Anti-flash control system and method for steel wire heat treatment line

Abstract

The invention discloses an anti-flash control system and method for a steel wire heat treatment line, and relates to the technical field of power grid control, and the control system comprises a power grid state detection unit, a double-ring backup power supply unit UPS and a central control unit. The power grid state detection unit is used for collecting three-phase voltage and current signals in real time and judging a flash event based on a phase sequence and an unbalance degree; the double-ring type backup power supply unit UPS comprises a super capacitor quick response module and an energy storage battery continuous power supply module which take over power supply at a millisecond level and a second level respectively; and the central control unit adopts an industrial-grade programmable logic controller (PLC), is internally provided with a redundant logic script, and realizes a switching decision between a power grid state and a backup power supply state. Through the power grid state detection unit and the double-ring type backup power supply unit UPS, millisecond flash detection and automatic power supply switching are achieved, the mistaken stop and tension unbalance of the take-up machine caused by mains supply transient interruption are eliminated, the flash response speed is increased, and the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of power grid control technology, specifically to a control system and method for preventing flashover of a steel wire heat treatment line. Background Technology

[0002] With the increasing demands for continuity and quality control in industrial production of steel wire heat treatment lines, the problems of equipment downtime and tension imbalance caused by short-term power grid interruptions are becoming increasingly prominent. Even a brief drop or imbalance in mains voltage, lasting only tens of milliseconds, can cause the winding machine's frequency converter to stop erroneously, leading to uncontrolled tension and consequently surface defects in the steel wire, breakage risks, or large-scale production interruptions. Currently, most solutions rely on manual restarts or simple UPS power supplies, but these are not fast enough to guarantee the restart sequence and parameter recovery, making it difficult to meet the needs of high-speed, high-precision steel wire production lines.

[0003] Patent CN110117709B discloses a digitally controlled heat treatment production line for tire bead wires. The above patent achieves the reduction of labor, improvement of production efficiency, and improvement of product quality.

[0004] The aforementioned patents have the advantages of reducing labor, improving production efficiency, improving product quality, low energy consumption, and no pollution. However, during the processing, short-term power grid interruptions can easily cause equipment shutdowns and production line tension imbalances.

[0005] Therefore, this application proposes a control system and method for preventing flashover of steel wire heat treatment lines, which realizes millisecond-level flashover detection and automatic power supply switching. Summary of the Invention

[0006] The purpose of this invention is to provide a control system and method for preventing flashover in steel wire heat treatment lines, in order to solve the technical problems mentioned in the background art, such as the short-term power grid interruption causing the winding machine frequency converter to stop erroneously, resulting in tension loss and thus causing steel wire surface defects, breakage risks, or large-scale production interruptions.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a flashover prevention control system for steel wire heat treatment line, the control system comprising a power grid status detection unit and a central control unit, wherein the power grid status detection unit is connected to the central control unit via a data bus and outputs signal data;

[0008] The power grid status detection unit is used to collect three-phase voltage and current signals in real time, and to determine flashover events based on phase sequence and unbalance.

[0009] The power grid status detection unit uses a digital signal processing (DSP) chip to perform real-time time-domain to frequency-domain transformation analysis, and combines the instantaneous voltage drop amplitude and duration to determine whether a flashover switch is triggered. The power grid status data of the power grid status detection unit is periodically reported to the central control unit in the form of event flags to trigger the switching determination of the central control unit.

[0010] The central control unit adopts an industrial-grade programmable logic controller (PLC) with built-in redundant logic scripts. It integrates switching decisions based on the power grid status and backup power status. Before issuing the switching command, the control parameter management unit completes the saving of the operating parameters of each take-up machine.

[0011] Preferably, the power grid status detection unit is connected to the dual-ring backup power unit UPS via a control line. The dual-ring backup power unit UPS includes a supercapacitor fast response module and a storage battery continuous power supply module, which take over power supply in milliseconds and seconds, respectively. When the dual-ring backup power unit UPS switches to backup power supply, the supercapacitor module completes voltage compensation within ≤5ms and smoothly transitions to storage battery power supply. When switching back to grid power supply, the battery and supercapacitor outputs are disconnected in reverse order.

[0012] Preferably, the dual-ring backup power unit UPS is configured with the following sequence in the takeover process and is controlled by the central control unit: during takeover, the supercapacitor is connected in the order of supercapacitor-energy storage battery. After receiving the switching command, the supercapacitor completes voltage compensation within ≤5ms and maintains the minimum stable voltage of the system. Then, the energy storage battery is connected after the supercapacitor output stabilizes. During recovery, the energy storage battery is disconnected in the reverse order of energy storage battery-supercapacitor. Finally, the mains power is restored and the reverse order grid connection is confirmed.

[0013] Preferably, the redundant logic scripts in the central control unit include:

[0014] Power grid low voltage detection procedure: When the voltage of any phase of the three phases is lower than the set threshold and lasts for more than 50ms, a backup power supply switching command is issued;

[0015] Power grid restoration detection procedure: When the three-phase voltage rises and stabilizes above the threshold for more than 100ms, a command to restore power grid supply is issued.

[0016] Suppress false triggering procedure: Ignore brief voltage drops of less than 20ms to prevent frequent system switching.

[0017] Preferably, the control system further includes a parameter management unit, which uses a non-volatile memory to record key operating parameters such as the inverter setting frequency, acceleration / deceleration curve, and load protection threshold of each take-up machine.

[0018] The parameter management unit automatically collects and updates the actual operating status of the frequency converter before and after each switchover, and restarts each take-up machine in sequence according to the original parameter sequence after switching back to the grid to ensure load balance and production line synchronization.

[0019] Preferably, the high-speed bidirectional data exchange between the central control unit and multiple winding machine frequency converters relies on a communication and synchronization unit;

[0020] The communication and synchronization unit supports EtherCAT and Modbus-TCP protocols, has a breakpoint resume mechanism, and continues to record key switching events locally in the event of network failure, so that they can be uploaded to the upper monitoring system in batches after communication is restored.

[0021] Preferably, the central control unit is connected to the execution drive unit via a data bus, and the execution drive unit performs precise start-stop control on each take-up machine according to the instructions of the central control unit through the servo drive and frequency converter module;

[0022] The drive unit, in conjunction with feedback from the torque sensor, prioritizes deceleration and shutdown when it detects that the instantaneous torque exceeds the limit, in order to prevent the steel wire from breaking and the equipment from being damaged.

[0023] Preferably, the control system further includes a human-machine interaction unit, including a touch screen and an event log module, for real-time display of power grid waveforms, switching status, fault alarms, and export of CSV format reports;

[0024] The human-computer interaction unit also has a multi-level user permission management function, which allows only authorized users to modify various thresholds and control logic, and automatically records the operator and timestamp when any parameter changes.

[0025] Preferably, the control method includes the following steps:

[0026] S1. Real-time monitoring: The power grid status detection unit continuously collects three-phase voltage, current and torque signals;

[0027] S2. Intermittent Disruption Detection: The central control unit runs the low-voltage power grid detection program. When the conditions of drop amplitude and duration are met, a backup power supply start command is sent.

[0028] S3. Parameter saving and switching: The parameter management unit automatically reads and saves the current inverter parameters before switching, and the dual-ring backup power module switches power supply according to the design delay.

[0029] S4. Automatic restart: After the backup power supply is stable, the central control unit restarts the take-up machine by executing the drive unit in sequence according to the pre-stored parameters and order, and performs torque closed-loop correction at the same time.

[0030] S5. Power Grid Restoration and Switchback: Continuously monitor the power grid status. When the restoration conditions are met, the central control unit performs a reverse-sequence disconnection of the backup power supply and restores power to the grid, followed by a self-test.

[0031] Preferably, the control method further includes step S6: before and after any switching action, the communication and synchronization unit uploads the event log to the upper monitoring system through breakpoint resume and local caching to realize remote comprehensive analysis and maintenance decision-making.

[0032] Compared with the prior art, the beneficial effects of the present invention are:

[0033] 1. This invention achieves millisecond-level fault detection and automatic power supply switching through a power grid status detection unit and a dual-ring backup power supply unit (UPS), eliminating the false stop of the take-up machine and tension imbalance caused by power outages, improving fault response speed, and increasing production efficiency;

[0034] 2. This invention uses a central control unit to accurately distinguish between intermittent interruptions and transient interference, suppress false switching, solve the production fluctuation problem caused by false triggering and frequent switching, reduce false triggering, and improve the overall production line efficiency and equipment reliability;

[0035] 3. This invention achieves automated and sequential restart of the take-up machine by installing parameter management and sequential restart, ensuring tension balance and production synchronization, significantly reducing wire breakage rate and surface defect rate, and reducing manual intervention and downtime maintenance costs;

[0036] 4. This invention achieves full-process closed-loop tension and torque protection through multi-level closed-loop drive protection, ensuring the continuity and safety of high-precision steel wire heat treatment production. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the anti-flicker control system of the present invention. Detailed Implementation

[0038] 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.

[0039] Please see Figure 1 The present invention provides an embodiment of a flashover prevention control system for steel wire heat treatment line, the control system comprising a power grid status detection unit and a central control unit, wherein the power grid status detection unit is connected to the central control unit via a data bus and outputs signal data.

[0040] The power grid status detection unit is used to collect three-phase voltage and current signals in real time, and to determine flashover events based on phase sequence and unbalance.

[0041] The power grid status detection unit uses a digital signal processing (DSP) chip to perform real-time time-domain to frequency-domain transformation analysis, and combines the instantaneous voltage drop amplitude and duration to determine whether a flashover switch is triggered. The power grid status data of the power grid status detection unit is periodically reported to the central control unit in the form of event flags to trigger the switching determination of the central control unit.

[0042] The central control unit adopts an industrial-grade programmable logic controller (PLC) with built-in redundant logic scripts. It integrates switching decisions on the power grid status and backup power status. Before issuing the switching command, the control parameter management unit completes the saving of the operating parameters of each take-up machine.

[0043] The redundant logic scripts in the central control unit include:

[0044] Power grid low voltage detection procedure: When the voltage of any phase of the three phases is lower than the set threshold and lasts for more than 50ms, a backup power supply switching command is issued;

[0045] Power grid restoration detection procedure: When the three-phase voltage rises and stabilizes above the threshold for more than 100ms, a command to restore power grid supply is issued.

[0046] Suppress false triggering procedure: Ignore brief voltage drops of less than 20ms to prevent frequent system switching;

[0047] Furthermore, the sampling device of the power grid status detection unit adopts a three-phase voltage transformer with anti-interference filtering circuit and a Hall current sensor, with the sampling rate of each phase set to 10kHz; signal processing: after converting the analog signal into a digital signal, the TITMS320F28379D DSP chip performs real-time time-domain to frequency-domain transformation (FFT length 256 points, time window overlap 50%), and calculates the three-phase voltage drop amplitude and duration; judgment logic: when the voltage drop amplitude of any phase exceeds 15% and lasts for ≥50ms, a "flashover" trigger signal is output; when the voltage recovers to ≥95% and lasts for ≥100ms, a "recovery" signal is output; short-term drops of ≤20ms are ignored.

[0048] Dual-ring backup power unit UPS: The supercapacitor module consists of two sets of 300F / 2.7V supercapacitors connected in series and parallel, with a built-in active balancing circuit. Peak discharge current can reach 100A, and the response time is ≤5ms. The energy storage battery module uses a 48V / 50Ah lithium-ion battery pack, supporting 20A continuous discharge and maintaining power for more than 30 seconds. Switching mechanism: Adopts a dual opposing thyristor architecture for seamless transition. After the central control unit issues a switching command, the supercapacitor is immediately connected, maintaining a 0.5ms trigger delay. When the supercapacitor voltage stabilizes, the battery output relay automatically closes; upon recovery, it disconnects in reverse order.

[0049] The central control unit uses a Siemens S7-1516 PLC, equipped with a redundant power supply module and a dual-channel digital input / output module; software structure:

[0050] 1. Low-voltage power grid detection program: Read the DSP "flashover" signal, and set the backup switching flag if the timer accumulates ≥50ms;

[0051] 2. Power grid recovery detection procedure: When the DSP "recovery" signal lasts for ≥100ms, clear the backup switching flag;

[0052] 3. Suppress false triggering: Monitor the duration of voltage drop and automatically ignore interference of ≤20ms;

[0053] Switching execution: The FB30 drives the thyristor module and controls the relay through digital output; at the same time, it triggers the read and write process of the parameter management unit.

[0054] Please see Figure 1 The present invention provides an embodiment of a steel wire heat treatment line anti-flash jump control system, wherein the control system further includes a parameter management unit, which uses a non-volatile memory to record key operating parameters such as the inverter setting frequency, acceleration and deceleration curve, and load protection threshold of each winding machine.

[0055] The parameter management unit automatically collects and updates the actual operating status of the frequency converter before and after each switchover, and restarts each take-up machine in sequence according to the original parameter sequence after switching back to the grid to ensure load balance and production line synchronization.

[0056] The high-speed bidirectional data exchange between the central control unit and multiple winding machine frequency converters relies on a communication and synchronization unit.

[0057] The communication and synchronization unit supports EtherCAT and Modbus-TCP protocols, has a breakpoint resume mechanism, and continues to record key switching events locally in the event of network failure, so that they can be uploaded to the upper monitoring system in batches after communication is restored.

[0058] Furthermore, the parameter management unit acquires and triggers data: within 5ms before each interruption switching command is issued, the PLC reads the operating status such as "actual frequency", "current acceleration segment number", and "real-time load percentage" from each frequency converter via Modbus-TCP; writing process: the PLC merges the read status with the original parameters and writes them in parallel to the corresponding sector of the EEPROM via the SPI bus, and reads the CRC check; update verification: after writing is completed, the complete block of data is read back and CRC check is performed to ensure storage reliability;

[0059] Communication and synchronization unit implementation:

[0060] Priority Strategy: Real-time-critical switching commands and parameter read / write operations are broadcast via the EtherCAT network, while low-bandwidth monitoring data (such as temperature and current trends) are reported via Modbus-TCP; Load Balancing: When the EtherCAT ring network load exceeds 70%, some non-critical data channels are automatically switched to Modbus-TCP to avoid ring network congestion; Event Structure: Critical switching events are recorded in JSON format, including event type, timestamp, and relevant parameter snapshots; Local Caching: When communication is interrupted, event data is written to the local SD card and saved in blocks of no more than 1MB; Resume Transmission: After network recovery, the communication module first performs a heartbeat check. After confirming the availability of the upper-level monitoring system, it uploads files sequentially via Modbus-TCP according to their creation order. After successful upload, the corresponding local file is automatically deleted.

[0061] Please see Figure 1 The present invention provides an embodiment of a flashover prevention control system for a steel wire heat treatment line, the control system comprising a power grid status detection unit, a dual-ring backup power supply unit (UPS), and a central control unit;

[0062] The power grid status detection unit is used to collect three-phase voltage and current signals in real time, and to determine flashover events based on phase sequence and unbalance.

[0063] The dual-ring backup power unit UPS includes a supercapacitor fast response module and an energy storage battery continuous power supply module, which take over power supply at the millisecond and second levels, respectively.

[0064] The central control unit adopts an industrial-grade programmable logic controller (PLC) with built-in redundant logic scripts to realize the switching decision between the power grid status and the backup power status.

[0065] The central control unit is connected to the execution drive unit via a data bus. The execution drive unit performs precise start-stop control on each take-up machine according to the instructions of the central control unit through the servo drive and frequency converter module.

[0066] The drive unit, combined with torque sensor feedback, achieves closed-loop servo control. When an instantaneous torque exceeds the limit, it prioritizes deceleration and stopping actions to prevent the steel wire from breaking and the equipment from being damaged.

[0067] Furthermore, sampling and sensing: a three-phase voltage transformer with an EMI filter and a clamp-on Hall current sensor are used. The three-phase voltage and current are differentially amplified, level-controlled and ADC-acquired, and then sent to the central control unit for analysis.

[0068] Event determination logic: Configure a dedicated function block FB within the PLC: calculate voltage drop amplitude and imbalance using a time-domain-frequency domain fusion algorithm; Determination conditions:

[0069] The voltage drop of any phase is ≥12% and the duration is ≥40ms;

[0070] Three-phase voltage imbalance ≥3%;

[0071] The "flashover trigger signal" will be output if any condition is met; it will be ignored if the drop is ≤20ms or the imbalance is ≤1%.

[0072] Seamless switching mechanism: The switching control is achieved by the PLC digital output controlling two SSRs.

[0073] 1. "Mainstream-Supercapacitor" SSR: Closes after a 2ms gap following flashover triggering;

[0074] 2. "Supercapacitor-Battery" SSR: Closes 5ms after the supercapacitor output stabilizes;

[0075] Reverse disconnection during recovery: first disconnect the battery SSR, then disconnect the supercapacitor SSR to ensure smooth mains power connection.

[0076] Execution drive unit:

[0077] Structure and Interface: Each take-up machine is equipped with a servo motor, driver and integrated torque sensor, and receives PLC commands and parameters via EtherCAT bus, with unified network cabling;

[0078] Closed-loop torque control: The PLC sends the speed and torque setpoints, and the servo drive performs dual closed-loop control using speed loop + torque loop; when the torque sensor feedback value is ≥110% of the set threshold, the drive prioritizes deceleration and stops; the torque over-limit stop command is simultaneously fed back to the FB record and triggers the HMI alarm.

[0079] Automatic start-stop process: After switching to backup power, the PLC sends start pulses through EtherCAT in a preset order, with an interval of 150ms; after each unit starts or stops successfully, the PLC reads the maximum torque during the start-up process from the torque sensor and stores it in the parameter management unit.

[0080] Please see Figure 1 The present invention provides an embodiment of a steel wire heat treatment line anti-flashover control system, wherein the control system further includes a human-machine interaction unit, including a touch screen and an event log module, for real-time display of power grid waveform, switching status, fault alarm and export of CSV format reports;

[0081] The human-computer interaction unit also has a multi-level user permission management function, which allows only authorized users to modify various thresholds and control logic, and automatically records the operator and timestamp when any parameter changes;

[0082] Furthermore, the software architecture of the human-computer interaction unit:

[0083] The underlying communication service is responsible for data interaction with the PLC or the upper-level SCADA system, and subscribes to the following data points: real-time waveforms of three-phase voltage / current, backup power supply switching status, torque sensor alarm status, user login / logout time and parameter modification requests; communication protocol: EtherCAT TCP / IP encapsulation, Modbus-TCP, automatic reconnection and heartbeat detection mechanism;

[0084] Data display and user interface:

[0085] Main interface: Real-time power grid waveform (XY scrolling curve) and current power supply mode indication are displayed in partitions;

[0086] Status panel: The three-state switching process of "mains power - supercapacitor - battery" is displayed in an icon-based manner, and the switching is dynamically highlighted;

[0087] Alarm Display: Displays the 20 most recent fault / alarm records in list format. Clicking on a record will bring up detailed reasons and troubleshooting suggestions.

[0088] Report Export: Supports selecting time ranges and exporting CSV files with one click, including fields such as: timestamp, event type, before and after status values, and operator ID;

[0089] Access control module:

[0090] User levels are divided into three levels: "Maintenancer", "Operator", and "Administrator".

[0091] Authentication methods: Touch ID fingerprint module or username + password authentication;

[0092] Access control:

[0093] Maintenance personnel can only view historical reports and alarms; they cannot modify any thresholds.

[0094] Operators: Non-safety-critical thresholds can be temporarily adjusted on the parameter settings page, but secondary confirmation and recording are required;

[0095] Administrator: Can modify all thresholds and control logic parameters, including voltage drop threshold, switching delay, restart sequence, etc.

[0096] Please see Figure 1 The present invention provides an embodiment of a method for preventing flashover in a steel wire heat treatment line, the method comprising the following steps:

[0097] S1. Real-time monitoring: The power grid status detection unit continuously collects three-phase voltage, current and torque signals;

[0098] S2. Intermittent Disruption Detection: The central control unit runs the low-voltage power grid detection program. When the conditions of drop amplitude and duration are met, a backup power supply start command is sent.

[0099] S3. Parameter saving and switching: The parameter management unit automatically reads and saves the current inverter parameters before switching, and the dual-ring backup power module switches power supply according to the design delay.

[0100] S4. Automatic restart: After the backup power supply is stable, the central control unit restarts the take-up machine by executing the drive unit in sequence according to the pre-stored parameters and order, and performs torque closed-loop correction at the same time.

[0101] S5. Power Grid Restoration and Switchback: Continuously monitor the power grid status. When the restoration conditions are met, the central control unit performs a reverse-sequence disconnection of the backup power supply and restores power to the grid, followed by a self-test.

[0102] The control method further includes step S6: before and after any switching action, the communication and synchronization unit uploads the event log to the upper monitoring system through breakpoint resume and local caching to realize remote comprehensive analysis and maintenance decision-making.

[0103] Working principle: The power grid status detection unit continuously collects three-phase voltage and current signals. Through the dedicated function block built into the DSP chip or PLC, it calculates the voltage drop amplitude, imbalance and duration in real time. When the voltage drop of any phase exceeds the set threshold and lasts for more than 50ms, or when the negative sequence component exceeds the limit, it is determined as "flashover triggering" and a switching trigger signal is generated. Instantaneous drops of less than 20ms are automatically ignored to avoid false triggering.

[0104] After receiving the trigger signal, the central control unit simultaneously drives the solid-state relays of the supercapacitor module and the energy storage battery module according to the predetermined timing. The supercapacitor quickly compensates the voltage within ≤5ms, and then the energy storage battery takes over to continuously supply power. 5ms before the switch, the parameter management unit automatically reads the set frequency, acceleration and deceleration curve and real-time load status of each take-up machine inverter through the high-speed bus and writes them into the non-volatile memory to ensure that the key operating parameters are completely saved during the power outage.

[0105] After the backup power supply is stable, the central control unit automatically starts the take-up machines one by one through the servo drive and frequency converter module according to the stored parameters and the predetermined sequence, and adjusts the acceleration to prevent breakage by combining the closed-loop feedback of the torque sensor; when the mains power is restored, the PLC detects that the three-phase voltage is stable above the threshold and lasts for more than 100ms, disconnects the battery and supercapacitor in reverse order, and smoothly switches back to the mains power; after the equipment completes the self-test, it resumes normal production and uploads the event log to the upper monitoring system.

[0106] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A flashover prevention control system for a steel wire heat treatment line, characterized in that: The control system includes a power grid status detection unit and a central control unit. The power grid status detection unit is connected to the central control unit via a data bus and outputs signal data. The power grid status detection unit is used to collect three-phase voltage and current signals in real time, and to determine flashover events based on phase sequence and unbalance. The power grid status detection unit uses a digital signal processing (DSP) chip to perform real-time time-domain to frequency-domain transformation analysis, and combines the instantaneous voltage drop amplitude and duration to determine whether a flashover switch is triggered. The power grid status data of the power grid status detection unit is periodically reported to the central control unit in the form of event flags to trigger the switching determination of the central control unit. The central control unit adopts an industrial-grade programmable logic controller (PLC) with built-in redundant logic scripts. It integrates switching decisions based on the power grid status and backup power status. Before issuing the switching command, the control parameter management unit completes the saving of the operating parameters of each take-up machine.

2. The anti-flashover control system for a steel wire heat treatment line according to claim 1, characterized in that: The power grid status detection unit is connected to the dual-ring backup power unit UPS via a control line. The dual-ring backup power unit UPS includes a supercapacitor fast response module and a storage battery continuous power supply module, which take over power supply in milliseconds and seconds, respectively. When the dual-ring backup power unit UPS switches to backup power, the supercapacitor module completes voltage compensation within ≤5ms and smoothly transitions to storage battery power supply. When switching back to grid power supply, the battery and supercapacitor outputs are disconnected in reverse order.

3. The anti-flashover control system for a steel wire heat treatment line according to claim 1, characterized in that: The dual-ring backup power unit UPS is configured with the following sequence during takeover and is controlled by the central control unit: during takeover, the supercapacitor is connected in the order of supercapacitor-energy storage battery. After receiving the switching command, the supercapacitor completes voltage compensation within ≤5ms and maintains the minimum stable voltage of the system. Then, the energy storage battery is connected after the supercapacitor output stabilizes. During recovery, the energy storage battery is disconnected in reverse order of energy storage battery-supercapacitor. Finally, the mains power is restored and the reverse order grid connection is confirmed.

4. The anti-flashover control system for a steel wire heat treatment line according to claim 1, characterized in that: The redundant logic scripts in the central control unit include: Power grid low voltage detection procedure: When the voltage of any phase of the three phases is lower than the set threshold and lasts for more than 50ms, a backup power supply switching command is issued; Power grid restoration detection procedure: When the three-phase voltage rises and stabilizes above the threshold for more than 100ms, a command to restore power grid supply is issued. Suppress false triggering procedure: Ignore brief voltage drops of less than 20ms to prevent frequent system switching.

5. The anti-flashover control system for a steel wire heat treatment line according to claim 1, characterized in that: The control system also includes a parameter management unit, which uses non-volatile memory to record key operating parameters such as the inverter setting frequency, acceleration and deceleration curves, and load protection threshold of each take-up machine. The parameter management unit automatically collects and updates the actual operating status of the frequency converter before and after each switchover, and restarts each take-up machine in sequence according to the original parameter sequence after switching back to the grid to ensure load balance and production line synchronization.

6. The anti-flashover control system for a steel wire heat treatment line according to claim 1, characterized in that: The high-speed bidirectional data exchange between the central control unit and multiple winding machine frequency converters relies on a communication and synchronization unit. The communication and synchronization unit supports EtherCAT and Modbus-TCP protocols, has a breakpoint resume mechanism, and continues to record key switching events locally in the event of network failure, so that they can be uploaded to the upper monitoring system in batches after communication is restored.

7. The anti-flashover control system for a steel wire heat treatment line according to claim 1, characterized in that: The central control unit is connected to the execution drive unit via a data bus. The execution drive unit performs precise start-stop control on each take-up machine according to the instructions of the central control unit through the servo drive and frequency converter module. The drive unit, in conjunction with feedback from the torque sensor, prioritizes deceleration and shutdown when it detects that the instantaneous torque exceeds the limit, in order to prevent the steel wire from breaking and the equipment from being damaged.

8. The anti-flashover control system for a steel wire heat treatment line according to claim 1, characterized in that: The control system also includes a human-machine interaction unit, including a touch screen and an event log module, for real-time display of power grid waveforms, switching status, fault alarms and export of CSV format reports; The human-computer interaction unit also has a multi-level user permission management function, which allows only authorized users to modify various thresholds and control logic, and automatically records the operator and timestamp when any parameter changes.

9. A method for preventing flashover control of a steel wire heat treatment line, applicable to the anti-flashover control system for a steel wire heat treatment line as described in any one of claims 1-8, characterized in that: The control method includes the following steps: S1. Real-time monitoring: The power grid status detection unit continuously collects three-phase voltage, current and torque signals; S2. Intermittent Disruption Detection: The central control unit runs the low-voltage power grid detection program. When the conditions of drop amplitude and duration are met, a backup power supply start command is sent. S3. Parameter saving and switching: The parameter management unit automatically reads and saves the current inverter parameters before switching, and the dual-ring backup power module switches power supply according to the design delay. S4. Automatic restart: After the backup power supply is stable, the central control unit restarts the take-up machine by executing the drive unit in sequence according to the pre-stored parameters and order, and performs torque closed-loop correction at the same time. S5. Power Grid Restoration and Switchback: Continuously monitor the power grid status. When the restoration conditions are met, the central control unit performs a reverse-sequence disconnection of the backup power supply and restores power to the grid, followed by a self-test.

10. The method for preventing flashover control of a steel wire heat treatment line according to claim 9, characterized in that: The control method further includes step S6: before and after any switching action, the communication and synchronization unit uploads the event log to the upper monitoring system through breakpoint resume and local caching to realize remote comprehensive analysis and maintenance decision-making.

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