Resistance wire reliability monitoring control system and control method

Abstract

The invention relates to a resistance wire reliability monitoring control system and a control method, in particular to a current and temperature monitoring control system and a control method for a resistance heating wire of a thermoforming furnace. Comprising a current transformer used for monitoring the current of a resistance wire; the solid-state relay is used for controlling the on-off of the current of the resistance wire; the thermocouple sensor is used for monitoring the temperature of a heating area of the heating furnace; the reliability data monitoring control module is used for system data acquisition and resistance wire heating control; the man-machine operation interface is used for inputting parameters and checking resistance reliability related data; the resistance wire serves as a heating element; the power distribution cabinet is used for installing and fixing all elements of the monitoring control system. The current and temperature states of the resistance wire are monitored and controlled in a multi-dimensional manner, and a mode of parallel linear heating and pulse heating is adopted, so that the problems of resistor aging, short circuit and fusing caused by long-time high-temperature and high-power work of the resistance wire are avoided, and timely monitoring, control and early warning of the reliability of the resistance wire are realized.

Description

Technical Field

[0001] The invention belongs to the field of industrial automation, and in particular relates to a reliability monitoring control system and a control method for a heating wire of a hot forming furnace. Background Art

[0002] In the hot forming industry, the resistance wire is the core component of the heating equipment, and its working state directly affects the heating efficiency and the quality of hot forming parts. However, due to the long-term high-temperature working environment of the resistance wire, the heat conduction is uneven, which can easily lead to local high temperature, causing problems such as resistance wire aging, short circuit, and melting, which not only affects production efficiency, but may also cause serious safety accidents. At present, most heating control systems on the market focus on temperature control, lack of real-time monitoring and intelligent regulation of the resistance wire state, and it is difficult to effectively prevent heating wire abnormalities, resulting in production interruptions and safety hazards. Summary of the invention

[0003] In order to solve the problems of heating resistance wire in hot forming furnace aging, short circuit and melting due to long-term high-power and high-temperature operation due to a single monitoring and control method, which in turn leads to equipment shutdown and line stoppage, the present invention provides a resistance wire reliability monitoring control system and control method, which can realize accurate monitoring of the resistance wire state through multi-dimensional measurement of temperature and current, and adopt an optimized control method to adjust the resistance wire heating mode, thereby improving the stability and safety of the resistance wire heating process, extending the equipment life, reducing the overall energy consumption and maintenance cost of the equipment, and improving production efficiency.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0005] The present invention provides a resistance wire reliability monitoring and control system, which is composed of the following parts:

[0006] Current transformer, used to receive the AC signal of the resistance wire and convert it into a safe current signal to accurately detect the current state of the resistance wire;

[0007] Solid-state relay, used to control the current on and off of the resistance wire, adjust the resistance wire heating mode regulation and safety control;

[0008] Thermocouple sensor is used to measure the temperature of the heating area and is placed near the resistance wire heating area.

[0009] The reliability data monitoring and control module, as the data acquisition and processing center, is responsible for receiving the current and temperature signals from the current transformer and thermocouple sensor, executing logic control, and outputting control signals;

[0010] Human-computer interaction interface, providing a user-friendly operation interface, including but not limited to the temperature control page and the current monitoring page, which are used to set and monitor the heating mode and current status of the resistance wire and display safety warning information;

[0011] The resistance wire, as a heating element, has a heating mode that can be set by the human-machine interface and controlled by the reliability data monitoring control module, including pulse heating and linear output pulse width heating modes;

[0012] Distribution cabinet, used to carry and fix the electrical components in the system.

[0013] Furthermore, the resistor wire reliability monitoring and control system detects the reliability of the resistor wire through temperature signal and current signal. The temperature signal is obtained through a thermocouple sensor. The signal information is a local area signal with a lag, which can easily cause local overheating of the resistor wire and melting. A current transformer is added to obtain the resistor wire current signal to realize real-time monitoring of the resistor wire current signal. By comparing the set current of the resistor wire and the actual output current, the resistance value of the resistor wire is calculated, and reliability indicators such as the degree of aging of the resistor wire and whether there is a risk of melting are evaluated, thereby realizing control and monitoring of the entire life cycle of the resistor wire.

[0014] Furthermore, the resistance wire reliability monitoring and control system uses a reliability data monitoring control module to control the on and off current of the resistance wire through a solid-state relay, thereby increasing the heating method of the resistance wire. Not only can a constant-power linear output pulse width heating method be used, but also the solid-state relay can be used to control the on and off current of the resistance wire for pulse heating. The combination of multiple heating methods is beneficial to the heat conduction around the resistance wire to avoid overheating of the resistance wire; on the other hand, the total energy consumption of the equipment is reduced, thereby improving the heating efficiency of the equipment.

[0015] Furthermore, the reliability data monitoring and control module of the resistor wire reliability monitoring and control system can perform overall control of the resistor wires in the equipment through solid-state relays. According to needs, the heating parameters and heating areas can be independently set through the human-machine interface. Through the system's built-in control algorithm, the number of resistor wires put into work can be planned and coordinated according to the target heating temperature and heating speed. Under the premise of ensuring the target temperature, energy saving and resistor wire reliability are comprehensively considered, the resistor wire output pulse is optimized, the same resistor wire is avoided from working at high power for a long time, the aging of the resistor wire is delayed, the life of the resistor wire is extended, and the overall energy consumption of the equipment is reduced.

[0016] Furthermore, the resistor wire reliability monitoring and control system sets a certain number of resistor wires as spare resistor wires, and uses solid-state relays to isolate them during normal operation. When some resistor wires in the system are blown or damaged by other reasons, the damaged resistor wires can be isolated in time by the solid-state relays, and the spare resistor wires can be activated to ensure the normal operation of the equipment and avoid line stoppages and production stoppages. When the equipment is maintained, the damaged resistor wire can be replaced.

[0017] Furthermore, the present invention provides a resistance wire reliability monitoring and control method, comprising the following steps:

[0018] Step S1: input the selected heating area and heating curve through the human-computer interaction interface, and set the safety current and safety temperature;

[0019] Step S2: The reliability data monitoring control module determines whether the temperature and current measured by the resistance wire are less than the set safety temperature and current according to the input information. If they meet the requirements, the heating program is entered. If not, the human-computer interaction interface displays an alarm message and starts the emergency program.

[0020] Step S3: The reliability data monitoring control module controls the system to enter the heating program, and outputs the heating power according to the function based on the feedback temperature and current signals. α is the temperature control coefficient. Plan the heating method and the number of resistance wires. Adjust the heating method and output power of the resistance wires in steps. Heat quickly to the input temperature according to the input instructions.

[0021] Step S4: When the measured temperature of the heating area reaches the input temperature, the reliability data monitoring control module enters the monitoring mode and uses low energy consumption heating power to maintain the temperature.

[0022] Furthermore, the reliability data monitoring and control module of the resistance wire reliability monitoring and control method divides the heating stage into three stages. In the first stage, the set temperature is reached by rapid heating, during which linear heating is mainly used; in the second stage, pulse heating is mainly used, supplemented by linear heating, and PID control is used to achieve accurate temperature control to reach the input temperature; in the third stage, when the temperature is too high, the pulse heating curve is optimized to maintain the input temperature and reduce energy consumption.

[0023] Furthermore, the resistor wire reliability monitoring and control method can monitor the resistor wire status in real time through the solid-state relay output status and the resistor wire current signal, and can determine whether the resistor has problems such as aging, breakdown, short circuit, etc., thereby realizing resistor wire risk safety warning.

[0024] Furthermore, in the heating stage, the resistance wire reliability monitoring and control method optimizes the heating output power of the resistance wire to quickly heat it to the input temperature while ensuring the safety of the resistance wire, thereby shortening the heating time; in the insulation stage, a pulse heating method is used to optimize the heating method and power of the resistance wire, reduce energy consumption, and avoid aging and overburning of the resistance wire caused by local high temperature.

[0025] The present invention provides a resistance wire reliability monitoring control system and control method, which changes the traditional single temperature measurement method, uses a current transformer to measure the temperature and current of the resistance wire in multiple dimensions, and realizes all-round and accurate monitoring of the resistance wire state and reliability; changes the traditional single linear heating method, and realizes the parallel use of linear heating and pulse heating of the resistance wire by adding a solid-state relay, cooperates with the optimization control method, regulates the resistance wire heating method and reserves spare resistance wire. On the one hand, it avoids the resistance wire from working at high temperature for a long time, effectively conducts excess heat, avoids aging, short circuit and fusing of the resistance wire caused by local high temperature, and prolongs the life of the resistance wire; on the other hand, when part of the resistance fails, it is isolated in time by the solid-state relay, and the spare resistance wire is activated, which improves the stability and safety of the resistance wire heating process, avoids equipment shutdown and line stoppage, reduces the overall energy consumption and maintenance cost of the equipment, and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] 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 will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0027] Figure 1 It is a resistance wire reliability monitoring control system and control method system structure diagram;

[0028] Figure 2 The invention relates to a resistance wire reliability monitoring control system and a control method logic control diagram.

[0029] In the figure: 1-current transformer; 2-solid-state relay; 3-thermocouple sensor; 4-reliability data monitoring control module; 5-human-machine interface; 6-resistance wire; 7-power distribution cabinet; S is the selected heating area; T 输入 I is the input target heating temperature; 安全 is the set safe current value; I 测 The current transformer measures the current; T 安全 is the set safety temperature value; T 测 Thermocouple sensor measures temperature; P 总输出 is the total output power; P 脉冲 P is the pulse current heating power;直线 P is the linear output pulse width heating power; 脉冲节能 P is the optimized pulse current heating power in monitoring mode; 直线节能 After optimization, the linear output pulse width heating power is displayed in the monitoring mode; C1, C2, C3, C4 and C5 are functions P 总输出 The coefficient is related to the number of resistance wires used. DETAILED DESCRIPTION

[0030] In order to further illustrate the system architecture, technical solutions and implementation methods of the present invention, the following examples are used for illustration:

[0031] Reference Figure 1 , a system architecture of a resistance wire reliability monitoring and control system includes at least the following parts:

[0032] Current transformer (1): The input signal range is 0 to 150A AC, and the output is 4 to 20mA current signal, which is used to monitor the current state of the resistance wire in real time with an accuracy of ±1%.

[0033] Solid-state relay (2): High-performance SSR solid-state relay is used to support fast response and ensure the accuracy and stability of current regulation.

[0034] Thermocouple sensor (3): K-type thermocouple is used, which has a wide operating temperature range and high accuracy. It is installed near the resistance wire heating area and is used to monitor the temperature of the heating area in real time.

[0035] Reliability data monitoring and control module (4): It uses Siemens S7 series programmable logic controller (PLC), which has powerful data processing capabilities and communication functions, and serves as the data acquisition and control center.

[0036] Human-computer interaction interface (5): It adopts a touch screen design and provides an intuitive operation interface, including a temperature control page and a current monitoring page to monitor the working status of the resistance wire.

[0037] The resistance wire (6) is used as a heating element. Its heating mode can be set by the human-machine interface, including pulse heating and linear output pulse width heating, and is controlled by the reliability data monitoring control module.

[0038] The power distribution cabinet (7) integrates all electrical components, including current transformers, solid-state relays, reliability data monitoring control modules and human-machine interaction interfaces, and provides stable power supply and safety protection.

[0039] A resistance wire reliability monitoring and control system described in this implementation example detects the reliability of the resistance wire through two methods: temperature signal and current signal. The temperature signal is obtained through a thermocouple sensor. The signal information is a local area signal with a lag, which can easily cause local overheating of the resistance wire and melting. The actual current of the resistance wire is measured by a current transformer, and the resistance wire current signal is increased to achieve real-time monitoring of the resistance wire current signal. By comparing the set current of the resistance wire and the actual output current, the resistance value of the resistance wire is calculated, and the aging degree of the resistance wire and whether there is a risk of melting are evaluated, thereby achieving control and monitoring of the entire life cycle of the resistance wire.

[0040] A resistance wire reliability monitoring and control system described in the present embodiment has established a reliability data monitoring and control module, and controls the on and off of the resistance wire current through a solid-state relay, so that the resistance wire has a pulse heating mode, combined with a constant-power linear output pulse width heating. On the one hand, when the resistance wire is overheated, the solid-state relay is disconnected and the resistance wire stops heating, which is conducive to the timely conduction of heat around the resistance wire and avoids the resistance wire from melting due to local overheating. On the other hand, compared with the full-power heating mode of linear output pulse width heating, the pulse heating mode reduces the heating power while maintaining the set temperature, thereby reducing the total energy consumption of the equipment and improving the heating efficiency of the equipment.

[0041] The reliability data monitoring and control module of a resistor wire reliability monitoring and control system described in this embodiment can comprehensively control the resistor wires in the equipment through solid-state relays. According to needs, the heating parameters and heating areas can be independently set through the human-machine interface. Through the system's built-in control algorithm, the number of resistor wires put into work is planned and coordinated according to the target heating temperature and heating speed. Under the premise of ensuring the target temperature, energy saving and resistor wire reliability are comprehensively considered, the output pulse of the resistor wire is optimized, the same resistor wire is avoided from working at high power for a long time, the aging of the resistor wire is delayed, the life of the resistor wire is extended, and the overall energy consumption of the equipment is reduced.

[0042] A resistance wire reliability monitoring and control system described in this implementation example sets a certain number of resistance wires as spare resistance wires, and uses solid-state relays to isolate them during normal operation. When some resistance wires in the system are blown or damaged due to other reasons, the solid-state relays can be used to isolate the damaged resistance wires in time, and the spare resistance wires can be activated to ensure the normal operation of the equipment and avoid line stoppages and production stoppages. When the equipment is maintained, the damaged resistance wires can be replaced.

[0043] Reference Figure 2 The steps of a resistance wire reliability monitoring and control method described in this embodiment are as follows:

[0044] Step S1: Select a heating area S from the 24 temperature control areas through the human-computer interaction interface and set the temperature T of each heating area of ​​the heating furnace. 输入=940~950℃, set safety current I 安全 and safety temperature T 安全 ;

[0045] Step S2: After clicking the start button, the system will heat the area S and the heating temperature T 输入 , the current state of the resistance wire I 测 , Heating area measurement temperature T 测 The signal is transmitted to the reliability data monitoring control module;

[0046] Step S3: The reliability data monitoring control module is based on the total output power function a=0.97~0.99, generate control command;

[0047] Step S4: The reliability data monitoring control module starts 90% of the resistance wires for heating through the solid-state relay. The resistance wires are heated according to the total output power function P 总输出 Continuous heating, heating is mainly linear heating, quickly complete the first stage of heating, when the measured temperature T 测 Arrive at a*T 输入 , enter the second stage of heating;

[0048] Step S5: In the second stage of heating, the reliability data monitoring control module, according to the function P 总输出 Perform pulse and linear heating in parallel, gradually switch to pulse heating as the main method and linear heating as the auxiliary method, and stabilize the heating temperature to the set temperature T 输入 =940~950℃;

[0049] Step S6: Entering the third stage of heating, the temperature may fluctuate due to signal lag, and the reliability data monitoring control module is used according to the function P 总输出 Output, the heating method is mainly pulse heating. By adjusting the output pulse cycle of the reliability data monitoring control module, while ensuring temperature stability, avoiding local overheating of the resistance wire, reducing energy consumption, and gradually stabilizing the furnace temperature;

[0050] Step S7: When the furnace temperature reaches the set temperature and stabilizes, the reliability data monitoring control module enters the monitoring mode, and the reliability data monitoring control module automatically adjusts the heating power of the resistance wire and outputs P 脉冲节能 and P 直线节能 , periodically adjust the resistance wire heating mode and heating time to avoid long-term high-power heating of the resistance wire. While ensuring the temperature stability of the heating area, it extends the life of the resistance wire and reduces the energy consumption of the equipment.

[0051] When there is a lag between the feedback temperature and the actual temperature, the reliability data monitoring control module starts again, and adjusts the pulse heating cycle and the current heating power P by adjusting the conduction time ratio of the solid-state relay. 脉冲 Coefficient C4 prevents the resistance wire from overheating and burning due to feedback temperature lag.

[0052] The current control method used in the resistance wire reliability monitoring control method described in this embodiment is to control the resistance wire current state through a solid-state relay, which indicates that the current is being output when it is on, and that the current is stopped when it is off. The current value is the real-time current of the resistance wire, and the real-time current of the resistance wire is fed back in real time according to the feedback signal of the current transformer. The resistance wire state is determined according to the output state of the solid-state relay and the current value of the resistance wire:

[0053] (1) When the output state of the solid-state relay is outputting, and the current value of the resistor is within the normal output current range, the resistor is judged to be in normal state;

[0054] (2) When the solid-state relay is in the output state, the current value of the resistor exceeds the normal output state current range, and the resistor is judged to be abnormal. The human-computer interaction interface displays a yellow alarm message, and it is recommended to check or replace the resistor;

[0055] (3) When the solid-state relay has no output, but the current value feedback of the current transformer shows that there is current, it is determined that the resistor wire thyristor is broken down, the human-machine interface displays a red alarm message, the solid-state relay is immediately disconnected, and it is recommended to replace the resistor wire;

[0056] (4) When the solid-state relay has no output and the resistor has no current, it is determined that there is no power;

[0057] (5) When the solid-state relay has output and the resistor has no current, it is determined that the resistor is burned out, the human-machine interface displays a red alarm message, the solid-state relay is immediately disconnected, and it is recommended to replace the resistor.

[0058] The resistance wire reliability monitoring control method described in this embodiment outputs the state of the solid-state relay, and the resistance wire monitors the current I 测 and resistance output status, realizing resistance wire risk safety warning. When the system detects abnormal current or temperature exceeds the preset T 设定 range, immediately trigger an alarm, notify the operator through the human-machine interface, and automatically start the emergency processing procedure, cut off the current through the solid-state relay to prevent the resistance wire from being damaged and ensure production safety.

[0059] This invention book describes in detail the structure and function of a reliability monitoring and control system for hot forming furnace heating wires, aiming to protect the innovative points of the system, including its composition, operating principle and application field. It provides a resistance wire reliability monitoring control system and control method, which integrates advanced monitoring technology and intelligent control algorithms to achieve real-time monitoring and precise control of the working state of the resistance wire, effectively improving the stability and safety of the heating process, extending equipment life, reducing maintenance costs, and improving production efficiency and product quality. It has broad application prospects.

Claims

1. A resistance wire reliability monitoring and control system, characterized in that: It consists of the following parts: The current transformer (1) is used to receive the AC signal of the resistance wire and convert it into a safe current signal to accurately detect the current state of the resistance wire; Solid-state relay (2), used to control the current on and off of the resistance wire, adjust the resistance wire heating mode regulation and safety control; The thermocouple sensor (3) is used to measure the temperature of the heating area and is arranged near the resistance wire heating area. The reliability data monitoring control module (4) serves as a data acquisition and processing center, is responsible for receiving current and temperature signals from the current transformer and the thermocouple sensor, executing logic control, and outputting control signals; A human-computer interaction interface (5) provides a user-friendly operation interface, including but not limited to a temperature control page and a current monitoring page, for setting and monitoring the heating mode and current status of the resistance wire, and displaying safety warning information; The resistance wire (6) is used as a heating element. Its heating mode can be set by a human-machine interface, including two modes: pulse heating and linear output pulse width heating, and is controlled by a reliability data monitoring control module; The power distribution cabinet (7) is used to carry and fix the electrical components in the system.

2. A resistance wire reliability monitoring and control system according to claim 1, characterized in that: The reliability of the resistor wire is tested through temperature signal and current signal. The temperature signal is obtained through a thermocouple sensor. The signal information is a local area signal with a lag, which can easily cause local overheating of the resistor wire and melting. A current transformer is added to obtain the resistor wire current signal to achieve real-time monitoring of the resistor wire current signal. By comparing the set current of the resistor wire with the actual output current, the resistance value of the resistor wire is calculated, and reliability indicators such as the degree of aging of the resistor wire and whether there is a risk of melting are evaluated, thereby achieving control and monitoring of the resistor wire throughout its life cycle.

3. A resistance wire reliability monitoring and control system according to claim 1, characterized in that: Through the reliability data monitoring control module, the solid-state relay is used to control the on-off current of the resistor wire and increase the heating method of the resistor wire. Not only can the constant power linear output pulse width heating method be adopted, but also the solid-state relay can be used to control the on-off current of the resistor wire for pulse heating. The combination of multiple heating methods is beneficial to the heat conduction around the resistor wire to avoid overheating of the resistor wire; on the other hand, the total energy consumption of the equipment is reduced, and the heating efficiency of the equipment is improved.

4. The resistance wire reliability monitoring and control system according to claim 1, characterized in that: The reliability data monitoring and control module can coordinately control the resistance wires in the equipment through solid-state relays. According to needs, the heating parameters and heating areas can be independently set through the human-machine interface. Through the system's built-in control method, the number of resistance wires put into work is planned and coordinated according to the target heating temperature and heating speed. Under the premise of ensuring the target temperature, energy saving and resistance wire reliability are comprehensively considered, the resistance wire output pulse is optimized, the same resistance wire is avoided from working at high power for a long time, the aging of the resistance wire is delayed, the life of the resistance wire is extended, and the overall energy consumption of the equipment is reduced.

5. The resistance wire reliability monitoring and control system according to claim 1, characterized in that: The system sets up a certain number of resistors as spare resistors, which are isolated by solid-state relays during normal operation. When some resistors in the system are blown or damaged by other reasons, the solid-state relays can be used to isolate the damaged resistors in time, and the spare resistors can be activated to ensure the normal operation of the equipment and avoid line stoppages. When the equipment is maintained, the damaged resistors can be replaced.

6. A resistance wire reliability monitoring and control method, applicable to any one of claims 1 to 5, characterized in that: The following steps are involved: Step S1: input the selected heating area and heating curve through the human-computer interaction interface, and set the safety current and safety temperature; Step S2: The reliability data monitoring control module determines whether the temperature and current measured by the resistance wire are less than the set safety temperature and current according to the input information. If they meet the requirements, the heating program is entered. If not, the human-computer interaction interface displays an alarm message and starts the emergency program. Step S3: The reliability data monitoring control module controls the system to enter the heating program, and outputs the heating power according to the function based on the feedback temperature and current signals. α is the temperature control coefficient. Plan the heating method and the number of resistance wires. Adjust the heating method and output power of the resistance wires in steps. Heat quickly to the input temperature according to the input instructions. Step S4: When the measured temperature of the heating area reaches the input temperature, the reliability data monitoring control module enters the monitoring mode and uses low energy consumption heating power to maintain the temperature.

7. A resistance wire reliability monitoring and control method according to claim 6, characterized in that: The reliability data monitoring and control module divides the heating stage into three stages. In the first stage, the set temperature is reached by rapid heating, during which linear heating is mainly used; in the second stage, pulse heating is mainly used, supplemented by linear heating, to achieve accurate temperature control and reach the input temperature; In the third stage, when the temperature is too high, the pulse heating curve is optimized to maintain the input temperature and reduce energy consumption.

8. A resistance wire reliability monitoring and control method according to claim 6, characterized in that: Through the output status of the solid-state relay and the resistor wire current signal, the resistor wire status can be monitored in real time, and it can be determined whether the resistor has problems such as aging, breakdown, short circuit, etc., to achieve resistor wire risk safety warning.

9. A resistance wire reliability monitoring and control method according to claim 6, characterized in that: In the heating stage, by optimizing the heating output power of the resistance wire, the resistance wire is quickly heated to the input temperature while ensuring its safety, thus shortening the heating time. During the insulation stage, pulse heating is used to optimize the heating method and power of the resistance wire, reduce energy consumption, and avoid resistance wire aging and overburning caused by local high temperature.

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