Novel quenching furnace oil pump control system

Abstract

The invention relates to the technical field of heat treatment equipment, and discloses a novel quenching furnace oil pump control system which comprises a temperature detection module used for detecting the temperature of insulating oil in real time; the flow detection module is used for detecting flow data in the pump body in real time; the control module is connected with the temperature detection module and the flow detection module and used for receiving the temperature and flow data and outputting a control instruction based on preset logic; and the motor driving plate is arranged on the outer side of the pump body, is electrically connected with the motor, receives an instruction of the control module and regulates the speed of the motor. The motor is integrally arranged in the sealed pump body filled with the insulating oil, and the front cover and the rear cover are additionally arranged for physical protection, so that the insulating oil is used as a medium to perform efficient heat conduction and heat dissipation on the motor, stable operation of the motor under a load is ensured, and external impurities are isolated by using the electrical insulation characteristic of the insulating oil and a sealing structure.

Description

Technical Field

[0001] This invention relates to the field of heat treatment equipment technology, specifically to a novel oil pump control system for a quenching furnace. Background Technology

[0002] In industrial heat treatment processes, quenching is a crucial step that determines the final mechanical properties of metallic materials, and the circulation and cooling efficiency of quenching oil directly affect the quenching quality. To achieve high-flow-rate circulation of quenching oil in the cooling system, axial flow pumps are typically used. As a type of low-head, high-flow-rate vane pump, the axial flow pump works by rotating an impeller installed in the pipeline after startup, driving the fluid medium along the axial direction. Subsequently, as the fluid passes through the guide vanes, the kinetic energy imparted by the impeller is converted into pressure energy, thereby achieving the transport of the medium.

[0003] In quenching furnace oil pump systems, a common technical solution is to use an oil-immersed axial flow oil pump. The structural characteristic of this type of pump is that its drive motor is directly immersed in the quenching oil, which serves as the working medium, and the oil itself cools and lubricates the motor. For speed control of this type of pump, existing technology typically relies on external speed control devices such as frequency converters to adjust the power supply frequency and change the motor speed to adapt to the flow requirements under different operating conditions.

[0004] However, existing oil-immersed axial flow pumps still have several shortcomings in practical applications. On the one hand, the external speed control devices such as frequency converters they rely on may be difficult to deploy and use in certain specific industrial applications due to space constraints, environmental interference, or cost factors. On the other hand, the structural design of these pumps themselves also presents challenges. Specifically, to ensure stable operation of the motor in an oil-immersed environment and effectively control its internal electromagnetic air gap, the design typically requires extremely high concentricity between the motor and the pump body. This places stringent requirements on the machining precision of related components, significantly increasing manufacturing difficulty and production costs, and making the installation and commissioning process more complex. Furthermore, in some traditional structural layouts, some key support components, such as bearings, are located outside the pump body. This design makes them susceptible to damage from external environmental impacts and contamination during operation, leading to an increased equipment failure rate and adversely affecting production continuity. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a novel quenching furnace oil pump control system, which solves the problems of existing quenching furnace oil pumps, such as high machining accuracy requirements, difficult installation and maintenance, inconvenient speed adjustment, and lack of automated safety protection functions.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a novel quenching furnace oil pump control system. This system is applied to an oil-immersed axial flow oil pump, which includes a pump body, an impeller, and a motor installed within the pump body. The innovative structure and control logic of this system are as follows: The pump body is equipped with a limiting step, through which the motor is detachably connected to the pump body. Using the limiting step as a positioning reference, when the motor is pressed into the pump body, it ensures that the central axis of the motor coincides with the central axis of the pump body, replacing the complex machining requirements for high concentricity and reducing manufacturing costs. This detachable connection method also simplifies the maintenance or replacement process of the motor.

[0007] To ensure long-term stable operation, the pump body is equipped with air vents, and sealing plugs are installed on these vents to form a sealed cavity. The motor is equipped with a front cover and a rear cover for physical protection. The pump body and motor are filled with insulating oil for heat dissipation and electrical insulation of the motor.

[0008] The system includes: A temperature detection module is used to detect the temperature of the insulating oil in real time; A flow detection module is used to detect the flow data within the pump body in real time; The control module, connected to the temperature detection module and the flow detection module, is used to receive temperature and flow data and output control commands based on preset logic; A motor drive board is located on the outside of the pump body. The motor drive board is electrically connected to the motor and receives instructions from the control module to adjust the speed of the motor.

[0009] The specific control logic of the control module is as follows: Start-up control: When the temperature W1 detected by the temperature detection module is greater than 40℃, the control module controls the motor to start.

[0010] Speed ​​and temperature linkage control: After the motor starts, the control module continuously receives temperature W2.

[0011] If 40℃≤W2≤85℃, the control module controls the motor speed R to increase linearly with temperature W2, with the speed range being 100rpm to 960rpm.

[0012] If W2 > 85℃, the control module will trigger an alarm for the entire device and instruct the motor drive board to further increase the motor speed to perform forced cooling.

[0013] If W2 > 100℃, the control module will shut down the entire equipment to prevent damage due to overheating.

[0014] If W2 < 40℃, the control module controls the motor to stop.

[0015] Flow-assisted regulation control: During operation, the control module receives the flow data Q1 detected by the flow detection module and compares it with the set rated flow Q.

[0016] The control module instructs the motor drive board to slightly increase the motor speed in order to perform flow compensation.

[0017] A novel control method for a quenching furnace oil pump includes the following steps: S1. Detect the internal temperature of the oil pump.

[0018] S2. Determine whether the detected temperature is higher than the first preset temperature threshold, and start the oil pump motor.

[0019] S3. When the motor is running, determine whether the detected temperature is between the first preset temperature threshold and the second preset temperature threshold, and adjust the motor speed according to the increase of temperature.

[0020] S4. Determine whether the detected temperature is higher than the second preset temperature threshold, control the device to alarm and increase the speed of the motor.

[0021] S5. Determine whether the detected temperature is higher than the third preset temperature threshold, and control the equipment to stop.

[0022] S6. Detect the flow rate data in the pump body and compare the flow rate data with the rated flow rate. Adjust the speed of the motor according to the deviation of the comparison result.

[0023] This invention provides a novel oil pump control system for quenching furnaces. It has the following beneficial effects: 1. This invention sets a limiting step in the pump body and allows the motor to be detachably connected to the pump body through the limiting step. On the one hand, the limiting step is used as a mechanical positioning reference to ensure that the central axis of the motor coincides with the central axis of the pump body after installation, thereby replacing the complex requirement of high-precision concentricity machining of parts and reducing manufacturing costs. On the other hand, the detachable structure makes the inspection or replacement of the motor simple and quick, improving the maintainability of the equipment.

[0024] 2. This invention constructs a closed-loop control system with temperature as the core feedback by setting up a temperature detection module, a control module, and a motor drive board. The control module can continuously and automatically adjust the motor speed according to the real-time detected temperature through a preset functional relationship, so that the cooling power of the oil pump is dynamically matched with the actual heat dissipation requirements of the system, thereby achieving precise control of the quenching oil temperature and ensuring the stability of the heat treatment process.

[0025] 3. This invention integrates the motor into a sealed pump body filled with insulating oil, and adds front and rear covers for physical protection. This not only utilizes the insulating oil as a medium for efficient heat conduction and dissipation of the motor, ensuring its stable operation under load, but also utilizes the electrical insulation properties of the insulating oil and the sealing structure to isolate external impurities, providing the motor with a clean and constant working environment and extending the motor's service life. Attached Figure Description

[0026] Figure 1 This is a system architecture diagram of the present invention; Figure 2 This is a flowchart of the method of the present invention. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Example: Please see the appendix Figure 1 This invention provides a novel quenching furnace oil pump control system, comprising: Temperature detection module, used to detect temperature; In this embodiment, the novel quenching furnace oil pump control system includes a temperature detection module, which is a fundamental component for realizing the automated operation and safety protection of the entire system. It is configured to accurately and continuously monitor the temperature of the working medium inside the oil pump.

[0029] The temperature sensing element of the temperature detection module is located inside the pump body of the oil-immersed axial flow pump and is directly immersed in the insulating oil used for cooling and insulation. This allows the sensing element to directly and without delay sense the real-time temperature of the insulating oil, which is the main heat exchange medium, thus ensuring the authenticity and timeliness of the temperature data and providing reliable data input for the accurate decision-making of the subsequent control module.

[0030] The temperature detection module includes a temperature sensing unit and a signal conversion unit. The temperature sensing unit can be an electronic component sensitive to temperature changes, such as a thermocouple, platinum resistance thermometer, or thermistor. This temperature sensing unit converts the sensed physical temperature of the insulating oil into a corresponding continuously changing analog electrical signal.

[0031] The signal conversion unit, an analog-to-digital converter module, is connected to the temperature sensing unit. Its function is to receive the analog electrical signal and convert it into a discrete digital temperature signal according to a preset sampling frequency and resolution. This digital signal can be directly recognized and processed by the control module, thus avoiding interference or attenuation problems that may occur during the transmission and processing of analog signals.

[0032] The signal output terminal of the temperature detection module is connected to the signal input terminal of the control module via a wired connection, which is used to transmit the converted digital temperature signal to the control module in real time and without interruption.

[0033] After receiving the digital temperature signal, the control module uses it as the core judgment criterion to execute the preset control logic. The role of the temperature detection module in the overall system operation is reflected in the following aspects: First, it serves as the trigger for starting and stopping the oil pump motor. The control module continuously compares the received real-time temperature with a first preset temperature threshold. When the detected temperature rises from below the threshold and exceeds it, the control module determines that the system needs active cooling and issues a command to start the motor; conversely, when the temperature drops below the threshold, it determines that active cooling is not needed and controls the motor to stop.

[0034] Secondly, it is the driving variable for linear and continuous adjustment of the motor speed. Within the motor's normal operating range, i.e., when the detected temperature is between the first and second preset temperature thresholds, the control module dynamically calculates the target speed matching the current temperature based on the received real-time temperature value through internal function calculations. This real-time changing target speed command is sent to the motor drive board, achieving a smooth increase in motor speed as the temperature rises, thereby ensuring that the cooling power of the cooling system matches the actual heat dissipation requirements.

[0035] Furthermore, it serves as the criterion for the system to enter abnormal operating condition alarm and protection states. When the temperature measured by the temperature detection module exceeds the second preset temperature threshold, it indicates an abnormal temperature rise in the system. At this time, the control module will not only instruct the motor to run at a higher speed to attempt to suppress the temperature rise, but will also trigger an external audible and visual alarm device to alert the operator. If the temperature further deteriorates and exceeds the third preset temperature threshold, which serves as the upper limit for safety, the control module will determine that the system is in a dangerous state and immediately execute the highest priority protection action, namely, controlling the entire equipment to shut down to prevent permanent damage to the motor and related components due to overheating.

[0036] Through the above structural and functional design, the temperature detection module, as the system's sensory organ, converts key physical quantities into information that can be processed by the digital system. It runs through the entire process of system start-up and shutdown, normal operation, abnormal alarm and emergency shutdown, and is a necessary technical prerequisite for realizing the intelligent, automated and highly reliable operation of the entire closed-loop control system.

[0037] The flow detection module is used to detect flow data within the pump body; In this embodiment, the novel quenching furnace oil pump control system integrates a flow detection module. As an important component of the control system, its core function is to dynamically monitor the actual flow rate of the working medium in the oil pump system pipeline and provide the monitoring data to the control module to achieve auxiliary adjustment and optimization of the motor speed.

[0038] The main component of the flow detection module is a flow sensing unit, which is installed on the circulation pipeline of the quenching furnace oil pump system to measure the volumetric flow rate of insulating oil flowing through its cross-section in real time. This flow sensing unit can be an electronic flow meter, which converts the physical fluid flow into a processable electrical signal. The module also includes a signal processing unit, which amplifies, filters, and converts the raw signal output from the flow sensing unit, ultimately forming a digital flow signal that can be accurately recognized by the control module.

[0039] To ensure reliable data transmission, a wired electrical connection is established between the signal output terminal of the flow detection module and the corresponding signal input terminal of the control module. Through this connection, the flow detection module continuously transmits digital signals representing the current flow data to the control module in real time, enabling it to monitor the actual circulation status of the cooling medium in the pipeline.

[0040] In the technical solution of this invention, the flow detection module is not used as a direct basis for system start-up, shutdown, or main speed adjustment. The main control logic of the system is driven by the temperature detection module, which determines the reference speed of the motor based on the temperature. The introduction of the flow detection module, on this basis, constructs a secondary closed-loop control with flow as feedback, the purpose of which is to finely adjust the operating state of the system.

[0041] The specific adjustment logic is as follows: After setting the basic target speed of the motor based on the temperature, the control module synchronously receives real-time flow data Q1 from the flow detection module. The control module has a preset rated flow value Q, which represents the ideal cooling medium circulation volume of the system under specific operating conditions. When the control module determines that the real-time flow data Q1 is within the preset normal deviation range around the rated flow Q, it considers the system to be operating basically normally, but there is room for optimization.

[0042] In this situation, the control module will perform compensatory adjustments. It will add a small speed increment to the base target speed determined by temperature. This is intended to dynamically compensate for minor flow drifts that may be caused by unforeseen factors such as changes in oil viscosity with temperature and slight fluctuations in pipeline resistance, ensuring that the actual cooling medium circulation volume remains stable near the optimal target value even under the influence of various disturbances.

[0043] Therefore, by introducing a flow detection module, the control system of this invention forms a dual closed-loop control structure with temperature as the primary factor and flow rate as the secondary factor. This structure can not only macroscopically adjust the cooling power according to the system's heat dissipation requirements, but also make microscopic corrections based on the actual circulation effect of the cooling medium, thereby ensuring the stability and accuracy of the entire quenching furnace oil pump control system.

[0044] The control module, connected to the temperature detection module and the flow detection module, is used to control the start and stop of the oil pump motor according to the temperature, and to adjust the motor speed according to the temperature and flow data.

[0045] In this embodiment, the novel quenching furnace oil pump control system includes a control module, which is the core unit for executing the automated control and safety strategies of the entire system. It is configured to receive data from the front-end sensor module, perform calculations and decisions based on internally preset complex logic, and output precise control commands to the actuators, thereby forming a complete closed-loop control system.

[0046] The control module can be a hardware-based microcontroller, digital signal processor, or programmable logic controller. This module has multiple input / output ports. Its input ports are electrically connected to the signal outputs of the temperature detection module and the flow detection module, respectively, while its output ports are connected to the control terminal of the motor drive board and an external alarm device.

[0047] During system operation, the function of the control module is to process the received information and execute multi-level and multi-dimensional control tasks.

[0048] First, the control module performs basic start-stop management. It continuously receives and analyzes real-time digital temperature signals from the temperature detection module. The control module has a pre-set temperature threshold. When it determines that the received temperature value has risen from below this threshold and exceeded it, it determines that the system has reached a condition requiring forced cooling and immediately sends a start command to the motor drive board through its output port. When the temperature drops back below the first preset temperature threshold, it controls the motor to stop to save energy.

[0049] Secondly, the control module implements the core speed-temperature linkage regulation. When the motor is running and the detected temperature is within the normal operating range defined by the first and second preset temperature thresholds, the control module executes a crucial, non-linear speed regulation algorithm. Based on the received real-time temperature value, it dynamically calculates a target speed value that precisely matches the current heat dissipation requirements using internally stored functional relationships or a lookup table. This target speed value and the current temperature exhibit a linear or piecewise linear increasing relationship within this range. After calculation, the control module encodes the target speed value into a corresponding control signal and outputs it to the motor drive board.

[0050] To improve the system's operational accuracy and stability, the control module also executes auxiliary adjustment logic based on flow rate feedback. While performing the aforementioned temperature-speed linkage control, it simultaneously receives real-time flow data from the flow detection module. The control module compares this real-time flow data with the internally set rated flow rate value. When it determines that the real-time flow rate fluctuates within the preset deviation range of the rated flow rate value, the control module judges that the system pipeline circulation is basically normal but has minor disturbances. Therefore, it superimposes a preset small speed increment onto the aforementioned base target speed calculated from temperature, and sends the superimposed final target speed command to the motor drive board. This actively compensates for minor flow rate drift caused by factors such as changes in oil viscosity, achieving precise maintenance of the cooling medium circulation volume.

[0051] The control module also undertakes crucial multi-level safety monitoring and protection functions. It internally has a second and a third preset temperature threshold to define abnormal and dangerous operating conditions of the system. When the detected temperature exceeds the second preset temperature threshold, the control module determines that the system has entered a high-temperature alarm state. At this time, it will perform two parallel actions: first, it sends an alarm signal to an external audible and visual alarm device through the output port to prompt personnel intervention; second, it instructs the motor drive board to operate at a speed higher than the normal range to perform forced cooling.

[0052] To cope with potential extreme or uncontrolled thermal conditions, when the detected temperature rises and exceeds the third preset temperature threshold, which serves as a safety red line, the control module executes the highest priority safety protection strategy. It will immediately issue an irreversible shutdown command to the motor drive board and simultaneously lock the system state to prevent irreversible damage to the oil pump motor, quenched workpiece, and even the entire equipment due to severe overheating.

[0053] The control module combines a stepped judgment based on multi-level temperature thresholds, continuous adjustment based on the temperature-speed function relationship, and auxiliary fine-tuning based on flow feedback to construct a hierarchical, multi-variable comprehensive control strategy, ensuring that the quenching furnace oil pump system can operate automatically, accurately, and safely under different working conditions.

[0054] Please see the appendix Figure 2 A novel control method for a quenching furnace oil pump includes the following steps: S1, Temperature detection; S2. When the detected temperature is higher than the first preset temperature threshold, start the oil pump motor; S3. When the detected temperature is between the first preset temperature threshold and the second preset temperature threshold, the motor speed is adjusted as the temperature increases. S4. When the detected temperature is higher than the second preset temperature threshold, the control device will alarm and increase the motor speed. S5. When the detected temperature is higher than the third preset temperature threshold, the control device will stop. S6. Detect the flow rate data inside the pump body, and adjust the motor speed according to the deviation between the flow rate data and the rated flow rate.

[0055] The method in this embodiment can be used to execute the above system embodiment, and its principle and technical effect are similar, so it will not be described again here.

[0056] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A novel oil pump control system for a quenching furnace, characterized in that, include: Temperature detection module, used to detect temperature; The flow detection module is used to detect flow data within the pump body; The control module, connected to the temperature detection module and the flow detection module, is used to control the start and stop of the oil pump motor according to the temperature, and to adjust the speed of the motor according to the temperature and the flow data.

2. The novel quenching furnace oil pump control system according to claim 1, characterized in that, The oil pump is an oil-immersed axial flow oil pump, which includes a pump body and a motor installed in the pump body; the pump body is provided with a limiting step, and the motor is detachably connected to the pump body through the limiting step, and after installation, the central axis of the motor coincides with the central axis of the pump body.

3. The novel quenching furnace oil pump control system according to claim 2, characterized in that, The pump body is provided with an air hole, and the air hole is provided with a sealing plug; the motor is provided with a front cover and a rear cover; the pump body and the motor are filled with insulating oil.

4. The novel quenching furnace oil pump control system according to claim 1, characterized in that, It also includes a motor drive board disposed on the outside of the pump body of the oil pump. The motor drive board is electrically connected to the motor and is controlled by the control module for speed regulation of the motor.

5. A novel quenching furnace oil pump control system according to claim 1, characterized in that, The control module is configured to start the motor when the temperature detected by the temperature detection module is greater than 40°C.

6. A novel quenching furnace oil pump control system according to claim 5, characterized in that, The control module is also configured to gradually increase the motor speed from 100 rpm to 960 rpm as the temperature increases when the detected temperature is in the range of 40°C to 85°C.

7. A novel quenching furnace oil pump control system according to claim 6, characterized in that, The control module is also configured to: when the detected temperature is greater than 85°C, control the overall equipment to alarm and increase the speed of the motor.

8. A novel quenching furnace oil pump control system according to claim 7, characterized in that, The control module is also configured to shut down the entire device when the detected temperature exceeds 100°C.

9. A novel quenching furnace oil pump control system according to claim 1, characterized in that, The control module is also configured to slightly increase the speed of the motor when the flow data detected by the flow detection module is within ±5% of the set rated flow.

10. A novel control method for a quenching furnace oil pump, comprising a novel quenching furnace oil pump control system according to any one of claims 1-9, characterized in that, Includes the following steps: S1, Temperature detection; S2. When the detected temperature is higher than the first preset temperature threshold, start the oil pump motor; S3. When the detected temperature is between the first preset temperature threshold and the second preset temperature threshold, the speed of the motor is adjusted as the temperature increases. S4. When the detected temperature is higher than the second preset temperature threshold, the control device alarms and increases the speed of the motor; S5. When the detected temperature is higher than the third preset temperature threshold, the control device will stop. S6. Detect the flow rate data in the pump body, and adjust the motor speed according to the deviation between the flow rate data and the rated flow rate.

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