Box-type furnace intelligent heat treatment production line management system

Abstract

The invention provides a box-type furnace intelligent heat treatment production line management system, which relates to the field of management systems and comprises a PLC module, a data acquisition module, a production scheduling module, a quality inspection module, a process management module and an intelligent production scheduling module. The data acquisition module is used for acquiring real-time working state data and process data of each heat treatment device of the intelligent heat treatment production line of the box-type furnace from the PLC module and integrating the real-time working state data and the process data to form real-time production line data; the production scheduling module timely schedules each production batch according to the production task information of the intelligent heat treatment production line of the box-type furnace, and transfers the production batch in processing in each process node of the intelligent heat treatment production line of the box-type furnace; and the intelligent production scheduling module adjusts the task state in real time according to the current production task information of the box-type furnace intelligent heat treatment production line and the change of the working state of the heat treatment equipment in the data acquisition module. The production task is adjusted in real time according to the change of the working state of the heat treatment equipment, and the production scheduling reliability of the heat treatment equipment is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of management systems, and in particular to a box-type furnace intelligent heat treatment production line management system. Background Art

[0002] Heat treatment equipment is used to perform heat treatment on materials or workpieces. Heat treatment equipment includes box-type furnaces. Current box-type furnaces can perform heat treatment on workpieces better.

[0003] A heat treatment production line usually includes various identical or different heat treatment equipment. Existing heat treatment production line management systems, such as CN119105349A, a method for a thick steel plate heat treatment centralized control management system, have the following problems: they only detect the equipment status, lack an intelligent scheduling module, and fail to adjust production tasks in real time according to changes in the working status of the heat treatment equipment, thus affecting the reliability of scheduling of the heat treatment equipment. Summary of the invention

[0004] The present invention provides a box-type furnace intelligent heat treatment production line management system to solve the technical problems raised by the above-mentioned background technology.

[0005] In order to solve the above technical problems, the present invention discloses a box-type furnace intelligent heat treatment production line management system, comprising:

[0006] PLC module: used to obtain the working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line through the communication network and heat treatment equipment self-diagnosis;

[0007] Data acquisition module: used to obtain the real-time working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line from the PLC module, and integrate them into real-time production line data;

[0008] Production scheduling module: Users log in new production batches of heat-treated objects on the box-type furnace intelligent heat treatment production line through the production scheduling module; the production scheduling module timely schedules each production batch according to the production task information of the box-type furnace intelligent heat treatment production line, and sends the scheduling-related instructions to the PLC module through the data acquisition module, and transfers the production batches in process to each process node of the box-type furnace intelligent heat treatment production line; the production scheduling module also notifies the quality inspection department to conduct physical and chemical inspections of the production batches in real time through the quality inspection module according to the status of the completed production tasks, and forms quality inspection reports and batch reports;

[0009] Process management module: used to set the process and process parameters for the heat-treated objects that need to be treated by the box-type furnace intelligent heat treatment production line;

[0010] Intelligent production scheduling module: used to adjust the task status in real time according to the current production task information of the box-type furnace intelligent heat treatment production line and the changes in the working status of the heat treatment equipment in the data acquisition module.

[0011] Preferably, each heat treatment equipment of the box-type furnace intelligent heat treatment production line includes:

[0012] The first acquisition module: used to collect the working status data of the heat treatment equipment of the box-type furnace intelligent heat treatment production line;

[0013] The second acquisition module: used to collect process data of heat treatment equipment in the box-type furnace intelligent heat treatment production line;

[0014] Heat treatment equipment self-diagnosis module: used to compare the working state data collected by the first acquisition module with the standard working state data range of the corresponding heat treatment equipment, and compare the process data of the heat treatment equipment collected by the second acquisition module with the corresponding set process parameter range, to determine the working state data and abnormal data in the process data of the heat treatment equipment;

[0015] Communication module: used to communicate with PLC module;

[0016] Equipment control module: used to control the operation of the heat treatment equipment of the intelligent heat treatment production line of the acquisition box furnace. The equipment control module is electrically connected to the first acquisition module, the second acquisition module, the heat treatment equipment self-diagnosis module, and the communication module respectively.

[0017] Preferably, the process data of the heat treatment equipment includes: the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the heat treatment equipment; the working state data of the heat treatment equipment includes: the actual temperature control related parameters of the heat treatment equipment, the actual working time of the heat treatment equipment;

[0018] The production task information includes: the number of the heat-treated object produced, the production batch number, and the task requirement information; the task requirement information includes: the total number of heat-treated objects, the target heat-treatment temperature range of each process of the heat-treated object, and the target heat-treatment time of each process of the heat-treated object;

[0019] The heat treatment equipment corresponding to each process of the heat treatment objects of the current production batch controls the corresponding temperature adjustment device to perform heat treatment on the heat treatment objects of the current production batch within the target heat treatment temperature range of the corresponding process.

[0020] Preferably, the data acquisition module includes:

[0021] Data acquisition unit: used to obtain the real-time working status data and process data of each heat treatment equipment of the box-type furnace intelligent heat treatment production line from the PLC module;

[0022] Data integration unit: used to integrate the real-time working status data and process data of each heat treatment equipment of the box-type furnace intelligent heat treatment production line acquired by the data acquisition unit to form real-time production line data;

[0023] Data storage unit: used to store real-time production line data;

[0024] Data transmission unit: used for data transmission between PLC modules;

[0025] The first early warning unit is used to issue an early warning after determining that there is abnormal data in the working status data and process data of the heat treatment equipment according to the real-time production line data, and determine that the heat treatment equipment corresponding to the abnormal data is the first early warning heat treatment equipment;

[0026] Working state confirmation unit: used to confirm that the working state of the first warning heat treatment equipment is an abnormal working state.

[0027] Preferably, the data acquisition module further includes:

[0028] The first calculation unit is used to calculate the actual working power evaluation value of the heat treatment equipment at each first time point during the heat treatment process of each heat treatment equipment for each production batch of heat treatment objects, after the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the heat treatment equipment is stabilized within the set process parameter range of the corresponding time period; the first time point is the time point when the actual temperature control related parameters of the heat treatment equipment are collected;

[0029] A first storage unit: used to store the actual working power evaluation value of the heat treatment equipment at each first time point;

[0030] A second early warning unit: used for issuing an early warning when the actual working power evaluation value of any heat treatment equipment is greater than the corresponding preset working power evaluation value, and determining the heat treatment equipment whose actual working power evaluation value is greater than the corresponding preset working power evaluation value as the second early warning heat treatment equipment;

[0031] First acquisition unit: after each calculation by the first calculation unit is completed, the first acquisition unit acquires the actual working power evaluation value of the target historical first time point corresponding to the current first time point; the target historical first time point corresponding to the current first time point is a continuous first time point with the current first time point, and the target first historical time point corresponds to an actual working power evaluation value;

[0032] A second calculation unit: used for calculating the actual power variation coefficient of each heat treatment equipment at a current first time point based on the first acquisition unit;

[0033] The third warning unit is used to issue a warning when the actual power variation coefficient of any heat treatment equipment at the current first time point is greater than the preset variation coefficient, and the heat treatment equipment whose actual power variation coefficient at the current first time point is greater than the preset variation coefficient is determined as the third warning heat treatment equipment;

[0034] The working state confirmation unit is also used to confirm that the working state of the second early warning heat treatment equipment and the third early warning heat treatment equipment is an abnormal working state.

[0035] Preferably, the data acquisition module further includes:

[0036] Curve construction unit: used for constructing a time point-actual temperature control related parameter change curve corresponding to each actual temperature control related parameter of each heat treatment equipment and a time point-actual working power change curve of each heat treatment equipment based on the data stored in the data storage unit during the heat treatment process of each heat treatment equipment on the heat treatment object of each production batch;

[0037] The third calculation unit is used to calculate the actual life loss value of each evaluation time of the heat treatment equipment based on the curve construction unit at the end of each evaluation time during the heat treatment process of each heat treatment equipment on the heat treatment object of each production batch;

[0038] The fourth calculation unit is used to calculate the current actual accumulated life loss value of each heat treatment equipment in the current continuous operation based on the third calculation unit; the time interval between the continuous opening or closing of the heat treatment equipment during the continuous operation and the restart is less than the first set time length;

[0039] Fourth warning unit: used for issuing a warning when the current actual accumulated life loss value of the current continuous operation of any heat treatment equipment is less than the corresponding preset comprehensive life loss value, and determining the heat treatment equipment whose current actual accumulated life loss value of the current continuous operation of the heat treatment equipment is less than the corresponding preset comprehensive life loss value as the fourth warning heat treatment equipment;

[0040] The second storage unit is used to associate and store the actual life loss value of each evaluation time, the model of the heat treatment equipment corresponding to the evaluation time, the heat treatment object number corresponding to the evaluation time, the heat treatment object process corresponding to the evaluation time, and the set process parameter range corresponding to the evaluation time.

[0041] Preferably, the third calculation unit calculates based on the following formula:

[0042] ;

[0043] is the actual life loss value of the s-th evaluation duration of the ith heat treatment equipment; The average actual working power of the time point-actual working power variation curve segment corresponding to the s-th evaluation duration of the i-th heat treatment equipment; for The corresponding preset life loss value per unit time; is the duration of the sth evaluation duration of the ith heat treatment equipment; is the fluctuation life loss adjustment coefficient of the s-th evaluation time of the ith heat treatment equipment based on the corresponding time point-actual temperature control related parameter change curve segment;

[0044] The fourth calculation unit is calculated based on the following formula:

[0045] ;

[0046] is the actual accumulated life loss value of the current continuous operation of the i-th heat treatment equipment; The number of evaluation hours for the current continuous operation of the i-th heat treatment equipment; It is the actual life loss value of the i-th heat treatment equipment which is currently working continuously for the r-th evaluation time.

[0047] Preferably, the intelligent production scheduling module includes:

[0048] Acquisition and screening unit: used to obtain the current production task information of the box-type furnace intelligent heat treatment production line, and screen the remaining production tasks at the end of the current evaluation time of each heat treatment equipment;

[0049] The second acquisition unit is used to acquire data from the data acquisition module;

[0050] The third acquisition unit is used to obtain, based on the second acquisition unit, the actual life loss value of the target evaluation time corresponding to the production task of each production batch in the remaining production tasks at the end of the current evaluation time of each heat treatment equipment; the production task of the d-th production batch of the current heat treatment equipment is the same as the heat treatment object number, heat treatment object number process and heat treatment equipment model produced during the corresponding target evaluation time; the heat treatment equipment corresponding to the target evaluation time works normally;

[0051] A fifth calculation unit: used for calculating, based on the acquisition and screening unit and the third acquisition unit, the predicted completion evaluation result of each remaining production task of each heat treatment equipment without warning when the current evaluation time of each heat treatment equipment without warning ends;

[0052] ;

[0053] ;

[0054] in, is the predicted completion evaluation result of the dth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning, is the predicted cumulative life loss value of the nth heat treatment equipment without warning for the kth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning; The total number of target evaluation durations corresponding to the kth remaining production tasks of the nth heat treatment equipment without warning when the current evaluation duration of the nth heat treatment equipment without warning ends; is the actual life loss value of the mth target evaluation time corresponding to the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation time of the nth heat treatment equipment without warning ends; The duration of the mth target evaluation duration corresponding to the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation duration of the nth heat treatment equipment without warning ends; The working time of the nth heat treatment equipment without warning required by the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation time of the nth heat treatment equipment without warning ends; The corresponding maximum value of the kth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning; , They are the first evaluation weight and the second evaluation weight respectively; is the actual accumulated life loss value of the nth heat treatment equipment without warning at the end of the current evaluation time; The maximum permissible cumulative life loss value of a single continuous operation of the nth heat treatment equipment without warning;

[0055] The first determination unit is used to:

[0056] when , determine that when the current evaluation time of the nth heat treatment equipment without warning ends, the task status of the dth remaining production task of the nth heat treatment equipment without warning is predicted to be unfinishable;

[0057] when , determine that when the current evaluation time of the nth heat treatment equipment without warning ends, the task status of the dth remaining production task of the nth heat treatment equipment without warning is predicted to be complete;

[0058] Scheduling unit: used to schedule the production of each heat treatment equipment without warning based on the task status of each remaining production task of each heat treatment equipment without warning at the end of the current evaluation time of each heat treatment equipment without warning.

[0059] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments.

[0060] Compared with the prior art, the present invention has the following beneficial effects:

[0061] In the present invention, the working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line are obtained through the communication network and the self-diagnosis of the heat treatment equipment, and the abnormal data in the working status data and process data of each heat treatment equipment are determined, so as to timely discover the abnormal data of the heat treatment equipment and then give an alarm, and determine the maintenance method of the heat treatment equipment according to the abnormal data of the heat treatment equipment.

[0062] In the present invention, the production scheduling module timely schedules each production batch according to the production task information of the box-type furnace intelligent heat treatment production line, and according to the status of the completed production tasks, notifies the quality inspection department through the quality inspection module in real time to conduct physical and chemical inspections of the production batches, and forms quality inspection reports and batch reports, thereby ensuring the orderly progress of the production tasks of the present invention.

[0063] In the present invention, the intelligent production scheduling module adjusts the task status in real time according to the current production task information of the box-type furnace intelligent heat treatment production line and the changes in the working status of the heat treatment equipment in the data acquisition module, thereby ensuring the reliability of the production scheduling of the heat treatment equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0065] Figure 1 It is a schematic diagram of the framework of the system of the present invention. DETAILED DESCRIPTION

[0066] The preferred embodiments of the present invention are described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0067] In addition, in the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes, and do not specifically refer to the order or sequence, nor are they used to limit the present invention. They are only used to distinguish components or operations described with the same technical terms, and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions and technical features between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0068] The present invention provides the following embodiments

[0069] Example 1, the present invention provides a box-type furnace intelligent heat treatment production line management system, such as Figure 1 As shown, including:

[0070] PLC module: used to obtain the working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line through the communication network and heat treatment equipment self-diagnosis;

[0071] Data acquisition module: used to obtain the real-time working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line from the PLC module, and integrate them into real-time production line data;

[0072] Production scheduling module: Users log in new production batches of heat-treated objects on the box-type furnace intelligent heat treatment production line through the production scheduling module; the production scheduling module timely schedules each production batch according to the production task information of the box-type furnace intelligent heat treatment production line, and sends the scheduling-related instructions to the PLC module through the data acquisition module, and transfers the production batches in process to each process node of the box-type furnace intelligent heat treatment production line; the production scheduling module also notifies the quality inspection department to conduct physical and chemical inspections of the production batches in real time through the quality inspection module according to the status of the completed production tasks, and forms quality inspection reports and batch reports;

[0073] Process management module: used to set the process and process parameters for the heat-treated objects that need to be treated by the box-type furnace intelligent heat treatment production line;

[0074] Intelligent production scheduling module: used to adjust the task status in real time according to the current production task information of the box-type furnace intelligent heat treatment production line and the changes in the working status of the heat treatment equipment in the data acquisition module.

[0075] Preferably, each heat treatment equipment of the box-type furnace intelligent heat treatment production line includes:

[0076] The first acquisition module: used to collect the working status data of the heat treatment equipment of the box-type furnace intelligent heat treatment production line;

[0077] The second acquisition module: used to collect process data of heat treatment equipment in the box-type furnace intelligent heat treatment production line;

[0078] Heat treatment equipment self-diagnosis module: used to compare the working state data collected by the first acquisition module with the standard working state data range of the corresponding heat treatment equipment, and compare the process data of the heat treatment equipment collected by the second acquisition module with the corresponding set process parameter range, to determine the working state data and abnormal data in the process data of the heat treatment equipment;

[0079] Communication module: used to communicate with PLC module;

[0080] Equipment control module: used to control the operation of the heat treatment equipment of the intelligent heat treatment production line of the acquisition box furnace. The equipment control module is electrically connected to the first acquisition module, the second acquisition module, the heat treatment equipment self-diagnosis module, and the communication module respectively.

[0081] Preferably, the process data of the heat treatment equipment includes: the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the heat treatment equipment; the working state data of the heat treatment equipment includes: the actual temperature control related parameters of the heat treatment equipment, the actual working time of the heat treatment equipment;

[0082] The production task information includes: the number of the heat-treated object produced, the production batch number, and the task requirement information; the task requirement information includes: the total number of heat-treated objects, the target heat-treatment temperature range of each process of the heat-treated object, and the target heat-treatment time of each process of the heat-treated object;

[0083] The corresponding heat treatment equipment of each process of the heat-treated materials of the current production batch controls the corresponding temperature regulating device to perform heat treatment on the heat-treated materials of the current production batch within the target heat treatment temperature range of the corresponding process. For example, the heat-treated materials of the current production batch include 2 processes: process A (target heat treatment temperature range is 108±0.5℃) and process B (target heat treatment temperature range is 120±0.5℃). Process A is performed by heat treatment equipment a, and process B is performed by heat treatment equipment b. When heat treatment equipment a performs heat treatment on the heat-treated materials of the current production batch, the temperature regulating device of heat treatment equipment a is controlled to work, so that the actual ambient temperature of the heat treatment area of ​​the heat-treated materials in heat treatment equipment a is 108±0.5℃ (108±0.5℃ is also the target temperature of heat treatment). The process parameter range of the heat treatment of the heat treatment object of the current production batch by the heat treatment device a is set; the actual temperature is set to 108, ±0.5℃ is the temperature error range of the device); when the heat treatment device b heats the heat treatment object of the current production batch, the temperature regulating device of the heat treatment device b is controlled to work, so that the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the heat treatment device b is 120±0.5℃; the temperature regulating device can be an electric heating device, and the working power of the electric heating device can be adjusted to adjust the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the corresponding heat treatment device;

[0084] Preferably, the data acquisition module includes:

[0085] Data acquisition unit: used to obtain the real-time working status data and process data of each heat treatment equipment of the box-type furnace intelligent heat treatment production line from the PLC module;

[0086] Data integration unit: used to integrate the real-time working status data and process data of each heat treatment equipment of the box-type furnace intelligent heat treatment production line acquired by the data acquisition unit to form real-time production line data;

[0087] Data storage unit: used to store real-time production line data;

[0088] Data transmission unit: used for data transmission between PLC modules;

[0089] The first early warning unit is used to issue an early warning after determining that there is abnormal data in the working status data and process data of the heat treatment equipment according to the real-time production line data, and determine that the heat treatment equipment corresponding to the abnormal data is the first early warning heat treatment equipment;

[0090] Working state confirmation unit: used to confirm that the working state of the first warning heat treatment equipment is an abnormal working state.

[0091] The intelligent production scheduling module adjusts the task status of the heat treatment equipment whose working status is abnormal to a suspended production task, and confirms that the assigned production tasks of the heat treatment equipment with suspended production tasks are the production tasks that need to be reallocated, and reallocates the production tasks that need to be reallocated (allocate the production tasks that need to be reallocated to other heat treatment equipment of the box-type furnace intelligent heat treatment production line with the same model as the heat treatment equipment with suspended production tasks corresponding to the production tasks that need to be reallocated (including heat treatment equipment in production and spare heat treatment equipment)).

[0092] The beneficial effects of the above technical solution are:

[0093] In the present invention, the working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line are obtained through the communication network and the self-diagnosis of the heat treatment equipment, and the abnormal data in the working status data and process data of each heat treatment equipment are determined, so as to timely discover the abnormal data of the heat treatment equipment and then give an alarm, and determine the maintenance method of the heat treatment equipment according to the abnormal data of the heat treatment equipment.

[0094] In the present invention, the production scheduling module timely schedules each production batch according to the production task information of the box-type furnace intelligent heat treatment production line, and according to the status of the completed production tasks, notifies the quality inspection department through the quality inspection module in real time to conduct physical and chemical inspections of the production batches, and forms quality inspection reports and batch reports, thereby ensuring the orderly progress of the production tasks of the present invention.

[0095] In the present invention, the intelligent production scheduling module adjusts the task status in real time according to the current production task information of the box-type furnace intelligent heat treatment production line and the changes in the working status of the heat treatment equipment in the data acquisition module, thereby ensuring the reliability of the production scheduling of the heat treatment equipment.

[0096] The present invention solves the following problems raised by the background technology: the existing heat treatment production line management system, such as CN119105349A, a method of a thick steel plate heat treatment centralized control management system, has: it only detects the equipment status, lacks an intelligent scheduling module, and does not adjust the production tasks in real time according to the changes in the working status of the heat treatment equipment, affecting the reliability of the heat treatment equipment scheduling.

[0097] Embodiment 2, based on embodiment 1, the data acquisition module further includes:

[0098] The first calculation unit is used to calculate the actual working power evaluation value of the heat treatment equipment at each first time point during the heat treatment process of each heat treatment equipment for each production batch of heat treatment objects, after the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the heat treatment equipment is stabilized within the set process parameter range of the corresponding time period; the first time point is the time point when the actual temperature control related parameters of the heat treatment equipment are collected; each temperature control related parameter in the actual temperature control related parameters is collected at the same first time point, and the actual interval between adjacent first time points is preset;

[0099] A first storage unit, used to store an actual working power evaluation value of the heat treatment equipment at each first time point;

[0100] A second early warning unit: used for issuing an early warning when the actual working power evaluation value of any heat treatment equipment is greater than the corresponding preset working power evaluation value, and determining the heat treatment equipment whose actual working power evaluation value is greater than the corresponding preset working power evaluation value as the second early warning heat treatment equipment;

[0101] First acquisition unit: after each calculation by the first calculation unit is completed, the first acquisition unit acquires the actual working power evaluation value of the target historical first time point corresponding to the current first time point; the target historical first time point corresponding to the current first time point is a continuous first time point with the current first time point, and the target first historical time point corresponds to an actual working power evaluation value;

[0102] The second calculation unit is used to calculate the actual power variation coefficient of each heat treatment equipment at the current first time point based on the first acquisition unit; when the first acquisition unit does not obtain the actual working power evaluation value, the second calculation unit does not perform calculation;

[0103] The third warning unit is used to issue a warning when the actual power variation coefficient of any heat treatment equipment at the current first time point is greater than the preset variation coefficient, and the heat treatment equipment whose actual power variation coefficient at the current first time point is greater than the preset variation coefficient is determined as the third warning heat treatment equipment;

[0104] The working state confirmation unit is also used to confirm that the working state of the second early warning heat treatment equipment and the third early warning heat treatment equipment is an abnormal working state.

[0105] The first calculation unit is calculated based on the following formula:

[0106] ;

[0107] Setting a process parameter range for the i-th heat treatment equipment at the k-th first time point; is the value of the i-th heat treatment equipment and Corresponding standard working power; is the actual working power evaluation value of the i-th heat treatment equipment at the k-th time point; is the actual working power of the i-th heat treatment equipment at the k-th first time point; is obtained based on the test when the i-th heat treatment equipment is initially used ( The initial actual ambient temperature of the heat treatment area of ​​the heat treatment equipment is adjusted to After that, the actual ambient temperature of the heat treatment area of ​​the heat treatment equipment of the i-th heat treatment device is maintained at The actual working power of the i-th heat treatment equipment required);

[0108] The second calculation unit is calculated based on the following formula:

[0109] ;

[0110] is the actual power variation coefficient of the i-th heat treatment equipment at the current first time point; is the minimum value of the actual working power evaluation value at the first time point of the target history corresponding to the current first time point of the i-th heat treatment equipment; is the actual working power evaluation value of the i-th heat treatment equipment at the first time point; is the current first time point of the i-th heat treatment equipment and The difference between the first time point of the corresponding target history; is the current first time point of the i-th heat treatment equipment and The corresponding first warning value ( is determined based on the actual working power of the i-th heat treatment equipment at the current first time point; different actual working power ranges correspond to different first warning values);

[0111] Different calculation formulas are used for different heat treatment equipment. When the temperature regulating device is an electric heating device, the actual temperature control related parameters may include voltage and current. The actual working power of the electric heating device is calculated based on the voltage and current.

[0112] The beneficial effects of the above technical solution are as follows: due to the long-term use of the heat treatment equipment, the thermal efficiency of the heat treatment equipment may decrease; as a result, the actual ambient temperature of the heat treatment area of ​​the heat treatment equipment for the heat treatment object must be maintained within the corresponding set process parameter range, and the actual working power of the heat treatment equipment changes (such as increases); when the actual working power evaluation value (reflecting the instantaneous power state) and / or the actual power variation coefficient (reflecting the power fluctuation state) are abnormal, the second early warning unit and / or the third early warning unit will issue an early warning in time to remind the heat treatment equipment to be repaired, thereby ensuring the reliable use of the heat treatment equipment.

[0113] The current actual power variation coefficient is determined based on the actual working power evaluation value of the target historical first time point corresponding to the current first time point and the actual working power evaluation value of the current first time point, and the calculation is reliable.

[0114] Embodiment 3, based on embodiment 1 or 2, the data acquisition module further includes:

[0115] Curve construction unit: used for constructing a time point-actual temperature control related parameter change curve corresponding to each actual temperature control related parameter of each heat treatment equipment based on the data stored in the data storage unit during the heat treatment process of each heat treatment equipment on the heat treatment object of each production batch (the horizontal axis is the time point, and the vertical axis is the actual temperature control related parameter corresponding to the time point) and a time point-actual working power change curve of each heat treatment equipment (the horizontal axis is the time point, and the vertical axis is the actual working power corresponding to the time point; the actual working power can be calculated based on the actual temperature control related parameter based on the formula, and the actual power detection module can also be set for detection);

[0116] The third calculation unit is used to calculate the actual life loss value of each evaluation time of the heat treatment equipment based on the curve construction unit at the end of each evaluation time during the heat treatment process of each heat treatment equipment on the heat treatment object of each production batch;

[0117] ;

[0118] is the actual life loss value of the s-th evaluation duration of the ith heat treatment equipment; The average actual working power of the time point-actual working power variation curve segment corresponding to the s-th evaluation duration of the i-th heat treatment equipment; for The corresponding preset life loss value per unit time (can be obtained based on testing); is the duration of the sth evaluation duration of the ith heat treatment equipment; is the fluctuation life loss adjustment coefficient of the s-th evaluation time of the ith heat treatment equipment based on the corresponding time point-actual temperature control related parameter change curve segment;

[0119] The fourth calculation unit is used to calculate the current actual accumulated life loss value of the current continuous operation of each heat treatment equipment based on the third calculation unit; the fourth calculation module also calculates the current actual accumulated life loss value of the current continuous operation once after each calculation by the third calculation unit;

[0120] ;

[0121] is the actual accumulated life loss value of the current continuous operation of the i-th heat treatment equipment; The number of evaluation hours for the current continuous operation of the i-th heat treatment equipment; is the actual life loss value of the i-th heat treatment equipment during the current continuous operation for the r-th evaluation time; the time interval between the continuous opening or closing of the heat treatment equipment during continuous operation and the restarting is less than the first set time;

[0122] If the i-th heat treatment equipment is Working, the working life span is , then the total allowable cumulative life loss value of the i-th heat treatment equipment is ;

[0123] Fourth warning unit: used for issuing a warning when the current actual accumulated life loss value of the current continuous operation of any heat treatment equipment is less than the corresponding preset comprehensive life loss value (determined according to different heat treatment equipment and the working state of the heat treatment equipment before the current continuous operation), and determining the heat treatment equipment whose current actual accumulated life loss value of the current continuous operation of the heat treatment equipment is less than the corresponding preset comprehensive life loss value as the fourth warning heat treatment equipment;

[0124] The second storage unit is used to associate and store the actual life loss value of each evaluation time, the model of the heat treatment equipment corresponding to the evaluation time, the heat treatment object number corresponding to the evaluation time, the heat treatment object process corresponding to the evaluation time, and the set process parameter range corresponding to the evaluation time.

[0125] in, ;

[0126] ;

[0127] ;

[0128] in, is the total number of actual temperature control related parameters of the i-th heat treatment equipment (when the actual temperature control related parameters of the i-th heat treatment equipment are current and voltage, is 2); The time point of the sth evaluation time of the i-th heat treatment equipment - the time duration of the h-th actual temperature control related parameter change curve segment in the positive slope; The time point of the sth evaluation time of the i-th heat treatment equipment - the time duration of the h-th actual temperature control related parameter change curve segment with a negative slope; is the average value of the positive slope of the time point of the sth evaluation duration - the hth actual temperature control related parameter change curve segment of the i-th heat treatment equipment; The average value of the negative slope of the curve segment of the hth actual temperature control related parameter change from the sth evaluation time point of the i-th heat treatment equipment; is the positive slope evaluation value of the time point of the sth evaluation duration - the hth actual temperature control related parameter change curve segment of the ith heat treatment equipment; is the negative slope evaluation value of the hth actual temperature control related parameter change curve segment from the sth evaluation time point of the i-th heat treatment equipment;

[0129] The life loss adjustment coefficient determined based on the time point-hth actual temperature control related parameter change curve segment for the sth evaluation time of the i-th heat treatment equipment; It is obtained based on a positive slope evaluation value-negative slope evaluation value-actual working power range mapping table corresponding to the hth actual temperature control related parameter of the i-th heat treatment equipment, or is calculated based on a function based on the positive slope evaluation value, the negative slope evaluation value, and the actual working power; The value is greater than or equal to 0 and less than 1 (the value can be greater than or equal to 0 and less than 0.1).

[0130] The evaluation time can be set to different values ​​according to different heat treatment equipment;

[0131] The beneficial effects of the above technical solution are:

[0132] The second storage unit stores the actual life loss value of each evaluation time, the model of the heat treatment equipment corresponding to the evaluation time, the heat treatment object number corresponding to the evaluation time, and the heat treatment object process corresponding to the evaluation time in association with each other, so as to provide a basis for the production scheduling of the intelligent production scheduling module according to the storage information of the second storage unit;

[0133] The fourth calculation unit is used to calculate the current actual accumulated life loss value of each heat treatment equipment in the current continuous operation based on the third calculation unit, so as to evaluate whether the remaining production tasks of the heat treatment equipment can be completed based on the maximum allowable comprehensive life loss value of a single continuous operation of the heat treatment equipment, and provide a basis for the production scheduling of the intelligent production scheduling module. When the current actual accumulated life loss value of the current continuous operation of the heat treatment equipment is close to the maximum allowable comprehensive life loss value of a single continuous operation of the heat treatment equipment, an early warning is issued to avoid the heat treatment equipment from being affected by long-term continuous operation.

[0134] Embodiment 4, based on any one of embodiments 1-3, the intelligent production scheduling module includes:

[0135] Acquisition and screening unit: used to obtain the current production task information of the box-type furnace intelligent heat treatment production line, and screen the remaining production tasks at the end of the current evaluation time of each heat treatment equipment;

[0136] The second acquisition unit is used to acquire data from the data acquisition module;

[0137] The third acquisition unit is used to obtain, based on the second acquisition unit, the actual life loss value of the target evaluation time corresponding to the production task of each production batch in the remaining production tasks at the end of the current evaluation time of each heat treatment equipment; the production task of the d-th production batch of the current heat treatment equipment is the same as the heat treatment object number, heat treatment object number process and heat treatment equipment model produced during the corresponding target evaluation time; the heat treatment equipment corresponding to the target evaluation time works normally;

[0138] A fifth calculation unit: used for calculating, based on the acquisition and screening unit and the third acquisition unit, the predicted completion evaluation result of each remaining production task of each heat treatment equipment without warning when the current evaluation time of each heat treatment equipment without warning ends;

[0139] ;

[0140] ;

[0141] in, is the predicted completion evaluation result of the dth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning, is the predicted cumulative life loss value of the nth heat treatment equipment without warning for the kth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning; The total number of target evaluation durations corresponding to the kth remaining production tasks of the nth heat treatment equipment without warning when the current evaluation duration of the nth heat treatment equipment without warning ends; is the actual life loss value of the mth target evaluation time corresponding to the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation time of the nth heat treatment equipment without warning ends; The duration of the mth target evaluation duration corresponding to the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation duration of the nth heat treatment equipment without warning ends; The working time of the nth heat treatment equipment without warning required by the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation time of the nth heat treatment equipment without warning ends; The corresponding maximum value of the kth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning; , are the first evaluation weight and the second evaluation weight (both values ​​are greater than 0 and less than 1, , The sum is 1, , The values ​​can be 0.2 and 0.8 respectively); is the actual accumulated life loss value of the nth heat treatment equipment without warning at the end of the current evaluation time; is the maximum allowable cumulative life loss value of a single continuous operation of the nth heat treatment equipment without warning; the value range of k is 1-d, is the predicted cumulative life loss value of the nth heat treatment equipment without warning in the first d remaining production tasks among the remaining production tasks of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning; at the end of the current evaluation time of the nth heat treatment equipment without warning, among all the remaining production tasks of the nth heat treatment equipment without warning: the kth remaining production task is carried out after the k-1th remaining production task;

[0142] The first determination unit is used to:

[0143] when , determine that when the current evaluation time of the nth heat treatment equipment without warning ends, the task status of the dth remaining production task of the nth heat treatment equipment without warning is predicted to be unfinishable;

[0144] when , determine that when the current evaluation time of the nth heat treatment equipment without warning ends, the task status of the dth remaining production task of the nth heat treatment equipment without warning is predicted to be complete;

[0145] Scheduling unit: used to schedule the production of each heat treatment equipment without warning based on the task status of each remaining production task of each heat treatment equipment without warning at the end of the current evaluation time of each heat treatment equipment without warning.

[0146] The beneficial effects of the above technical solution are:

[0147] Calculate the predicted completion evaluation results of each remaining production task of each heat treatment equipment without warning at the end of the current evaluation time of each heat treatment equipment without warning, so as to determine the task status of each remaining production task of each heat treatment equipment without warning at the end of the current evaluation time of each heat treatment equipment without warning; then the production scheduling unit is used to schedule the production of each heat treatment equipment without warning based on the task status of each remaining production task of each heat treatment equipment without warning at the end of the current evaluation time of each heat treatment equipment without warning (do not schedule the remaining production tasks corresponding to the heat treatment equipment without warning that are predicted to be unfinished), so as to dynamically adjust the production scheduling of each heat treatment equipment without warning, so as to ensure the reliability of the production scheduling.

[0148] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. Box-type furnace intelligent heat treatment production line management system, characterized by: include: PLC module: used to obtain the working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line through the communication network and heat treatment equipment self-diagnosis; Data acquisition module: used to obtain the real-time working status data and process data of each heat treatment equipment in the box-type furnace intelligent heat treatment production line from the PLC module, and integrate them into real-time production line data; Production scheduling module: Users can log in new production batches of heat-treated products on the box-type furnace intelligent heat treatment production line through the production scheduling module; The production scheduling module timely schedules each production batch according to the production task information of the box-type furnace intelligent heat treatment production line, and sends the scheduling related instructions to the PLC module through the data acquisition module, and transfers the production batches being processed in each process node of the box-type furnace intelligent heat treatment production line; The production scheduling module also notifies the quality inspection department to conduct physical and chemical inspections of production batches through the quality inspection module in real time according to the status of completed production tasks, and generates quality inspection reports and batch reports; Process management module: used to set the process and process parameters for the heat-treated objects that need to be treated by the box-type furnace intelligent heat treatment production line; Intelligent production scheduling module: used to adjust the task status in real time according to the current production task information of the box-type furnace intelligent heat treatment production line and the changes in the working status of the heat treatment equipment in the data acquisition module.

2. The box-type furnace intelligent heat treatment production line management system according to claim 1 is characterized by: Each heat treatment equipment of the box-type furnace intelligent heat treatment production line includes: The first acquisition module: used to collect the working status data of the heat treatment equipment of the box-type furnace intelligent heat treatment production line; The second acquisition module: used to collect process data of heat treatment equipment in the box-type furnace intelligent heat treatment production line; Heat treatment equipment self-diagnosis module: used to compare the working state data collected by the first acquisition module with the standard working state data range of the corresponding heat treatment equipment, and compare the process data of the heat treatment equipment collected by the second acquisition module with the corresponding set process parameter range, to determine the working state data and abnormal data in the process data of the heat treatment equipment; Communication module: used to communicate with PLC module; Equipment control module: used to control the operation of the heat treatment equipment of the intelligent heat treatment production line of the acquisition box furnace. The equipment control module is electrically connected to the first acquisition module, the second acquisition module, the heat treatment equipment self-diagnosis module, and the communication module respectively.

3. The box-type furnace intelligent heat treatment production line management system according to claim 1 is characterized by: The process data of the heat treatment equipment includes: the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the heat treatment equipment; the working status data of the heat treatment equipment includes: the actual temperature control related parameters of the heat treatment equipment and the actual working time of the heat treatment equipment; The production task information includes: the number of the heat-treated object produced, the production batch number, and the task requirement information; the task requirement information includes: the total number of heat-treated objects, the target heat-treatment temperature range of each process of the heat-treated object, and the target heat-treatment time of each process of the heat-treated object; The heat treatment equipment corresponding to each process of the heat treatment objects of the current production batch controls the corresponding temperature adjustment device to perform heat treatment on the heat treatment objects of the current production batch within the target heat treatment temperature range of the corresponding process.

4. The box-type furnace intelligent heat treatment production line management system according to claim 1 is characterized by: The data acquisition module includes: Data acquisition unit: used to obtain the real-time working status data and process data of each heat treatment equipment of the box-type furnace intelligent heat treatment production line from the PLC module; Data integration unit: used to integrate the real-time working status data and process data of each heat treatment equipment of the box-type furnace intelligent heat treatment production line acquired by the data acquisition unit to form real-time production line data; Data storage unit: used to store real-time production line data; Data transmission unit: used for data transmission between PLC modules; The first early warning unit is used to issue an early warning after determining that there is abnormal data in the working status data and process data of the heat treatment equipment according to the real-time production line data, and determine that the heat treatment equipment corresponding to the abnormal data is the first early warning heat treatment equipment; Working state confirmation unit: used to confirm that the working state of the first warning heat treatment equipment is an abnormal working state.

5. The box-type furnace intelligent heat treatment production line management system according to claim 4 is characterized in that: The data acquisition module also includes: The first calculation unit is used to calculate the actual working power evaluation value of the heat treatment equipment at each first time point during the heat treatment process of each heat treatment equipment for each production batch of heat treatment objects, after the actual ambient temperature of the heat treatment area of ​​the heat treatment object in the heat treatment equipment is stabilized within the set process parameter range of the corresponding time period; the first time point is the time point when the actual temperature control related parameters of the heat treatment equipment are collected; A first storage unit: used to store the actual working power evaluation value of the heat treatment equipment at each first time point; A second early warning unit: used for issuing an early warning when the actual working power evaluation value of any heat treatment equipment is greater than the corresponding preset working power evaluation value, and determining the heat treatment equipment whose actual working power evaluation value is greater than the corresponding preset working power evaluation value as the second early warning heat treatment equipment; First acquisition unit: after each calculation by the first calculation unit is completed, the first acquisition unit acquires the actual working power evaluation value of the target historical first time point corresponding to the current first time point; the target historical first time point corresponding to the current first time point is a continuous first time point with the current first time point, and the target first historical time point corresponds to an actual working power evaluation value; A second calculation unit: used for calculating the actual power variation coefficient of each heat treatment equipment at a current first time point based on the first acquisition unit; The third warning unit is used to issue a warning when the actual power variation coefficient of any heat treatment equipment at the current first time point is greater than the preset variation coefficient, and the heat treatment equipment whose actual power variation coefficient at the current first time point is greater than the preset variation coefficient is determined as the third warning heat treatment equipment; The working state confirmation unit is also used to confirm that the working state of the second early warning heat treatment equipment and the third early warning heat treatment equipment is an abnormal working state.

6. The box-type furnace intelligent heat treatment production line management system according to claim 4 is characterized in that: The data acquisition module also includes: Curve construction unit: used for constructing a time point-actual temperature control related parameter change curve corresponding to each actual temperature control related parameter of each heat treatment equipment and a time point-actual working power change curve of each heat treatment equipment based on the data stored in the data storage unit during the heat treatment process of each heat treatment equipment on the heat treatment object of each production batch; The third calculation unit is used to calculate the actual life loss value of each evaluation time of the heat treatment equipment based on the curve construction unit at the end of each evaluation time during the heat treatment process of each heat treatment equipment on the heat treatment object of each production batch; The fourth calculation unit is used to calculate the current actual accumulated life loss value of each heat treatment equipment in the current continuous operation based on the third calculation unit; the time interval between the continuous opening or closing of the heat treatment equipment during the continuous operation and the restart is less than the first set time length; Fourth warning unit: used for issuing a warning when the current actual accumulated life loss value of the current continuous operation of any heat treatment equipment is less than the corresponding preset comprehensive life loss value, and determining the heat treatment equipment whose current actual accumulated life loss value of the current continuous operation of the heat treatment equipment is less than the corresponding preset comprehensive life loss value as the fourth warning heat treatment equipment; The second storage unit is used to associate and store the actual life loss value of each evaluation time, the model of the heat treatment equipment corresponding to the evaluation time, the heat treatment object number corresponding to the evaluation time, the heat treatment object process corresponding to the evaluation time, and the set process parameter range corresponding to the evaluation time.

7. The box-type furnace intelligent heat treatment production line management system according to claim 6 is characterized by: The third calculation unit is calculated based on the following formula: ； is the actual life loss value of the s-th evaluation duration of the ith heat treatment equipment; The average actual working power of the time point-actual working power variation curve segment corresponding to the s-th evaluation duration of the i-th heat treatment equipment; for The corresponding preset life loss value per unit time; is the duration of the sth evaluation duration of the ith heat treatment equipment; is the fluctuation life loss adjustment coefficient of the s-th evaluation time of the ith heat treatment equipment based on the corresponding time point-actual temperature control related parameter change curve segment; The fourth calculation unit is calculated based on the following formula: ； is the actual accumulated life loss value of the current continuous operation of the i-th heat treatment equipment; The number of evaluation hours for the current continuous operation of the i-th heat treatment equipment; It is the actual life loss value of the i-th heat treatment equipment which is currently working continuously for the r-th evaluation time.

8. The box-type furnace intelligent heat treatment production line management system according to claim 6 is characterized by: The intelligent production scheduling module includes: Acquisition and screening unit: used to obtain the current production task information of the box-type furnace intelligent heat treatment production line, and screen the remaining production tasks at the end of the current evaluation time of each heat treatment equipment; The second acquisition unit is used to acquire data from the data acquisition module; The third acquisition unit is used to obtain, based on the second acquisition unit, the actual life loss value of the target evaluation time corresponding to the production task of each production batch in the remaining production tasks at the end of the current evaluation time of each heat treatment equipment; the production task of the d-th production batch of the current heat treatment equipment is the same as the heat treatment object number, heat treatment object number process and heat treatment equipment model produced during the corresponding target evaluation time; the heat treatment equipment corresponding to the target evaluation time works normally; A fifth calculation unit: used for calculating, based on the acquisition and screening unit and the third acquisition unit, the predicted completion evaluation result of each remaining production task of each heat treatment equipment without warning when the current evaluation time of each heat treatment equipment without warning ends; ； ； in, is the predicted completion evaluation result of the dth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning, is the predicted cumulative life loss value of the nth heat treatment equipment without warning for the kth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning; The total number of target evaluation durations corresponding to the kth remaining production tasks of the nth heat treatment equipment without warning when the current evaluation duration of the nth heat treatment equipment without warning ends; is the actual life loss value of the mth target evaluation time corresponding to the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation time of the nth heat treatment equipment without warning ends; The duration of the mth target evaluation duration corresponding to the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation duration of the nth heat treatment equipment without warning ends; The working time of the nth heat treatment equipment without warning required by the kth remaining production task of the nth heat treatment equipment without warning when the current evaluation time of the nth heat treatment equipment without warning ends; The corresponding maximum value of the kth remaining production task of the nth heat treatment equipment without warning at the end of the current evaluation time of the nth heat treatment equipment without warning; , They are the first evaluation weight and the second evaluation weight respectively; is the actual accumulated life loss value of the nth heat treatment equipment without warning at the end of the current evaluation time; The maximum permissible cumulative life loss value of a single continuous operation of the nth heat treatment equipment without warning; The first determination unit is used to: when , determine that when the current evaluation time of the nth heat treatment equipment without warning ends, the task status of the dth remaining production task of the nth heat treatment equipment without warning is predicted to be unfinishable; when , determine that when the current evaluation time of the nth heat treatment equipment without warning ends, the task status of the dth remaining production task of the nth heat treatment equipment without warning is predicted to be complete; Scheduling unit: used to schedule the production of each heat treatment equipment without warning based on the task status of each remaining production task of each heat treatment equipment without warning at the end of the current evaluation time of each heat treatment equipment without warning.

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