adjust the heating rate according to the temperature gradient.

8. The intelligent induction heating control method according to claim 1, characterized in that: S600, including: S610: Real-time detection of temperature fluctuations and calculation of the temperature fluctuation amplitude: ΔT fluctuation =max(T actual )-min(T actual ); In the formula, ΔT fluctuation is the temperature fluctuation amplitude, T actual It is the actual temperature fed back from the system or equipment; S620: If the temperature fluctuation amplitude exceeds a preset threshold, fluctuation suppression is initiated.

9. The intelligent induction heating control method according to claim 1, characterized in that: S700, including: S710: When the actual temperature reaches the target temperature, the heating is stopped and the cooling system is started; S720: Use PDM control to adjust the flow of cooling medium to ensure the temperature drops; S730: Monitor the temperature change during the cooling process in real time. When the temperature drops to a predetermined cooling end temperature, stop cooling and complete the quenching process.

10. An intelligent induction heating control system using the intelligent induction heating control method according to any one of claims 1 to 9, characterized in that: include: Initialization module: set the target temperature and determine the temperature control gear and the first flushing temperature; Detection module: detects the initial temperature and makes a judgment on whether the machine is hot or cold; Segmented module: heating by combining temperature segments and pulse cycles; Temperature control module: real-time monitoring and adaptive adjustment of the heating process; Gradient optimization module: temperature gradient optimization; Fluctuation suppression module: temperature fluctuation suppression; Cooling module: performs quenching cooling control and completes the quenching process.

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