Electric heating tube early warning protection system and method

Abstract

The invention discloses an electric heating tube early warning protection system and method. The electric heating tube early warning protection system comprises an electric heating tube, a cooling mechanism, an alternating current contactor, a relay, a temperature control assembly, a resistance sensor and a current sensor. Wherein the temperature control assembly comprises an automatic reset temperature controller and a manual reset temperature controller; the resistance sensor and the current sensor are connected in series and then are connected with the power supply side of the alternating current contactor; and the automatic reset temperature controller and the manual reset temperature controller are connected in series and then are connected with a contact of the alternating current contactor.

Description

Technical Field

[0001] The present invention belongs to the technical field of electric heating tubes, and more particularly, relates to an electric heating tube early warning protection system and method. Background Art

[0002] The heating tube is a tubular electric heating element. It is composed of a metal tube, a spiral resistance wire and crystalline magnesium oxide powder. Electric heating tube products are generally made of high-quality imported stainless steel tubes, imported high-temperature magnesium oxide powder, high-quality heating wire and other materials.

[0003] During the use of electric heating tubes, problems such as cooling mechanism failure, electric heating tube power attenuation or poor contact of the electric heating tube may occur. If these faults cannot be detected in time, the power supply of the electric heating tube cannot be cut off in time, and the user is prompted to troubleshoot and repair the problem, the circuit of the electric heating device may be easily burned out, resulting in abnormal interruption of heating and other problems. In serious cases, it may also cause safety hazards such as fire. Summary of the Invention

[0004] In response to the problem that existing electric heating pipes are unable to detect these faults in a timely manner when there are problems such as cooling mechanism failure, electric heating pipe power attenuation, or poor contact of the electric heating pipe, and promptly cut off the power supply of the electric heating pipe and prompt the user to perform troubleshooting and maintenance, resulting in abnormal interruption of heating and heating, causing safety hazards such as fire, the purpose of the present invention is to provide an electric heating pipe early warning protection system. The electric heating pipe early warning protection system includes: an electric heating pipe, a cooling mechanism, an AC contactor, a relay, a temperature control component, a resistance sensor, and a current sensor; wherein the temperature control component includes an automatic reset thermostat and a manual reset thermostat; the resistance sensor and the current sensor are connected in series and then connected to the power supply side of the AC contactor; the automatic reset thermostat and the manual reset thermostat are connected in series and then connected to the contacts of the AC contactor.

[0005] Furthermore, the electric heating pipe early warning protection system also includes: an alarm module electrically connected to the temperature control component, the resistance sensor and the current sensor.

[0006] The present invention provides an electric heating pipe early warning protection method, which uses the electric heating pipe early warning protection system as described above. The electric heating pipe early warning protection method includes: the resistance sensor obtains the resistance value of the electric heating pipe in real time; and controls the switching state of the cooling mechanism and / or the on-off of the contacts of the AC contactor according to the relationship between the resistance value and the resistance threshold.

[0007] Furthermore, controlling the switching state of the cooling mechanism and / or the on / off of the contacts of the AC contactor according to the relationship between the resistance value and the resistance threshold includes: if the resistance value is greater than the first resistance threshold, controlling the contacts of the AC contactor to be disconnected, and controlling the cooling mechanism to continue running for a preset period of time before cutting off the power supply.

[0008] Furthermore, the electric heating tube early warning protection method further includes: while cutting off the power supply, controlling the alarm module to send out a first alarm signal to prompt the user to replace the electric heating tube.

[0009] Furthermore, the electric heating tube early warning protection method also includes: the resistance sensor obtains the resistance value of the electric heating tube in real time; according to the resistance value being less than a second resistance threshold, the contacts of the AC contactor are controlled to be disconnected and the power supply is cut off.

[0010] Furthermore, the electric heating pipe early warning protection method further includes: while cutting off the power supply, controlling the alarm module to send out a second alarm signal to prompt the user to perform phase failure troubleshooting.

[0011] Furthermore, the electric heating tube early warning protection method also includes: the current sensor obtains the current value in real time; if the current value meets the first preset condition, the power supply is cut off; wherein, the first preset condition includes: the current value increases exponentially, and the increase multiple of the current value is greater than the multiple threshold.

[0012] Furthermore, the electric heating pipe early warning protection method further includes: if the current value meets the first preset condition, controlling the alarm module to send a third alarm signal to prompt the user to perform phase failure troubleshooting.

[0013] Furthermore, the electric heating tube early warning protection method also includes: if the first temperature value of the automatic reset thermostat is greater than the first temperature threshold, the cooling mechanism is determined to be faulty, the automatic reset thermostat is disconnected, the contacts of the AC contactor are disconnected, and the cooling fan continues to run for a preset period of time before the power is cut off.

[0014] Furthermore, the electric heating pipe early warning protection method also includes: if the second temperature value of the manual reset thermostat is greater than the second temperature threshold, the automatic reset thermostat is determined to be invalid, the manual reset thermostat is disconnected, the contacts of the AC contactor are disconnected, and the cooling fan continues to run for a preset period of time before the power is cut off.

[0015] The technical effects and advantages of the present invention are as follows:

[0016] 1. By setting the temperature control component to the form of automatic reset thermostat and manual reset thermostat in series, a double insurance can be formed through the series automatic reset thermostat and manual reset thermostat. The manual reset thermostat can disconnect the contacts of the AC contactor when the automatic reset thermostat fails, and promptly cut off the power supply of the electric heating tube, avoiding the problem of failure of the automatic reset thermostat to cut off the power supply of the electric heating tube in time. The alarm module can send an alarm signal when the electric heating tube has problems such as cooling mechanism failure, electric heating tube power attenuation or poor contact of the electric heating tube, prompting the user to troubleshoot and repair the problem.

[0017] 2. By controlling the cooling mechanism to continue running for a preset period of time after the contacts of the AC contactor are disconnected, the electric heating tube can continue to dissipate heat and cool down for a period of time after the power supply of the electric heating tube is cut off. In this way, the user will not be burned by the electric heating tube when replacing the electric heating tube, and the problem of the electric heating tube being too high after the power supply is cut off and unable to be replaced can be avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is an electrical schematic diagram of an electric heating pipe early warning protection system provided by the present invention.

[0019] In the picture:

[0020] 10. Electric heating tube; 20. Cooling fan; 30. AC contactor; 40. Resistance sensor; 50. Current sensor; 60. Automatic reset thermostat; 70. Manual reset thermostat; 80. Solid-state relay; 90. Power supply for electric control cabinet. DETAILED DESCRIPTION

[0021] The present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments. The embodiments of the present invention are provided for purposes of illustration and description and are not intended to be exhaustive or to limit the invention to the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. The embodiments are chosen and described to better illustrate the principles of the invention and its practical application, and to enable those skilled in the art to understand the invention and design various embodiments with various modifications suitable for specific applications.

[0022] See also Figure 1 , which is an electrical schematic diagram of an electric heating pipe early warning protection system provided by the present invention, the electric heating pipe early warning protection system includes, for example: an electric heating pipe 10, a cooling mechanism, an AC contactor 30, a relay, a temperature control component, a resistance sensor 40, and a current sensor 50. For example, the cooling mechanism can use air cooling or water cooling for heat dissipation, which is not limited here.

[0023] The temperature control assembly includes an automatic reset thermostat 60 and a manual reset thermostat 70. The automatic reset thermostat 60 and the manual reset thermostat 70 are connected in series and connected to the contacts of the AC contactor 30. The first temperature threshold of the automatic reset thermostat 60 is lower than the second temperature threshold of the manual reset thermostat 70. The temperature control assembly can monitor the temperature in real time and determine whether the device's cooling mechanism has malfunctioned based on the temperature.

[0024] For example, if a device's cooling mechanism malfunctions and the real-time temperature exceeds a set threshold, the automatic reset thermostat 60 can promptly disconnect the circuit, thereby opening the contacts of the AC contactor 30 and cutting off the power supply to the electric heating tube 10. This prevents the electric heating tube 10 from continuing to operate, causing the temperature inside the device to overheat and burn out the circuit of the electric heating device, while the heat inside the device cannot be dissipated in time. When the temperature returns to normal, the automatic reset thermostat 60 automatically resumes conduction.

[0025] By setting the temperature control component in the form of an automatic reset thermostat 60 and a manual reset thermostat 70 connected in series, a double insurance can be formed by the automatic reset thermostat 60 and the manual reset thermostat 70 connected in series. The manual reset thermostat 70 can disconnect the contacts of the AC contactor 30 when the automatic reset thermostat 60 fails, and cut off the power supply of the electric heating tube 10 in time, avoiding the problem that the power supply of the electric heating tube 10 cannot be cut off in time due to the failure of the automatic reset thermostat 60.

[0026] Furthermore, the resistance sensor 40 and the current sensor 50 are connected in series and then connected to the power supply side of the AC contactor 30. The electric heating pipe early warning protection system can determine whether the power of the electric heating pipe 10 is attenuated, whether the electric heating pipe 10 needs to be replaced, and whether the product has a phase loss problem based on the resistance value of the resistance sensor 40.

[0027] Furthermore, the electric heating pipe early warning protection system further includes an alarm module electrically connected to the temperature control assembly, the resistance sensor 40, and the current sensor 50. The alarm module can issue an alarm signal when the electric heating pipe 10 has a cooling mechanism failure, power attenuation, or poor contact, prompting the user to perform troubleshooting and repair.

[0028] In one embodiment, an electrical control cabinet power supply 90 is connected to an AC contactor 30 and a solid-state relay 80. An automatic reset thermostat 60, a manual reset thermostat 70, a resistance sensor 40, and a current sensor 50 are connected in series and then connected to the AC contactor 30. When any of the automatic reset thermostat 60, the manual reset thermostat 70, the resistance sensor 40, and the current sensor 50 detects a fault, contacts A1 and A2 of the AC contactor 30 are disconnected, cutting off power to the electric heating tube 10.

[0029] Furthermore, the present application provides a method for early warning protection of an electric heating pipe. The method utilizes the aforementioned early warning protection system for the electric heating pipe, and includes, for example, the following steps: the resistance sensor 40 acquires the resistance value of the electric heating pipe 10 in real time; and controls the switching state of the cooling mechanism and / or the opening and closing of the contacts of the AC contactor 30 based on the relationship between the resistance value and a resistance threshold.

[0030] Furthermore, controlling the on / off state of the cooling mechanism and / or the opening and closing of the contacts of the AC contactor 30 based on the relationship between the resistance value and the resistance threshold includes: if the resistance value is greater than a first resistance threshold, controlling the contacts of the AC contactor 30 to open, and controlling the cooling mechanism to continue operating for a preset period of time before power is cut off. For example, the first resistance threshold is 105% of the default resistance value.

[0031] Furthermore, the electric heating tube early warning protection method further includes: while cutting off the power supply, controlling the alarm module to send out a first alarm signal to prompt the user to replace the electric heating tube 10 .

[0032] It should be noted that as the operating time of the heating element in the electric heating tube 10 increases, the power of the electric heating tube 10 will decrease, resulting in an increase in the resistance of the electric heating tube 10. When the resistance sensor 40 detects that the resistance value is greater than the first resistance threshold, that is, it indicates that the electric heating tube 10 needs to be replaced, the contacts of the AC contactor 30 are controlled to open, cutting off the power supply to the electric heating tube 10. After the cooling mechanism continues to operate for a preset period of time, the power supply to the cooling mechanism is cut off and a first alarm signal is issued, prompting the user to replace the electric heating tube 10.

[0033] It can be understood that by controlling the cooling mechanism to continue to operate for a preset period of time after the contacts of the AC contactor 30 are disconnected, the electric heating tube 10 can continue to dissipate heat and cool for a period of time after the power supply of the electric heating tube 10 is cut off. In this way, the user will not be burned by the electric heating tube 10 when replacing the electric heating tube 10, and the problem of the electric heating tube 10 being too high after the power supply is cut off and being unable to be replaced can be avoided.

[0034] In one specific embodiment, the cooling mechanism is a cooling fan 20. During factory inspection, the voltage of the heating tube 10 is adjusted to the rated voltage via a voltage regulator. After the heating tube 10 is powered on and operated for 30 minutes at the rated voltage, the computer automatically detects the resistance value, which is set as the default resistance value. If the resistance sensor 40 detects an increase in resistance of 5% or more, it is determined that the resistance value is greater than a first resistance threshold, meeting the conditions for replacing the heating tube 10. Therefore, the contacts of the AC contactor 30 are controlled to open, and the cooling fan 20 continues to operate for 10 minutes before power is cut off. The alarm module then issues a first alarm signal, prompting the user to replace the heating tube 10.

[0035] Furthermore, the electric heating tube early warning protection method also includes: the resistance sensor 40 obtains the resistance value of the electric heating tube 10 in real time; according to the resistance value being less than a second resistance threshold, the contacts of the AC contactor 30 are controlled to be disconnected and the power supply is cut off.

[0036] Furthermore, the electric heating pipe early warning protection method further includes: while cutting off the power supply, controlling the alarm module to send out a second alarm signal to prompt the user to perform phase failure troubleshooting.

[0037] It should be noted that when the product is out of phase, the resistance of the electric heating tube 10 will also change, that is, the resistance of the electric heating tube 10 will exceed the factory default value range. For example, the second resistance threshold value is 2 / 3 of the default resistance value.

[0038] In a specific embodiment, if the resistance value of the electric heating tube 10 is less than the second resistance threshold, that is, the resistance value of the electric heating tube 10 is reduced by 1 / 3, it is determined that the product has a phase loss fault, so the contacts of the AC contactor 30 are controlled to open, the power is cut off, and an alarm sounds to prompt the user to troubleshoot the phase loss fault. The user must press the reset button on the computer board before the machine can be turned on.

[0039] Furthermore, the electric heating pipe early warning protection method further includes: obtaining the current value of the current sensor 50 in real time; and cutting off the power supply if the current value satisfies a first preset condition; wherein the first preset condition includes: the current value increases exponentially, and the increase multiple of the current value is greater than a multiple threshold. For example, the multiple threshold is 1.5 times.

[0040] Furthermore, if the current value satisfies the first preset condition, the alarm module is controlled to send a third alarm signal to remind the user that the electric heating tube 10 has a poor contact fault.

[0041] It should be noted that if a poor contact fault occurs, such as sparking at the joint of the electric heating tube 10 or the cold pin of the electric heating tube 10 is about to burn out, the current value will increase exponentially. In one specific embodiment, if the current value detected by the current sensor 50 increases by more than 1.5 times, it is determined that the electric heating tube 10 has a poor contact fault, and the power supply is immediately cut off and a third alarm signal is issued to prompt the user to repair it.

[0042] Furthermore, the electric heating tube early warning protection method also includes: if the first temperature value of the automatic reset thermostat 60 is greater than the first temperature threshold, it is determined that the electric heating tube 10 has a heat dissipation failure, the automatic reset thermostat 60 is disconnected, the contacts of the AC contactor 30 are disconnected, and the cooling mechanism continues to run for a preset period of time before cutting off the power supply.

[0043] Furthermore, the electric heating tube early warning protection method also includes: if the second temperature value of the manual reset thermostat 70 is greater than the second temperature threshold, the automatic reset thermostat 60 is determined to be invalid, the manual reset thermostat 70 is disconnected, the contacts of the AC contactor 30 are disconnected, and the cooling mechanism continues to run for a preset period of time before cutting off the power supply.

[0044] In one specific embodiment, the cooling mechanism is a cooling fan 20. When the air inlet of the device is blocked or the cooling fan 20 is stuck, the heat dissipation effect of the electric heating pipe 10 deteriorates, and the temperature of the automatic reset thermostat 60 and the manual reset thermostat 70 increases. When the first temperature value of the automatic reset thermostat 60 exceeds the first temperature threshold, the automatic reset thermostat 60 is disconnected, the contacts of the AC contactor 30 are opened, and the cooling fan 20 continues to operate for 10 minutes before the power is cut off.

[0045] If the automatic reset thermostat 60 fails, the temperature at the manual reset thermostat 70 continues to rise. When the second temperature value of the manual reset thermostat 70 exceeds the second temperature threshold, the manual reset thermostat 70 is disconnected, the contacts of the AC contactor 30 are opened, and the cooling fan 20 continues to operate for 10 minutes before being powered off. For example, the first temperature threshold is 90°C and the second temperature threshold is 120°C.

[0046] In the description of the present invention, it should be understood that the indicated orientations or positional relationships are 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 cannot be understood as a limitation on the present invention.

[0047] Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field and related fields without making creative efforts should fall within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described and explained in the present invention shall be implemented in accordance with conventional means in the field unless otherwise specified or limited.

Claims

1. An electric heating pipe early warning protection system, characterized in that: The electric heating pipe early warning protection system comprises: an electric heating pipe (10), a cooling mechanism, an AC contactor (30), a relay, a temperature control component, a resistance sensor (40), and a current sensor (50); wherein the temperature control component comprises an automatic reset thermostat (60) and a manual reset thermostat (70); the resistance sensor (40) and the current sensor (50) are connected in series and then connected to the power supply side of the AC contactor (30); the automatic reset thermostat (60) and the manual reset thermostat (70) are connected in series and then connected to the contact of the AC contactor (30).

2. The electric heating pipe early warning protection system according to claim 1, characterized in that: The electric heating pipe early warning protection system further comprises an alarm module electrically connected to the temperature control component, the resistance sensor (40) and the current sensor (50).

3. A method for early warning protection of electric heating pipes, characterized in that: The electric heating pipe early warning protection method uses the electric heating pipe early warning protection system according to claim 2, and the electric heating pipe early warning protection method includes: The resistance sensor (40) acquires the resistance value of the electric heating tube (10) in real time; The switching state of the cooling mechanism and / or the on / off state of the contacts of the AC contactor (30) are controlled according to the magnitude relationship between the resistance value and the resistance threshold.

4. The electric heating pipe early warning protection method according to claim 3, characterized in that: The controlling of the switching state of the cooling mechanism and / or the on / off of the contacts of the AC contactor (30) according to the magnitude relationship between the resistance value and the resistance threshold value comprises: If the resistance value is greater than a first resistance threshold, the contacts of the AC contactor (30) are controlled to be disconnected, and the cooling mechanism is controlled to continue operating for a preset time period before cutting off the power supply.

5. The electric heating pipe early warning protection method according to claim 4, characterized in that: The electric heating pipe early warning protection method further includes: When the power is cut off, the alarm module is controlled to send out a first alarm signal to prompt the user to replace the electric heating tube (10).

6. The electric heating pipe early warning protection method according to claim 3, characterized in that: The electric heating pipe early warning protection method further includes: The resistance sensor (40) acquires the resistance value of the electric heating tube (10) in real time; If the resistance value is less than a second resistance threshold, the contacts of the AC contactor (30) are controlled to be disconnected, and the power supply is cut off.

7. The electric heating pipe early warning protection method according to claim 6, characterized in that: The electric heating pipe early warning protection method further includes: When the power is cut off, the alarm module is controlled to send out a second alarm signal to prompt the user to conduct phase failure troubleshooting.

8. The electric heating pipe early warning protection method according to claim 3, characterized in that: The electric heating pipe early warning protection method further includes: The current sensor (50) acquires the current value in real time; If the current value meets the first preset condition, cutting off the power supply; The first preset condition includes: the current value increases exponentially, and the increase multiple of the current value is greater than a multiple threshold.

9. The electric heating pipe early warning protection method according to claim 8, characterized in that: The electric heating pipe early warning protection method further includes: If the current value satisfies the first preset condition, the alarm module is controlled to issue a third alarm signal to alert the user that the electric heating tube (10) has a poor contact fault.

10. The electric heating pipe early warning protection method according to claim 3, characterized in that: The electric heating pipe early warning protection method further includes: If the first temperature value of the automatic reset thermostat (60) is greater than a first temperature threshold, it is determined that a heat dissipation failure has occurred in the electric heating tube (10), the automatic reset thermostat (60) is disconnected, the contacts of the AC contactor (30) are disconnected, and the cooling mechanism continues to operate for a preset time period before the power supply is cut off.

11. The electric heating pipe early warning protection method according to claim 10, characterized in that: The electric heating pipe early warning protection method further includes: If the second temperature value of the manual reset thermostat (70) is greater than a second temperature threshold, the automatic reset thermostat (60) is determined to be inoperative, the manual reset thermostat (70) is disconnected, the contacts of the AC contactor (30) are disconnected, and the cooling mechanism continues to operate for a preset time before the power supply is cut off.

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