Monitoring method, device and system of electric heating roller kiln

Abstract

The invention discloses a method, a device and a system for monitoring an electric heating roller kiln, which are applied to the field of roller kilns.According to the method, the states of a roller way, a heating rod and a heat preservation layer are monitored, and prompt information is sent out under the condition that the state of a certain object in the roller way, the heating rod and the heat preservation layer is an abnormal state; therefore, an operator can timely find that the electric heating roller kiln is abnormal, and then the electric heating roller kiln can be timely overhauled. Besides, the priorities of the first object, the second object, the third object and the third object are sequentially reduced, so that the state of the object with the higher priority is detected firstly, and under the condition that the state of the object with the higher priority is an abnormal state, prompt information for overhauling the object with the higher priority and the object with the lower priority than the object with the higher priority can be sent out; and the state of the object with the lower priority is not detected any more, so that unnecessary detection operation is avoided, and the monitoring efficiency of the electric heating roller kiln is improved.

Description

Technical Field

[0001] The present application relates to the field of roller kilns, and in particular to a monitoring method, device, and system for an electrically heated roller kiln. Background Art

[0002] In the production process of lithium-ion battery electrode materials, roller kilns can be used for the sintering process. Among them, roller kilns are suitable for the sintering of different types of lithium battery electrode materials due to their large production capacity and stable and reliable operation. They are widely used by domestic and foreign users.

[0003] In the related art, when an abnormality occurs in a roller kiln, if the abnormal information cannot be discovered in time, it may bring huge safety hazards to the production process. Summary of the Invention

[0004] The present invention provides a monitoring method, device and system for an electrically heated roller kiln. The technical solution includes:

[0005] In one aspect, a monitoring method for an electrically heated roller kiln is provided. The electrically heated roller kiln includes a roller, a heating rod, and an insulation layer. The method comprises:

[0006] Obtain the status of the first object in the roller, heating rod and insulation layer;

[0007] If the state of the first object is abnormal, a first prompt message for repairing the roller, the heating rod and the insulation layer is issued;

[0008] If the state of the first object is normal, and the state of the second object in the roller, heating rod and insulation layer is abnormal, a second prompt message is issued to inspect the other objects except the first object;

[0009] If the status of the second object is normal and the status of the third object among the roller, heating rod and insulation layer is abnormal, a third prompt message for maintenance of the third object is issued, and the priorities of the first to third objects decrease in sequence.

[0010] Optionally, the priorities of the roller, heating rod and insulation layer decrease in sequence, and the priority of each object in the roller, heating rod and insulation layer is positively correlated with the importance of the object.

[0011] Optionally, the electrically heated roller kiln further includes a plurality of sequentially connected temperature zones; obtaining the state of the first object in the roller, the heating rod, and the insulation layer includes:

[0012] When the target temperature zone is the first temperature zone, or the target temperature zone is located after the first temperature zone and the state of the temperature zone located before the target temperature zone is normal, obtaining the state of the target temperature zone;

[0013] If the state of the target temperature zone is abnormal, the state of the first object among the roller, the heating rod and the insulation layer is obtained.

[0014] Optionally, when the temperature variation of the target temperature zone is outside the temperature threshold range, the state of the target temperature zone is an abnormal state;

[0015] The temperature change is obtained by inputting historical temperature data of the third object within a preset time period before the current moment into the temperature prediction model.

[0016] Optionally, the first object includes a roller, and the roller includes a roller bar; when the wavelet entropy of the vibration signal of the roller bar is greater than or equal to an entropy value threshold, the state of the roller is an abnormal state;

[0017] The second object includes a heating rod, and when the current of the heating rod is outside a current threshold range, or the resistance of the heating rod is outside a resistance threshold range, the state of the heating rod is an abnormal state;

[0018] The third object includes a thermal insulation layer. When a defect score of the thermal insulation layer is greater than or equal to a defect score threshold, the state of the thermal insulation layer is an abnormal state.

[0019] Optionally, the method further includes:

[0020] Get the aging degree of the heating rod;

[0021] If the aging degree of the heating rod is greater than or equal to the aging degree threshold, a fourth prompt message is issued.

[0022] Optionally, the method further includes:

[0023] Obtaining a target gradient of a target model, where the target model is used to determine states of the first object to the third object;

[0024] Update the gradient of the target model to the target gradient;

[0025] The target gradient is obtained by weighted average of the historical gradients of the target models corresponding to multiple electric heating roller kilns.

[0026] Optionally, the statuses of the first object to the third object are obtained from the cloud.

[0027] On the other hand, a computer-readable storage medium is provided, on which a computer program is stored. When the computer program is executed by a processor, the monitoring method of the electric heating roller kiln described in the above aspect is implemented.

[0028] On the other hand, a controller is provided, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the monitoring method of the electric heating roller kiln described in the above aspects is implemented.

[0029] In another aspect, a monitoring device for an electrically heated roller kiln is provided. The electrically heated roller kiln includes a roller, a heating rod, and an insulation layer. The monitoring device is configured to:

[0030] Obtain the status of the first object in the roller, heating rod and insulation layer;

[0031] If the state of the first object is abnormal, a first prompt message for repairing the roller, the heating rod and the insulation layer is issued;

[0032] If the state of the first object is normal, and the state of the second object in the roller, heating rod and insulation layer is abnormal, a second prompt message is issued to inspect the other objects except the first object;

[0033] If the status of the second object is normal and the status of the third object among the roller, heating rod and insulation layer is abnormal, a third prompt message for maintenance of the third object is issued, and the priorities of the first to third objects decrease in sequence.

[0034] On the other hand, a monitoring system for an electrically heated roller kiln is provided. The monitoring system for an electrically heated roller kiln comprises: the controller described in the above aspect, or the monitoring device for an electrically heated roller kiln described in the above aspect.

[0035] Optionally, the monitoring system includes: a plurality of temperature sensors arranged in each temperature zone, a vibration sensor arranged on the roller, a current sensor and a voltage sensor connected to the heating rod, and an infrared thermal imager;

[0036] Each temperature sensor is used to detect the temperature of a corresponding temperature zone, and the temperature of the temperature zone is used to determine whether the state of the temperature zone is abnormal; wherein, when the temperature change amount of the temperature zone is outside the temperature threshold range, the state of the temperature zone is abnormal, and the temperature change amount is determined based on the temperature of the temperature zone;

[0037] The vibration sensor is used to detect the vibration signal of the roller, and the vibration signal is used to determine whether the state of the roller is abnormal; wherein, when the wavelet entropy of the vibration signal of the roller is greater than or equal to the entropy value threshold, the state of the roller is abnormal;

[0038] The current sensor is used to detect the current of the heating rod, and the voltage sensor is used to detect the voltage of the heating rod. The current and voltage are used to determine whether the state of the heating rod is abnormal. If the current of the heating rod is outside a current threshold range, or if the resistance of the heating rod is outside a resistance threshold range, the state of the heating rod is abnormal. The resistance of the heating rod is determined based on the current and voltage of the heating rod.

[0039] The infrared thermal imager is used to obtain a thermal image of the insulation layer, and the thermal image is used to determine whether the insulation layer is in an abnormal state. When the defect score of the insulation layer is greater than or equal to the defect score threshold, the insulation layer is in an abnormal state.

[0040] In summary, the embodiments of the present application provide a monitoring method, device, and system for an electric heating roller kiln. The method monitors the status of the roller, heating rod, and insulation layer, and issues a prompt message when the status of an object among the roller, heating rod, and insulation layer is abnormal, thereby enabling the operator to promptly detect abnormalities in the electric heating roller kiln and then promptly inspect and repair the electric heating roller kiln.

[0041] In addition, since the priorities of the first to third objects decrease in sequence, the status of the object with a higher priority is detected first. When the status of the object with a higher priority is abnormal, a prompt message for inspection of the object with a higher priority and objects with a lower priority than the object with a higher priority can be issued, and the status of the object with a lower priority will no longer be detected. This avoids the execution of unnecessary detection operations and improves the efficiency of monitoring the electric heating roller kiln.

[0042] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 This is a flow chart of a monitoring method for an electric heating roller kiln provided in an embodiment of the present application;

[0044] Figure 2 This is a flow chart of another monitoring method for an electrically heated roller kiln provided in an embodiment of the present application;

[0045] Figure 3 This is a schematic diagram of the structure of a controller provided in an embodiment of the present application. DETAILED DESCRIPTION

[0046] The following describes embodiments of the present invention in detail, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and are not to be construed as limiting the present invention.

[0047] In the production process of lithium-ion battery electrode materials, roller kilns can be used for the sintering process. Among them, roller kilns are suitable for the sintering of different types of lithium battery electrode materials due to their large production capacity and stable and reliable operation. They are widely used by domestic and foreign users.

[0048] In the related art, when an abnormality occurs in a roller kiln, if the abnormal information cannot be discovered in time, it may bring huge safety hazards to the production process.

[0049] In one implementation, roller kiln operators are required to conduct regular inspections, carefully observing any faults in the kiln with their naked eyes. However, this approach may not capture fault information promptly, resulting in delayed fault handling and response, which can pose a significant safety hazard to the production process.

[0050] An embodiment of the present application provides a monitoring method for an electric heating roller kiln. The method monitors the status of the roller, heating rod and insulation layer, and issues a prompt message when the status of an object among the roller, heating rod and insulation layer is abnormal, thereby enabling the operator to promptly detect abnormalities in the electric heating roller kiln and then promptly inspect and repair the electric heating roller kiln.

[0051] In addition, since the priorities of the first to third objects decrease in sequence, the status of the object with a higher priority is detected first. When the status of the object with a higher priority is abnormal, a prompt message for inspection of the object with a higher priority and objects with a lower priority than the object with a higher priority can be issued, and the status of the object with a lower priority will no longer be detected. This avoids the execution of unnecessary detection operations and improves the efficiency of monitoring the electric heating roller kiln.

[0052] Figure 1 This is a flow chart of a monitoring method for an electric heating roller kiln provided in an embodiment of the present application. The electric heating roller kiln may include a roller, a heating rod and an insulation layer. Figure 1 As shown, the method includes:

[0053] Step 101: Acquire the status of the roller, the heating rod, and the first object in the insulation layer.

[0054] The controller can obtain the status of the roller, the heating rod and the first object in the insulation layer periodically or in real time.

[0055] The state of the first object may include a normal state or an abnormal state, and the first object is the object with the highest priority among the roller, the heating rod, and the insulation layer.

[0056] Step 102: If the state of the first object is abnormal, a first prompt message for repairing the roller, the heating rod and the insulation layer is issued.

[0057] If the state of the first object is an abnormal state, the controller may issue a first prompt message for repairing the roller, the heating rod and the insulation layer.

[0058] Step 103: If the state of the first object is normal, obtain the state of the second object in the roller, the heating rod, and the insulation layer.

[0059] If the state of the first object is normal, the controller can obtain the state of the second object in the roller, the heating rod and the insulation layer.

[0060] The state of the second object may include a normal state or an abnormal state. The second object is the object with the second highest priority among the roller, the heating rod, and the insulation layer.

[0061] Step 104: If the state of the first object is normal and the state of the second object is abnormal, a second prompt message for repairing the objects other than the first object is issued.

[0062] If the state of the first object is normal and the state of the second object is abnormal, the controller can issue a second prompt message for repairing other objects except the first object, thereby ensuring that the operator can repair other objects except the first object in time.

[0063] Step 105: If the states of the first object and the second object are both normal, obtain the state of the third object among the roller, the heating rod, and the insulation layer.

[0064] If the states of the first and second objects are both normal, the controller can obtain the state of the third object among the roller, heating rod, and insulation layer. The priorities of the first to third objects decrease in descending order, i.e., the third object has the lowest priority among the roller, heating rod, and insulation layer.

[0065] Step 106: If the states of the first object and the second object are both normal, and the state of the third object is abnormal, a third prompt message for repairing the third object is issued.

[0066] If the states of the first object and the second object are both normal, and the state of the third object is abnormal, the controller may issue a third prompt message for repairing the third object.

[0067] In an embodiment of the present application, since the priorities of the first to third objects decrease in sequence, the status of the first object with the highest priority is detected first. When the status of the first object is abnormal, a first prompt message is issued to inspect the roller, heating rod and insulation layer, and the status of other objects is no longer detected. When the status of the first object is normal, the status of the second object with the second highest priority is further determined. When the status of the second object is abnormal, a second prompt message is issued to inspect other objects except the first object, and the status of other objects except the first object is no longer detected. When the status of the first object and the second object are both normal, the status of the third object with the lowest priority is determined. Thus, the status of the object with a higher priority is detected first. When the status of the object with a higher priority is abnormal, a prompt message is issued to inspect the object with a higher priority and objects with a lower priority than the object with a higher priority, and the status of the object with a lower priority is no longer detected, thereby improving the efficiency of monitoring the electric heating roller kiln.

[0068] In summary, the embodiment of the present application provides a monitoring method for an electric heating roller kiln. The method monitors the status of the roller, heating rod and insulation layer, and issues a prompt message when the status of an object among the roller, heating rod and insulation layer is abnormal, thereby enabling the operator to promptly detect abnormalities in the electric heating roller kiln and then promptly inspect and repair the electric heating roller kiln.

[0069] In addition, since the priorities of the first to third objects decrease in sequence, the status of the object with a higher priority is detected first. When the status of the object with a higher priority is abnormal, a prompt message for inspection of the object with a higher priority and objects with a lower priority than the object with a higher priority can be issued, and the status of the object with a lower priority will no longer be detected. This avoids the execution of unnecessary detection operations and improves the efficiency of monitoring the electric heating roller kiln.

[0070] Figure 2 This is a flow chart of another monitoring method for an electric heating roller kiln provided in an embodiment of the present application. The electric heating roller kiln may include a roller, a heating rod, an insulation layer, and a plurality of temperature zones connected in sequence. Figure 2 As shown, the method may include:

[0071] Step 201: Obtain the status of the target temperature zone.

[0072] In one possible implementation, when the target temperature zone is the first temperature zone, the controller can obtain the status of the target temperature zone, or when the target temperature zone is located after the first temperature zone and the status of the temperature zone located before the target temperature zone is normal, the controller can obtain the status of the target temperature zone.

[0073] Since multiple temperature zones are connected in sequence, if the temperature of one temperature zone is abnormal, the temperatures of the temperature zones following it will also be affected. Therefore, if the state of the target temperature zone is abnormal, the controller can execute the following step 202, i.e., obtain the state of the first object, without obtaining the state of the next temperature zone, thereby avoiding unnecessary detection and improving the monitoring efficiency of the electric heating roller kiln. If the state of the target temperature zone is normal and the target temperature zone is not the last temperature zone, the controller can continue to obtain the state of the next temperature zone.

[0074] Optionally, when the temperature variation of the target temperature zone is outside the temperature threshold range, the state of the target temperature zone is abnormal. When the temperature variation of the target temperature zone is within the temperature threshold range, the state of the target temperature zone is normal.

[0075] The temperature change is obtained by inputting the historical temperature data of the target temperature zone within a preset time period before the current moment into the temperature prediction model.

[0076] Because abnormal roller vibration, heating rod abnormality, and insulation layer cracking can cause abnormal temperature in the temperature zone, the controller can first detect whether the temperature in the target temperature zone is abnormal. If the temperature in the target temperature zone is abnormal, the controller will execute the following steps to further determine the cause of the abnormal temperature in the target temperature zone.

[0077] The temperature change refers to the difference in the target temperature zone's temperature beyond the preset temperature range. If the target temperature zone's temperature is greater than the upper limit of the preset temperature range, the difference is the difference between the upper limit and the target temperature zone's temperature. If the target temperature zone's temperature is less than the lower limit of the preset temperature range, the difference is the difference between the target temperature zone's temperature and the lower limit.

[0078] By predicting the temperature of a temperature zone in advance, it is possible to detect in advance whether the temperature of the temperature zone is abnormal, and then detect in advance the cause of the abnormal temperature of the temperature zone, ensuring that the fault can be responded to in a timely manner.

[0079] The historical temperature data can be the historical temperatures of the target temperature zone at multiple historical moments within a preset time period. The controller can normalize the multiple historical temperatures and input the multiple historical temperatures into the temperature prediction model to obtain the temperature change. For example, the multiple historical moments can be 60 moments, and the preset time period can be 60 minutes.

[0080] Each temperature zone can be equipped with multiple temperature sensors, which can be thermocouple arrays. For example, a thermocouple array is set at the top, middle and bottom of the temperature zone respectively. The temperature collector can obtain the analog voltage output by the thermocouple array and convert the analog voltage into temperature.

[0081] The temperature zone collector may include a signal conditioning circuit and an analog-to-digital conversion circuit. The signal conditioning circuit is connected to the thermocouple probes in the thermocouple array. The signal conditioning circuit is used to obtain the analog voltage, and filter and amplify the analog voltage before sending it to the analog-to-digital conversion circuit. The analog-to-digital conversion circuit converts the received signal into temperature and sends it to the controller.

[0082] The temperature can meet: V is the analog voltage value, and 40.5 is the conversion coefficient of the K-type thermocouple, which means that the voltage changes by about 40.5 microvolts for every 1 degree Celsius (°C) increase in temperature. The unit of temperature is °C, and the accuracy is approximately ±5°C.

[0083] In addition, the signal conditioning circuit is connected to the thermocouple probe via a shielded twisted pair cable, and a cold end compensation circuit is provided at the cold end of the thermocouple array, thereby achieving anti-interference.

[0084] In another optional implementation, the historical temperature data may include the historical temperatures of each temperature zone at multiple historical moments. The controller inputs the multiple historical temperatures of each temperature zone into a temperature prediction model to obtain the temperature change of each temperature zone. The temperature prediction model may be a long short-term memory (LSTM) network.

[0085] The temperature prediction model may include an input layer, an LSTM layer, a tanh activation function, a dropout layer, and an output layer. The input layer includes historical temperature data, and the LSTM layer processes this data. The LSTM layer is a specialized neural network that effectively captures dependencies within time series data. The LSTM layer consists of 32 units, meaning the network has 32 "memory cells" to process and store temperature time series information. The tanh activation function helps the network learn nonlinear relationships within the temperature data, ensuring that the output more closely reflects actual temperature fluctuations.

[0086] The Dropout layer prevents overfitting, a condition in which a model learns too many unnecessary details during training, resulting in a decrease in its ability to predict new data. Setting a Dropout rate of 1 effectively forces the model to be less reliant on certain specific requirements during training, thereby improving its generalization ability.

[0087] Finally, the data processed by the LSTM layer and the Dropout layer will enter the output layer. The output layer here uses a linear activation function. This is mainly because temperature changes are continuous values, so we need to use linear regression to predict future temperature changes.

[0088] Step 202: If the state of the target temperature zone is abnormal, the state of the roller, the heating rod, and the first object in the insulation layer is obtained.

[0089] If the target temperature zone is in an abnormal state, the controller can obtain the state of the first object among the roller, heating rod, and insulation layer. The priority of the roller, heating rod, and insulation layer is descending, and the priority of each object is positively correlated with the importance of the object.

[0090] The first object may include a roller table, and the state of the first object may include a normal state or an abnormal state. The abnormal state of the first object means that vibration of the first object is abnormal.

[0091] Different temperature zones require different temperatures, and each zone is equipped with a heating rod. Materials enter each zone at a constant speed via rollers, and the heating rods heat the corresponding zone, maintaining it within a stable temperature range and thereby heating the material. Abnormal vibration of the rollers can cause abnormal material conveying conditions (e.g., material conveying speed), which can lead to abnormal temperatures in a particular zone, and thus abnormal heating rods in that zone.

[0092] In addition, abnormal vibration of the roller conveyor can cause continuous impact or alternating stress on the insulation layer through mechanical transmission, which may cause the insulation layer to crack and cause abnormalities in the insulation layer. Because abnormal roller conveyor vibration affects the heating rods and the insulation layer, the roller conveyor is of the highest importance.

[0093] While the roller vibration is normal, aging of the heater rods can cause abnormal current or resistance. This can lead to abnormal temperatures in the corresponding temperature zone. This abnormal temperature can directly damage the insulation layer through thermal stress shock, leading to cracking. Because heater rod abnormalities can affect the insulation layer, they are considered the second most important factor.

[0094] In the embodiment of the present application, the roller conveyor may include a roller bar. When the wavelet entropy of the vibration signal of the roller bar is greater than or equal to an entropy value threshold, the state of the roller conveyor is abnormal.

[0095] The process of determining whether the roller conveyor is in a normal state or an abnormal state can be executed by the controller or by the cloud. The embodiment of the present application is described by taking the controller execution as an example.

[0096] Optionally, there may be multiple rollers. If a first number of rollers are in an abnormal state and the first number is greater than or equal to a first threshold, the controller may determine that the state of the first object is abnormal. If the number of rollers in the abnormal state is less than the first number, the controller may determine that the state of the first object is normal.

[0097] For each roller, the controller can obtain the roller's vibration signal. If the wavelet entropy of the vibration signal is greater than or equal to an entropy threshold, the roller's state can be determined to be abnormal. If the wavelet entropy of the vibration signal is less than the entropy threshold, the roller's state can be determined to be normal. For example, the entropy threshold can be 0.85.

[0098] Each roller is supported by at least two bearings. The vibration signal of each roller may include vibration signals of at least two bearings supporting the roller. Each bearing is provided with a vibration sensor. The controller may obtain the vibration signal of the bearing through the vibration sensor.

[0099] For each roller, the controller can obtain vibration signals from at least two bearings supporting the roller. If the wavelet entropy of the vibration signals of a target number of bearings is greater than or equal to an entropy threshold, and the target number is greater than a preset number, the controller can determine that the roller is in an abnormal state. If the number of bearings whose vibration signals are greater than or equal to the entropy threshold is less than the target number, the controller can determine that the roller is in a normal state. The entropy threshold, the first number threshold, and the target number can be pre-stored in the controller.

[0100] If the wavelet entropy of the roller vibration signal is greater than or equal to the entropy threshold, the roller is eccentric. If a first number of rollers are in an abnormal state and the first number is greater than or equal to the first threshold, the controller can determine that a large number of bearings are severely worn. In this case, the roller is severely eccentric, which may affect the normal operation of the electric heated roller kiln.

[0101] Among them, roller eccentricity refers to the phenomenon that when the roller is rotating, its geometric center does not coincide with the rotation axis (that is, there is eccentricity), which causes periodic radial runout or offset of the roller during operation.

[0102] Wavelet entropy reflects the complexity of the vibration signal. The larger the wavelet entropy, the more complex and irregular the signal. When the bearing is worn, the vibration signal usually becomes more complex and the entropy value is also higher.

[0103] In an embodiment of the present application, the controller may perform multi-layer decomposition of the vibration signal to obtain multiple layers of signal components, each with a different frequency range. For each layer of signal components, the controller may then sum the squares of the wavelet coefficients of that signal component to obtain the energy of that signal component, and sum these multiple energies to obtain the total energy. The controller may then calculate the proportion of the energy of each layer of signal components in the total energy, and calculate the wavelet entropy of the vibration signal based on the multiple proportions.

[0104] Wavelet entropy can satisfy:

[0105] Among them, H k Characterizes the proportion of the energy of the k-th layer signal component in the total energy, where k is a positive integer less than or equal to the total number of signal component layers.

[0106] Step 203: If the state of the first object is abnormal, a first prompt message for repairing the roller, the heating rod and the insulation layer is issued.

[0107] If the state of the first object is an abnormal state, the controller may issue a first prompt message for repairing the roller, the heating rod and the insulation layer.

[0108] Since the rollers affect both the heating rods and the insulation layer, if the rollers experience abnormal vibration, an immediate reminder message will be issued to inspect the rollers, heating rods, and insulation layer, allowing operators to carry out repairs in a timely manner, thereby improving the reliability of monitoring the electric-heated roller kiln. At the same time, since there is no need to check the status of the heating rods and insulation layer, the monitoring process of the electric-heated roller kiln is simplified and the efficiency of the monitoring is improved.

[0109] In the embodiment of the present application, the first prompt information may include: position information of the roller rod in an abnormal state, and position information of the heating rod and the insulation layer.

[0110] If the state of the first object is abnormal, the controller can obtain the first prompt information corresponding to the first object from the knowledge graph reasoning. The first prompt information may also include the cause of the abnormality of the first object, as well as other abnormalities caused by the abnormality of the first object. For example, high vibration entropy (symptom) indicates bearing wear (fault), and bearing wear (fault) is caused by high vibration entropy (symptom), and bearing wear (fault) can also cause temperature fluctuations (symptoms).

[0111] The knowledge graph pre-stores the relationship between different objects in the electric heating roller kiln, and the controller can also obtain the cause of the abnormality of the first object from the knowledge graph.

[0112] Step 204: If the state of the first object is normal, obtain the state of the second object in the roller, the heating rod, and the insulation layer.

[0113] If the state of the first object is normal, the controller can obtain the state of the second object in the roller, the heating rod and the insulation layer.

[0114] The second object includes a heating rod, and a current sensor is installed on a contact or circuit of the heating rod. The current sensor is used to monitor the current of the heating rod in real time. The controller can detect the current of the heating rod through the current sensor. In an optional implementation, if the current of the heating rod is outside a current threshold range, the state of the heating rod is abnormal. If the current of the heating rod is within the current threshold range, the state of the heating rod is normal.

[0115] The process of determining whether the state of the heating rod is normal or abnormal can be executed by the controller or by the cloud. The embodiment of the present application is described by taking the controller execution as an example.

[0116] When multiple heating rods are provided in each temperature zone, if the currents of a second number of heating rods are outside a current threshold range, and the second number is greater than or equal to the second threshold, the controller may determine that the heating rods are in an abnormal state. If the number of heating rods with currents outside the current threshold range is less than the second number, the controller may determine that the heating rods are in a normal state. The current threshold range is pre-stored in the controller.

[0117] In another implementation, a voltage sensor is further installed on the contact or circuit of the heating rod, and the voltage sensor is used to monitor the voltage of the heating rod in real time. The controller can also obtain the voltage of the heating rod through the voltage sensor and determine the resistance of the heating rod based on the ratio of the voltage and current of the heating rod. If the resistance of the heating rod is outside the resistance threshold range (such as too high or too low resistance, which may result in poor heating effect or damage), it can be determined that the state of the heating rod is abnormal. If the resistance is within the resistance threshold range, it can be determined that the state of the heating rod is normal.

[0118] Step 205: If the state of the first object is normal and the state of the second object is abnormal, a second prompt message for repairing the objects other than the first object is issued.

[0119] If the state of the first object is normal and the state of the second object is abnormal, the controller may determine that the heating rod is aged, and thus issue a second prompt message for repairing other objects except the first object.

[0120] The controller may obtain second prompt information corresponding to the second object from the knowledge graph reasoning. In an embodiment of the present application, the second prompt information may include: location information of the heating rod in an abnormal state, and location information of the insulation layer.

[0121] If a heating rod anomaly occurs, it may affect the heating effect of the temperature zone and, in turn, the normal operation of the equipment. Since the heating rod affects the insulation layer, the controller can issue a second prompt to inspect the second object and the insulation layer in the event of a heating rod anomaly. This allows operators to perform timely repairs, avoiding equipment damage or production interruptions, ensuring normal operation of the equipment, and improving the reliability of electric roller kiln monitoring. Furthermore, since there is no need to check the status of the insulation layer, the monitoring process of the electric roller kiln is simplified and the efficiency of the monitoring is improved.

[0122] The controller can also obtain the aging degree of the heating rod. If the aging degree of the heating rod is greater than or equal to the aging degree threshold, it can be determined that the heating rod is seriously aged, and thus a fourth prompt message can be issued to remind the operator to replace the heating rod in time to avoid complete damage to the heating rod.

[0123] It's understandable that the resistance of a heater's resistance wire increases with age. This is especially true during heating, where the wire may oxidize or corrode due to the high temperatures, leading to increased resistance. Real-time monitoring of the heater's resistance allows for immediate detection of aging and any potential anomalies.

[0124] In an embodiment of the present application, the controller may input the resistance of the heating rod into an aging prediction model to obtain the aging degree of the heating rod.

[0125] The aging prediction model may be obtained by training a plurality of sample data using a machine learning algorithm, wherein each sample data may include a sample resistance and a sample aging degree of a sample heating rod. The machine learning algorithm may include a support vector machine, a neural network, or a decision tree.

[0126] For each sample heater rod, the controller may obtain a sample voltage and a sample current of the sample heater rod, and determine a sample resistance based on a ratio of the sample voltage to the sample current.

[0127] Optionally, the controller can also obtain influencing parameters, which may include parameters such as temperature, load, and current. Changes in these influencing parameters will affect the resistance, resulting in the determined resistance not accurately reflecting the degree of aging of the heating rod. Therefore, each sample data can include the sample resistance and sample influencing parameters of the sample heating rod, as well as the sample aging degree. The controller can input the influencing parameters and resistance into the aging prediction model to obtain the aging degree of the heating rod. The aging prediction model can eliminate the influence of the influencing parameters on the resistance, thereby ensuring the reliability of the determined aging degree of the heating rod.

[0128] In an embodiment of the present application, the controller can also input multiple historical resistances of the heating rod into a resistance trend prediction model to obtain the resistance growth trend of the heating rod and then the predicted failure time of the heating rod, thereby optimizing the maintenance plan.

[0129] In an embodiment of the present application, the controller may further obtain operating parameters of the heating rod and input the operating parameters into a remaining life prediction model to obtain the remaining life of the heating rod.

[0130] The operating parameters may include the operating time, number of starts and stops, and average temperature of the heater. For example, the operating time may be 1500 hours, the number of starts and stops may be 320, and the average temperature may be 980° C. The remaining life prediction model may be obtained by training an XGBoost regression model using existing data.

[0131] Step 206: If the states of the first object and the second object are both normal, obtain the state of the third object among the roller, the heating rod, and the insulation layer.

[0132] In an embodiment of the present application, if the states of the first object and the second object are both normal, the controller can obtain the state of a third object among the roller, the heating rod, and the insulation layer. The third object may include the insulation layer, and the state of the third object may include a normal state and an abnormal state.

[0133] If the defect score of the insulation layer is greater than or equal to the defect score threshold, the insulation layer is in an abnormal state. If the defect score of the insulation layer is less than the defect score threshold, the insulation layer is in a normal state. For example, the defect score threshold may be 0.8.

[0134] The process of determining whether the state of the insulation layer is normal or abnormal can be executed by the controller or by the cloud. The embodiment of the present application is described by taking the controller execution as an example.

[0135] The abnormal state of the insulation layer may refer to cracking of the insulation layer. The controller may obtain a thermal image of the insulation layer using an infrared thermal imager and analyze the thermal image to determine a defect score of the insulation layer.

[0136] Step 207: If the states of the first object and the second object are both normal, and the state of the third object is abnormal, a third prompt message for repairing the third object is issued.

[0137] If the states of the first object and the second object are both normal, and the state of the third object is abnormal, the controller may issue a third prompt message for repairing the third object.

[0138] The controller may obtain third prompt information corresponding to the third object from the knowledge graph reasoning. The third prompt information may also include the location of the third object.

[0139] In the embodiment of the present application, after issuing the prompt information, the controller can also generate a maintenance plan and display the maintenance operation process in a three-dimensional visual manner, thereby guiding maintenance personnel to perform equipment maintenance while ensuring safety during the maintenance process.

[0140] Optionally, the controller can load a 3D maintenance guide model to help users understand repair or maintenance procedures. This model can include the location of the object requiring repair, a maintenance video, and safety tips. This reduces maintenance time (including roller replacement and fault repairs), reduces manual labor, and shortens the training period for new employees.

[0141] For example, a video guide could include a disassembly and assembly animation related to equipment maintenance, helping maintenance personnel understand how to disassemble or assemble a faulty device. Safety reminders could also alert personnel that the equipment may be in a high-temperature area and needs to be cooled to below 50°C, ensuring safety during maintenance.

[0142] The controller can also obtain the operator's voice information, identify keywords in the voice information, and then display corresponding data based on the keywords.

[0143] For example, the keywords include: "temperature history" or "historical temperature", and "temperature zone 3". Then the controller can determine that the user wants to query the temperature history data of temperature zone 3, so the historical data corresponding to the temperature zone number "3" in the keyword can be displayed to the operator.

[0144] After issuing a prompt, the controller can also generate a work order and push it to the corresponding mobile terminal for timely processing by staff. The work order information can include the object to be repaired, the repair priority, the repair steps, the parts required for the repair, the duration of the repair, and the risk level of the repair.

[0145] In the embodiment of the present application, the above-mentioned acquisition of the states of the first object to the third object, determination of the state of the temperature zone, and determination of the aging degree of the heating rod can all be determined by the target model.

[0146] The controller can also obtain the target gradient of the target model and update the gradient of the target model to the target gradient. The target gradient is obtained by weighted average of the historical gradients of the target models corresponding to multiple electric heating roller kilns.

[0147] Each controller in an electric roller kiln can encrypt the historical gradients of each target model and send them to the cloud. The cloud decrypts the received historical gradients, takes a weighted average of them, and then sends the encrypted target gradients to each controller. This data encryption ensures data security and prevents the leakage of private factory data.

[0148] In an embodiment of the present application, by predicting the temperature of each temperature zone, when the temperature of any temperature zone is abnormal, the status of the first object with the highest priority among the roller, heating rod and insulation layer is obtained. When the status of the first object is abnormal, a first prompt message is issued to inspect the roller, heating rod and insulation layer, thereby no longer detecting the status of other objects. When the status of the first object is normal, the status of the second object with the second highest priority is further determined. When the status of the second object is abnormal, a second prompt message is issued to inspect other objects except the first object, thereby no longer detecting the status of other objects except the first object. When the status of the first object and the second object are both normal, the status of the third object with the lowest priority is determined. In this way, the causes of the abnormal temperature in the temperature zones are detected in turn, thereby realizing intelligent fault diagnosis and maintenance decision-making for the equipment.

[0149] When the cloud determines the status of any of the first through third objects, four types of heterogeneous sensor data—temperature, thermal current (or resistance), vibration signals, and thermal imaging—are collaboratively processed at the edge layer (i.e., the controller) and in the cloud. Fault root cause analysis is achieved through a dual-driven approach using physical mechanism models (such as Ohm's law and wavelet entropy) and AI models, achieving a dual-level early warning system of "rapid edge response + in-depth cloud analysis." This solves the data silo problem of traditional kilns and enables cross-sensor correlation diagnosis of hidden faults (such as bearing wear and heating rod aging).

[0150] Existing technologies suffer from delayed fault response: Traditional electric-heated roller kilns rely on manual inspections, unable to detect hidden defects such as temperature control anomalies (such as heating rod deterioration), transmission failures (such as roller sticking), and poor sintering performance (temperature uniformity fluctuations) in real time. Operational and maintenance efficiency is low: Fault diagnosis relies heavily on engineer experience, resulting in an average repair time exceeding four hours and production downtime losses reaching as high as 10,000 yuan per hour. Data silos are severe: Multi-source data, including temperature sensors, current monitoring, and PLC control, is not integrated and analyzed, leading to a lack of predictive maintenance.

[0151] The solution provided by the embodiment of the present application solves the above-mentioned problems and realizes cross-sensor data fusion, fault root cause analysis, and maintenance strategy generation. Early warning of mechanical failures such as bearing wear improves the sensitivity of heating rod aging detection and reduces the false alarm rate. The proportion of predictive maintenance has increased significantly, avoiding unplanned downtime, reducing operation and maintenance costs, reducing the frequency of emergency repairs, and improving spare parts inventory turnover (AI accurately predicts life). And energy consumption is saved. The temperature control accuracy is more precise, reducing redundant energy consumption due to overheating, and early fault processing avoids heat loss (such as timely repair of cracks in the insulation layer). In addition, through the blockchain evidence maintenance record and multi-level safety protection mechanism, the risk of accidents is reduced, high-temperature scalding accidents are reduced to zero (AR real-time prompts of dangerous areas), and the data credibility is 100%. Operation records cannot be tampered with, and equipment health files are completely traceable.

[0152] In summary, the embodiment of the present application provides a monitoring method for an electric heating roller kiln. The method monitors the status of the roller, heating rod and insulation layer, and issues a prompt message when the status of an object among the roller, heating rod and insulation layer is abnormal, thereby enabling the operator to promptly detect abnormalities in the electric heating roller kiln and then promptly inspect and repair the electric heating roller kiln.

[0153] In addition, since the priorities of the first to third objects decrease in sequence, the status of the object with a higher priority is detected first. When the status of the object with a higher priority is abnormal, a prompt message for inspection of the object with a higher priority and objects with a lower priority than the object with a higher priority can be issued, and the status of the object with a lower priority will no longer be detected. This avoids the execution of unnecessary detection operations and improves the efficiency of monitoring the electric heating roller kiln.

[0154] An embodiment of the present application provides a computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, the monitoring method of the electric heating roller kiln described in the above aspects is implemented.

[0155] Figure 3 This is a structural diagram of a controller provided in an embodiment of the present application, including a memory 301, a processor 302, and a computer program stored in the memory 301 and executable on the processor 302. When the processor executes the computer program, the monitoring method of the electric heating roller kiln described in the above aspects is implemented.

[0156] The present application provides a monitoring device for an electrically heated roller kiln. The electrically heated roller kiln includes a roller, a heating rod, and an insulation layer. The monitoring device is configured to:

[0157] Obtain the status of the first object in the roller, heating rod and insulation layer;

[0158] If the state of the first object is abnormal, a first prompt message for repairing the roller, the heating rod and the insulation layer is issued;

[0159] If the state of the first object is normal, and the state of the second object in the roller, heating rod and insulation layer is abnormal, a second prompt message is issued to inspect the other objects except the first object;

[0160] If the status of the second object is normal and the status of the third object among the roller, heating rod and insulation layer is abnormal, a third prompt message for maintenance of the third object is issued, and the priorities of the first to third objects decrease in sequence.

[0161] Optionally, the priorities of the roller, heating rod and insulation layer decrease in sequence, and the priority of each object in the roller, heating rod and insulation layer is positively correlated with the importance of the object.

[0162] Optionally, the electrically heated roller kiln further includes a plurality of sequentially connected temperature zones; obtaining the state of the first object in the roller, the heating rod, and the insulation layer includes:

[0163] When the target temperature zone is the first temperature zone, or the target temperature zone is located after the first temperature zone and the state of the temperature zone located before the target temperature zone is normal, obtaining the state of the target temperature zone;

[0164] If the state of the target temperature zone is abnormal, the state of the first object among the roller, the heating rod and the insulation layer is obtained.

[0165] Optionally, when the temperature variation of the target temperature zone is outside the temperature threshold range, the state of the target temperature zone is an abnormal state;

[0166] The temperature change is obtained by inputting historical temperature data of the third object within a preset time period before the current moment into the temperature prediction model.

[0167] Optionally, the first object includes a roller, and the roller includes a roller bar; when the wavelet entropy of the vibration signal of the roller bar is greater than or equal to an entropy value threshold, the state of the roller is an abnormal state;

[0168] The second object includes a heating rod, and when the current of the heating rod is outside a current threshold range, or the resistance of the heating rod is outside a resistance threshold range, the state of the heating rod is an abnormal state;

[0169] The third object includes a thermal insulation layer. When a defect score of the thermal insulation layer is greater than or equal to a defect score threshold, the state of the thermal insulation layer is an abnormal state.

[0170] Optionally, a monitoring device for:

[0171] Get the aging degree of the heating rod;

[0172] If the aging degree of the heating rod is greater than or equal to the aging degree threshold, a fourth prompt message is issued.

[0173] Optionally, a monitoring device for:

[0174] Obtaining a target gradient of a target model, where the target model is used to determine states of the first object to the third object;

[0175] Update the gradient of the target model to the target gradient;

[0176] The target gradient is obtained by weighted average of the historical gradients of the target models corresponding to multiple electric heating roller kilns.

[0177] Optionally, the statuses of the first object to the third object are obtained from the cloud.

[0178] In summary, the embodiment of the present application provides a monitoring device for an electric heating roller kiln. The device monitors the status of the roller, heating rod and insulation layer, and issues a prompt message when the status of an object among the roller, heating rod and insulation layer is abnormal, thereby enabling the operator to promptly detect abnormalities in the electric heating roller kiln and then promptly inspect and repair the electric heating roller kiln.

[0179] In addition, since the priorities of the first to third objects decrease in sequence, the status of the object with a higher priority is detected first. When the status of the object with a higher priority is abnormal, a prompt message for inspection of the object with a higher priority and objects with a lower priority than the object with a higher priority can be issued, and the status of the object with a lower priority will no longer be detected. This avoids the execution of unnecessary detection operations and improves the efficiency of monitoring the electric heating roller kiln.

[0180] An embodiment of the present application provides a monitoring system for an electric heating roller kiln. The monitoring system for the electric heating roller kiln includes: the controller described in the above aspect, or the monitoring device for the electric heating roller kiln described in the above aspect.

[0181] Optionally, the monitoring system includes: a plurality of temperature sensors arranged in each temperature zone, a vibration sensor arranged on the roller, a current sensor and a voltage sensor connected to the heating rod, and an infrared thermal imager;

[0182] Each temperature sensor is used to detect the temperature of a corresponding temperature zone, and the temperature of the temperature zone is used to determine whether the state of the temperature zone is abnormal; wherein, when the temperature change amount of the temperature zone is outside the temperature threshold range, the state of the temperature zone is abnormal, and the temperature change amount is determined based on the temperature of the temperature zone;

[0183] The vibration sensor is used to detect the vibration signal of the roller, and the vibration signal is used to determine whether the state of the roller is abnormal; wherein, when the wavelet entropy of the vibration signal of the roller is greater than or equal to the entropy value threshold, the state of the roller is abnormal;

[0184] The current sensor is used to detect the current of the heating rod, and the voltage sensor is used to detect the voltage of the heating rod. The current and voltage are used to determine whether the state of the heating rod is abnormal. If the current of the heating rod is outside a current threshold range, or if the resistance of the heating rod is outside a resistance threshold range, the state of the heating rod is abnormal. The resistance of the heating rod is determined based on the current and voltage of the heating rod.

[0185] The infrared thermal imager is used to obtain a thermal image of the insulation layer, and the thermal image is used to determine whether the insulation layer is in an abnormal state. When the defect score of the insulation layer is greater than or equal to the defect score threshold, the insulation layer is in an abnormal state.

[0186] It should be noted that the logic and / or steps represented in the flowcharts or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing the logical functions, and can be embodied in any computer-readable medium for use by an instruction execution system, apparatus, or device (such as a computer-based system, a system including a processor, or other system that can fetch and execute instructions from an instruction execution system, apparatus, or device), or in conjunction with such instruction execution system, apparatus, or device. For the purposes of this specification, a "computer-readable medium" can be any device that can contain, store, communicate, propagate, or transmit a program for use by an instruction execution system, apparatus, or device, or in conjunction with such instruction execution system, apparatus, or device. More specific examples (non-exhaustive list) of computer-readable media include the following: an electrical connection portion having one or more wires (electronic device), a portable computer disk cartridge (magnetic device), random access memory (RAM), read-only memory (ROM), erasable and programmable read-only memory (EPROM or flash memory), fiber optic devices, and portable compact disc read-only memory (CDROM). Furthermore, the computer-readable medium may even be paper or other suitable medium on which the program is printed, since the program may be obtained electronically, for example, by optically scanning the paper or other medium and then editing, interpreting or processing it in another suitable manner if necessary, and then storing it in a computer memory.

[0187] It should be understood that various parts of the present invention can be implemented using hardware, software, firmware, or a combination thereof. In the above-described embodiments, multiple steps or methods can be implemented using software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented using hardware, as in another embodiment, any one of the following technologies known in the art or a combination thereof can be used: a discrete logic circuit having a logic gate circuit for implementing a logic function on a data signal, an application-specific integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0188] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0189] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0190] In addition, the terms "first" and "second" used in the embodiments of the present invention are only used for descriptive purposes and should not be understood as indicating or implying relative importance, or implicitly indicating the number of technical features indicated in this embodiment. Therefore, the features defined by the terms "first" and "second" in the embodiments of the present invention can explicitly or implicitly indicate that the embodiment includes at least one of such features. In the description of the present invention, the word "plurality" means at least two or two or more, such as two, three, four, etc., unless otherwise clearly and specifically defined in the embodiments.

[0191] In the present invention, unless otherwise clearly specified or limited in the embodiments, the terms "installed," "connected," "connect," and "fixed" appearing in the embodiments should be understood in a broad sense. For example, the connection may be a fixed connection, a detachable connection, or an integral connection. It can also be a mechanical connection, an electrical connection, etc.; of course, it can also be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication between two elements, or the interaction between two elements. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood based on the specific implementation.

[0192] In the present invention, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0193] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention.

Claims

1. A monitoring method for an electrically heated roller kiln, characterized in that: The electric heating roller kiln includes a roller, a heating rod and an insulation layer; the method includes: Acquiring the states of the roller, the heating rod, and the first object in the insulation layer; If the state of the first object is abnormal, issuing a first prompt message for repairing the roller, the heating rod and the insulation layer; If the state of the first object is normal, and the states of the roller, the heating rod, and the second object in the insulation layer are abnormal, a second prompt message is issued to inspect the objects other than the first object; If the status of the second object is normal and the status of the third object in the roller, the heating rod and the insulation layer is abnormal, a third prompt message for maintenance of the third object is issued, and the priorities of the first object to the third object decrease in sequence.

2. The method according to claim 1, characterized in that The priorities of the roller, the heating rod, and the insulation layer decrease in sequence, and the priority of each object among the roller, the heating rod, and the insulation layer is positively correlated with the importance of the object.

3. The method according to claim 1, characterized in that The electrically heated roller kiln further includes a plurality of sequentially connected temperature zones; obtaining the status of the roller, the heating rod, and the first object in the insulation layer, including: When the target temperature zone is the first temperature zone, or the target temperature zone is located after the first temperature zone and the state of the temperature zone located before the target temperature zone is normal, obtaining the state of the target temperature zone; If the state of the target temperature zone is an abnormal state, the states of the roller, the heating rod, and the first object in the insulation layer are acquired.

4. The method according to claim 3, characterized in that When the temperature change of the target temperature zone is outside the temperature threshold range, the state of the target temperature zone is an abnormal state; The temperature change is obtained by inputting historical temperature data of the third object within a preset time period before the current moment into a temperature prediction model.

5. The method according to any one of claims 1 to 4, characterized in that: The first object includes the roller, and the roller includes a roller bar; when the wavelet entropy of the vibration signal of the roller bar is greater than or equal to an entropy value threshold, the state of the roller is an abnormal state; The second object includes the heating rod, and when the current of the heating rod is outside the current threshold range, or the resistance of the heating rod is outside the resistance threshold range, the state of the heating rod is an abnormal state; The third object includes the thermal insulation layer. When a defect score of the thermal insulation layer is greater than or equal to a defect score threshold, the state of the thermal insulation layer is an abnormal state.

6. The method according to any one of claims 1 to 4, further comprising: Obtaining the aging degree of the heating rod; If the aging degree of the heating rod is greater than or equal to the aging degree threshold, a fourth prompt message is issued.

7. The method according to any one of claims 1 to 4, characterized in that: The method further comprises: obtaining a target gradient of a target model, wherein the target model is used to determine states of the first object to the third object; Updating the gradient of the target model to the target gradient; The target gradient is obtained by weighted averaging the historical gradients of target models corresponding to multiple electric heating roller kilns.

8. The method according to any one of claims 1 to 4, wherein the statuses of the first object to the third object are obtained from the cloud.

9. A computer-readable storage medium, characterized in that A computer program is stored thereon, and when the computer program is executed by a processor, the monitoring method for an electric heating roller kiln according to any one of claims 1 to 8 is implemented.

10. A controller, characterized in that: The invention comprises a memory, a processor and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the monitoring method for the electric heating roller kiln according to any one of claims 1 to 8 is implemented.

11. A monitoring device for an electrically heated roller kiln, characterized in that: The electrically heated roller kiln comprises a roller, a heating rod and an insulation layer; the monitoring device is used to: Acquiring the states of the roller, the heating rod, and the first object in the insulation layer; If the state of the first object is abnormal, issuing a first prompt message for repairing the roller, the heating rod and the insulation layer; If the state of the first object is normal, and the states of the roller, the heating rod, and the second object in the insulation layer are abnormal, a second prompt message is issued to inspect the objects other than the first object; If the status of the second object is normal and the status of the third object in the roller, the heating rod and the insulation layer is abnormal, a third prompt message for maintenance of the third object is issued, and the priorities of the first object to the third object decrease in sequence.

12. A monitoring system for an electrically heated roller kiln, characterized in that: The monitoring system for the electric heating roller kiln comprises: the controller according to claim 10, or the monitoring device for the electric heating roller kiln according to claim 11.

13. The system according to claim 12, wherein: The monitoring system also includes: a plurality of temperature sensors arranged in each temperature zone, a vibration sensor arranged on the roller, a current sensor and a voltage sensor connected to the heating rod, and an infrared thermal imager; Each of the temperature sensors is used to detect the temperature of a corresponding temperature zone, and the temperature of the temperature zone is used to determine whether the state of the temperature zone is abnormal; wherein, when the temperature change of the temperature zone is outside a temperature threshold range, the state of the temperature zone is abnormal, and the temperature change is determined based on the temperature of the temperature zone; The vibration sensor is used to detect a vibration signal of the roller, and the vibration signal is used to determine whether the state of the roller is abnormal; wherein, when the wavelet entropy of the vibration signal of the roller is greater than or equal to an entropy value threshold, the state of the roller is abnormal; The current sensor is used to detect the current of the heating rod, and the voltage sensor is used to detect the voltage of the heating rod, and the current and the voltage are used to determine whether the state of the heating rod is abnormal; wherein, when the current of the heating rod is outside a current threshold range, or when the resistance of the heating rod is outside a resistance threshold range, the state of the heating rod is abnormal, and the resistance of the heating rod is determined based on the current and the voltage of the heating rod; The infrared thermal imager is used to obtain a thermal image of the insulation layer, and the thermal image is used to determine whether the state of the insulation layer is abnormal; when the defect score of the insulation layer is greater than or equal to a defect score threshold, the state of the insulation layer is abnormal.

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