Intermediate frequency furnace heat analysis system and method
The intermediate frequency furnace analysis system, which combines intelligent algorithms and sensors, solves the problems of low efficiency and inaccurate data in traditional manual recording. It enables real-time and accurate acquisition of intermediate frequency furnace production data and refined energy consumption management, thereby improving production efficiency and energy efficiency.
Patent Information
- Application Number
- CN202511711652.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-20
- Publication Date
- 2026-02-27
AI Technical Summary
Traditional intermediate frequency furnace production data recording relies on manual handwriting, which has problems such as high error rate, non-real-time data, and inability to accurately analyze energy consumption. Moreover, existing systems are difficult to adapt to different equipment configurations and identify the impact of special operations.
The intelligent system, which employs data acquisition units, a computing center, and a display terminal, automatically determines the furnace number and status and analyzes energy consumption through intelligent algorithms. Combined with sensors and operator input, it achieves real-time data acquisition and accurate analysis.
It enables real-time and accurate recording of furnace information, automatic identification of abnormal operations, provides detailed energy consumption analysis, supports production management and cost control, adapts to different equipment configurations, and improves production efficiency and energy efficiency management.
Smart Images
Figure CN121579899A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of casting technology, and in particular to a system and method for analyzing the furnace cycles of a medium-frequency furnace. Background Technology
[0002] In the casting production field, the intermediate frequency furnace is a key piece of equipment widely used in metal smelting and casting processes. Its operation typically includes multiple stages such as furnace start-up, smelting, holding, tilting, and shutdown, each corresponding to different process requirements and energy consumption characteristics. A furnace cycle, as a basic unit for measuring production efficiency, refers to the cycle from start-up to completion of one full smelting operation by the intermediate frequency furnace. A ladle cycle, on the other hand, refers to the number of times molten steel is poured from the intermediate frequency furnace into the ladle within a single furnace cycle, and is usually related to the amount of charge, ladle capacity, and casting requirements.
[0003] Traditionally, the recording of this production data relied primarily on operators manually filling out paper reports on-site, including information such as furnace start time, ladle quantity, and power consumption. However, this manual recording method has significant limitations. In the high-temperature, noisy, and busy smelting environment, operators often need to simultaneously manage equipment operation and data recording, making them highly susceptible to errors, omissions, or delays due to operational negligence or time pressure. Furthermore, the inefficient circulation and storage of paper reports prevents real-time feedback of production data to management, severely impacting timely monitoring of production progress and cost control.
[0004] With the advancement of industrial automation technology, some foundry workshops have begun to introduce sensors and computer systems to assist in data acquisition. However, these existing systems still have many shortcomings. On the one hand, most systems have relatively simple functions, only able to achieve basic data acquisition, lacking intelligent algorithms for in-depth data analysis and processing, and unable to automatically identify the start time of furnace runs, classify operating states, or accurately count ladle runs. On the other hand, the equipment configurations of different foundry workshops vary greatly; some workshops only have a few sensors, while others rely on manual input, making it difficult for the system to adapt to the needs of various workshops in practical applications.
[0005] Furthermore, special operations commonly encountered in the production process, such as hot-pressing, can easily interfere with the batch counting, and traditional systems struggle to automatically identify and eliminate such influences. More importantly, in terms of energy management, existing technologies typically only provide total power consumption data, failing to precisely break down energy consumption to each batch or specific operational state, making it difficult for companies to identify energy efficiency bottlenecks and implement refined cost control. Summary of the Invention
[0006] To address the aforementioned technical problems, this invention provides a medium-frequency furnace furnace batch analysis system and method. This system utilizes intelligent algorithms to classify furnace batches, determine their status, and analyze energy consumption, effectively solving problems such as low efficiency, inaccurate data, and lagging production data management associated with traditional manual recording. Specifically, this is achieved through the following technical solutions.
[0007] This invention provides a furnace cycle analysis system for medium-frequency furnaces, comprising: The data acquisition unit includes an input terminal and a timing module. The input terminal is located near the medium-frequency furnace at the smelting and casting site and is used for operator input. The timing module is used to record time. The computing center is connected to the data acquisition unit, the database, and the display terminal. The computing center is used to perform calculations based on the data acquired by the data acquisition unit, obtain furnace-related conclusion data, and transmit the conclusion data to the database and the display terminal. A database, wherein the database is used to store the conclusion data; The display terminal is used to display the conclusion data.
[0008] Preferably, the data acquisition unit further includes an electrical acquisition module and an angle sensor. The electrical acquisition module is installed in the electrical cabinet of the medium-frequency furnace and is used to acquire the incoming power and medium-frequency power. The angle sensor is installed on the outside of the medium-frequency furnace body and is used to detect the tilt angle of the furnace body.
[0009] Preferably, the computing center is a cloud server, and the database is a cloud database.
[0010] Preferably, the database is connected to multiple user terminals, which are mobile terminals including but not limited to mobile phones and computers.
[0011] This invention also provides a method for analyzing the furnace cycles of an intermediate frequency furnace. Based on the aforementioned intermediate frequency furnace cycle analysis system, and depending on the configuration of the data acquisition unit, it is executed in one of the following three ways: Method 1: When the data acquisition unit includes an electrical acquisition module and an angle sensor, the following steps are included: Step 1: The data acquisition unit collects incoming power, intermediate frequency power, flip angle, and time data, and transmits them to the computing center; Step 2: The computing center determines the status of the intermediate frequency furnace based on the data. The status includes melting, holding, tilting, shutdown, and failure. Step 3: The computing center determines the start time of the furnace cycle based on the intermediate frequency power and flip angle data, combined with the tilting tag and smelting tag; Step 4: The computing center divides each furnace batch into state intervals based on the state change time points, and calculates the power consumption of each state, the total power consumption of the furnace batch, and the power consumption ratio of each state. Step 5: The calculation center determines the batch number based on the number of times the furnace is tilted; Step 6: The computing center synchronously transmits the data on furnace number, package number, and power consumption to the database and display terminal for storage and display; Method 2: When the data acquisition unit includes an angle sensor but not an electrical acquisition module, the following steps are included: Step 1: The data acquisition unit collects the flip angle and time data and transmits them to the computing center; Step 2: The computing center determines whether a furnace tilt has occurred based on the flipping angle; Step 3: The computing center determines the start time of the furnace batch by having the operator click the "New Furnace" button on the input terminal; Step 4: The computing center records the number of times the furnace enters the tilting state as a package number; Step 5: The computing center synchronously transmits the furnace number, package number, and start time data to the database and display terminal for storage and display; Method 3: When the data acquisition unit does not include an electrical acquisition module and an angle sensor, the following steps are included: Step 1: The data acquisition unit collects time data and transmits it to the computing center; Step 2: The computing center determines the start time of the furnace by having the operator click the "New Furnace" button on the input terminal, and then inputs the theoretical batch number; Step 3: The computing center records the actual number of packages by having the operator click the "Out-of-Battery Weight" button on the input terminal; Step 4: The computing center synchronously transmits the furnace number, package number, and start time data to the database and display terminal for storage and display.
[0012] Preferably, in Method 1, the step of determining the start time of the furnace run includes: S1: Filter out free data segments and abnormal data segments; S2: Perform Fourier fitting on the intermediate frequency power and the flip angle to obtain the fitting curves respectively, and then normalize the fitting curves to obtain the final fitting curve; S3: Label the final fitted curve with tilting tags and perform peak finding to obtain peak points. Then, use each peak point as a reference to search for tilting tags forward and backward to preliminarily determine the furnace number corresponding to multiple peak cycles. S4: Filter and screen the furnace batches, remove duplicate furnace batches, and merge short-duration furnace batches into the previous furnace batch; S5: Label the final fitted curve with smelting tags. Using the last tilting tag of the consecutively appearing tilting tags as the benchmark, take the time point corresponding to the first smelting tag in the backward search as the start time of the furnace.
[0013] Preferably, in method one, the state determination includes: Melting condition: Medium frequency power > melting medium frequency power threshold, and furnace body tilting angle < furnace body tilting angle minimum threshold; In heat preservation condition: the furnace opening medium frequency power threshold ≤ medium frequency power ≤ melting medium frequency power threshold, and the furnace body rotation angle < the minimum furnace body rotation angle threshold; Tilting state: Furnace body tilting angle ≥ minimum threshold of furnace body tilting angle; Shutdown status: Medium frequency power < start-up medium frequency power threshold, and the duration of medium frequency power ≥ shutdown power duration threshold, or furnace body tilting angle > furnace body tilting angle maximum threshold, and the duration of furnace body tilting angle ≥ shutdown tilting duration threshold; Failure status: Furnace start-up time ≥ failure threshold time.
[0014] Preferably, in the first method, the division of the state interval is achieved by performing a difference operation on the state label.
[0015] Preferably, in methods one, two, and three, when a hot stamping operation occurs, the count is ignored by clicking the "hot stamping" button on the input terminal.
[0016] Preferably, in methods one, two, and three, the data is stored and displayed in the form of a furnace information report.
[0017] After adopting the above technical solution, the beneficial effects of the present invention are: 1. The data acquisition unit automatically collects key parameters such as incoming power, intermediate frequency power, furnace tilt angle and time. Combined with the intelligent analysis of the computing center, it completely replaces the traditional method of relying on operators to write records by hand. This effectively avoids data errors, omissions and delays caused by human negligence or interference from the on-site environment, and ensures the real-time, accurate and complete information of furnace batches.
[0018] 2. The furnace analysis system can automatically generate and output reports containing information such as furnace number, batch number, power consumption, time consumption in each state, and energy consumption ratio. These reports are displayed on display terminals and user terminals, enabling managers to keep track of production progress, energy costs, and operational efficiency at any time, providing a reliable basis for production scheduling, cost control, and process optimization.
[0019] 3. By automatically determining the status of furnace runs and identifying abnormal operations, such as short-term furnace merging or marking failed furnace runs, the system can objectively reflect the actual work performance of operators, reduce reliance on manual records, thereby urging operators to follow standardized procedures, improve work efficiency, and provide data support for enterprises to implement performance appraisals and operational training.
[0020] 4. The furnace analysis system can break down the total power consumption into each furnace and each operating state, such as smelting and heat preservation, and calculate the corresponding energy consumption ratio. This helps enterprises accurately identify high-energy-consuming links, optimize energy use strategies, reduce production costs, and provide a data foundation for energy-saving technology transformation and energy efficiency management.
[0021] 5. Depending on the equipment configuration of different foundry workshops, the system can flexibly adopt various analysis modes such as fully automatic, semi-automatic or manual assistance. It can work effectively in both advanced workshops equipped with complete sensors and ordinary workshops with only basic inputs, ensuring the wide applicability and scalability of the technology. Attached Figure Description
[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0023] Figure 1 This is a schematic diagram of the structure of the medium-frequency furnace batch analysis system; Figure 2 This is a report of furnace information output by the medium-frequency furnace furnace analysis system. Detailed Implementation
[0024] The features and exemplary embodiments of various aspects of the present invention will now be described in detail. To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only configured to explain the present invention and are not configured to limit the present invention. For those skilled in the art, the present invention can be practiced without some of these specific details. The following description of the embodiments is merely intended to provide a better understanding of the present invention by illustrating examples of the invention.
[0025] An embodiment of the present invention provides a furnace analysis system, see below. Figure 1 The furnace analysis system includes a data acquisition unit, a computing center, a database, and a display terminal. The computing center is connected to the data acquisition unit, the database, and the display terminal via signals.
[0026] The data acquisition unit includes an input terminal and a timing module. The input terminal is located near the medium-frequency furnace in the smelting and casting site and is operated by the operator. It is used for operation input during special stages of the smelting or casting process to ensure the accuracy and completeness of the data acquisition. The timing module is used to cooperate with the nodes of the data acquisition unit to record time, so as to clearly mark and record the correspondence between nodes and time points.
[0027] In addition, depending on the application scenario, in some more advanced foundry workshops, the data acquisition unit also includes an electrical acquisition module and an angle sensor. The electrical acquisition module is installed in the electrical cabinet of the medium frequency furnace to collect the incoming power and medium frequency power; the angle sensor is installed on the outside of the medium frequency furnace body to detect the tilt angle of the furnace body.
[0028] The computing center performs corresponding calculations and judgments based on data such as incoming power, intermediate frequency power, furnace tilt angle, and time collected by the data acquisition unit to obtain conclusions such as furnace number, batch number, power consumption, and time. The conclusion data is then synchronously transmitted to the database and display terminal. The database stores the conclusion data for easy retrieval, while the display terminal displays data during the workshop production process.
[0029] The conclusion data is stored and displayed in the form of furnace information reports, such as... Figure 2 As shown, the furnace information report displays data such as furnace number, batch number, power consumption, and furnace time in sequence.
[0030] In addition, the database is connected to multiple user terminals, including mobile phones, computers, or other mobile devices, making it convenient for enterprise staff and managers to track and view the actual production situation.
[0031] As a feasible solution, the computing center is preferably a cloud server, which stores and runs the algorithm of the furnace analysis method. Of course, the computing center can also be a traditional physical server; the database is preferably a cloud database, but the database can also be a traditional database.
[0032] Another embodiment of the present invention also provides a furnace analysis method. This furnace analysis method is based on the above furnace analysis system and uses different methods to complete the furnace analysis depending on whether the data acquisition unit in the application scenario includes an electrical acquisition module and an angle sensor.
[0033] When the data acquisition unit includes both an electrical acquisition module and an angle sensor, the furnace analysis method includes the following steps: Step 1. Data Acquisition The data acquisition unit collects real-time data during the production process, including incoming power P1, intermediate frequency power P2, flip angle A, and time T, and transmits the data to the computing center.
[0034] In the normal casting and smelting process, a furnace goes through the processes of opening the furnace, smelting, holding the furnace, tilting the furnace, and stopping the furnace. The state of each process can be judged by the combination and change of parameters. Therefore, collecting the above parameters is convenient for determining the state of the medium frequency furnace in the subsequent smelting process.
[0035] Step 2. Status Determination Based on the parameters collected in step 1, the state of the induction furnace at each time point is determined. According to the differences in parameters, it can be divided into melting, holding, tilting, shutdown and failure states. The determination criteria for each state are as follows: Under smelting conditions, the intermediate frequency power P2 is greater than the intermediate frequency power threshold for smelting, and the furnace body rotation angle is less than the minimum threshold for furnace body rotation angle. The intermediate frequency power threshold for smelting is 20% of the maximum power of the unit, and the minimum threshold for furnace body rotation angle is 10 degrees.
[0036] Under heat preservation conditions, the furnace start-up intermediate frequency power threshold ≤ intermediate frequency power P2 ≤ melting intermediate frequency power threshold, and the furnace body rotation angle < furnace body rotation angle minimum threshold. The furnace start-up intermediate frequency power threshold is 3% of the unit's maximum power, the melting intermediate frequency power threshold is 20% of the unit's maximum power, and the furnace body rotation angle minimum threshold is 10 degrees.
[0037] In the tilting state, the furnace body rotation angle is greater than or equal to the minimum threshold for the furnace body rotation angle, where the minimum threshold for the furnace body rotation angle is 10 degrees. In the shutdown state, the intermediate frequency power P2 is less than the intermediate frequency power threshold for starting the furnace, and the duration of intermediate frequency power P2 is greater than or equal to the duration threshold for shutdown power. Alternatively, the furnace body rotation angle is greater than the maximum threshold for furnace body rotation angle, and the duration of furnace body rotation angle is greater than or equal to the duration threshold for shutdown rotation. The intermediate frequency power threshold for starting the furnace is 3% of the maximum power of the unit, the duration threshold for shutdown power is 3 minutes, the maximum threshold for furnace body rotation angle is 80 degrees, and the duration threshold for shutdown rotation is 0.2 seconds.
[0038] In addition, if no operation is performed after the induction furnace is started, or if no operation is performed after one of the melting, holding, or tilting stages, the furnace is deemed to have failed.
[0039] In the failure state, the furnace start-up time is greater than or equal to the failure threshold time, where the failure threshold time is 24 hours.
[0040] It is worth noting that when only one intermediate frequency furnace is working, the intermediate frequency power P2 is equal to the input power P1. In this case, the item involving intermediate frequency power P2 in the above-mentioned state determination can be replaced by the input power P1.
[0041] Of course, depending on the application scenario, equipment specifications, equipment model, etc., the above thresholds can be adaptively adjusted according to the actual production needs to meet the usage requirements of state differentiation and judgment.
[0042] Step 3. Determine the start time of the furnace run. Using the real-time changes in the intermediate frequency power P2 and the flip angle A collected in step 1 relative to time T as source data, MATLAB is used for analysis and calculation to determine the start time of the furnace cycle. The method is as follows: S1: Filter out free data segments and abnormal data segments.
[0043] The idle data segment is the data segment of the medium frequency furnace in the shutdown state, and the abnormal data segment is the data segment that is obviously contrary to common sense and suddenly deviates from the theoretical range due to factors such as acquisition factors, recording factors, and interference factors. The above data should be cleared to avoid affecting the accuracy of the calculation results.
[0044] S2: Perform a 7th-order Fourier fit on the intermediate frequency power P2 and the flip angle A to obtain the fitted curves fitdata_power(fdp) and fitdata_angle(fda), respectively. Normalize both to obtain the final fitted curve fitdata. The normalization process is as follows: .
[0045] Among them, the first-order Fourier fitting can decompose any periodic function into an infinite number of superpositions of sine and cosine waves. The first-order Fourier fitting effectively realizes the signal data processing of intermediate frequency power P2 and flip angle A, which makes it easy to make a preliminary judgment on the furnace number based on the position of the wave peak.
[0046] The above normalization process adjusts the power data according to the angle, which is applicable to this linear compensation scenario, thereby obtaining a waveform structure that matches a single furnace.
[0047] S3: Label the final fitted curve fitdata with tilting tags, and perform peak finding on the final fitted curve fitdata to obtain the coordinates of each peak point. Using each peak point as a reference, perform forward and backward searches for tilting tags to preliminarily determine the furnace number corresponding to each peak period.
[0048] In the above process, the peak of the final fitted curve fitdata is searched. Based on each peak point, the tilting label is searched in both forward and backward directions. The time point of the tilting label in the forward search is the start time of the furnace, and the time point of the tilting label in the backward search is the end time of the furnace, thus initially determining the furnace.
[0049] The tilting label is the label that is marked when the medium frequency furnace is determined to be in a tilting state according to the state determination criteria in step 2.
[0050] S4: Filter and screen the furnace batches, remove duplicate furnace batches, merge short-duration furnace batches into the previous furnace batch, and finally determine the furnace batches.
[0051] Because the metal smelting process in a single furnace requires multiple temperature increases and holding cycles to meet smelting requirements, there may be multiple peak values corresponding to the same furnace in the furnace determined by the above method, resulting in furnace duplication.
[0052] In addition, in actual production, after the medium frequency furnace smelting is completed, there are situations where the furnace is tilted multiple times to pour molten steel into the ladle. Using the above-mentioned method of searching the tilting tag to determine the heat number will result in the same heat number being identified as multiple heat numbers.
[0053] Among them, the situation of pouring molten steel into the ladle by tilting the furnace multiple times corresponds to a short-time heat. Generally, the time interval between tilting the furnace multiple times in the production process is relatively short. Therefore, a short-time heat is defined as a heat with a heat time of less than or equal to 20 minutes. The heat time is determined by the heat start time and heat end time initially determined in step S3.
[0054] Based on the above, the furnace results were further calibrated, duplicate furnaces were removed, and short-term furnaces were merged into the previous furnace to finally determine the furnace.
[0055] S5: Label the fitting curve fitdata with smelting labels. Using the last tilting label of the consecutively appearing tilting labels as the reference, the first smelting label obtained by backward search is used as the time point corresponding to the smelting label as the start time of the next batch.
[0056] Among them, the last tilting label that appears multiple times in a row indicates that the molten steel in the medium frequency furnace has been poured out, that is, the end of the heat. The first smelting label obtained by the backward search indicates that the charging of the next heat has been completed and smelting has begun. It is more accurate to take the time point corresponding to the smelting label as the start time of the next heat.
[0057] In addition, for the first furnace after the medium frequency furnace is started, the start time of the furnace cannot be determined by the above-mentioned furnace tilting tag method. In this case, the first smelting tag of the first furnace after the medium frequency furnace is started shall be taken as the start time of the furnace.
[0058] Step 4. Division of Furnace Periods The furnace is divided into different furnaces based on the start time determined in step 3. Within the same furnace, according to the state determination method in step 2, a state label is marked for each time point based on time. The state labels are then subjected to differential calculation to determine the specific state change time point. Based on the state change time point, the furnace is divided into different state intervals according to time. By accumulating the power consumption in each state interval, the power consumption of each state in the furnace can be obtained. By accumulating the power consumption of each state, the total power consumption of the furnace can be obtained. The power consumption ratio of each state to the total power consumption can be obtained.
[0059] Step 5. Analyze the package Based on the furnace division results in step 4, the number of times the medium-frequency furnace enters the tilting state in that furnace batch is counted, which is the corresponding batch of that furnace batch.
[0060] It is worth noting that in actual on-site production, in order to ensure the quality of castings, it is often necessary to preheat the ladle before pouring. The usual method used on-site is to pour a small amount of molten steel from the medium-frequency furnace into the ladle to preheat it.
[0061] During the hot stamping process, the induction furnace enters the tilting state and cannot count the number of batches. The operator needs to click the "hot stamping" button on the input terminal, and the computing center will automatically ignore the process of entering the tilting state to eliminate the impact on the batch data.
[0062] Step 6. Data summarization, recording, and output The computing center will simultaneously transmit the furnace number, furnace start time, total power consumption of the furnace, power consumption of each state, power consumption percentage of each state, and time consumption of each state obtained in step 4, and the package number obtained in step 5, to the database and display terminal for storage and display.
[0063] The data is transmitted every half hour to ensure the timeliness of the data display. In addition, the data is temporarily stored in the computing center between the two nodes of the data transmission to avoid data loss.
[0064] As an explanation and supplement to the above embodiments, when the data acquisition unit includes an angle sensor but not an electrical acquisition module, the furnace analysis method includes the following steps: Step 1. Data Acquisition The data acquisition unit collects real-time data during the production process, namely the flipping angle A and the time T, and transmits the data to the computing center.
[0065] Step 2. Status Determination Based on the flip angle A collected in step 1, it is determined whether a tilting state has occurred in this furnace.
[0066] In the tilting state, the furnace body rotation angle is greater than or equal to the minimum threshold for the furnace body rotation angle, where the minimum threshold for the furnace body rotation angle is 10 degrees. Of course, depending on the application scenario, equipment specifications, equipment model, etc., the minimum threshold for furnace body rotation angle can be adaptively adjusted according to the actual production needs to meet the usage requirements for state differentiation and judgment.
[0067] Step 3. Determine the start time of the furnace run. The start time of a furnace cycle is determined by the operator clicking the "New Furnace" button on the input terminal and entering the theoretical number of batches that should be produced in this furnace cycle based on the feed quality. Clicking this button generates a furnace cycle start time.
[0068] This application scenario lacks an electrical data acquisition module, making it impossible to collect corresponding power data and identify and determine the start time of the furnace cycle through power data. Therefore, the start time of the furnace cycle is determined by the operator clicking to input the data.
[0069] Step 4. Package Analysis Record the number of times the furnace enters the tilting state in step 2, and use it as the batch number of the furnace. When the batch number reaches the batch number data entered by the operator in step 2, the furnace is considered to be over.
[0070] Similarly, during the hot-pressing process, the operator needs to click the "hot-press" button on the input terminal. The computing center automatically ignores the process of entering the tilting state to eliminate the impact on the batch data.
[0071] Step 5. Data summarization, recording, and output The computing center synchronously transmits the furnace number and furnace start time obtained in step 3, and the package number obtained in step 4 to the database and display terminal for storage and display.
[0072] The data is transmitted every half hour to ensure the timeliness of the data display. In addition, the data is temporarily stored in the computing center between the two nodes of the data transmission to avoid data loss.
[0073] In summary, in the application scenarios mentioned above that do not include the electrical acquisition module, only data on the furnace number, package number, and furnace start time can be stored and displayed.
[0074] As an explanation and supplement to the above embodiments, when the data acquisition unit includes neither an electrical acquisition module nor an angle sensor, the furnace analysis method includes the following steps: Step 1. Data Acquisition The data acquisition unit collects real-time data during the production process and transmits the time T data to the computing center.
[0075] Step 2. Determine the start time of the furnace run. The start time of a furnace cycle is determined by the operator clicking the "New Furnace" button on the input terminal and entering the theoretical number of batches that should be produced in this furnace cycle based on the feed quality. Clicking this button generates a furnace cycle start time.
[0076] This application scenario lacks an electrical data acquisition module, making it impossible to collect corresponding power data and identify and determine the start time of the furnace cycle through power data. Therefore, the start time of the furnace cycle is determined by the operator clicking to input the data.
[0077] Step 3. Package Analysis During the pouring process, the operator clicks the "Burning Weight" button on the input terminal according to the actual number of ladles. Each time this button is clicked, it is counted as one ladle. When the number of ladles reaches the number of ladles entered by the operator in step 2, the furnace is considered to be finished.
[0078] Similarly, during the hot-pressing process, the operator needs to click the "hot-press" button on the input terminal. The computing center automatically ignores the process of entering the tilting state to eliminate the impact on the batch data.
[0079] Step 4. Data summarization, recording, and output The computing center synchronously transmits the furnace number and furnace start time obtained in step 2, and the package number obtained in step 3 to the database and display terminal for storage and display.
[0080] The data is transmitted every half hour to ensure the timeliness of the data display. In addition, the data is temporarily stored in the computing center between the two nodes of the data transmission to avoid data loss.
[0081] In summary, in the above application scenarios excluding electrical acquisition modules and angle sensors, only data on furnace number, batch number, and furnace start time can be stored and displayed.
[0082] The embodiments described above are not exhaustive, nor do they limit the invention to any specific embodiments. Clearly, many modifications and variations can be made based on the above description. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to effectively utilize the invention and its modifications. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the scope of protection of the invention.
Claims
1. A furnace cycle analysis system for a medium-frequency furnace, characterized in that, include: The data acquisition unit includes an input terminal and a timing module. The input terminal is located near the medium-frequency furnace at the smelting and casting site and is used for operator input. The timing module is used to record time. The computing center is connected to the data acquisition unit, the database, and the display terminal. The computing center is used to perform calculations based on the data acquired by the data acquisition unit, obtain furnace-related conclusion data, and transmit the conclusion data to the database and the display terminal. A database, wherein the database is used to store the conclusion data; The display terminal is used to display the conclusion data.
2. The medium-frequency furnace batch analysis system according to claim 1, characterized in that, The data acquisition unit also includes an electrical acquisition module and an angle sensor. The electrical acquisition module is installed in the electrical cabinet of the medium-frequency furnace and is used to acquire the incoming power and medium-frequency power. The angle sensor is installed on the outside of the medium-frequency furnace body and is used to detect the tilt angle of the furnace body.
3. The intermediate frequency furnace batch analysis system according to claim 1 or 2, characterized in that, The computing center is a cloud server, and the database is a cloud database.
4. The medium-frequency furnace batch analysis system according to claim 1 or 2, characterized in that, The database is connected to multiple user terminals, which are mobile terminals including but not limited to mobile phones and computers.
5. A method for analyzing the batches of a medium-frequency furnace, characterized in that, Based on the system described in claim 1, depending on the configuration of the data acquisition unit, it can be executed in one of the following three ways: Method 1: When the data acquisition unit includes an electrical acquisition module and an angle sensor, the following steps are included: Step 1: The data acquisition unit collects incoming power, intermediate frequency power, flip angle, and time data, and transmits them to the computing center; Step 2: The computing center determines the status of the intermediate frequency furnace based on the data. The status includes melting, holding, tilting, shutdown, and failure. Step 3: The computing center determines the start time of the furnace cycle based on the intermediate frequency power and flip angle data, combined with the tilting tag and smelting tag; Step 4: The computing center divides each furnace batch into state intervals based on the state change time points, and calculates the power consumption of each state, the total power consumption of the furnace batch, and the power consumption ratio of each state. Step 5: The calculation center determines the batch number based on the number of times the furnace is tilted; Step 6: The computing center synchronously transmits the data on furnace number, package number, and power consumption to the database and display terminal for storage and display; Method 2: When the data acquisition unit includes an angle sensor but not an electrical acquisition module, the following steps are included: Step 1: The data acquisition unit collects the flip angle and time data and transmits them to the computing center; Step 2: The computing center determines whether a furnace tilt has occurred based on the flipping angle; Step 3: The computing center determines the start time of the furnace batch by having the operator click the "New Furnace" button on the input terminal; Step 4: The computing center records the number of times the furnace enters the tilting state as a package number; Step 5: The computing center synchronously transmits the furnace number, package number, and start time data to the database and display terminal for storage and display; Method 3: When the data acquisition unit does not include an electrical acquisition module and an angle sensor, the following steps are included: Step 1: The data acquisition unit collects time data and transmits it to the computing center; Step 2: The computing center determines the start time of the furnace batch by having the operator click the "New Furnace" button on the input terminal, and then inputs the theoretical batch number; Step 3: The computing center records the actual number of packages by having the operator click the "Out-of-Battery Weight" button on the input terminal; Step 4: The computing center synchronously transmits the furnace number, package number, and start time data to the database and display terminal for storage and display.
6. The method for analyzing the batches of a medium-frequency furnace according to claim 5, characterized in that, In Method 1, the step of determining the start time of the furnace run includes: S1: Filter out free data segments and abnormal data segments; S2: Perform Fourier fitting on the intermediate frequency power and the flip angle to obtain the fitting curves respectively, and then normalize the fitting curves to obtain the final fitting curve; S3: Label the final fitted curve with tilting tags and perform peak finding to obtain peak points. Then, use each peak point as a reference to search for tilting tags forward and backward to preliminarily determine the furnace number corresponding to multiple peak cycles. S4: Filter and screen the furnace batches, remove duplicate furnace batches, and merge short-duration furnace batches into the previous furnace batch; S5: Label the final fitted curve with smelting tags. Using the last tilting tag of the consecutively appearing tilting tags as the benchmark, take the time point corresponding to the first smelting tag in the backward search as the start time of the furnace.
7. The method for analyzing the batches of a medium-frequency furnace according to claim 5, characterized in that, In method one, the state determination includes: Melting condition: Medium frequency power > melting medium frequency power threshold, and furnace body tilting angle < furnace body tilting angle minimum threshold; In heat preservation condition: the furnace opening medium frequency power threshold ≤ medium frequency power ≤ melting medium frequency power threshold, and the furnace body rotation angle < the minimum furnace body rotation angle threshold; Tilting state: Furnace body tilting angle ≥ minimum threshold of furnace body tilting angle; Shutdown status: Medium frequency power < start-up medium frequency power threshold, and the duration of medium frequency power ≥ shutdown power duration threshold, or furnace body tilting angle > furnace body tilting angle maximum threshold, and the duration of furnace body tilting angle ≥ shutdown tilting duration threshold; Failure status: Furnace start-up time ≥ failure threshold time.
8. The method for analyzing the batches of a medium-frequency furnace as described in claim 5, characterized in that, In the first method, the division of state intervals is achieved by performing a difference operation on the state labels.
9. The method for analyzing the batches of a medium-frequency furnace as described in claim 5, characterized in that, In methods one, two, and three, when a hot-pressing operation occurs, the count is ignored by clicking the "Hot-pressing" button on the input terminal.
10. The method for analyzing the batches of a medium-frequency furnace according to claim 5, characterized in that, In Method 1, Method 2 and Method 3, the data is stored and displayed in the form of furnace information reports.