MPC-based high-precision ceramic sintering process improvement method

Abstract

The invention relates to an MPC-based high-precision ceramic sintering process improvement method, and belongs to the technical field of ceramic material manufacturing processes. The MPC-based high-precision ceramic sintering process improvement method comprises the following steps: data acquisition and modeling: acquiring temperature data in a sintering furnace in real time by a plurality of temperature sensors, and establishing a dynamic model of the sintering furnace; a model prediction control algorithm is designed, an MPC controller is designed according to the established dynamic model, and the controller can predict the temperature change trend in a period of time in the future; by optimizing the control strategy, the energy consumption can be reduced, the production cost can be reduced, the temperature sensors can comprehensively cover the whole sintering area, the multiple temperature sensors are used for collecting temperature information of different positions in the sintering process in real time, accurate data are improved, and quick response of the system is achieved. And meanwhile, the quality consistency of ceramic products can be improved, and the requirements of high-end markets are met.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic material manufacturing process, in particular to a method for improving a high-precision ceramic sintering process based on MPC. Background Art

[0002] Ceramic sintering is a very important step in the process of manufacturing ceramic materials. It refers to heating the formed ceramic green body at a high temperature, but the temperature is lower than the melting point of the raw materials, to promote the bonding between particles, thereby improving the mechanical strength, density and hardness of the product. This process usually causes the green body to shrink and can improve its physical and chemical stability.

[0003] In the ceramic sintering process, temperature control is one of the key factors affecting product quality. Existing temperature control systems often rely on simple PID controllers or other basic control algorithms. These methods have problems such as slow response speed and low adjustment accuracy when dealing with complex working conditions. With the development of Industry 4.0, higher requirements are placed on the control of the ceramic sintering process, and more precise and efficient control strategies are needed to ensure the consistency and stability of product quality. Summary of the invention

[0004] Based on this, it is necessary to provide an improved method for the high-precision ceramic sintering process based on MPC to address the problems of slow response speed and low adjustment accuracy when dealing with complex working conditions.

[0005] MPC-based high-precision ceramic sintering process improvement method, including:

[0006] S1: Data collection and modeling: multiple temperature sensors collect temperature data in the sintering furnace in real time and establish a dynamic model of the sintering furnace;

[0007] S2: Model predictive control algorithm design. Based on the established dynamic model, an MPC controller is designed. The controller can predict the temperature change trend in the future and calculate the optimal control quantity through the optimization algorithm.

[0008] S3: Control execution and feedback, transmit the control signal output by the MPC controller to the heating element to achieve precise control of the temperature in the sintering furnace, monitor the actual temperature in real time, and feed back the data to the MPC controller;

[0009] S4: System integration and monitoring, integrating the above parts into a control system, operating and monitoring through the human-machine interface, and providing alarm function.

[0010] In one of the embodiments, a plurality of the temperature sensors need to be installed at key positions of the sintering furnace to ensure full coverage of the entire sintering area, and to use the plurality of temperature sensors to collect temperature information at different positions during the sintering process in real time.

[0011] In one embodiment, the dynamic model includes a mathematical model of a heat conduction model and a heat radiation model.

[0012] In one of the embodiments, the MPC controller needs to use a linear or nonlinear programming method to solve the control problem, and consider multiple objective functions such as minimizing energy consumption and minimizing temperature difference to perform algorithm optimization.

[0013] In one embodiment, the system integration includes the above-mentioned temperature sensor, heating element, MPC controller and human-computer interaction interface.

[0014] In one of the embodiments, the monitoring has an abnormality detection capability, and automatically issues an alarm when it detects that the temperature deviates from a preset range, and takes corresponding measures to avoid accidents.

[0015] In one embodiment, constraints are set in the MPC controller, and the constraints include an upper temperature limit, a lower temperature limit, and a maximum power limit of the heating element.

[0016] In one embodiment, the human-computer interaction interface facilitates operators to set parameters, view status and alarm information.

[0017] In one embodiment, system identification techniques are used to calibrate model parameters to improve the accuracy and robustness of the model.

[0018] The MPC-based high-precision ceramic sintering process improvement method provided by the present invention can significantly improve the accuracy and stability of temperature control. By optimizing the control strategy, it can reduce energy consumption, reduce production costs, and achieve comprehensive coverage of the entire sintering area by temperature sensors. Multiple temperature sensors are used to collect temperature information at different positions during the sintering process in real time, improve accurate data, and achieve rapid response of the system. At the same time, it helps to improve the quality consistency of ceramic products and meet the needs of the high-end market. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the present invention or the prior art, a brief introduction will be given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] Figure 1 It is a system structure block diagram of the method for improving the high-precision ceramic sintering process based on MPC of the present invention;

[0021] Figure 2The MPC controller workflow diagram of the MPC-based high-precision ceramic sintering process improvement method of the present invention;

[0022] Figure 3 It is a core code example of the method for improving the high-precision ceramic sintering process based on MPC of the present invention;

[0023] Figure 4 The present invention is a flow chart of the method for improving the high-precision ceramic sintering process based on MPC. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are 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.

[0025] It should be noted that when a component is referred to as being "fixed to" or "disposed on" another component, it may be directly on the other component or there may be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may be a central component at the same time. The terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used in the specification of the present invention are for illustrative purposes only and do not represent the only implementation method.

[0026] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0027] In the present invention, unless otherwise clearly specified and limited, a first feature being “above” or “below” a second feature may mean that the first feature is directly in contact with the second feature, or the first feature and the second feature are indirectly in contact through an intermediate medium. Moreover, a first feature being “above”, “above” or “above” a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “below”, “below” or “below” a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0028] Unless otherwise defined, all technical and scientific terms used in the specification of the present invention have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used in the specification of the present invention includes any and all combinations of one or more related listed items.

[0029] Combine the following Figure 1-Figure 4 The invention describes the improved method of the high-precision ceramic sintering process based on MPC.

[0030] In one embodiment, a method for improving a high-precision ceramic sintering process based on MPC includes:

[0031] S1: Data collection and modeling: multiple temperature sensors collect temperature data in the sintering furnace in real time and establish a dynamic model of the sintering furnace;

[0032] In this embodiment, a plurality of the temperature sensors need to be installed at key positions of the sintering furnace to ensure full coverage of the entire sintering area, and to use the plurality of temperature sensors to collect temperature information at different positions during the sintering process in real time.

[0033] The dynamic model includes a mathematical model of a heat conduction model and a heat radiation model.

[0034] The model parameters are corrected using system identification techniques to improve the accuracy and robustness of the model.

[0035] S2: Model predictive control algorithm design. Based on the established dynamic model, an MPC controller is designed. The controller can predict the temperature change trend in the future and calculate the optimal control quantity through the optimization algorithm.

[0036] In this embodiment, the MPC controller needs to use a linear or nonlinear programming method to solve the control problem, and consider multiple objective functions such as minimizing energy consumption and minimizing temperature difference to perform algorithm optimization.

[0037] The MPC controller is provided with constraints, which include an upper temperature limit, a lower temperature limit, and a maximum power limit of the heating element.

[0038] The optimal control quantity is calculated through the optimization algorithm to achieve the set temperature target.

[0039] S3: Control execution and feedback, transmit the control signal output by the MPC controller to the heating element to achieve precise control of the temperature in the sintering furnace, monitor the actual temperature in real time, and feed back the data to the MPC controller;

[0040] In this embodiment, signal transmission: the control instruction output by the MPC controller is sent to the heating element in the sintering furnace.

[0041] Temperature regulation: The heating element adjusts its working state according to the control signal received to achieve precise control of the internal temperature of the sintering furnace.

[0042] Closed-loop feedback: Monitor the actual temperature in real time and feed the data back to the MPC controller for prediction and control adjustment in the next cycle.

[0043] Specifically, the control signal output by the MPC controller is transmitted to the heating element to achieve precise control of the temperature in the sintering furnace. The actual temperature is monitored in real time and the data is fed back to the MPC controller for the next prediction and control.

[0044] S4: System integration and monitoring, integrating the above parts into a control system, operating and monitoring through the human-machine interface, and providing alarm function.

[0045] In this embodiment, the system integration includes the above-mentioned temperature sensor, heating element, MPC controller and human-computer interaction interface.

[0046] The monitoring system has the capability of detecting abnormalities, and when it detects that the temperature deviates from a preset range, it automatically issues an alarm and takes corresponding measures to avoid accidents.

[0047] The human-machine interactive interface is convenient for operators to set parameters, view status and alarm information. When the temperature is detected to deviate from the preset range, an alarm is automatically issued and corresponding measures are taken to avoid accidents.

[0048] Experimental verification:

[0049] Experimental setup: Build a complete experimental platform, including a standard-sized sintering furnace, various types of temperature sensors and a programmable controller.

[0050] Test process: Conduct multiple experiments under different working conditions to compare the effects of traditional PID control and MPC control.

[0051] Result analysis: The experimental data were recorded and analyzed to prove the superior performance of the MPC method in improving temperature control accuracy and reducing energy consumption.

[0052] It should be noted that the MPC controller, temperature sensor, heating element and human-computer interaction interface in the above description are all devices with relatively mature application of existing technologies. The specific models can be selected according to actual needs. At the same time, the MPC controller, temperature sensor, heating element and human-computer interaction interface can be powered by a built-in power supply or by AC power. The specific power supply method is selected according to the situation and will not be elaborated here.

[0053] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0054] The above-described embodiments only express several implementation methods of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the present invention. It should be pointed out that, for a person of ordinary skill in the art, several modifications and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the attached claims.

Claims

1. A method for improving high-precision ceramic sintering process based on MPC, characterized in that: include: S1: Data collection and modeling: multiple temperature sensors collect temperature data in the sintering furnace in real time and establish a dynamic model of the sintering furnace; S2: Model predictive control algorithm design. Based on the established dynamic model, an MPC controller is designed. The controller can predict the temperature change trend in the future and calculate the optimal control quantity through the optimization algorithm. S3: Control execution and feedback, transmit the control signal output by the MPC controller to the heating element to achieve precise control of the temperature in the sintering furnace, monitor the actual temperature in real time, and feed back the data to the MPC controller; S4: System integration and monitoring, integrating the above parts into a control system, operating and monitoring through the human-machine interface, and providing alarm function.

2. The method for improving the high-precision ceramic sintering process based on MPC according to claim 1, characterized in that: A plurality of the temperature sensors need to be installed at key positions of the sintering furnace to ensure full coverage of the entire sintering area, and to use the plurality of temperature sensors to collect temperature information at different positions during the sintering process in real time.

3. The method for improving the high-precision ceramic sintering process based on MPC according to claim 1, characterized in that: The dynamic model includes a mathematical model of a heat conduction model and a heat radiation model.

4. The method for improving the high-precision ceramic sintering process based on MPC according to claim 1, characterized in that: The MPC controller needs to use linear or nonlinear programming methods to solve the control problem, and consider multiple objective functions such as minimizing energy consumption and minimizing temperature difference to perform algorithm optimization.

5. The method for improving the high-precision ceramic sintering process based on MPC according to claim 1, characterized in that: The system integration includes the above-mentioned temperature sensor, heating element, MPC controller and human-computer interaction interface.

6. The method for improving the high-precision ceramic sintering process based on MPC according to claim 1, characterized in that: The monitoring system has the capability of detecting abnormalities, and when it detects that the temperature deviates from a preset range, it automatically issues an alarm and takes corresponding measures to avoid accidents.

7. The method for improving the high-precision ceramic sintering process based on MPC according to claim 4, characterized in that: The MPC controller is provided with constraints, which include an upper temperature limit, a lower temperature limit, and a maximum power limit of the heating element.

8. The method for improving the high-precision ceramic sintering process based on MPC according to claim 1, characterized in that: The human-machine interaction interface facilitates operators to set parameters, view status and alarm information.

9. The method for improving the high-precision ceramic sintering process based on MPC according to claim 1, characterized in that: The model parameters are corrected using system identification techniques to improve the accuracy and robustness of the model.

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