Infrared quartz lamp tube and heating wire parameter setting method
By setting the heating wire parameters with a pitch gradient distribution, the thermal field imbalance problem of infrared quartz lamps during sintering of solar cells is solved, the temperature consistency of all parts of the heating wire is achieved, and the sintering yield of solar cells and the equipment control accuracy are improved.
Patent Information
- Application Number
- CN202510864065.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-25
- Publication Date
- 2025-09-19
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
When existing infrared quartz lamps are used to sinter cells, the sintering temperature at the edge of the cell is insufficient, resulting in an unbalanced thermal field and a black edge phenomenon at the edge of the cell, which reduces the product yield.
A heating wire parameter setting method with winding pitch gradient distribution is adopted. The temperature and power of each cross section of the heating wire are calculated through thermal imaging samples. Noise points are eliminated and the winding pitch is optimized to ensure the temperature consistency of all parts of the heating wire. The time series data of thermal imaging samples is used to analyze the heat retention, heat generation and heat dissipation, and the winding pitch is adjusted in the opposite direction to balance the temperature field.
The sintering yield of battery cells has been significantly improved. By precisely controlling the temperature of the heating wire, the black edge phenomenon has been eliminated, the accuracy and reliability of thermal imaging temperature measurement have been improved, the accuracy of temperature data has been optimized, and the adaptability of equipment and process controllability have been enhanced.
Smart Images
Figure CN120676746A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of infrared quartz lamps, and in particular to an infrared quartz lamp and a method for setting heating wire parameters. Background Art
[0002] Infrared heat irradiation quartz lamps are infrared radiation sources made of high-temperature resistant quartz glass. TOPCon battery sintering furnaces mostly use a conventional uniform power distribution lamp heating mode. When powered on, the quartz lamps heat up rapidly, radiating infrared photons and accompanying visible light. This light is transmitted through the high-temperature resistant, highly transparent quartz tube and acts on the heated furnace belt and battery cells. When the spiral winding pitch of the heating filament is consistent, the resistance distribution is uniform. According to the power formula P=I²R, all parts of the lamp generate the same amount of heat at the same current, i.e., the power density is the same, resulting in a homogeneous lamp. Theoretically, there is no temperature difference between the center and the sides.
[0003] In practice, TOPCon cells are supported by the ejector pins of the furnace belt in the sintering furnace. Due to the low temperature of the ejector pins, the heat of the cell is lost quickly in the part in contact with the ejector pins. The edge area also loses heat quickly, resulting in a thermal field imbalance. The sintering temperature at the edge of the cell is insufficient, and the electrode contact resistance increases. The characteristic phenomenon is the appearance of black edges on both sides of the cell during EL test imaging. Black edges in EL imaging indicate defective products, and the product yield is reduced. Summary of the Invention
[0004] In response to the shortcomings of the existing technology, the present invention provides an infrared quartz lamp tube and a method for setting the heating wire parameters, which solves the technical problem that when the existing infrared quartz lamp tube is sintering the battery cell, the sintering temperature in the edge area of the battery cell is insufficient, resulting in an unbalanced thermal field of the battery cell.
[0005] To solve the above technical problems, the present invention provides the following technical solution: a method for setting parameters of a heating filament of an infrared quartz lamp, comprising a heating filament with a gradient winding pitch distribution and a quartz tube body for protecting the heating filament, the parameter setting method specifically comprising the following steps: S1. Obtain basic parameters of a quartz lamp sample and a heating filament corresponding to when the edge of the cell turns black, and obtain a thermal imaging sample of the quartz lamp sample in real time; S2. calculating the average temperature of the heating wire at any cross section of the quartz lamp sample based on the thermal imaging sample; S3. Calculate the power of the heating filament at any cross section of the quartz lamp sample based on the basic parameters of the heating filament; S4. Calculate the retained heat, generated heat, and dissipated heat of the heating wire at any cross section of the quartz lamp sample based on the thermal imaging sample, average temperature, and power; S5. Calculate the winding distance of the heating wire at any cross section of the quartz lamp sample, with the goal of ensuring consistent heat retention at each cross section of the heating wire.
[0006] Preferably, in step S2, the following steps are specifically included: S21. Obtaining an average temperature of the heating filament at any cross section of the quartz lamp sample according to the thermal imaging sample; S22, setting a central area where the average maximum temperature and the average minimum temperature are within the peak temperature range in the middle portion of the heating wire; S23, setting the direction from the center area to both ends of the quartz lamp to be the negative direction of the x-axis; S24, sequentially calculating the difference between the average temperature of the heating filament at any cross section of the quartz lamp sample and the average temperature of the heating filament at an adjacent cross section close to the end of the quartz lamp, to obtain an adjacent temperature difference; S25. Obtain a cross section at the end of the quartz lamp tube when the adjacent temperature difference is a negative value, and mark it as an abnormal cross section; S26. Obtain the average temperature of two adjacent cross sections on both sides of the abnormal cross section, and take the temperature value between the two as the average temperature of the abnormal cross section.
[0007] Preferably, in step S21, the following steps are specifically included: S211. Divide the quartz lamp sample into several cross sections; S212, obtaining the real-time temperature of each pixel point on any cross section of the heating wire according to the thermal imaging sample; S213, calculating the average value and standard deviation of the real-time temperature of each pixel point on any cross section to obtain a first average temperature and a first standard deviation, respectively, and then calculating the difference between the real-time temperature of each pixel point on the cross section and the first average temperature to obtain a first temperature difference; S214, extracting the real-time temperature of the pixel points on the cross section where the first temperature difference is within a multiple of the first standard deviation, and marking it as the preprocessing temperature; S215 , respectively calculating the average value of the pretreatment temperature on each cross section to obtain the average temperature of the heating wire on the cross section.
[0008] Preferably, in step S212, the following steps are specifically included: S2121. Acquire the real-time temperature of each pixel point on any cross section of the heating wire according to the thermal imaging sample; S2122, establishing a screening circle with each pixel point as the center; S2123, calculating the difference in real-time temperature corresponding to each pixel point on the heating wire within the screening circle and the pixel point at the center of the circle to obtain a screening temperature difference; S2124. Calculate the absolute value of the average value of each screening temperature difference to obtain the absolute temperature difference; S2125: Set an absolute temperature difference threshold, and determine whether the pixel point at the center of the screening circle corresponding to the temperature difference threshold is a noise point based on whether the absolute temperature difference is greater than the absolute temperature difference threshold; If so, the average of the real-time temperatures of all pixels within the screening circle is calculated as the real-time temperature of the pixel at the center of the circle; If not, the real-time temperature of the pixel at the center of the screening circle is retained.
[0009] Preferably, in step S3, the following steps are specifically included: S31. Obtaining the winding distance of the heating filament at any cross section of the quartz lamp sample according to basic parameters of the heating filament; S32, calculating the length of the heating wire within one winding distance according to the basic parameters; S33. Calculate the cross-sectional length of the heating filament at any cross-section of the quartz lamp sample based on its basic parameters. The calculation formula for the cross-sectional length is: In the above formula, Indicates the length of the heating wire at any cross section, that is, the cross-sectional length, Indicates the length of the heating wire within one winding distance, Indicates the number of splits; S34. Calculate the resistance of a heating wire having a length equal to the cross-sectional length at any temperature. The resistance calculation formula is: In the above formula, It represents the resistance of the heating wire when the temperature is T and the length is the cross-sectional length, represents the resistivity of the heating wire at temperature T, Indicates the cross-sectional length of the heating wire at any cross section, Indicates the diameter of the heating wire; S35. Calculate the power of the heating wire at any cross section of the quartz lamp sample. The power calculation formula is: In the above formula, It represents the power when the temperature of the heating wire at any cross section of the quartz lamp sample is T. Indicates the current in the heating wire, It represents the resistance of the heating wire when the temperature is T and the length is the cross-sectional length.
[0010] Preferably, in step S4, the following steps are specifically included: S41. Calculate the difference in average temperature of any cross section at any two adjacent moments based on the thermal imaging sample to obtain a cross-sectional temperature difference; S42, calculating the difference between any two adjacent moments to obtain the cross-section duration; S43, calculating the retained heat of any cross section of the heating wire according to the cross-sectional temperature difference and the cross-sectional duration; S44. Calculate the product of the power of the heating filament at any cross section of the quartz lamp sample and the cross section duration to obtain the generated heat; S45. Calculate the difference between the generated heat and the retained heat on each cross section of the heating wire to obtain the heat dissipation.
[0011] Preferably, in step S5, the following steps are specifically included: S51, obtaining the retained heat at the middle position of the heating wire; S52, taking the retained heat at the middle position of the heating wire as the retained heat on each cross section of the heating wire, and marking it as a virtual retained heat; S53, calculating the sum of the virtual retained heat and the heat dissipation on each cross section of the heating wire to obtain the virtual generated heat; S54, calculating the virtual power of the heating wire according to the virtual heat generated on each cross section, and calculating the winding distance of each cross section of the heating wire according to the virtual power.
[0012] Preferably, in step S32, the calculation formula of the length of the heating wire within one winding distance is: In the above formula, Indicates the length of the heating wire within one winding distance, Indicates the maximum outer diameter of the spiral coil wound by the heating wire. Indicates the maximum inner diameter of the spiral coil wound by the heating wire. Indicates the winding distance of the heating wire.
[0013] Preferably, in step S43, the calculation formula for the retained heat is: In the above formula, Indicates the retained heat of any cross section on the heating wire, represents the specific heat capacity of the heating wire, Indicates the diameter of the heating wire, Indicates the cross-sectional length of the heating wire at any cross section, is the cross-sectional temperature difference.
[0014] Preferably, in step S44, the calculation formula for heat generation is: In the above formula, It represents the heat generated by the heating wire at any cross section of the quartz lamp sample. It represents the power when the temperature of the heating wire at any cross section of the quartz lamp sample is T. Indicates the cross-section duration.
[0015] The present invention also provides an infrared quartz lamp tube, comprising a quartz tube body, with wires provided at both ends of the quartz tube body, a heating wire conductively connected between the two wires provided in the quartz tube body, and the winding pitch of the heating wire gradually decreasing from the middle to the two ends.
[0016] By means of the above technical solution, the present invention provides a method for setting parameters of an infrared quartz lamp and a heating wire, which has at least the following beneficial effects: 1. The present invention first obtains quartz lamp samples and heating wire parameters and real-time thermal imaging samples corresponding to the blackening of the battery cell edge, calculates the temperature of the heating wire in each cross section through the thermal imaging samples, eliminates noise points and smoothes abnormal data, and calculates the power of each cross section in segments based on the material properties, resistivity and geometric parameters of the heating wire. The time series data of the thermal imaging samples is used to analyze the retained heat, generated heat and heat dissipation. Finally, based on the heat retained in the middle position as a benchmark, the winding distance of each cross section is adjusted in reverse to ensure the consistency of the temperature of the heating wire at all locations, balance the temperature field of each area of the quartz lamp, reduce heat loss at the edge of the battery cell, thereby eliminating the black edge phenomenon and significantly improving the sintering yield.
[0017] 2. This invention significantly improves the accuracy and reliability of thermal imaging temperature measurement through innovative noise point elimination and data smoothing technology. It adopts a pixel-centered screening circle algorithm and effectively identifies and corrects noise points by calculating the absolute value of the screening temperature difference and comparing it with the threshold, thereby avoiding interference of abnormal temperature data on subsequent calculations.
[0018] 3. The present invention combines standard deviation screening pre-processing temperature and abnormal cross-section temperature interpolation correction to further optimize the accuracy of temperature data. This multi-level data cleaning method ensures the accurate calculation of the average temperature of each cross-section of the heating wire, providing a reliable basis for the dynamic adjustment of the power gradient distribution, thereby improving the control accuracy and stability of the overall system.
[0019] 4. Based on the time series data of thermal imaging samples, the present invention's system can calculate the retained heat, generated heat and heat dissipation of each cross-section in real time, and use the virtual retained heat to reversely deduce the required winding pitch parameters. This closed-loop control method not only adapts to thermal field changes under different working conditions, but also optimizes power distribution by adjusting the winding pitch to ensure temperature consistency in various areas of the quartz lamp tube, providing a quantifiable and replicable technical solution for industrial production, significantly improving equipment adaptability and process controllability. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings: Figure 1 A flowchart of a method for setting heating wire parameters of an infrared quartz lamp of the present invention; Figure 2 Schematic diagram of the infrared quartz lamp of the present invention; Figure 3 For the present invention Figure 2 Enlarged view of point A in the middle; Figure 4 Schematic diagram of the heating wire of the present invention. DETAILED DESCRIPTION
[0021] To make the above-mentioned objectives, features, and advantages of the present invention more clearly understood, the present invention is further described below in detail with reference to the accompanying drawings and specific embodiments. This will enable a full understanding of how this application uses technical means to solve technical problems and achieve technical effects, and to implement the invention accordingly.
[0022] In order to solve the technical problem that when existing infrared quartz lamps are sintering cells, the sintering temperature at the edge of the cell is insufficient, resulting in an unbalanced thermal field in the cell, the present invention provides a method for setting the parameters of the heating wire of an infrared quartz lamp, comprising a heating wire with a winding gradient distribution and a quartz tube body for protecting the heating wire. In order to reasonably set the winding distance of the heating wire to ensure the consistency of the sintering temperature at all locations on the surface of the heating wire with the winding gradient distribution, thereby ensuring the yield of the cell sintering, such as Figure 1 As shown, the parameter setting method specifically includes the following steps: S1. Obtain the basic parameters of the quartz lamp sample and the heating wire corresponding to the blackening of the battery cell edge, and obtain the thermal imaging sample of the quartz lamp sample in real time. The basic parameters include the material, specific heat capacity, diameter, maximum outer diameter of the spiral coil of the heating wire, maximum inner diameter of the spiral coil of the heating wire, resistivity of the heating wire at various temperatures, and current in the heating wire. S2. Calculate the average temperature of the heating filament at any cross section of the quartz lamp sample based on the thermal imaging sample. In a high-temperature environment, the thermal imaging sample obtained may contain a large number of noise points. Therefore, when calculating the average temperature, these noise points need to be eliminated first. The specific steps include the following: S21. Obtain the average temperature of the heating filament at any cross section of the quartz lamp sample based on the thermal imaging sample. Theoretically, a cylinder has countless cross sections, which are segmented here to obtain a specific number of cross sections. Theoretically, if the lamp is homogeneous, the temperature of each cross section decreases from the center to the ends. However, since the temperature of the pixel points on the heating filament may contain noise points, the average temperature of the heating filament on some cross sections may be greater than or less than the average temperature of the cross sections on both sides. To ensure the accuracy of subsequent calculations, smoothing processing is required, which specifically includes the following steps: S211. Divide the quartz lamp sample into several cross sections. The more cross sections are divided, the more accurate the subsequent calculation is, but the amount of calculation is greater. The fewer cross sections are divided, the less amount of calculation is, but the calculated winding distance result is rougher.
[0023] S212: Acquire the real-time temperature of each pixel point on any cross section of the heating wire based on the thermal imaging sample. Identify and remove noise points on the heating wire. This specifically includes the following steps: S2121. Acquire the real-time temperature of each pixel point on any cross section of the heating wire according to the thermal imaging sample; S2122. Establish a screening circle with each pixel point as the center. The radius of the screening circle can be set according to the resolution of the thermal imaging sample, for example, 3 pixels are set.
[0024] S2123, calculating the difference in real-time temperature corresponding to each pixel point on the heating wire within the screening circle and the pixel point at the center of the circle to obtain a screening temperature difference; S2124. Calculate the absolute value of the average value of each screening temperature difference to obtain the absolute temperature difference; S2125. Set an absolute temperature difference threshold. Based on whether the absolute temperature difference is greater than the absolute temperature difference threshold, determine whether the pixel at the center of the screening circle corresponding to the temperature difference threshold is a noise point. The absolute temperature difference threshold is generally determined by taking several screening circles within the normal data and obtaining the maximum screening temperature difference among the several screening circles as the absolute temperature difference threshold. Alternatively, the threshold can be set based on experience. If so, the average of the real-time temperatures of all pixels within the screening circle is calculated as the real-time temperature of the pixel at the center of the circle; If not, the real-time temperature of the pixel at the center of the screening circle is retained.
[0025] S213. Calculate the average value and standard deviation of the real-time temperature of each pixel point on any cross section to obtain a first average temperature and a first standard deviation, respectively. Then calculate the difference between the real-time temperature of each pixel point on the cross section and the first average temperature to obtain a first temperature difference, that is, subtract the first average temperature from the real-time temperature of each pixel point on any cross section to obtain the first temperature difference.
[0026] S214 , extracting the real-time temperature of the pixel points on the cross section whose first temperature difference is within a certain number of times of the first standard deviation, and marking it as the preprocessing temperature, generally 3 times of the first standard deviation.
[0027] S215 , respectively calculating the average value of the pretreatment temperature on each cross section to obtain the average temperature of the heating wire on the cross section.
[0028] S22. Set the average maximum temperature and the average minimum temperature in the middle part of the heating wire in the center area of the peak temperature range. When setting the peak temperature range, the highest temperature in the middle part of the heating wire is generally taken as the upper limit, and then a certain temperature difference is set, such as 10°C, and the highest temperature minus the temperature difference is used as the lower limit.
[0029] S23, setting the direction from the center area to both ends of the quartz lamp to be the negative direction of the x-axis; S24, sequentially calculating the difference between the average temperature of the heating filament at any cross section of the quartz lamp sample and the average temperature of the heating filament at an adjacent cross section close to the end of the quartz lamp, to obtain an adjacent temperature difference; S25. Obtain a cross section at the end of the quartz lamp tube when the adjacent temperature difference is a negative value, and mark it as an abnormal cross section; S26. Obtain the average temperature of two adjacent cross sections on both sides of the abnormal cross section, and take the temperature value between the two as the average temperature of the abnormal cross section, such as taking the average value of the two to simplify the calculation amount. Of course, other function models can also be set to represent the relationship between temperature and distance, so as to obtain the temperature at each location of the abnormal cross section based on the average temperature of the two adjacent cross sections on both sides of the abnormal cross section.
[0030] S3. Calculate the power of the heating filament at any cross section of the quartz lamp sample based on the basic parameters of the heating filament. The power of the heating filament is related to the basic parameters of the heating filament. In this scenario, the calculation of the power at any cross section of the quartz lamp sample specifically includes the following steps: S31. Obtaining the winding distance of the heating filament at any cross section of the quartz lamp sample according to basic parameters of the heating filament; S32, calculating the length of the heating wire within one winding distance based on the basic parameters; Figure 4 As shown in the figure, the calculation formula for the length of the heating wire within one winding distance is: In the above formula, Indicates the length of the heating wire within one winding distance, Indicates the maximum outer diameter of the spiral coil wound by the heating wire. Indicates the maximum inner diameter of the spiral coil wound by the heating wire. Indicates the winding distance of the heating wire; S33. Calculate the cross-sectional length of the heating filament at any cross-section of the quartz lamp sample based on its basic parameters. The calculation formula for the cross-sectional length is: In the above formula, Indicates the length of the heating wire at any cross section, that is, the cross-sectional length, Indicates the length of the heating wire within one winding distance, Indicates the number of splits; S34. Calculate the resistance of a heating wire having a length equal to the cross-sectional length at any temperature. The resistance calculation formula is: In the above formula, It represents the resistance of the heating wire when the temperature is T and the length is the cross-sectional length, represents the resistivity of the heating wire at temperature T, Indicates the cross-sectional length of the heating wire at any cross section, Indicates the diameter of the heating wire; S35. Calculate the power of the heating wire at any cross section of the quartz lamp sample. The power calculation formula is: In the above formula, It represents the power when the temperature of the heating wire at any cross section of the quartz lamp sample is T. Indicates the current in the heating wire, It represents the resistance of the heating wire when the temperature is T and the length is the cross-sectional length.
[0031] S4. Calculate the retained heat, generated heat, and heat dissipation of the heating filament at any cross-section of the quartz lamp sample based on the thermal imaging sample, average temperature, and power. The heat dissipation is difficult to obtain directly. Therefore, according to the law of conservation of energy, the sum of the retained heat and the heat dissipation is the generated heat. That is, part of the generated heat of the heating filament remains stored in the heating filament to maintain its temperature, and the other part is dissipated to the external environment and objects, i.e., the heat dissipation. The calculation of the heat dissipation specifically includes the following steps: S41. Calculate the difference in average temperature of any cross section at any two adjacent moments based on the thermal imaging sample to obtain a cross-sectional temperature difference; S42, calculating the difference between any two adjacent moments to obtain the cross-section duration; S43. Calculate the retained heat of any cross section of the heating wire based on the cross-sectional temperature difference and the cross-sectional duration. The calculation formula for the retained heat is: In the above formula, Indicates the retained heat of any cross section on the heating wire, represents the specific heat capacity of the heating wire, Indicates the diameter of the heating wire, Indicates the cross-sectional length of the heating wire at any cross section, is the cross-sectional temperature difference; S44. Calculate the product of the power of the heating filament at any cross section of the quartz lamp sample and the cross section duration to obtain the generated heat. The calculation formula for the generated heat is: In the above formula, It represents the heat generated by the heating wire at any cross section of the quartz lamp sample. It represents the power when the temperature of the heating wire at any cross section of the quartz lamp sample is T. Indicates the cross-section duration; S45. Calculate the difference between the generated heat and the retained heat on each cross section of the heating wire to obtain the heat dissipation.
[0032] S5. Calculate the winding distance of the heating wire at any cross section of the quartz lamp sample, with the goal of ensuring consistent heat retention at each cross section of the heating wire.
[0033] In step S5, the following steps are specifically included: S51. Obtain the retained heat at the middle position of the heating wire. Due to the positional relationship, the temperature at the middle position is roughly the same, so the retained heat is also basically the same. The battery cell sintered here is also a qualified product, so it is used as a benchmark.
[0034] S52, taking the retained heat at the middle position of the heating wire as the retained heat on each cross section of the heating wire, and marking it as a virtual retained heat; S53, calculating the sum of the virtual retained heat and the heat dissipation on each cross section of the heating wire to obtain the virtual generated heat, that is, only when the virtual generated heat is obtained on each cross section of the heating wire can the temperature consistency of the surface be guaranteed; S54. Calculate the virtual power of the heating wire according to the virtual heat generated on each cross section, and calculate the winding pitch of each cross section of the heating wire according to the virtual power. Substitute the virtual heat generated into the formula at step S44 to obtain the virtual power. Then substitute the virtual power into step S35, substitute the calculation result of step S35 into step S34, substitute the calculation result of step S34 into step S33, and substitute the calculation result of step S33 into step S32 to finally obtain the winding pitch.
[0035] The present invention first obtains quartz lamp samples and heating wire parameters corresponding to the blackening of the battery cell edge, combines them with real-time thermal imaging samples, calculates the temperature of the heating wire in each cross section through the thermal imaging samples, eliminates noise points and smoothes abnormal data, and calculates the power of each cross section in sections based on the material properties, resistivity and geometric parameters of the heating wire. Utilizing the time series data of the thermal imaging samples, the retained heat, generated heat and heat dissipation are analyzed to establish an energy conservation model. Finally, based on the retained heat in the middle position as a benchmark, the winding pitch of each cross section is adjusted in reverse so that the overall retained heat is evenly distributed to ensure the consistency of the temperature of each part of the heating wire. This method optimizes the power density of the heating wire through gradient distribution of the winding pitch, balances the temperature field of each area of the quartz lamp tube, reduces heat loss at the edge of the battery cell, thereby eliminating the black edge phenomenon and significantly improving the sintering yield.
[0036] The present invention also provides an infrared quartz lamp, such as Figure 2 and Figure 3 As shown, it includes a quartz tube body 1, with wires 2 provided at both ends of the quartz tube body 1, and a heating wire 3 conductively connected between the two wires provided in the quartz tube body 1. The winding pitch of the heating wire 3 gradually decreases from the middle to the two ends. The winding pitch of the heating wire 3 is calculated by the parameter setting method of the heating wire 3 of the infrared quartz lamp tube 1.
[0037] Those skilled in the art will appreciate that all or part of the steps in the above-described embodiment methods can be accomplished by instructing related hardware through a program. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.
[0038] Each embodiment in this specification is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to in detail. For the above embodiments, since they are basically similar to the method embodiments, the description is relatively simple. For relevant parts, please refer to the partial description of the method embodiments.
[0039] The above embodiments provide a detailed introduction to the present invention. Specific examples are used herein to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only used to help understand the method of the present invention and its core ideas. At the same time, for those skilled in the art, according to the ideas of the present invention, there may be changes in the specific implementation methods and application scopes. In summary, the contents of this specification should not be understood as limiting the present invention.
Claims
1. A method for setting parameters of a heating wire of an infrared quartz lamp, comprising a heating wire with a gradient pitch distribution and a quartz tube body for protecting the heating wire, characterized in that: The parameter setting method specifically includes the following steps: S1. Obtain basic parameters of a quartz lamp sample and a heating filament corresponding to when the edge of the cell turns black, and obtain a thermal imaging sample of the quartz lamp sample in real time; S2. calculating the average temperature of the heating wire at any cross section of the quartz lamp sample based on the thermal imaging sample; S3. Calculate the power of the heating filament at any cross section of the quartz lamp sample based on the basic parameters of the heating filament; S4. Calculate the retained heat, generated heat, and dissipated heat of the heating wire at any cross section of the quartz lamp sample based on the thermal imaging sample, average temperature, and power; S5. Calculate the winding distance of the heating wire at any cross section of the quartz lamp sample, with the goal of ensuring consistent heat retention at each cross section of the heating wire.
2. The method for setting heating wire parameters according to claim 1, characterized in that: In step S2, the following steps are specifically included: S21. Obtaining an average temperature of the heating filament at any cross section of the quartz lamp sample according to the thermal imaging sample; S22, setting a central area where the average maximum temperature and the average minimum temperature are within the peak temperature range in the middle portion of the heating wire; S23, setting the direction from the center area to both ends of the quartz lamp to be the negative direction of the x-axis; S24, sequentially calculating the difference between the average temperature of the heating filament at any cross section of the quartz lamp sample and the average temperature of the heating filament at an adjacent cross section close to the end of the quartz lamp, to obtain an adjacent temperature difference; S25. Obtain a cross section at the end of the quartz lamp tube when the adjacent temperature difference is a negative value, and mark it as an abnormal cross section; S26. Obtain the average temperature of two adjacent cross sections on both sides of the abnormal cross section, and take the temperature value between the two as the average temperature of the abnormal cross section.
3. The method for setting heating wire parameters according to claim 2, characterized in that: In step S21, the following steps are specifically included: S211. Divide the quartz lamp sample into several cross sections; S212, obtaining the real-time temperature of each pixel point on any cross section of the heating wire according to the thermal imaging sample; S213, calculating the average value and standard deviation of the real-time temperature of each pixel point on any cross section to obtain a first average temperature and a first standard deviation, respectively, and then calculating the difference between the real-time temperature of each pixel point on the cross section and the first average temperature to obtain a first temperature difference; S214, extracting the real-time temperature of the pixel points on the cross section where the first temperature difference is within a multiple of the first standard deviation, and marking it as the preprocessing temperature; S215 , respectively calculating the average value of the pretreatment temperature on each cross section to obtain the average temperature of the heating wire on the cross section.
4. The method for setting heating wire parameters according to claim 3, characterized in that: In step S212, the following steps are specifically included: S2121. Acquire the real-time temperature of each pixel point on any cross section of the heating wire according to the thermal imaging sample; S2122, establishing a screening circle with each pixel point as the center; S2123, calculating the difference in real-time temperature corresponding to each pixel point on the heating wire within the screening circle and the pixel point at the center of the circle to obtain a screening temperature difference; S2124. Calculate the absolute value of the average value of each screening temperature difference to obtain the absolute temperature difference; S2125: Set an absolute temperature difference threshold, and determine whether the pixel point at the center of the screening circle corresponding to the temperature difference threshold is a noise point based on whether the absolute temperature difference is greater than the absolute temperature difference threshold; If so, the average of the real-time temperatures of all pixels within the screening circle is calculated as the real-time temperature of the pixel at the center of the circle; If not, the real-time temperature of the pixel at the center of the screening circle is retained.
5. The method for setting heating wire parameters according to claim 1, characterized in that: In step S3, the following steps are specifically included: S31. Obtaining the winding distance of the heating filament at any cross section of the quartz lamp sample according to basic parameters of the heating filament; S32, calculating the length of the heating wire within one winding distance according to the basic parameters; S33. Calculate the cross-sectional length of the heating filament at any cross-section of the quartz lamp sample based on its basic parameters. The calculation formula for the cross-sectional length is: In the above formula, Indicates the length of the heating wire at any cross section, that is, the cross-sectional length, Indicates the length of the heating wire within one winding distance, Indicates the number of splits; S34. Calculate the resistance of a heating wire having a length equal to the cross-sectional length at any temperature. The resistance calculation formula is: In the above formula, It represents the resistance of the heating wire when the temperature is T and the length is the cross-sectional length, represents the resistivity of the heating wire at temperature T, Indicates the cross-sectional length of the heating wire at any cross section, Indicates the diameter of the heating wire; S35. Calculate the power of the heating wire at any cross section of the quartz lamp sample. The power calculation formula is: In the above formula, It represents the power when the temperature of the heating wire at any cross section of the quartz lamp sample is T. Indicates the current in the heating wire, It represents the resistance of the heating wire when the temperature is T and the length is the cross-sectional length.
6. The method for setting heating wire parameters according to claim 1, characterized in that: In step S4, the following steps are specifically included: S41. Calculate the difference in average temperature of any cross section at any two adjacent moments based on the thermal imaging sample to obtain a cross-sectional temperature difference; S42, calculating the difference between any two adjacent moments to obtain the cross-section duration; S43, calculating the retained heat of any cross section of the heating wire according to the cross-sectional temperature difference and the cross-sectional duration; S44. Calculate the product of the power of the heating filament at any cross section of the quartz lamp sample and the cross section duration to obtain the generated heat; S45. Calculate the difference between the generated heat and the retained heat on each cross section of the heating wire to obtain the heat dissipation.
7. The method for setting heating wire parameters according to claim 1, characterized in that: In step S5, the following steps are specifically included: S51, obtaining the retained heat at the middle position of the heating wire; S52, taking the retained heat at the middle position of the heating wire as the retained heat on each cross section of the heating wire, and marking it as a virtual retained heat; S53, calculating the sum of the virtual retained heat and the heat dissipation on each cross section of the heating wire to obtain the virtual generated heat; S54, calculating the virtual power of the heating wire according to the virtual heat generated on each cross section, and calculating the winding distance of each cross section of the heating wire according to the virtual power.
8. The method for setting heating wire parameters according to claim 5, characterized in that: In step S32, the calculation formula of the length of the heating wire within one winding distance is: In the above formula, Indicates the length of the heating wire within one winding distance, Indicates the maximum outer diameter of the spiral coil wound by the heating wire. Indicates the maximum inner diameter of the spiral coil wound by the heating wire. Indicates the winding distance of the heating wire.
9. The method for setting heating wire parameters according to claim 6, characterized in that: In step S43, the calculation formula for the retained heat is: In the above formula, Indicates the retained heat of any cross section on the heating wire, represents the specific heat capacity of the heating wire, Indicates the diameter of the heating wire, Indicates the cross-sectional length of the heating wire at any cross section, is the cross-sectional temperature difference.
10. An infrared quartz lamp tube, comprising a quartz tube body (1), with wires (2) provided at both ends of the quartz tube body, and a heating wire (3) provided in the quartz tube body (1) and electrically connected between the two wires, characterized in that: The winding pitch of the heating wire (3) gradually decreases from the middle to both ends.