A method, module and device for monitoring abnormality of a heating device

Abstract

The present invention provides a method, module and device for monitoring abnormality of a heating device, which relate to the technical field of solar cell production and are applied to an ABC three-phase circuit, and include: obtaining the output current of each phase of the three-phase circuit and the number of heating elements of each phase; for any phase of the three-phase circuit, calculating the current corresponding to each heating element according to the output current and the number of heating elements; comparing the current corresponding to each heating element under any two phases of the three-phase circuit, and outputting an abnormal alarm signal when the phase difference exceeds a threshold, so as to solve the problem that the existing heating process relies on manual monitoring, has hysteresis and high safety risks.

Description

Technical Field

[0001] The present invention relates to the technical field of solar cell production, and in particular to a method, module and device for monitoring abnormality of a heating device. Background Art

[0002] The production of solar cells is a complex process involving multiple steps and equipment. During the heating process, the heavy electric heating wire of the control system may be damaged during operation due to excessive current, poor heat dissipation, surface oxidation corrosion, etc., which may lead to loss of heating function, circuit short circuit and fire risk, increased energy consumption, and system fault spread. Therefore, it is important to judge and warn of faults during the heating process, which can reduce the risk of fire and provide early warning of problems.

[0003] However, existing abnormal monitoring of the heating process is often discovered only after the device is damaged, and therefore mostly relies on manual judgment or monitoring, which has a lag in handling abnormal problems in the heating process and can lead to greater safety risks. Summary of the invention

[0004] In order to overcome the above technical defects, the purpose of the present invention is to provide a method, module and device for monitoring abnormalities of a heating device, so as to solve the problem that the existing heating process relies on manual monitoring, has lag and high safety risks.

[0005] The present invention discloses a method for monitoring abnormality of a heating device, which is applied to an ABC three-phase circuit, and comprises:

[0006] Obtain the output current of each phase of the three-phase circuit and the number of heating elements of each phase;

[0007] For any phase of the three-phase circuit, the current corresponding to each heating element is calculated according to the output current and the number of heating elements;

[0008] The current corresponding to each heating element under any two phases of the three-phase circuit is compared, and when the phase difference exceeds a threshold value, an abnormal alarm signal is output.

[0009] Preferably, the output current of each phase of the three-phase circuit is sampled in real time to perform real-time monitoring.

[0010] Preferably, when the current difference between any two phases corresponding to each heating element exceeds a threshold value, the position of the abnormality is determined according to the difference.

[0011] Preferably, determining the location of the abnormality according to the difference comprises:

[0012] The threshold, denoted as H, is set to be no less than 1;

[0013] When the difference between the currents corresponding to each heating element in the i-phase and j-phase circuits is greater than H, the heating element in the i-phase circuit is abnormal;

[0014] When the difference between the currents corresponding to each heating element in the i-phase and j-phase circuits is less than -H, the heating element in the j-phase circuit is abnormal;

[0015] Among them, phases i and j are any two phases in the ABC three-phase circuit.

[0016] Preferably, before outputting the abnormal alarm signal, the method further comprises:

[0017] Resample multiple times within a preset time period, and record the number of times the current difference corresponding to each heating element under the two phases exceeds the threshold;

[0018] When the preset number of times is exceeded, an abnormal alarm is output.

[0019] Preferably, before outputting the abnormal alarm signal, the method further comprises:

[0020] When the current difference between any two phases of each heating element exceeds the threshold, the duration is recorded. When the duration exceeds the preset time period, an abnormal alarm is output.

[0021] Preferably, the obtaining of the output current of each phase of the three-phase circuit includes:

[0022] The output current is obtained from the power regulator, and the output current of each phase of the three-phase circuit is calculated according to the output current.

[0023] The present invention also provides a heating device abnormality monitoring module, comprising:

[0024] An acquisition unit, used for acquiring the output current of each phase of the three-phase circuit and the number of heating elements of each phase;

[0025] A calculation unit, for any phase of the three-phase circuit, calculates the current corresponding to each heating element according to the output current and the number of heating elements;

[0026] The execution unit compares the current corresponding to each heating element under any two phases of the three-phase circuit, and outputs an abnormal alarm signal when the difference exceeds a threshold.

[0027] The present invention also provides a heating device, which uses the above-mentioned heating device abnormality monitoring module.

[0028] Compared with the prior art, the above technical solution has the following beneficial effects:

[0029] The present application provides a method, module and device for monitoring abnormalities in a heating device. The method reads the output current of each phase in a three-phase circuit through the output of a power regulator, calculates the current corresponding to each heating element by using the read current of each phase and the number of heating elements on the hardware, subtracts the obtained currents from each other between any two phases, monitors each heating element, and issues an abnormality warning when the difference between any two phases exceeds a threshold. No additional hardware cost is required, and real-time monitoring is performed during the heating process. Hardware abnormalities are actively and quickly alarmed, thereby solving the problem of relying on manual monitoring in the existing heating process, which has lags and high safety risks. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A method flow chart of an embodiment of a method, module and device for monitoring abnormality of a heating device according to the present invention;

[0031] Figure 2 A schematic diagram of a method specific flow of an abnormality monitoring method, module and device for a heating device according to the present invention;

[0032] Figure 3 A module schematic diagram of an abnormality monitoring method, module and device embodiment of a heating device according to the present invention.

[0033] Reference numerals:

[0034] 4- heating device abnormality monitoring module; 41- acquisition unit; 42- calculation unit; 43- execution unit. DETAILED DESCRIPTION

[0035] The advantages of the present invention are further described below in conjunction with the accompanying drawings and specific embodiments.

[0036] Exemplary embodiments will be described in detail herein, examples of which are shown in the accompanying drawings. When the following description refers to the drawings, the same numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present disclosure. Instead, they are merely examples of devices and methods consistent with some aspects of the present disclosure as detailed in the appended claims.

[0037] The terms used in this disclosure are for the purpose of describing specific embodiments only and are not intended to limit the disclosure. The singular forms of "a", "said" and "the" used in this disclosure and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0038] It should be understood that although the terms first, second, third, etc. may be used in the present disclosure to describe various information, such information should not be limited to these terms. These terms are only used to distinguish the same type of information from each other. For example, without departing from the scope of the present disclosure, the first information may also be referred to as the second information, and similarly, the second information may also be referred to as the first information. Depending on the context, the word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining".

[0039] In the description of the present invention, it is necessary to understand that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0040] In the description of the present invention, unless otherwise specified and limited, it should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a mechanical connection or an electrical connection, or it can be the internal connection between two components. It can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to the specific circumstances.

[0041] In the following description, the suffixes such as "module", "component" or "unit" used to represent elements are only used to facilitate the description of the present invention, and have no specific meanings. Therefore, "module" and "component" can be used interchangeably.

[0042] Example: This embodiment provides a method for monitoring abnormalities of a heating device, which is applied to an ABC three-phase circuit. The output current of the heating device under actual operating conditions is detected by combining software methods and hardware devices. When an abnormality occurs, the system is warned to prompt the operator, thereby improving the immediacy of abnormal response and reducing safety risks. For details, see Figure 1-Figure 2 ,include:

[0043] S10: Obtaining the output current of each phase of the three-phase circuit and the number of heating elements of each phase;

[0044] In this embodiment, in order to improve the accuracy and immediacy of the monitoring results, the output current of each phase of the three-phase circuit is sampled in real time for real-time monitoring. Specifically, the acquisition of the output current of each phase of the three-phase circuit includes: acquiring the output current from the power regulator, and calculating the output current of each phase of the three-phase circuit according to the output current. The power regulator is mainly used to adjust the power in the AC circuit. In heating applications, the power regulator can be used to accurately control the heating power (output voltage) and maintain constant temperature conditions. It can also realize soft start and soft stop of the load, and control each phase circuit after the following abnormal alarm signal.

[0045] It is understandable that the output current of each phase is determined according to the output of the power regulator. Specifically, a power regulator with communication function can be set to read the current value of each phase through the communication interface. For example, the RK33P three-phase power and voltage regulator integrated power regulator can read IA, IB, and IC through communication to represent the current values ​​of phase A, phase B, and phase C respectively; it can also be calculated and determined by a preset formula, and determined by hardware (sensors, etc.). It is understandable that other public methods that can replace the above calculations can also be used, which can be applied according to actual scenarios.

[0046] S20: For any phase of the three-phase circuit, calculate the current corresponding to each heating element according to the output current and the number of heating elements;

[0047] In this embodiment, for any item in the ABC three-phase circuit, the ratio of the output current and the number of heating elements (wires) is calculated (i.e., the current corresponding to each heating element). In theory, since the same heating element (electric heating wire) is used in the heating device, although the number of each phase may be different, the ratio of the output current and the number of heating elements in each phase should be consistent, that is, the current corresponding to each heating element corresponding to each phase circuit) is theoretically consistent. In actual application, due to the loss of the circuit itself or the fluctuation in the relative range, this parameter is used to monitor the status of each heating element. When any heating element in any phase circuit is abnormal, the current corresponding to each heating element in the phase will cause a large change. As an example, a monitoring value is obtained under normal conditions, but when any heating element in one of the phases is damaged, the output current will become smaller, because only the remaining heating element is working, but at this time, the output current still needs to calculate the current corresponding to each heating element corresponding to the total number of heating elements. At this time, the current corresponding to each heating element will become smaller, while the current corresponding to each heating element in other phases is still normal. At this time, the abnormality can be found by comparing any two phases.

[0048] As shown in the figure, "A phase current / A phase heating tube" refers to the ratio of the current of phase A to the number of electric heating wires of the A phase heating tube in a three-phase circuit. This ratio can determine the working state and load condition of each electric heating wire under the A phase current, that is, the current corresponding to each heating element under the above phase A. The same applies to phases B and C.

[0049] S30: comparing the current corresponding to each heating element under any two phases of the three-phase circuit, and when the phase difference exceeds a threshold, outputting an abnormal alarm signal.

[0050] In this embodiment, the threshold value is set to be no less than 1, that is, if the difference between any two phases is greater than 1, it is judged to be abnormal. Specifically, as an illustration, when judging, the phase difference between any two phases is realized by taking the absolute value after the difference. For the monitoring values ​​of any two phases in the three-phase circuit, if the subtraction value is less than 1, it means that the equipment is operating normally (it may be due to the fluctuation caused by the circuit layout itself). If one of the heating wires in one item is abnormal, the ratio will be low, and at this time, one of the subtraction values ​​will exceed 1. Therefore, when any heating element in any item is abnormal, the absolute value of the difference between the monitoring values ​​of any two phases will be greater than 1.

[0051] Specifically, as mentioned above, the phase difference of the current corresponding to each heating element under any two phases is determined by taking the absolute value after difference, and compared with the threshold. Since the absolute value is taken, the positive and negative difference cases will be included. Therefore, the location of the abnormality can be determined according to the difference (with positive and negative representations). For the convenience of description, the threshold is recorded as H; when the difference formed by the difference of the i and j phase circuit monitoring values ​​is greater than H, the heating element under the i phase circuit is abnormal; when the difference formed by the difference of the i and j phase circuit monitoring values ​​is less than -H, the heating element under the j phase circuit is abnormal; wherein, i and j phases are any two phases in the ABC three-phase circuit.

[0052] Based on the above examples, if the A-phase monitoring value - the B-phase monitoring value > 1, the heating element in the A-phase circuit is abnormal; if the A-phase monitoring value - the B-phase monitoring value <-1, the heating element in the B-phase circuit is abnormal. The same applies to phases A and C, and the same applies to phases B and C.

[0053] It can be understood that the above threshold value can be adjusted according to the actual circuit layout of the heating device.

[0054] Furthermore, in a preferred embodiment, before outputting the abnormal alarm signal, it also includes: re-sampling multiple times within a preset time period, recording the number of times the current difference corresponding to each heating element of the two phases exceeds the threshold; when the preset number is exceeded, an abnormal alarm is output. The purpose of multiple sampling is to reduce the situation of misjudgment caused by the fluctuation of circuit voltage / current and improve the accuracy of monitoring results.

[0055] In a preferred embodiment, as an option, similar to the above purpose, in order to reduce the situation of misjudgment caused by the operation of other components of the circuit setting, in addition to multiple sampling, before outputting the abnormal alarm signal, it may also include: when the current difference corresponding to each heating element under any two phases exceeds the threshold, the duration is recorded, and when the duration exceeds the preset time period, an abnormal alarm is output, that is, the calculation of the monitoring value is maintained in this process to filter out the situation of misjudgment caused by the circuit itself.

[0056] In any of the above two implementations of reducing misjudgment, the preset time period can be set to 5S, and can be adjusted according to actual conditions.

[0057] In this embodiment, as an example, refer to Figure 2 First, read the current value feedback output by the power regulator through 485 communication, then compare the read current of each phase with the number of electric heating wires on the hardware, and subtract the obtained ratios. If the absolute value of the subtraction value is less than 1, it means that the equipment is operating normally. If one of the heating wires is abnormal, the ratio will be low. At this time, the absolute value of the subtraction will exceed 1. When the time exceeding 1 is greater than 5 seconds, the fluctuating part is filtered out, and the system will output an alarm for the problematic item, so as to feedback to the operator based on the above judgment where the heating problem is.

[0058] This embodiment also provides a heating device abnormality monitoring module 4, which executes the above heating device abnormality monitoring method. For details, see Figure 3 ,include:

[0059] The acquisition unit 41 is used to acquire the output current of each phase of the three-phase circuit and the number of heating elements of each phase; the output current of each phase can be acquired by real-time sampling and / or using a power regulator.

[0060] A calculation unit 42, for any phase of the three-phase circuit, calculates the current corresponding to each heating element according to the output current and the number of heating elements;

[0061] The execution unit 43 compares the current corresponding to each heating element in any two phases of the three-phase circuit, and outputs an abnormal alarm signal when the phase difference exceeds a threshold.

[0062] In the above-mentioned execution unit, it is also possible to specifically determine which phase has an abnormal heating element based on the difference in current corresponding to each heating element of any two phases. That is, as above, if the A phase monitoring value - the B phase monitoring value > 1, then the heating element in the A phase circuit is abnormal; if the A phase monitoring value - the B phase monitoring value <-1, then the heating element in the B phase circuit is abnormal; the same applies to the comparison between A and C, and the same applies to the comparison between B and C.

[0063] In this embodiment, based on the above-mentioned acquisition module, calculation module, and execution module, the current value is read, and the read current of each item is compared with the number of electric heating wires on the hardware to monitor whether the heating elements under each phase are in normal operation. Real-time monitoring can be carried out during the heating process, and active alarms can be issued for hardware abnormalities without relying on manual labor, thereby reducing safety risks.

[0064] This embodiment also provides a heating device, which uses the above-mentioned heating device abnormality monitoring module. The heating device of this embodiment is applied to solar cell production equipment and can also be connected to other components and / or devices to realize the application together.

[0065] Each step of the above method can be implemented by software, hardware or a combination thereof. The software-based implementation can be uploaded, downloaded or accessed remotely through communication means, including but not limited to the Internet, electronic communication, etc. Specifically, the above method can be implemented by a computer device, which can be a smart phone, tablet computer, laptop computer, desktop computer, etc. that executes the program. The computer device of this embodiment includes at least but is not limited to: a memory and a processor that can be interconnected through a system bus, and also includes multiple storage media, such as flash memory, hard disk, multimedia card, etc., on which a computer program is stored. When the program is executed by the processor, the corresponding function is realized to implement the method of the above embodiment. The memory can be coupled to the processor so that the processor can read and write information from / to the storage medium, and execute the corresponding program module to execute the above steps.

[0066] It should be noted that the embodiments of the present invention have better practicability and do not impose any form of limitation on the present invention. Any technician familiar with the field may use the technical content disclosed above to change or modify it into an equivalent effective embodiment. However, any modification or equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A method for monitoring abnormality of a heating device, characterized in that: Applied to ABC three-phase circuit, including: Obtain the output current of each phase of the three-phase circuit and the number of heating elements of each phase; For any phase of the three-phase circuit, the current corresponding to each heating element is calculated according to the output current and the number of heating elements; the current corresponding to each heating element under any two phases in the three-phase circuit is compared, and when the phase difference exceeds a threshold, an abnormal alarm signal is output.

2. The method for monitoring abnormality of a heating device according to claim 1, characterized in that: The output current of each phase of the three-phase circuit is sampled in real time for real-time monitoring.

3. The method for monitoring abnormality of a heating device according to claim 1, characterized in that: When the current difference between any two phases corresponding to each heating element exceeds a threshold value, the position of the abnormality is determined according to the difference.

4. The method for monitoring abnormality of a heating device according to claim 3, characterized in that: Determining the position of the abnormality according to the difference includes: The threshold, denoted as H, is set to be no less than 1; When the difference between the currents corresponding to each heating element in the i-phase and j-phase circuits is greater than H, the heating element in the i-phase circuit is abnormal; When the difference between the currents corresponding to each heating element in the i-phase and j-phase circuits is less than -H, the heating element in the j-phase circuit is abnormal; Among them, phases i and j are any two phases in the ABC three-phase circuit.

5. The method for monitoring abnormality of a heating device according to claim 1, characterized in that: Before outputting the abnormal alarm signal, it also includes: Resample multiple times within a preset time period, and record the number of times the current difference corresponding to each heating element under the two phases exceeds the threshold; When the preset number of times is exceeded, an abnormal alarm is output.

6. The method for monitoring abnormality of a heating device according to claim 1, characterized in that: Before outputting the abnormal alarm signal, it also includes: When the current difference between any two phases of each heating element exceeds the threshold, the duration is recorded. When the duration exceeds the preset time period, an abnormal alarm is output.

7. The method for monitoring abnormality of a heating device according to claim 1, characterized in that: The step of obtaining the output current of each phase of the three-phase circuit comprises: The output current is obtained from the power regulator, and the output current of each phase of the three-phase circuit is calculated according to the output current.

8. A heating device abnormality monitoring module, characterized in that: include: An acquisition unit, used for acquiring the output current of each phase of the three-phase circuit and the number of heating elements of each phase; A calculation unit, for any phase of the three-phase circuit, calculates the current corresponding to each heating element according to the output current and the number of heating elements; The execution unit compares the current corresponding to each heating element under any two phases of the three-phase circuit, and outputs an abnormal alarm signal when the phase difference exceeds a threshold.

9. A heating device, characterized in that: The heating device abnormality monitoring module described in claim 8 above is used.

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