Temperature control method and system for heat treatment process

Abstract

The present application relates to the field of heat treatment technology, and proposes a temperature control method and system for a heat treatment process, the method comprising: in the current heating stage of the heat treatment process, obtaining the heating rate of the next process stage of the heating chamber; if the heating rate is zero, obtaining the remaining time of the current heating stage; if the remaining time is less than a predetermined time threshold, obtaining the temperature measurement value of the heating chamber; determining the difference between the temperature measurement value and the insulation setting value of the heat treatment process; if the difference is greater than the predetermined difference threshold, pausing the timing operation of the current heating stage, and continuing to heat the heating chamber until the difference is less than or equal to the predetermined difference threshold, continuing the timing operation of the current heating stage, and entering the insulation stage as the next process stage at the end of the timing of the current heating stage. This technical solution realizes the temperature balanced connection between the heating and insulation stages in the heat treatment process through an intelligent timing and temperature control coordination mechanism.

Description

Technical Field

[0001] The present application relates to the field of heat treatment technology, and in particular to a temperature control method and system for a heat treatment process. Background Art

[0002] In the heat treatment process, precise control of the holding stage is crucial to the product's performance. In traditional temperature control systems, when switching from the heating stage to the holding stage, due to factors such as the heating chamber's furnace structure, heating power limitations, and thermal inertia, even after the temperature detection value reaches the holding set value, it still takes a certain amount of time to achieve temperature balancing after entering the holding stage because the actual temperature distribution in the heating chamber is uneven. This temperature balancing time takes up the original holding time, resulting in insufficient effective holding time for the product during the heat treatment process and uneven heating inside and outside, which affects product performance. At the same time, because the actual temperature distribution in the heating chamber is uneven, the speed of temperature balancing in each area varies significantly, further exacerbating the uncontrollability of the holding time. In addition, the heating power design of the heating chamber is usually based on the holding requirement. For example, if the heating power in the heating stage is set to 140% of the heating power in the holding stage, this often cannot meet the rapid heating requirements in the heating stage, exacerbating the deviation between the temperature detection value and the holding set value in the aforementioned holding scenario, thereby affecting product performance.

[0003] Therefore, how to effectively achieve temperature balance while ensuring that the actual insulation time strictly meets the process requirements has become a technical problem that needs to be solved urgently. Summary of the Invention

[0004] The embodiments of the present application provide a temperature control method and system for a heat treatment process, which aims to solve the technical problem in the related art that the temperature equalization process after heating takes up the insulation time, resulting in insufficient effective insulation time of the product, which affects the product performance.

[0005] In a first aspect, an embodiment of the present application provides a temperature control method for a heat treatment process, comprising:

[0006] In the current heating stage of the heat treatment process, obtaining the heating rate of the heating chamber in the next process stage;

[0007] If the heating rate is zero, obtaining the remaining duration of the current heating stage;

[0008] If the remaining time is less than a predetermined time threshold, obtaining a temperature measurement value of the heating chamber;

[0009] determining a difference between the temperature measurement and a hold set point for the thermal treatment process;

[0010] If the difference is greater than a predetermined difference threshold, pausing the timing operation of the current heating stage and continuing to heat the heating chamber until the difference is less than or equal to the predetermined difference threshold;

[0011] If the difference is less than or equal to the predetermined difference threshold, the timing operation of the current heating stage is continued, and when the timing of the current heating stage ends, the heat preservation stage as the next process stage is entered.

[0012] In one embodiment of the present application, optionally, obtaining the heating rate of the heating chamber in the next process stage includes:

[0013] At every specified time interval, the temperature rise rate of the heating chamber in the heat treatment process curve is obtained.

[0014] In one embodiment of the present application, optionally, the continuing to heat the heating chamber includes:

[0015] Performing a PID calculation based on the temperature measurement value and the insulation setting value to determine the heating power required for continued heating;

[0016] Based on the heating power, the heating chamber continues to be heated.

[0017] In one embodiment of the present application, optionally, obtaining the temperature measurement value of the heating chamber includes:

[0018] Temperature measurements are obtained for each of a plurality of heating zones of the heating chamber.

[0019] In one embodiment of the present application, optionally, determining the difference between the temperature measurement value and the insulation setting value of the heat treatment process includes:

[0020] For each of the multiple heating zones, determine the difference between the temperature measurement value of the heating zone and the common insulation setting value of all the heating zones in the insulation stage in the heat treatment process; or determine the difference between the temperature measurement value of the heating zone and the independent temperature setting value corresponding to the heating zone.

[0021] In one embodiment of the present application, optionally, if the difference is greater than a predetermined difference threshold, pausing the timing operation of the current heating stage includes:

[0022] If the difference between any number of the multiple heating zones is greater than the predetermined difference threshold, the timing operation of the current heating stage is suspended; or, if the number of the multiple heating zones whose difference is greater than the predetermined difference threshold is greater than a specified number threshold, the timing operation of the current heating stage is suspended.

[0023] In one embodiment of the present application, optionally, the continuing to heat the heating chamber includes:

[0024] For a heating zone to be continued heated in the heating chamber where the difference is greater than the predetermined difference threshold, performing a PID operation based on the temperature measurement value of the heating zone to be continued heated and the heat preservation set value to determine a heating power required for the heating zone to be continued heated;

[0025] The heating zone to be further heated is further heated according to the heating power required by the heating zone to be further heated.

[0026] In a second aspect, an embodiment of the present application provides a temperature control system for a heat treatment process, comprising:

[0027] Heating chamber, used to contain products that need to be heated and kept warm during the heat treatment process, including multiple heating zones;

[0028] a plurality of thermocouples, each of the thermocouples being disposed in a corresponding heating zone and configured to collect temperature measurements of the heating zone;

[0029] a plurality of temperature control instruments, each of which is connected to a corresponding thermocouple via a thermocouple compensation line and configured to receive the temperature measurement value collected by the thermocouple;

[0030] a programmable logic controller connected to the plurality of temperature control instruments via a communication circuit, and configured to perform the method described in any one of the embodiments of the first aspect above, wherein when a difference between the temperature measurement value and the holding set value of the heat treatment process is greater than a predetermined difference threshold, the timing operation of the current heating stage is suspended, and the heating chamber is continued to be heated until the difference is less than or equal to the predetermined difference threshold, and then the timing operation of the current heating stage is continued, so as to enter the holding stage as the next process stage when the timing of the current heating stage ends;

[0031] a heating power supply, connected to the plurality of temperature control instruments via a power control loop, and configured to obtain the heating power calculated by the programmable logic controller via the power control loop, and drive a heater based on the heating power to continue heating the heating chamber;

[0032] The heater is connected to the heating power supply and is used to heat the heating chamber.

[0033] In a third aspect, an embodiment of the present application provides a computer-readable storage medium storing computer-executable instructions, wherein the computer-executable instructions are used to execute the method described in the first aspect above.

[0034] The above technical solution addresses the technical problem in the related art that the temperature equalization process after heating takes up the insulation time, resulting in insufficient effective insulation time for the product and affecting product performance. This application breaks through the limitations of traditional fixed timing control by adding dynamic timing control to the closed-loop control process, dynamically binding the process time to the actual temperature, and ensuring the effectiveness and accuracy of the insulation stage. During the heating stage, by real-time monitoring of the heating rate and the remaining time, the temperature equalization requirement can be predicted in advance at the end of the heating stage, and the heating operation for the temperature equalization requirement can be triggered in time, effectively solving the temperature detection lag problem caused by thermal inertia in the traditional process. Specifically, this solution upgrades the traditional fixed timing control to an intelligent dynamic adjustment mechanism. By combining the PID algorithm with the timing pause function, the heating power and process time are automatically adjusted according to the actual temperature changes. The invalid time consumed in waiting for temperature equalization in the insulation stage is replaced by the temperature control behavior at the end of the heating stage. This improvement greatly increases the effective duration of the insulation stage, increases the uniformity of heating inside and outside the product, and provides a reliable guarantee for obtaining stable product performance. Furthermore, this technical solution not only solves the technical challenge of estimating temperature equilibration time in traditional processes, but also effectively compensates for the insufficient power margin of the heating system through dynamic power regulation. This solution maintains stable heating results for heat treatment production with varying batches and loads, significantly improving the adaptability and reliability of the production process, increasing the utilization of heating resources, and reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0036] Figure 1 A flow chart showing a temperature control method for a heat treatment process according to an embodiment of the present application is shown;

[0037] Figure 2 A flow chart showing a temperature control method for a heat treatment process according to another embodiment of the present application is shown;

[0038] Figure 3 A block diagram of a temperature control system for a heat treatment process according to an embodiment of the present application is shown;

[0039] Figure 4 A block diagram of a computer device according to an embodiment of the present application is shown;

[0040] Figure 5A block diagram of a computer device according to another embodiment of the present application is shown. DETAILED DESCRIPTION

[0041] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0042] Figure 1 A flow chart of a temperature control method for a heat treatment process according to an embodiment of the present application is shown.

[0043] like Figure 1 As shown, a temperature control method for a heat treatment process according to an embodiment of the present application includes:

[0044] Step 102 : In the current heating stage of the heat treatment process, the heating rate of the heating chamber in the next process stage is obtained.

[0045] During heat treatment, products are placed in a heating chamber, where they are heated and maintained. During the current heating phase of the heat treatment process, the temperature control system dynamically monitors the execution of the heat treatment process curve by collecting the heating rate of the heating chamber in real time.

[0046] In one possible design, the heating rate of the heating chamber in the heat treatment process curve is obtained at specified time intervals, that is, the heating rate of the heating chamber is periodically collected. The specified time interval can be set based on actual process requirements.

[0047] Alternatively, the temperature control system can be implemented using a programmable logic controller (PLC). The PLC periodically reads the heating chamber's heating rate from the process curve data via the temperature control instrument's communication interface (e.g., RS-485). The heating rate reflects the level of temperature change in the heating chamber during the heating phase. Therefore, by periodically collecting the heating chamber's heating rate, the temperature changes during the heating phase can be monitored in a timely manner, allowing for dynamic control of the temperature balancing process based on the temperature changes during the heating phase.

[0048] Step 104: If the heating rate is zero, obtain the remaining time of the current heating stage.

[0049] Step 106: If the remaining time is less than a predetermined time threshold, obtain a temperature measurement value of the heating chamber.

[0050] If the heating rate is zero, it indicates that the heating chamber has reached its maximum temperature during the heating process and has met the initial conditions for entering the insulation phase. However, before entering the insulation phase, the temperature equalization process needs to be dynamically controlled. At this point, the remaining duration of the current heating phase can be obtained. If the remaining duration is less than the predetermined duration threshold, it indicates that the time has come to dynamically control the temperature equalization process. Conversely, if the remaining duration is greater than or equal to the predetermined duration threshold, it indicates that the time has not yet come to dynamically control the temperature equalization process, and the process needs to continue extending along the heating phase curve until the remaining duration is less than the predetermined duration threshold.

[0051] Among them, the predetermined time threshold refers to the time when the end of the heating stage is close enough to the insulation stage. If the remaining time is less than the predetermined time threshold, it means that the process curve has entered the end of the heating stage and is about to enter the insulation stage. At this time, dynamic control of temperature balance can be triggered to achieve temperature balance in the heating chamber before entering the insulation stage, so that the product can be heated evenly during the insulation stage, thereby improving product performance.

[0052] Step 108: Determine the difference between the temperature measurement value and the insulation setting value of the heat treatment process.

[0053] The hold set point for the heat treatment process is the threshold for entering the hold phase. The smaller the difference between the measured temperature in the heating chamber and the hold threshold, the closer the product temperature in the heating chamber is to the standard temperature required for entering the hold phase, and the more necessary it is to enter the hold phase. Conversely, the larger the difference between the measured temperature in the heating chamber and the hold threshold, the further the product temperature in the heating chamber is from the standard temperature required for entering the hold phase, the less necessary it is to enter the hold phase, and the more urgent it is to maintain temperature equilibrium.

[0054] Step 110 : If the difference is greater than a predetermined difference threshold, suspend the timing operation of the current heating stage, and continue heating the heating chamber until the difference is less than or equal to the predetermined difference threshold.

[0055] The predetermined difference threshold refers to the maximum difference between the product temperature in the heating chamber and the hold stage threshold value, which satisfies the conditions for entering the hold stage. Therefore, if the difference between the measured temperature and the set hold temperature exceeds the predetermined difference threshold, it indicates that the product temperature in the heating chamber is too low, significantly below the required hold stage temperature, and thus does not meet the conditions for entering the hold stage. In this case, the heating chamber can be heated further to raise the product temperature until the product temperature in the heating chamber meets the conditions for entering the hold stage.

[0056] A PID (Proportional Integral Differential) calculation can be performed based on the measured temperature value and the hold setting value to determine the heating power required for continued heating. The heating chamber can then continue heating based on the heating power. In other words, the heating power can be determined based on the difference between the measured temperature value and the hold setting value, ensuring that the product temperature within the heating chamber rises to the point where the holding setting conditions are met.

[0057] Step 112: If the difference is less than or equal to the predetermined difference threshold, continue the timing operation of the current heating stage, and enter the holding stage as the next process stage when the timing of the current heating stage ends.

[0058] If it is detected that the difference between the temperature measurement value and the insulation setting value is less than or equal to the predetermined difference threshold, or after detecting that the difference between the temperature measurement value and the insulation setting value is greater than the predetermined difference threshold, the difference is reduced to a range less than or equal to the predetermined difference threshold by heating, since the product temperature in the heating chamber has reached the standard for entering the insulation stage, the timing of the heating stage can be continued, and the remaining time in the heating stage that is less than the predetermined time threshold can be spent to successfully enter the insulation stage.

[0059] The above technical solution, through an intelligent timing and temperature control coordination mechanism, achieves temperature balancing during the heating and holding phases of the heat treatment process. It first monitors the heating rate of the heating chamber in real time during the heating phase. When it detects that the heating rate is zero and the heating phase has reached the end, it triggers temperature balancing control and calculates the difference between the actual temperature of the heating chamber and the holding set value. If the difference exceeds the limit, the timing at the end of the heating phase is paused and the heating power is adjusted by PID to continue heating the heating chamber until the difference is reduced to meet the conditions for entering the holding phase. Then the timing at the end of the heating phase is resumed to smoothly enter the holding phase.

[0060] In summary, the present application breaks through the limitations of traditional fixed timing control by adding dynamic timing control to the closed-loop control process, dynamically binds the process time to the actual temperature, ensures the effectiveness and accuracy of the insulation stage, and solves the long-standing problem of insufficient effective insulation time due to temperature equilibrium lag in the heat treatment process. In the heating stage, by real-time monitoring of the heating rate and the remaining time, it is possible to predict the temperature equilibrium requirement in advance at the end of the heating stage, and timely trigger the heating operation for the temperature equilibrium requirement, effectively solving the temperature detection lag problem caused by thermal inertia in the traditional process. Specifically, this solution upgrades the traditional fixed timing control to an intelligent dynamic adjustment mechanism. By combining the PID algorithm with the timing pause function, it automatically adjusts the heating power and process time according to the actual temperature changes, and replaces the invalid time consumed in waiting for temperature equilibrium in the insulation stage by the temperature control behavior at the end of the heating stage. This improvement greatly increases the effective duration of the insulation stage, increases the uniformity of heating inside and outside the product, and provides a reliable guarantee for obtaining stable product performance. Furthermore, this technical solution not only solves the technical challenge of estimating temperature equilibration time in traditional processes, but also effectively compensates for the insufficient power margin of the heating system through dynamic power regulation. This solution maintains stable heating results for heat treatment production with varying batches and loads, significantly improving the adaptability and reliability of the production process, increasing the utilization of heating resources, and reducing production costs.

[0061] Figure 2 A flow chart of a temperature control method for a heat treatment process according to another embodiment of the present application is shown.

[0062] like Figure 2 As shown, in a temperature control method for a heat treatment process according to another embodiment of the present application, the heating chamber may include multiple heating zones, and each heating zone may be individually temperature-controlled by a temperature control system. Specifically, the method includes:

[0063] Step 202 : In the current heating stage of the heat treatment process, the heating rate of the heating chamber in the next process stage is obtained.

[0064] During the current heating phase of the heat treatment process, the temperature control system dynamically monitors the execution of the heat treatment process curve by collecting real-time data on the heating chamber's heating rate. Specifically, the overall heating chamber heating rate is monitored in real time and used as a criterion for determining whether the entire heating chamber can enter the holding phase.

[0065] Step 204: If the heating rate is zero, obtain the remaining time of the current heating stage.

[0066] When the temperature control system detects that the overall heating speed of the heating chamber has returned to zero, it indicates that the entire heating chamber has basically reached the preset temperature range. The purpose of obtaining the remaining time at this time is to determine whether the entire heating chamber has entered the end of the heating stage, that is, whether it has entered the critical period for taking temperature balancing control operations.

[0067] Another possible design for a large, multi-zone heating chamber is to monitor the heating rate of each heating zone in real time, using that rate as a criterion for determining whether that zone should enter the hold phase. For a single heating zone, if the heating rate is zero, the remaining time in the hold phase is determined.

[0068] For large multi-zone heating chambers, due to factors such as the furnace structure, heating power limitations, and thermal inertia, after the temperature detection value of the entire heating chamber reaches the insulation set value, the actual temperature distribution of the heating chamber is uneven. For example, the heating zones on both sides of the heating chamber have a large heat dissipation area and a lower temperature, while the heating zone in the middle of the heating chamber has a small heat dissipation area and a higher temperature. Based on this actual situation, corresponding process curves can be set for different heating zones, and the heating period of heating zones with large heat dissipation areas and poor heating capabilities can be extended. In this way, each heating zone can be tailored to its specific conditions and determine the appropriate temperature balance timing for each zone to avoid misjudging the overall status due to individual zones reaching the standard early.

[0069] On this basis, when obtaining the remaining duration of the current heating stage, the remaining duration of the heating stage of each heating zone can also be obtained to determine whether a single heating zone has reached the temperature equilibrium timing.

[0070] Step 206: If the remaining time is less than a predetermined time threshold, obtain temperature measurement values ​​of each of the plurality of heating zones of the heating chamber.

[0071] For the entire heating chamber, if the remaining time is less than the predetermined time threshold, it means that the heating chamber has entered the end of the heating stage. At this time, the heating chamber has a higher temperature balance requirement, and corresponding temperature control measures can be taken.

[0072] For a single heating zone, if the remaining time is less than the predetermined time threshold, it means that the heating zone has entered the end of the heating stage. At this time, the heating zone has a higher temperature balance requirement and corresponding temperature control measures can be taken.

[0073] Step 208 : For each of the plurality of heating zones, determine a difference between a temperature measurement value of the heating zone and a common holding set value for all the heating zones in the holding phase of the heat treatment process.

[0074] The temperature measurement value of each heating zone reflects its actual temperature level, and the common insulation setting value of all the heating zones in the heat treatment process during the insulation stage reflects the temperature level that each heating zone needs to reach to enter the insulation stage. Therefore, the difference between the temperature measurement value of the heating zone and the common insulation setting value reflects the degree of heating required for the heating zone to enter the insulation stage.

[0075] In another possible design, the difference between the temperature measurement value of the heating zone and the independent temperature setting value corresponding to the heating zone is determined.

[0076] Due to the large space and complex structure of large multi-zone heating chambers, the heating and insulation capabilities of each heating zone within them are significantly different. Therefore, it is possible to set independent temperature setpoints for each heating zone based on their own heating and insulation capabilities, which serve as the standard for entering the insulation phase. In addition, since the products processed in a large multi-zone heating chamber in a single process may not all be the same, the process temperatures required for different products in different heating zones will also vary. Therefore, it is possible to set independent temperature setpoints for each heating zone based on the actual heating and insulation requirements of the product.

[0077] This technical solution sets an independent temperature setting value for each heating zone, which is equivalent to setting a standard for entering the insulation stage for each heating zone. It effectively solves the problem of uneven thermal field in large multi-zone heating systems and significantly improves the accuracy of temperature control in large multi-zone heating systems. At the same time, considering the possible needs of multi-variety co-line processing in actual production, the setting method of independent temperature setting values ​​can flexibly adapt to the differentiated requirements of different products for process temperature, making the system more process adaptable. This partitioned independent temperature control mechanism not only ensures that each heating zone can achieve the best heat treatment effect, but also effectively improves energy utilization efficiency by avoiding a one-size-fits-all temperature control strategy. In actual applications, this technical solution can significantly improve product quality consistency, especially for products with complex structures or special materials, the temperature uniformity and heat treatment effect have been significantly improved.

[0078] Step 210: If the difference between any number of the heating zones in the plurality of heating zones is greater than the predetermined difference threshold, suspend the timing operation of the current heating stage.

[0079] As long as there is a heating zone among multiple heating zones whose difference is greater than the predetermined difference threshold, that is, as long as there is at least one heating zone that does not meet the standard for entering the insulation stage, the timing operation of the heating stage in the process curve will be suspended to ensure that all heating zones can synchronously enter the optimal insulation state after temperature balancing.

[0080] In another possible design, if the number of heating zones in the plurality of heating zones whose difference is greater than the predetermined difference threshold is greater than a specified number threshold, the timing operation of the current heating stage is suspended.

[0081] Therefore, the timing will only be paused when the number of heating zones that have not reached the standard for entering the insulation stage exceeds the limit. This ensures the process requirements of key areas while taking production efficiency into consideration. This avoids the situation under traditional control methods where delays in individual areas affect the overall process progress, and ensures that the temperature of key heating zones meets the standards accurately.

[0082] In another possible design, the above two technical solutions can be set as two optional process modes. In actual scenarios, one of the two process modes can be selected based on actual product production requirements.

[0083] In summary, this step significantly improves the quality stability of heat treatment of complex products, while increasing equipment utilization by optimizing the heating sequence.

[0084] Step 212: For the heating zone to be continued heated in the heating chamber where the difference is greater than the predetermined difference threshold, a PID operation is performed based on the temperature measurement value of the heating zone to be continued heated and the insulation setting value to determine the heating power required for the heating zone to be continued heated.

[0085] Step 214 : Continue heating the heating zone to be further heated according to the heating power required by the heating zone to be further heated until the difference is less than or equal to the predetermined difference threshold.

[0086] Step 216: If the difference is less than or equal to the predetermined difference threshold, continue the timing operation of the current heating stage, and enter the holding stage as the next process stage when the timing of the current heating stage ends.

[0087] Through intelligent zoned temperature control strategies, precise energy regulation with balanced temperatures across multiple zones is achieved. This step uses independent PID calculation modules to perform dynamic power calculations for specific heating zones with excessive temperature differences. This allows for personalized power regulation based on the actual temperature differences in each heating zone, avoiding the energy waste associated with traditional integrated heating.

[0088] At the same time, real-time PID calculations ensure a precise match between heating power and the current temperature difference, preventing both delayed heating due to insufficient power and temperature overshoots caused by excessive power. Furthermore, independent zone control logic allows the temperature control system to simultaneously perform differentiated processing on multiple areas with excessive temperature differences. This is particularly suitable for handling large, multi-zone heating equipment with complex heat distributions. This multi-point temperature difference detection mechanism can accurately identify temperature unevenness caused by heat dissipation differences in different areas, significantly improving the consistency of temperature distribution. This targeted heating mechanism significantly improves energy efficiency while ensuring temperature uniformity, providing reliable protection for the product's heat treatment process.

[0089] Figure 3 A block diagram of a temperature control system for a heat treatment process according to an embodiment of the present application is shown.

[0090] like Figure 3 As shown, a temperature control system for a heat treatment process according to an embodiment of the present application includes: a programmable logic controller (PLC) 1, multiple temperature control instruments 2, multiple thermocouples 3, a heating power supply 4, a heater 5, and a heating chamber 9.

[0091] The heating chamber 9 is used to accommodate products that need to be heated and kept warm during the heat treatment process, and includes multiple heating zones. Each of the thermocouples 3 is disposed in a corresponding heating zone and is configured to collect temperature measurements of the heating zone and upload the temperature measurements to the corresponding temperature control instrument 2 via the thermocouple compensation line 7. Conversely, each of the temperature control instruments 2 is connected to the corresponding thermocouple 3 via the thermocouple compensation line 7 and is configured to receive the temperature measurements collected by the thermocouple 3 and upload them to the programmable logic controller 1.

[0092] The programmable logic controller 1 is connected to the plurality of temperature control instruments 2 via a communication circuit 6 and is configured to execute Figure 1 and Figure 2 In the method described in any part of the embodiments, when the difference between the temperature measurement value and the insulation setting value of the heat treatment process is greater than a predetermined difference threshold, the timing operation of the current heating stage is suspended, and the heating chamber 9 continues to heat until the difference is less than or equal to the predetermined difference threshold, and then the timing operation of the current heating stage is continued, so that when the timing of the current heating stage ends, the insulation stage as the next process stage is entered. The programmable logic controller establishes a real-time data connection with multiple temperature control instruments through an RS-485 communication interface, periodically collects data such as the real-time temperature measurement value of each heating zone, the heating rate set by the process curve, the remaining time of the current stage, and the deviation between the temperature setting value and the actual value, and implements its own temperature control algorithm based on this data to complete temperature balance adjustment.

[0093] The heating power supply 4 is connected to the plurality of temperature control instruments 2 via a power control circuit 8 and is configured to obtain the heating power calculated by the programmable logic controller 1 via the power control circuit 8 and drive the heater 5 based on the heating power to continue heating the heating chamber 9. The heater 5 is connected to the heating power supply 4 for heating the heating chamber 9.

[0094] Generally speaking, the heat treatment process curve includes two key processes: the heating stage and the insulation stage. The heating stage mainly ensures that the product is heated evenly to avoid defects such as cracking, while the insulation stage is the core link to ensure the final performance of the product. The duration of the insulation stage directly determines the uniformity of heating inside and outside the product, and is a key parameter affecting product quality. When the traditional process switches from the heating stage to the insulation stage, due to factors such as thermal inertia, it still takes a long time for temperature balance after the actual temperature reaches the set value. This waiting time squeezes out the originally designed effective insulation time. The resulting actual insulation time is insufficient, resulting in uneven heating inside and outside the product, and product performance is difficult to meet the standards. In addition, due to the differences in the loading volume of each batch of products, the uncertainty of this temperature balance time brings significant troubles to production management.

[0095] In this regard, combined with Figure 3 The temperature control system shown for heat treatment processes uses a communication circuit to collect real-time measurements and setpoints from each temperature control instrument. The system calculates the absolute deviation between the two and compares it with the preset tolerance. If the deviation in any or multiple temperature zones exceeds the tolerance, the system automatically activates HOLD mode, pausing the process curve timing. Simultaneously, the heating power is dynamically adjusted using a PID algorithm. Specifically, the system consists of a ground-mounted holding furnace, internally divided into three independent temperature zones: upper, middle, and lower. Each zone is equipped with its own thermocouple, heater, and control circuit. The PLC coordinates control of each zone via a communication network, specifically providing compensatory heating to address the rapid heat dissipation in the edge zones (upper and lower zones). Once all zones reach the desired temperature, HOLD mode is released and timing continues. This dynamic control mechanism effectively ensures the effective duration of each holding stage, ensuring optimal product performance.

[0096] In actual operation, due to the larger heat dissipation area of ​​the upper and lower temperature zones, their temperature response lags significantly behind that of the central zone. After the temperature control system for the heat treatment process is activated, the PLC collects temperature data from each temperature zone in real time. If it detects an excessive deviation during the insulation phase, it immediately pauses the process timing and initiates PID control. The heating power supply precisely adjusts the power output of each heater based on the control signal, forming a closed-loop control. This process continues until all temperature zones meet the specified temperature, ensuring that each insulation stage receives its full operating time. This design specifically addresses the challenge of temperature balancing in multi-temperature zone systems, significantly improving the stability and consistency of heat treatment quality.

[0097] Of course, the above three independent temperature zones are only an example. In actual scenarios, the number and positions of the heating zones of the heating chamber, i.e., the insulation furnace body, are divided based on the actual furnace body structure and production requirements, and are not limited to the above example.

[0098] In addition, the temperature control system for the heat treatment process uses the above Figure 1 and Figure 2 The solution described in any one of the embodiments therefore has all the above-mentioned technical effects and will not be described in detail here.

[0099] In one embodiment, the present application also provides a computer device, which can be a server, and its internal structure diagram can be as follows: Figure 4 As shown. The computer device includes a processor, memory, network interface and database connected via a system bus. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes non-volatile and / or volatile storage media and internal memory. The non-volatile storage medium stores an operating system, a computer program and a database. The internal memory provides an environment for the operation of the operating system and computer program in the non-volatile storage medium. The network interface of the computer device is used to communicate with an external client via a network connection. When the computer program is executed by the processor, it can implement the method described in any of the above embodiments.

[0100] In one embodiment, the present application further provides a computer device, which may be a client, and its internal structure diagram may be as follows: Figure 5As shown. The computer device includes a processor, memory, a network interface, a display screen, and an input device connected via a system bus. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system and a computer program. The internal memory provides an environment for the operation of the operating system and computer program in the non-volatile storage medium. The network interface of the computer device is used to communicate with an external server via a network connection. When executed by the processor, the computer program can implement the method described in any of the above embodiments.

[0101] Any of the aforementioned computer devices in the embodiments of the present application may exist in various forms, including but not limited to:

[0102] (1) Mobile communication devices: These devices are characterized by their mobile communication capabilities and their primary purpose is to provide voice and data communications. These terminals include smartphones, multimedia phones, feature phones, and low-end phones.

[0103] (2) Ultra-mobile personal computer devices: These devices fall under the category of personal computers, have computing and processing capabilities, and generally also have mobile Internet access. These terminals include PDAs, MIDs, and UMPCs.

[0104] (3) Portable entertainment devices: These devices can display and play multimedia content. These devices include audio and video players, handheld game consoles, e-books, as well as smart toys, wearable devices, and portable car navigation devices.

[0105] (4) Server: A device that provides computing services. The server consists of a processor, hard disk, memory, system bus, etc. The server is similar to a general computer architecture, but because it needs to provide highly reliable services, it has higher requirements in terms of processing power, stability, reliability, security, scalability, and manageability.

[0106] (5) Other electronic devices with data interaction functions.

[0107] In addition, an embodiment of the present application provides a computer-readable storage medium storing computer-executable instructions, wherein the computer-executable instructions are used to perform the following steps:

[0108] In the current heating stage of the heat treatment process, obtaining the heating rate of the heating chamber in the next process stage;

[0109] If the heating rate is zero, obtaining the remaining duration of the current heating stage;

[0110] If the remaining time is less than a predetermined time threshold, obtaining a temperature measurement value of the heating chamber;

[0111] determining a difference between the temperature measurement and a hold set point for the thermal treatment process;

[0112] If the difference is greater than a predetermined difference threshold, pausing the timing operation of the current heating stage and continuing to heat the heating chamber until the difference is less than or equal to the predetermined difference threshold;

[0113] If the difference is less than or equal to the predetermined difference threshold, the timing operation of the current heating stage is continued, and when the timing of the current heating stage ends, the heat preservation stage as the next process stage is entered.

[0114] It should be noted that the above functions or steps that can be implemented by the computer-readable storage medium or computer device can refer to the relevant description in the aforementioned method embodiment. To avoid repetition, they will not be described one by one here.

[0115] The above describes in detail the technical solution of the present application in combination with the accompanying drawings. Through the technical solution of the present application, dynamic timing control is added to the closed-loop control process, breaking through the limitations of traditional fixed timing control, and dynamically binding the process time to the actual temperature, ensuring the effectiveness and accuracy of the insulation stage, and solving the long-standing problem of insufficient effective insulation time due to temperature equilibrium lag in the heat treatment process. It can significantly improve the adaptability and reliability of the production process, increase the utilization rate of heating resources, and reduce production costs.

[0116] The word "if," as used herein, may be interpreted as "at the time of" or "when" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrases "if it is determined" or "if (stated condition or event) is detected" may be interpreted as "when it is determined" or "in response to the determination" or "when detecting (stated condition or event)" or "in response to detecting (stated condition or event)," depending on the context.

[0117] The terms used in the embodiments of the present application are for the purpose of describing specific embodiments only and are not intended to limit the present application. The singular forms "a", "an", "the" and "the" used in the embodiments of the present application and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise.

[0118] Those skilled in the art will understand that all or part of the processes in the above-mentioned embodiments can be implemented by instructing the relevant hardware through a computer program. The computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to memory, storage, database or other media used in the embodiments provided in this application may include non-volatile and / or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in many forms such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), Synchronous Link DRAM (SLDRAM), Rambus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0119] The embodiments described above are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention, and should all be included in the scope of protection of the present invention.

Claims

1. A temperature control method for a heat treatment process, characterized in that: include: In the current heating stage of the heat treatment process, obtaining the heating rate of the heating chamber; If the heating rate is zero, obtaining the remaining duration of the current heating stage; If the remaining time is less than a predetermined time threshold, obtaining a temperature measurement value of the heating chamber; determining a difference between the temperature measurement and a hold set point for the thermal treatment process; If the difference is greater than a predetermined difference threshold, pausing the timing operation of the current heating stage and continuing to heat the heating chamber until the difference is less than or equal to the predetermined difference threshold; If the difference is less than or equal to the predetermined difference threshold, the timing operation of the current heating stage is continued, and the heat preservation stage is entered when the timing of the current heating stage ends.

2. The method according to claim 1, characterized in that The obtaining of the heating rate of the heating chamber includes: At every specified time interval, the temperature rise rate of the heating chamber in the heat treatment process curve is obtained.

3. The method according to claim 1, characterized in that The step of continuing to heat the heating chamber comprises: Performing a PID calculation based on the temperature measurement value and the insulation setting value to determine the heating power required for continued heating; Based on the heating power, the heating chamber continues to be heated.

4. The method according to claim 1, wherein The obtaining of the temperature measurement value of the heating chamber includes: Temperature measurements are obtained for each of a plurality of heating zones of the heating chamber.

5. The method according to claim 4, characterized in that Determining the difference between the temperature measurement value and the insulation setting value of the heat treatment process includes: For each of the multiple heating zones, determine the difference between the temperature measurement value of the heating zone and the common insulation setting value of all the heating zones in the insulation stage in the heat treatment process; or determine the difference between the temperature measurement value of the heating zone and the independent insulation setting value corresponding to the heating zone.

6. The method according to claim 5, characterized in that If the difference is greater than a predetermined difference threshold, pausing the timing operation of the current heating stage includes: If the difference between any number of the multiple heating zones is greater than the predetermined difference threshold, the timing operation of the current heating stage is suspended; or, if the number of the multiple heating zones whose difference is greater than the predetermined difference threshold is greater than a specified number threshold, the timing operation of the current heating stage is suspended.

7. The method according to claim 6, characterized in that The step of continuing to heat the heating chamber comprises: For a heating zone to be continued heated in the heating chamber where the difference is greater than the predetermined difference threshold, performing a PID operation based on the temperature measurement value of the heating zone to be continued heated and the heat preservation set value to determine a heating power required for the heating zone to be continued heated; The heating zone to be further heated is further heated according to the heating power required by the heating zone to be further heated.

8. A temperature control system for a heat treatment process, characterized in that: include: Heating chamber, used to contain products that need to be heated and kept warm during the heat treatment process, including multiple heating zones; a plurality of thermocouples, each of the thermocouples being disposed in a corresponding heating zone and configured to collect temperature measurements of the heating zone; a plurality of temperature control instruments, each of which is connected to a corresponding thermocouple via a thermocouple compensation line and is configured to receive the temperature measurement value collected by the thermocouple; a programmable logic controller, connected to the plurality of temperature control instruments via a communication circuit, and configured to execute the method according to any one of claims 1 to 7, wherein when the difference between the temperature measurement value and the insulation setting value of the heat treatment process is greater than a predetermined difference threshold, the timing operation of the current heating stage is suspended, and the heating chamber is continued to be heated until the difference is less than or equal to the predetermined difference threshold, and the timing operation of the current heating stage is continued, so as to enter the insulation stage when the timing of the current heating stage ends; a heating power supply, connected to the plurality of temperature control instruments via a power control loop, and configured to obtain the heating power calculated by the programmable logic controller via the power control loop, and drive a heater based on the heating power to continue heating the heating chamber; The heater is connected to the heating power supply and is used to heat the heating chamber.

9. A computer-readable storage medium, characterized in that Computer-executable instructions are stored, and the computer-executable instructions are configured to execute the method according to any one of claims 1 to 7.

Images