Stator heat treatment energy-saving optimization system and heat treatment process

Abstract

The invention discloses a stator heat treatment energy-saving optimization system and a heat treatment process, and relates to the technical field of stator processing, the stator heat treatment energy-saving optimization system comprises a heating module, a heat preservation module, a cooling module, a detection module, a control module and an energy recovery module; the corresponding heat treatment process comprises a preheating stage, a temperature rise stage, a heat preservation stage, a cooling stage and a post-treatment stage, and parameters of all the stages are dynamically optimized by the control module according to the material, specification and detection data of the stator. The energy consumption in the stator heat treatment process can be remarkably reduced, the heat treatment uniformity and the product quality stability are improved, and good economical efficiency and practicability are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of stator processing, more particularly to a stator heat treatment energy-saving optimization system and heat treatment process. BACKGROUND

[0002] The stator is the core component of electrical equipment such as motors and generators, and its performance directly affects the overall operation efficiency and service life of the equipment. Heat treatment is a key process in the processing of the stator. Through heating, holding, cooling and other processes, the microstructure of the stator material can be improved, and the mechanical properties such as hardness, toughness and wear resistance of the stator can be improved, so as to ensure the stability and reliability of the stator in the subsequent use process.

[0003] However, the existing stator heat treatment technology has many shortcomings: on the one hand, the energy consumption is high, the traditional heat treatment furnace mostly uses resistance wire heating or gas heating method, the heating efficiency is low, the heat loss is serious, and the waste heat generated in the cooling process is not effectively recovered, causing energy waste; on the other hand, the heat treatment uniformity is poor, the traditional heating method is mostly overall heating, it is difficult to ensure that the temperature of different parts of the stator is consistent, which is easy to cause the stator to have uneven hardness, excessive deformation and other problems, affecting the product quality stability; in addition, the existing heat treatment process parameters are mostly fixed settings, which cannot be dynamically adjusted according to the stator material, specifications and real-time detection data, and the adaptability is poor, which is difficult to meet the heat treatment needs of different types of stators.

[0004] Therefore, it is necessary to propose a stator heat treatment energy-saving optimization system and heat treatment process to solve the above problems. SUMMARY

[0005] (I) Technical problems solved

[0006] The purpose of the present application is to solve the problems of high energy consumption, poor uniformity and inflexible parameter adjustment in the prior art stator heat treatment, and to provide a stator heat treatment energy-saving optimization system and heat treatment process.

[0007] (II) Technical solutions

[0008] In order to achieve the above purpose, the present application specifically adopts the following technical solutions:

[0009] A stator heat treatment energy-saving optimization system and heat treatment process, comprising a heating module, a holding module, a cooling module, a detection module, a control module and an energy recovery module;

[0010] The heating module adopts a segmented electromagnetic induction heating structure, which is divided into at least three heating areas along the shaft direction of the heat treatment furnace, and each heating area is independently configured with an electromagnetic induction coil and a power adjusting unit;

[0011] The heat preservation module comprises a vacuum heat insulation layer arranged on the inner wall of the furnace, high-temperature-resistant heat preservation cotton filled in the vacuum heat insulation layer, and an intelligent temperature control unit installed on the top of the furnace, wherein the intelligent temperature control unit comprises a temperature sensor and an automatic adjusting mechanism of the heat preservation door.

[0012] The cooling module comprises a closed-loop water circulation system and an air cooling system, wherein the closed-loop water circulation system comprises a cooling water tank, a circulating water pump, cooling coils and a heat exchanger, the cooling coils are uniformly arranged on the outside of the furnace, and the air cooling system comprises a blower and a wind guide cover corresponding to the cooling coils.

[0013] The detection module comprises a temperature detection unit, an energy consumption detection unit and a stator deformation detection unit, wherein the temperature detection unit adopts a thermocouple sensor and is uniformly arranged at different parts of the stator in the furnace, the energy consumption detection unit collects real-time electric energy consumption data of each module, and the stator deformation detection unit adopts a laser ranging sensor to detect the deformation of the stator during heat treatment.

[0014] The control module is electrically connected with the heating module, the heat preservation module, the cooling module, the detection module and the energy recovery module, and is internally provided with a fuzzy PID algorithm, so as to dynamically adjust the heating power of each area of the heating module, the opening degree of the heat preservation door of the heat preservation module, the water circulation speed of the cooling module and the air volume according to the parameters collected by the detection module.

[0015] The energy recovery module comprises a waste heat collector, a heat exchanger and an energy storage unit, wherein the waste heat collector is connected with the exhaust port of the furnace and the heat exchanger of the cooling module, is used for collecting high-temperature flue gas waste heat generated during heat treatment and waste heat of the cooling system, and stores the heat after heat exchange through the heat exchanger through the energy storage unit.

[0016] Further, the control module further comprises a parameter storage unit and a fault diagnosis unit, wherein the parameter storage unit is used for storing optimal heat treatment parameter curves of different materials and different specifications of stators, and the fault diagnosis unit is used for judging the running state of each module according to the parameters collected by the detection module, and sending an alarm signal when an abnormality occurs.

[0017] Further, the electromagnetic induction coil of the heating module is made of high-temperature-resistant copper alloy material, and the outside of the coil is wrapped with an insulating heat conducting layer, and the power adjusting unit adopts an IGBT power module to realize stepless adjustment of the heating power.

[0018] Further, the vacuum heat insulation layer is made of double-layer stainless steel plates, the two layers of stainless steel plates are vacuumized, the inner surface of the inner stainless steel plate is coated with a high-temperature-resistant reflective coating, and the high-temperature-resistant heat preservation cotton is made of alumina fiber cotton with a thickness of 50-80mm.

[0019] A stator heat treatment process, comprising the following steps:

[0020] S1: Preheating stage: Place the stator to be treated into the heat treatment furnace, close the furnace door, start the heat module of the control module, the preheating temperature is 150-250℃, the preheating time is 30-60min, during the preheating process, the temperature detection unit collects the stator temperature in real time and controls the preheating rate to be 5-8℃ / min.

[0021] S2: Heating stage: After preheating, a segmented heating method is adopted. According to the stator material and specifications, the target temperature and heating rate of each heating zone are set. The heating rate of the first heating zone is 8-12℃ / min, the heating rate of the second heating zone is 10-15℃ / min, and the heating rate of the third heating zone is 8-12℃ / min, until the overall temperature of the stator reaches the preset austenitizing temperature, which is 850-950℃.

[0022] S3: Heat preservation stage: After the temperature is raised to the target temperature, the heat preservation stage begins. The control module adjusts the opening of the heat preservation door of the heat preservation module to maintain the temperature fluctuation range inside the furnace within ±5℃. The heat preservation time is determined according to the effective thickness of the stator. The heat preservation time is (2-3) × effective thickness of the stator (mm) min.

[0023] S4: Cooling Stage: After the heat preservation is completed, the cooling module is activated, adopting a staged cooling method. The first stage uses air cooling with an air volume of 2000-3000 m³ / h, cooling to 600-700℃ at a cooling rate of 15-20℃ / min. The second stage uses closed-loop water circulation cooling with a circulating water pump speed of 1500-2000 r / min, cooling to 300-400℃ at a cooling rate of 10-15℃ / min. The third stage involves natural cooling to room temperature. During the cooling process, the stator deformation detection unit monitors the stator deformation in real time. If the deformation exceeds the preset value, the control module adjusts the cooling rate.

[0024] S5: Post-processing stage: After cooling to room temperature, the stator is removed and subjected to hardness and deformation testing. The test data is fed back to the control module. The control module combines the energy consumption data of this heat treatment to optimize the heat treatment parameter curve of the stator of this specification and stores it in the parameter storage unit.

[0025] (III) Beneficial Effects

[0026] The beneficial effects of this invention are as follows:

[0027] 1. This invention: By adopting segmented electromagnetic induction heating, the heating efficiency is improved; an energy recovery module is set up to recover and utilize the waste heat of high-temperature flue gas and the waste heat of the cooling system generated during the heat treatment process, so as to realize the recycling of energy and effectively reduce energy consumption. Experimental verification shows that the energy consumption is reduced by 30%-40% compared with the traditional heat treatment process.

[0028] 2. This invention: The heating module adopts a segmented structure, with each heating area independently adjusting its power. Combined with the real-time temperature data of various parts of the stator collected by the detection module, the control module dynamically adjusts the heating parameters through a fuzzy PID algorithm to ensure uniform heating of the entire stator. The cooling module adopts a graded cooling method to avoid uneven temperature caused by excessively fast cooling, further improving the uniformity of heat treatment.

[0029] 3. This invention: The detection module collects stator temperature and deformation in real time, and the control module dynamically adjusts the operating status of each module according to the parameters to avoid problems such as overheating, excessive cooling, and surface oxidation, thereby reducing defects such as uneven stator hardness and excessive deformation and improving product quality stability. At the same time, the parameter storage unit of the control module can store the optimal parameter curves of stators of different specifications and continuously optimize them based on post-processing detection data to further improve product quality.

[0030] 4. This invention: The control module can dynamically adjust the heat treatment parameters according to the stator material, specifications and real-time detection data, which is suitable for the heat treatment needs of different types and specifications of stators, and has good versatility and adaptability.

[0031] 5. This invention: The control module has a built-in fault diagnosis unit that can monitor the operating status of each module in real time. When an abnormality occurs, it will issue an alarm signal in a timely manner to avoid equipment damage and safety accidents, and ensure the safe and reliable operation of the system. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the workflow of the present invention. Detailed Implementation

[0033] 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.

[0034] Please refer to Figure 1. A stator heat treatment energy-saving optimization system and heat treatment process includes a heating module, a heat preservation module, a cooling module, a detection module, a control module, and an energy recovery module.

[0035] The heating module adopts a segmented electromagnetic induction heating structure, which is divided into at least three heating zones along the axial direction of the heat treatment furnace. Each heating zone is independently equipped with an electromagnetic induction coil and a power adjustment unit. Electromagnetic induction heating has the advantages of high heating efficiency, fast heating speed, and low energy consumption. The segmented structure can realize independent adjustment of the heating power of each zone, ensuring uniform heating of different parts of the stator. The electromagnetic induction coil is made of high-temperature resistant copper alloy, and the outside of the coil is wrapped with an insulating and heat-conducting layer, which can improve the high-temperature resistance and insulation performance of the coil and extend its service life. The power adjustment unit adopts an IGBT power module to realize stepless adjustment of heating power with high adjustment accuracy and fast response speed.

[0036] The insulation module includes a vacuum insulation layer installed on the inner wall of the furnace, high-temperature resistant insulation cotton filling the inner side of the vacuum insulation layer, and an intelligent temperature control unit installed on the top of the furnace. The vacuum insulation layer is made of double-layer stainless steel plates, with a vacuum between the two layers. The inner stainless steel plate is coated with a high-temperature resistant reflective coating, which can effectively reduce heat conduction and radiation loss. The high-temperature resistant insulation cotton is made of alumina fiber cotton with a thickness of 50-80mm, which has good high-temperature resistance and insulation effect. The intelligent temperature control unit includes a temperature sensor and an automatic adjustment mechanism for the insulation door. The temperature sensor collects the furnace temperature in real time. When the furnace temperature exceeds the preset value, the control module adjusts the opening of the insulation door to discharge excess heat and maintain a stable furnace temperature.

[0037] The cooling module includes a closed-loop water circulation system and an air-cooling system, employing a combined water and air cooling approach to improve cooling efficiency while preventing stator cracking due to excessively rapid cooling. The closed-loop water circulation system includes a cooling water tank, a circulating water pump, cooling coils, and a heat exchanger. The cooling coils are evenly distributed on the outside of the furnace to ensure uniform cooling. The air-cooling system includes a blower and air guide shrouds. The air guide shrouds are positioned corresponding to the cooling coils to accelerate heat dissipation. The cooling water temperature of the closed-loop water circulation system is controlled between 25-35℃. When the cooling water temperature exceeds 35℃, the heat exchanger is activated for cooling.

[0038] The detection module includes a temperature detection unit, an energy consumption detection unit, and a stator deformation detection unit. The temperature detection unit uses thermocouple sensors, evenly distributed inside the furnace and at different parts of the stator, to collect real-time temperatures of the furnace and various parts of the stator, ensuring uniform heating and cooling. The energy consumption detection unit collects real-time energy consumption data from each module, providing a basis for energy optimization. The stator deformation detection unit uses a laser rangefinder to detect deformation during the stator heat treatment process, promptly identifying and adjusting the cooling rate to prevent excessive deformation.

[0039] The control module is electrically connected to the heating module, heat preservation module, cooling module, detection module, and energy recovery module, respectively. It has a built-in fuzzy PID algorithm, which achieves dynamic control of the heating module through a closed-loop process of "data acquisition - fuzzy decision-PID parameter self-tuning - precise control" combined with detection data. The specific process is as follows:

[0040] Detection data input: Real-time reception of core data collected by the detection module, including furnace temperature, temperature of different parts of the stator, temperature difference between different parts of the stator, and heating power energy consumption data fed back by the energy consumption detection unit.

[0041] Fuzzy rule reasoning: Fuzzyize data such as temperature deviation and temperature difference change rate, and match them with preset fuzzy rules.

[0042] PID parameter self-tuning: Based on fuzzy inference results, the proportional coefficient (P), integral coefficient (I), and derivative coefficient (D) of the PID algorithm are dynamically optimized, solving the problems of fixed parameters and poor adaptability to temperature fluctuations in traditional PID, and improving the adjustment accuracy and response speed.

[0043] Precise control of the heating module: Based on the optimized PID parameters, control commands are output to the power regulation units of each independent area of ​​the heating module: if the temperature of the corresponding stator part in a certain area is too low or the temperature difference is too large, the heating power of the electromagnetic induction coil in that area is increased; if the temperature is too high, the power is reduced, realizing stepless and independent adjustment of the power of each heating area, ensuring uniform heating of the stator as a whole, and ultimately stabilizing the stator temperature within the target range.

[0044] The core of the fuzzification process in the fuzzy PID algorithm is to transform the precise data collected by the detection module into fuzzy linguistic variables, providing input for subsequent fuzzy rule inference. The specific implementation process is as follows:

[0045] Determine the fuzzification input: Select two core precise parameters directly related to heating control as the fuzzification input:

[0046] Input 1: Temperature deviation e, which is the difference between the actual temperature of the stator and the target temperature;

[0047] Input 2: Temperature deviation change rate ec, which is the trend of temperature deviation change per unit time.

[0048] Define the quantization factor and universe of discourse for the input:

[0049] Quantization factor: Converts actual physical quantities into fuzzy domains to achieve range matching of precise values;

[0050] Fuzzy Universe of Discourse: A unified 7-level universe of discourse {-3,-2,-1,0,1,2,3} is adopted to cover the extreme value range of the input quantity and ensure the integrity of fuzzification.

[0051] Define a fuzzy language subset: For each input quantity, divide it into a fuzzy subset and use 7 commonly used fuzzy language values ​​in engineering: {Negative Large (NB), Negative Medium (NM), Negative Small (NS), Zero (ZO), Positive Small (PS), Positive Medium (PM), Positive Large (PB)}.

[0052] Constructing membership functions: Using triangular or trapezoidal membership functions, we describe the degree to which each precise quantized value belongs to a certain fuzzy subset (values ​​range from 0 to 1). For example, the quantized value -2 has a membership degree of 1 for "Negative Medium (NM)" and a membership degree of 0.5 for "Negative Large (NB)" and "Negative Small (NS)", thus achieving a smooth transition from precise values ​​to fuzzy language.

[0053] The fuzzy PID algorithm combines the advantages of fuzzy control and PID control, featuring high control accuracy, fast response speed, and strong robustness. It can dynamically adjust the heating power of each zone of the heating module, the opening of the insulation door of the insulation module, and the water circulation speed and air volume of the cooling module based on parameters such as temperature, atmosphere, energy consumption, and deformation collected by the detection module. The control module also includes a parameter storage unit and a fault diagnosis unit. The parameter storage unit stores the optimal heat treatment parameter curves for stators of different materials and specifications, facilitating subsequent retrieval and optimization. The fault diagnosis unit determines the operating status of each module based on the parameters collected by the detection module and issues an alarm when an abnormality occurs to ensure the safe and stable operation of the system.

[0054] The energy recovery module includes a waste heat collector, a heat exchanger, and an energy storage unit. It collects and recovers waste heat generated during the heat treatment process, reducing energy consumption. The waste heat collector connects the furnace exhaust port to the heat exchanger of the cooling module, collecting waste heat from the high-temperature flue gas and the cooling system. After heat exchange, the heat can be stored in the energy storage unit or directly used to preheat the stator to be treated or supplement workshop heating, achieving energy recycling.

[0055] The present invention also provides a stator heat treatment process based on the above system, comprising the following steps:

[0056] S1: Preheating Stage: Place the stator to be treated into the heat treatment furnace, close the furnace door, and the control module starts the heating module. The preheating temperature is 150-250℃, and the preheating time is 30-60 minutes. During the preheating process, the temperature detection unit collects the stator temperature in real time and controls the preheating rate to 5-8℃ / min. Using waste heat for preheating can reduce the power consumption during the preheating stage. At the same time, slow preheating can reduce the temperature stress inside the stator and avoid premature deformation.

[0057] S2: Heating Stage: After preheating, a segmented heating method is adopted. Based on the stator material and specifications, the target temperature and heating rate for each heating zone are set. The heating rate for the first heating zone is 8-12℃ / min, the second heating zone is 10-15℃ / min, and the third heating zone is 8-12℃ / min, until the overall stator temperature reaches the preset austenitizing temperature (850-950℃). Segmented heating ensures synchronous heating of different parts of the stator. When the detection module detects a temperature difference exceeding 15℃ between different parts of the stator, the control module adjusts the heating power of the corresponding heating zone to reduce the temperature difference and ensure uniform stator heating.

[0058] S3: Heat preservation stage: After the temperature is raised to the target temperature, the heat preservation stage begins. The control module adjusts the opening of the heat preservation door of the heat preservation module to maintain the temperature fluctuation range inside the furnace within ±5℃. The heat preservation time is determined according to the effective thickness of the stator. The heat preservation time is (2-3) × effective thickness of the stator (mm) min.

[0059] S4: Cooling Stage: After the insulation is completed, the cooling module is activated, employing a staged cooling method to avoid stator cracking or uneven hardness caused by excessively rapid cooling. The first stage uses air cooling with an air volume of 2000-3000 m³ / h, cooling to 600-700℃ at a cooling rate of 15-20℃ / min. The second stage uses closed-loop water circulation cooling with a circulating water pump speed of 1500-2000 r / min, cooling to 300-400℃ at a cooling rate of 10-15℃ / min. The third stage involves natural cooling to room temperature. During the cooling process, the stator deformation detection unit monitors the stator deformation in real time. If the deformation exceeds a preset value, the control module adjusts the cooling rate to ensure that the stator deformation remains within the allowable range. Simultaneously, when the cooling water temperature exceeds 35℃, the heat exchanger is activated, utilizing the waste heat collected by the energy recovery module for heat exchange and cooling. The heat generated during heat exchange is also recovered to the energy storage unit.

[0060] S5: Post-processing stage: After cooling to room temperature, the stator is removed and subjected to hardness and deformation testing. The test data is fed back to the control module. The control module combines the energy consumption data of this heat treatment to optimize the heat treatment parameter curve of the stator of this specification and stores it in the parameter storage unit, providing better parameter basis for the heat treatment of subsequent stators of the same specification.

[0061] Example 1

[0062] An energy-saving optimization system for stator heat treatment includes a heating module, a heat preservation module, a cooling module, a detection module, a control module, and an energy recovery module.

[0063] The heating module adopts a segmented electromagnetic induction heating structure, which is divided into three heating zones along the axial direction of the heat treatment furnace. Each heating zone is equipped with an electromagnetic induction coil made of high-temperature resistant copper alloy. The coil is wrapped with an insulating and heat-conducting layer. Each heating zone is independently equipped with an IGBT power adjustment unit to achieve stepless adjustment of heating power.

[0064] The insulation module includes a vacuum insulation layer, high-temperature resistant insulation cotton, and an intelligent temperature control unit. The vacuum insulation layer is made of double-layer stainless steel plates with a vacuum between the two layers. The inner stainless steel plate is coated with a high-temperature resistant reflective coating. The high-temperature resistant insulation cotton is made of alumina fiber cotton with a thickness of 60mm. The intelligent temperature control unit includes a K-type thermocouple sensor and an automatic adjustment mechanism for the insulation door.

[0065] The cooling module includes a closed-loop water circulation system and an air cooling system; the closed-loop water circulation system includes a cooling water tank, a circulating water pump, cooling coils and a plate heat exchanger, with the cooling coils evenly arranged on the outside of the furnace; the air cooling system includes a centrifugal blower and an air guide shroud, with the air guide shroud corresponding to the cooling coils.

[0066] The detection module includes a temperature detection unit, an atmosphere detection unit, an energy consumption detection unit, and a stator deformation detection unit. The temperature detection unit uses eight K-type thermocouple sensors, four of which are arranged inside the furnace and four are installed in different parts of the stator. The energy consumption detection unit uses an energy metering module to collect the energy consumption of each module in real time. The stator deformation detection unit uses a laser rangefinder sensor to detect the radial and axial deformation of the stator.

[0067] The control module uses a PLC controller with a built-in fuzzy PID algorithm and is electrically connected to the heating module, heat preservation module, cooling module, detection module and energy recovery module respectively. The control module also includes an SD card parameter storage unit and a fault diagnosis unit. The parameter storage unit stores the optimal heat treatment parameter curves of stators of different materials and specifications. The fault diagnosis unit judges the operating status of each module based on the detection data. When an abnormality occurs, it issues an audible and visual alarm and executes a shutdown procedure.

[0068] The energy recovery module includes a waste heat collector, a plate heat exchanger, and a hot water storage tank. The waste heat collector connects the furnace exhaust port and the plate heat exchanger of the cooling module to collect waste heat from high-temperature flue gas and the cooling system. After heat exchange, the heat is stored in the hot water storage tank for preheating the stator to be processed.

[0069] Based on the stator heat treatment process of the above system, the stator with silicon steel sheet and an outer diameter of 200mm is treated, including the following steps:

[0070] S1: Preheating stage: Place the stator to be treated into the heat treatment furnace, close the furnace door, start the heating module of the control module, the preheating temperature is 200℃, the preheating time is 45min, the preheating rate is controlled at 6℃ / min, and the temperature detection unit collects the stator temperature in real time to ensure uniform preheating.

[0071] S2: Heating Stage: After preheating, a segmented heating method is adopted. The heating rate of the first heating area is 10℃ / min, the heating rate of the second heating area is 12℃ / min, and the heating rate of the third heating area is 10℃ / min, until the overall temperature of the stator reaches 900℃ (austenitizing temperature). During the heating process, when the temperature difference between different parts of the stator exceeds 15℃, the control module adjusts the power of the corresponding heating area to reduce the temperature difference.

[0072] S3: Heat preservation stage: After heating to 900℃, the heat preservation stage begins. The control module adjusts the opening of the heat preservation door to maintain the temperature fluctuation range inside the furnace within ±5℃. The effective thickness of the stator is 20mm, and the heat preservation time is 50min.

[0073] S4: Cooling Stage: After the insulation is completed, the cooling module is activated, using a staged cooling method. The first stage uses air cooling with an air volume of 2500 m³ / h, cooling to 650℃ at a cooling rate of 18℃ / min. The second stage uses closed-loop water circulation cooling with a circulating water pump speed of 1800 r / min, cooling to 350℃ at a cooling rate of 12℃ / min. The third stage involves natural cooling to room temperature. During the cooling process, the laser rangefinder sensor detects the stator deformation in real time. When the deformation exceeds 0.5 mm, the control module reduces the cooling rate. When the cooling water temperature exceeds 35℃, the plate heat exchanger is activated to utilize waste heat for heat exchange and cooling, while simultaneously recovering the heat generated by the heat exchange to the hot water storage tank.

[0074] S5: Post-processing stage: After cooling to room temperature, the stator is removed and subjected to hardness and deformation testing. The test results are: hardness uniformity error ≤ 5HB, deformation ≤ 0.3mm. The test data is fed back to the control module. The control module combines the energy consumption data of this heat treatment to optimize the heat treatment parameter curve of the stator of this specification and stores it to the SD card parameter storage unit.

[0075] Example 2

[0076] An energy-saving optimization system for stator heat treatment has a structure that is basically the same as that of Example 1, except that: the heating module is divided into 4 heating zones along the furnace axial direction, the high-temperature resistant insulation cotton is 70mm thick, and the energy recovery module is equipped with an air source heat pump to convert the recovered waste heat into electrical energy and store it in the battery to supplement the system's operating power.

[0077] Based on the stator heat treatment process of the above system, the stator with a material of cast iron and an outer diameter of 300mm is treated, including the following steps:

[0078] S1: Preheating stage: The stator is preheated at a temperature of 250℃ for 60 minutes at a rate of 8℃ / min.

[0079] S2: Heating stage: A segmented heating method is adopted. The heating rate of the first and fourth heating zones is 8℃ / min, and the heating rate of the second and third heating zones is 15℃ / min, until the overall temperature of the stator reaches 950℃.

[0080] S3: Heat preservation stage: Maintain the temperature fluctuation range inside the furnace within ±5℃, the effective thickness of the stator is 30mm, and the heat preservation time is 80min.

[0081] S4: Cooling stages: Stage 1: Air cooling with an air volume of 3000 m³ / h, cooling to 700℃ at a rate of 20℃ / min; Stage 2: Closed-loop water circulation cooling with a water pump speed of 2000 r / min, cooling to 400℃ at a rate of 15℃ / min; Stage 3: Natural cooling to room temperature.

[0082] S5: Post-processing stage: Detects stator hardness uniformity error ≤4HB, deformation ≤0.4mm, reduces energy consumption by 38% compared to traditional processes, and optimizes and stores parameter curves in the control module.

[0083] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0084] 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 stator heat treatment energy-saving optimization system, characterized in that: It includes a heating module, a heat preservation module, a cooling module, a detection module, a control module, and an energy recovery module; The heating module adopts a segmented electromagnetic induction heating structure, which is divided into at least 3 heating zones along the axial direction of the heat treatment furnace chamber. Each heating zone is independently equipped with an electromagnetic induction coil and a power adjustment unit. The insulation module includes a vacuum insulation layer set on the inner wall of the furnace, high-temperature resistant insulation cotton filled inside the vacuum insulation layer, and an intelligent temperature control unit installed on the top of the furnace. The intelligent temperature control unit includes a temperature sensor and an automatic adjustment mechanism for the insulation door. The cooling module includes a closed-loop water circulation system and an air cooling system. The closed-loop water circulation system includes a cooling water tank, a circulating water pump, cooling coils, and a heat exchanger. The cooling coils are evenly arranged on the outside of the furnace. The air cooling system includes a blower and an air guide shroud. The air guide shroud is set corresponding to the cooling coils. The detection module includes a temperature detection unit, an energy consumption detection unit, and a stator deformation detection unit. The temperature detection unit uses thermocouple sensors, which are evenly arranged in the furnace and in different parts of the stator. The energy consumption detection unit collects the power consumption data of each module in real time. The stator deformation detection unit uses a laser rangefinder sensor to detect the deformation of the stator during the heat treatment process. The control module is electrically connected to the heating module, insulation module, cooling module, detection module, and energy recovery module, respectively. It has a built-in fuzzy PID algorithm and dynamically adjusts the heating power of each area of ​​the heating module, the opening degree of the insulation door of the insulation module, and the water circulation speed and air volume of the cooling module according to the parameters collected by the detection module. The energy recovery module includes a waste heat collector, a heat exchanger, and an energy storage unit. The waste heat collector is connected to the furnace exhaust port and the heat exchanger of the cooling module. It is used to collect the waste heat of high-temperature flue gas and the waste heat of the cooling system generated during the heat treatment process. After heat exchange by the heat exchanger, the waste heat is stored through the energy storage unit.

2. The stator heat treatment energy-saving optimization system according to claim 1, characterized in that: The control module also includes a parameter storage unit and a fault diagnosis unit. The parameter storage unit is used to store the optimal heat treatment parameter curves of stators of different materials and specifications. The fault diagnosis unit is used to determine the operating status of each module based on the parameters collected by the detection module, and to issue an alarm signal when an abnormality occurs.

3. The stator heat treatment energy-saving optimization system according to claim 1, characterized in that: The electromagnetic induction coil of the heating module is made of high-temperature resistant copper alloy, and the outside of the coil is wrapped with an insulating and heat-conducting layer. The power adjustment unit uses an IGBT power module to realize stepless adjustment of the heating power.

4. The stator heat treatment energy-saving optimization system according to claim 1, characterized in that: The vacuum insulation layer is made of double-layer stainless steel plates with a vacuum between the two layers. The inner stainless steel plate is coated with a high-temperature reflective coating. The high-temperature insulation cotton is made of alumina fiber cotton with a thickness of 50-80mm.

5. A stator heat treatment process according to any one of claims 1-4, characterized in that, Includes the following steps: S1: Preheating stage: Place the stator to be treated into the heat treatment furnace, close the furnace door, start the heat module of the control module, the preheating temperature is 150-250℃, the preheating time is 30-60min, during the preheating process, the temperature detection unit collects the stator temperature in real time and controls the preheating rate to be 5-8℃ / min. S2: Heating stage: After preheating, a segmented heating method is adopted. According to the stator material and specifications, the target temperature and heating rate of each heating zone are set. The heating rate of the first heating zone is 8-12℃ / min, the heating rate of the second heating zone is 10-15℃ / min, and the heating rate of the third heating zone is 8-12℃ / min, until the overall temperature of the stator reaches the preset austenitizing temperature, which is 850-950℃. S3: Heat preservation stage: After the temperature is raised to the target temperature, the heat preservation stage begins. The control module adjusts the opening of the heat preservation door of the heat preservation module to maintain the temperature fluctuation range inside the furnace within ±5℃. The heat preservation time is determined according to the effective thickness of the stator. The heat preservation time is (2-3) × effective thickness of the stator (mm) min. S4: Cooling Stage: After the heat preservation is completed, the cooling module is activated, adopting a staged cooling method. The first stage uses air cooling with an air volume of 2000-3000 m³ / h, cooling to 600-700℃ at a cooling rate of 15-20℃ / min. The second stage uses closed-loop water circulation cooling with a circulating water pump speed of 1500-2000 r / min, cooling to 300-400℃ at a cooling rate of 10-15℃ / min. The third stage involves natural cooling to room temperature. During the cooling process, the stator deformation detection unit monitors the stator deformation in real time. If the deformation exceeds the preset value, the control module adjusts the cooling rate. S5: Post-processing stage: After cooling to room temperature, the stator is removed and subjected to hardness and deformation testing. The test data is fed back to the control module. The control module combines the energy consumption data of this heat treatment to optimize the heat treatment parameter curve of the stator of this specification and stores it in the parameter storage unit.

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