Current automatic division system

Abstract

The invention discloses an automatic current division system, and belongs to the technical field of industrial automation. Comprising a central control unit, a main power supply monitoring module, an equipment end execution module, a dual-mode communication module, a man-machine interaction module and a load trend analysis unit. According to the invention, with the target of full-load operation of the main power supply, a multi-dimensional optimization function is fused, a control algorithm and working condition perception are introduced, and accurate matching of current distribution and actual requirements of equipment is realized; a three-level grading protection mechanism is constructed, overload and faults are handled in advance, and tripping of a main power supply is avoided; dual-mode communication backup is adopted, and an industrial field complex electromagnetic environment is adapted; predictive maintenance and efficient operation and maintenance are realized through load trend analysis, data tracing and visual monitoring; the problems that a traditional system is rigid in distribution, insufficient in safety protection and poor in working condition adaptation are solved, and the complex production requirements of an industrial site are met.

Description

Automatic Current Distribution System Technical Field

[0001] This invention relates to the field of industrial automation technology, and in particular to an automatic current distribution system suitable for various high-power converter equipment such as resistance furnaces and electric arc furnaces. It is used to realize dynamic, accurate and safe current distribution in scenarios where multiple devices are centrally powered, and to ensure that the main power supply operates at full load. Background Technology

[0002] In industrial production, the centralized power supply of high-power converter equipment requires addressing the issue of rational distribution of the main power supply current. Existing technologies suffer from the following key shortcomings:

[0003] ① Rigid allocation logic: Traditional systems allocate current only according to the equipment startup sequence, without taking into account differences in operating conditions (such as higher current requirements in the sintering state) and load trends, resulting in insufficient power supply to critical equipment and redundant current being used by non-critical equipment;

[0004] ② Insufficient allocation accuracy: Relying solely on a simple allocation algorithm cannot cope with sudden changes in equipment load, and is prone to current supply and demand imbalance;

[0005] ③ Limited safety protection: Relying solely on overload trip protection, lacking predictive early warning and graded protection mechanisms, which can easily lead to main power outages or equipment damage;

[0006] ④ Low communication reliability: Most systems only support wired communication, and electromagnetic interference in industrial sites can easily cause communication interruptions, leading to distribution outages;

[0007] ⑤ Weak operation and maintenance support: lack of operating condition identification, load trend analysis and complete data traceability, making it difficult to locate the cause after a failure and resulting in low maintenance efficiency.

[0008] Therefore, based on the fundamental idea of ​​"allocating residual current according to the startup sequence and operating the main power supply at full load", the applicant has integrated functions such as operating condition sensing and hierarchical protection to improve the system's practicality and stability. Summary of the Invention

[0009] The purpose of this invention is to propose an automatic current distribution system to achieve full-load operation of the main power supply.

[0010] To achieve the above objectives, the present invention adopts the following technical solution:

[0011] The automatic current distribution system includes: a central control unit, a main power monitoring module, an equipment-side execution module, a dual-mode communication module, a human-machine interaction module, and a load trend analysis unit;

[0012] The main power monitoring module collects the total current, residual current, voltage, and harmonic data of the main power supply; the device-side execution module monitors device parameters, identifies the operating condition type, and executes current allocation commands; the load trend analysis unit analyzes the load change trend; and the central control unit integrates the residual current dynamic allocation algorithm and the PID fuzzy control algorithm to calculate the optimal current allocation value for each device.

[0013] In some embodiments, the central control unit allocates current according to the device startup order by default. High-priority devices receive current supplementation first, and when the current demand of low-priority devices is insufficient, the redundant current is redistributed to high-priority devices.

[0014] In some embodiments, the dual-mode communication module includes an industrial Ethernet wired communication unit and an industrial 5G / WiFi wireless communication unit, supporting automatic switching between the two modes; when one communication mode is interrupted, it automatically switches to the other communication mode.

[0015] In some embodiments, it further includes: a safety protection module; used to implement graded protection and alarm for overload, short circuit, harmonic exceedance and equipment failure.

[0016] In some embodiments, the hierarchical protection mechanism of the security protection module includes:

[0017] Level 1 protection: When the equipment current reaches 90% of the preset threshold, the human-machine interface module issues an audible and visual warning;

[0018] Level 2 protection: When the equipment current reaches 95% of the preset threshold, the intelligent current regulator automatically limits the current.

[0019] Level 3 protection: When the equipment current exceeds the preset threshold, a short circuit occurs, or the harmonic content of the main power supply exceeds the standard, the power supply to the equipment will be cut off immediately, and the fault circuit will be isolated.

[0020] In some embodiments, the central control unit adopts an integrated architecture of industrial-grade PLC and edge computing module; it localizes the processing of load trend analysis data and real-time allocation calculations, reducing data transmission latency.

[0021] In some embodiments, the load trend analysis unit, based on historical operating data and real-time operating parameters of the equipment, can accurately predict the load trend in the short term and output a reference current demand range. This provides a basis for the central control unit to adjust the current distribution strategy in advance and avoid supply and demand imbalance caused by sudden load changes.

[0022] In some embodiments, the human-computer interaction module is used to set system parameters, visualize operating data, and display alarm information.

[0023] In some embodiments, it further includes: a data traceability module; used to store key data for system operation and support historical querying and export.

[0024] In some embodiments, the key data stored by the data traceability module includes main power supply operation data, equipment current distribution data, operating condition change records, load trend analysis results, alarm information, and maintenance records.

[0025] Compared with the prior art, the present invention provides an automatic current distribution system, which has the following beneficial effects.

[0026] 1. This invention aims to achieve full-load operation of the main power supply, integrates multi-dimensional optimization functions, introduces control algorithms and operating condition sensing to achieve precise matching of current distribution with actual equipment needs; constructs a three-level hierarchical protection mechanism to proactively address overload and faults and prevent main power supply tripping; adopts dual-mode communication backup to adapt to the complex electromagnetic environment of industrial sites; and achieves predictive maintenance and efficient operation and maintenance through load trend analysis, data traceability, and visual monitoring; it solves the problems of rigid distribution, insufficient safety protection, and poor operating condition adaptability of traditional systems, and adapts to the complex production needs of industrial sites.

[0027] Other advantages, objectives and features of the invention will be set forth in part in the description which follows; and in part will be apparent to those skilled in the art upon examination of the following description; or may be learned from practice of the invention. Attached Figure Description

[0028] Figure 1 is a schematic diagram of the process of the present invention. Detailed Implementation

[0029] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0030] The automatic current distribution system, with the core objective of "main power supply operating at full load," integrates multi-dimensional optimization functions, including: a central control unit, a main power supply monitoring module, an equipment-side execution module, a dual-mode communication module, a human-machine interaction module, a safety protection module, a load trend analysis unit, and a data traceability module, all of which work collaboratively.

[0031] The main power monitoring module collects the total current, residual current, voltage, and harmonic data of the main power supply and transmits them to the central control unit. The device-side execution module monitors the device temperature and load parameters, automatically identifies the operating condition type, collects the real-time current and operating status of the device, and executes the current allocation commands issued by the central control unit. The load trend analysis unit analyzes the load change trend based on the historical operating data and real-time operating parameters of the device. The central control unit integrates the residual current dynamic allocation algorithm and the PID fuzzy control algorithm, combines the main power supply residual current, device priority, operating condition type, and load trend analysis results to calculate the optimal current allocation value for each device and sends it to the corresponding intelligent current regulator. The safety protection module is used to realize graded protection and alarm for overload, short circuit, harmonic exceedance, and device faults.

[0032] In use: The central control unit allocates current according to the device startup order by default. High-priority devices can receive current supplementation first. When the current demand of low-priority devices is insufficient, the redundant current is redistributed to high-priority devices.

[0033] The following is a detailed explanation.

[0034] 1. Central control unit:

[0035] It provides automatic power distribution to the main power supply; it adopts an integrated architecture of industrial-grade PLC (such as Siemens S7-1500) and edge computing module as the core decision-making unit of the system; it adopts an integrated architecture, with the edge computing module used for localized processing of load trend analysis data and real-time allocation calculation, reducing data transmission latency.

[0036] 1.1 Integrated dual algorithms: Residual current dynamic allocation algorithm (allocates residual current according to startup sequence) + PID fuzzy control algorithm (dynamically corrects allocation value).

[0037] Detailed logic of the dynamic residual current allocation algorithm: The core algorithm, based on the initial startup sequence allocation logic, combines equipment operating conditions, priorities, and residual current margins to achieve precise and dynamic current allocation, ensuring the main power supply approaches full load; simultaneously, it prevents individual devices from exceeding threshold operating conditions; details are as follows:

[0038] Core goal of the algorithm:

[0039] Based on the principle of "start-up priority", the main power supply utilization is maximized; at the same time, the current requirements of high-priority equipment and special operating conditions (such as sintering state) are met, ensuring that there is no waste of residual current and no conflict in its allocation.

[0040] Core allocation principle:

[0041] ① Basic sequence principle: When priority adjustment is not triggered or the operating condition changes suddenly, the remaining current of the main power supply shall be allocated strictly according to the order of equipment startup;

[0042] ② Operating condition adaptation principle: The basic allocation value of equipment in sintering state shall not be lower than the lower limit of the corresponding operating condition threshold, and the value of equipment in maintenance state shall not exceed the upper limit;

[0043] ③ Priority tilt principle: High-priority equipment (such as level 3) can preempt the redundant current (non-essential operating current) of low-priority (level 1-2) equipment.

[0044] ④ Threshold constraint principle: Under any operating condition, the current of a single device shall not exceed the upper limit of the corresponding operating condition threshold, and all thresholds shall be completely consistent with the parameter setting module.

[0045] The step-by-step implementation process is detailed below.

[0046] Step 1: Initialize parameter reading; After startup, read the preset parameters of the human-machine interaction module, including the maximum rated current of the main power supply, the priority of each device, the current threshold of each operating condition, and the basic allocation coefficient of a single device (such as sintering 1.0, normal 0.8, heat preservation 0.5, maintenance 0.2, corresponding to the operating condition allocation ratio).

[0047] Step 2: Real-time calculation of residual current; Based on the data collected by the main power supply monitoring module, the residual current is updated in real time. The calculation formula is: Residual current = Rated current of main power supply - Current of started equipment.

[0048] Step 3: Base current allocation (by startup sequence): When a new device starts up, the base current is allocated according to the startup sequence to ensure that the base allocation does not exceed the residual current.

[0049] Step 4: Dynamic Adjustment (Operating Condition + Priority Linkage):

[0050] After the basic allocation, if there is residual current, it will be allocated again in the order of "operating condition priority > equipment priority":

[0051] ① Prioritize powering the sintering equipment until it reaches its operating threshold limit;

[0052] ②After the sintering equipment is fully charged, power is supplied to the high-priority (level 3) equipment until the corresponding operating condition threshold limit is reached;

[0053] ③ After the high-priority equipment reaches its full capacity, power is supplied to other equipment in order of equipment priority until the remaining current is ≤5A (for emergency redundancy).

[0054] Step 5: Redundant current recovery and redistribution: When the current of a low-priority device is lower than its own operating condition threshold (non-fault fluctuation), or when the load trend analysis unit predicts that the load of a low-priority device will decrease, the redundant current is recovered (I = current current of the device - lower limit of the operating condition threshold of the device), and the recovered current is redistributed to high-priority, sintering-state devices to ensure efficient utilization of redundant current.

[0055] Step 6: Threshold verification and correction: After each allocation, verify whether the current of a single device exceeds the operating threshold; if it does, automatically adjust it to the upper limit of the threshold, and the adjusted part is included in the remaining current for redistribution; if the remaining current is insufficient to replenish the upper limit of the threshold, it is allocated to each target device proportionally to ensure that the allocation is compliant.

[0056] Key adaptation logic: The algorithm is linked with the load trend analysis unit to reserve redundant current in advance. When it is predicted that the equipment operating condition will switch (such as Furnace No. 3 will switch from normal to sintering), the corresponding incremental current is recovered from the low-priority equipment in advance and stored as reserved current to avoid insufficient current during the operating condition switch. At the same time, the algorithm response time is ≤30ms, which is adapted to the overall response time of the central control unit (≤50ms) to ensure the real-time performance of dynamic adjustment, and the recovered current is not lower than the lower limit of the operating condition threshold of the low-priority equipment.

[0057] In conjunction with the PID fuzzy control algorithm: After the residual current dynamic allocation algorithm outputs the theoretical allocation value, the PID fuzzy control algorithm fine-tunes the allocation value based on voltage fluctuation and sudden changes in equipment load data. The correction formula is: final allocation value = I + ΔI (ΔI is the PID correction amount, calculated based on deviation e = target current - actual current and deviation change rate ec), which improves allocation accuracy and avoids current fluctuations.

[0058] 1.2 Data Processing: Receive multi-dimensional data from the main power monitoring module, the device-side execution module, and the load trend analysis unit; combine this data with device priority and operating condition type to calculate the optimal current allocation value for each device.

[0059] 1.3 Command Issuance: The dual-mode communication module issues allocation commands to the intelligent current regulator, receives execution feedback, and forms a closed-loop control with a response time of no more than 50ms.

[0060] 2. Main power monitoring module:

[0061] It consists of a Hall-effect high-precision current sensor, a voltage sensor, and a harmonic detector, with a measurement accuracy of no less than 0.2% and a data acquisition frequency of no less than 10Hz.

[0062] 2.1 Data collected: main power supply total current, residual current (total current - allocated current), line voltage and harmonic content (THD≤5%).

[0063] 2.2 Data transmission: Data is transmitted to the central control unit in real time through the dual-mode communication module, providing basic support for current distribution and avoiding current runaway caused by voltage fluctuations.

[0064] 3. Device-side execution module:

[0065] Each high-power converter corresponds to a specific device, including an intelligent current regulator, a high-precision current sensor, and a working condition identification unit.

[0066] 3.1 High-precision current sensor: The measurement accuracy is not less than 0.2 class, the acquisition frequency is not less than 20Hz, and the operating current of the equipment is acquired in real time and fed back to the central control unit;

[0067] 3.2 Operating Condition Identification Unit: Integrates temperature sensor and load detector. By monitoring equipment temperature (e.g., sintering >1200℃, normal 800-1200℃, heat preservation 400-800℃, maintenance <400℃) and load parameters, it automatically identifies the operating condition type. It can also be manually set through the human-machine interaction module. The temperature range and current threshold of each operating condition correspond one-to-one with each other without cross-conflict.

[0068] 3.3 Intelligent current regulator: Receives distribution instructions from the central control unit, precisely adjusts the input current of the equipment, provides feedback on the execution status, and ensures that the current distribution is implemented effectively.

[0069] 4. Load Trend Analysis Unit:

[0070] The system employs a dual-drive prediction logic of "time series data modeling + operating condition feature matching". Based on historical operating data of the equipment (such as the current change cycle under different operating conditions) and real-time operating parameters (running time, temperature, load rate, etc.), it can accurately predict the load trend in the short term (such as 3~10 minutes) and output a reference current demand range (error ±5%). This provides a basis for the central control unit to adjust the current distribution strategy in advance and avoid supply and demand imbalance caused by sudden load changes.

[0071] The core design is as follows:

[0072] 4.1 Core Basis for Prediction: Taking into account both historical patterns and real-time conditions to ensure that the prediction results closely match the actual operating scenario:

[0073] ①Historical operating data: Preload the equipment with full operating condition data for the past 6 months (within the storage period), including current change curves, operating condition switching time, temperature-current correspondence, load fluctuation cycle, etc. under different operating conditions (sintering, normal, heat preservation, maintenance), to build a historical feature library;

[0074] ② Real-time operating parameters: Synchronously collect the current temperature, running time, current value, load rate of the equipment, as well as auxiliary parameters such as main power supply voltage fluctuation and ambient temperature (normal temperature of 20-35℃ in industrial workshops) as prediction input variables;

[0075] ③ Operating condition switching rules: Based on the preset temperature threshold (e.g., sintering state > 1200℃), predict the operating condition switching node and deduce the corresponding current demand increment (e.g., normal → sintering requires an increase of 15-20A).

[0076] 4.2 Prediction Algorithm Selection: A hybrid algorithm combining LSTM (Long Short-Term Memory) and linear regression is adopted to adapt to the long dependency characteristics of load time series data and scenarios of sudden changes in operating conditions.

[0077] ①LSTM module: Processes historical time series data, captures the potential patterns of current changes with time and temperature (such as the duration distribution of current stability under sintering conditions), and outputs basic trend prediction values.

[0078] ② Linear regression module: Corrects deviations for real-time parameters (such as temperature rise rate and voltage fluctuation value) to compensate for the lack of adaptation of pure time series models to sudden factors;

[0079] ③ Algorithm optimization: A sliding window mechanism (window size 5 min) is introduced to update input data in real time, with a prediction response time of ≤20ms, which is adapted to the calculation rhythm of the central control unit.

[0080] 4.3 Step-by-step prediction process:

[0081] ① Data preprocessing: Clean the collected historical and real-time data, remove outliers (such as sudden data caused by short circuits or sensor failures), standardize parameters of different dimensions such as temperature, current, and duration (map them uniformly to the 0-1 range), and retain effective features;

[0082] ② Feature extraction: Extract core feature variables, including current operating condition type, temperature value and rate of increase / decrease, current current value, current fluctuation amplitude in the past 1 minute, and cumulative operating time of the equipment, and assign different weights (e.g., temperature rate weight 0.3, current fluctuation weight 0.25, operating condition type weight 0.2, and the rest weight 0.25).

[0083] ③ Model prediction: The LSTM module outputs the current trend curve for the next 3 to 10 minutes based on the historical feature library. The linear regression module combines real-time feature variables to correct the prediction results and outputs a reference current demand range (e.g., Furnace No. 1 will maintain the sintering state for the next 30 minutes, with a current demand of 35 to 70A).

[0084] ④ Result verification: Compare the degree of agreement between the predicted interval and historical data under the same working conditions. If the deviation exceeds ±5%, automatically adjust the feature weights and recalculate to ensure prediction accuracy.

[0085] ⑤ Output Results: Transmit the prediction results (including operating condition switching prediction, reference current range, and trend stability rating) to the central control unit to provide a basis for current distribution.

[0086] 4.4 Precision control measures:

[0087] ① Dynamic calibration: Every 24 hours, based on the deviation between actual operating data and prediction results, the model parameters are calibrated and feature weights are optimized to ensure that the long-term prediction error is ≤ ±5%;

[0088] ② Operating condition adaptation: Set up dedicated prediction models for different operating conditions (such as the sintering state model focusing on current stability prediction, and the normal state model focusing on fluctuation trend prediction) to improve the adaptability of subdivided scenarios.

[0089] ③ Abnormal warning: When the predicted current fluctuation exceeds ±10A (outside the normal range), a warning is triggered simultaneously, prompting the central control unit to reserve more emergency redundant current.

[0090] 4.5 System Coordination Logic:

[0091] ① Linked with the residual current dynamic allocation algorithm: Predict the switching of operating conditions in advance (such as furnace No. 3 switching from normal to sintering), output the required current increment, guide the algorithm to reserve the corresponding redundancy (such as 15A), and avoid insufficient current when switching operating conditions;

[0092] ② Linkage with safety protection module: When it is predicted that the equipment current will approach 90% of the threshold, feedback is sent to the safety protection module in advance to prepare for the first-level warning;

[0093] ③ Linked with the data traceability module: Stores the deviation between each prediction result and the actual operating data, serving as the basis for model calibration and system optimization.

[0094] 5. Dual-mode communication module:

[0095] Provides wired or wireless network connection and control, optimizing communication reliability;

[0096] It includes an industrial Ethernet wired communication unit and an industrial 5G / WiFi wireless communication unit.

[0097] It supports automatic switching between dual modes, with wired communication as the default. When the wired link is interrupted due to electromagnetic interference or line damage, it automatically switches to wireless communication. The switching time is no more than 1 second, ensuring continuous data transmission and avoiding uncontrolled allocation.

[0098] 6. Human-Computer Interaction Module:

[0099] It adopts an industrial touch screen to provide a user-friendly operating interface.

[0100] Parameter settings: Manually input the maximum rated current of the main power supply, equipment priority (e.g., level 1-3), current distribution ratio for each operating condition, and alarm threshold;

[0101] Visual display: Main power supply total current / residual current, device current distribution value, operating condition type, load trend curve, communication status, alarm information;

[0102] Manual control: In an emergency, the current distribution can be manually intervened or the power supply to a designated device can be cut off.

[0103] 7. Safety Protection Module:

[0104] A three-level hierarchical protection mechanism is constructed to prevent overload and failure from affecting system operation.

[0105] Level 1 protection (early warning): When the device current reaches 90% of the preset threshold, an audible and visual warning will be issued, and the warning device will be marked on the screen.

[0106] Level 2 protection (current limiting): When the equipment current reaches 95% of the preset threshold, the central control unit issues a current limiting command, and the intelligent current regulator automatically limits the current increase; corresponding to the threshold values ​​of each working condition: such as sintering 95A (100A×95%), normal 76A (80A×95%), heat preservation 47.5A (50A×95%), maintenance 14.25A (15A×95%), with precise value matching.

[0107] Level 3 protection (cut-off): When the equipment current exceeds the threshold, a short circuit occurs, or the main power supply harmonics exceed the standard (THD>5%), the power supply to the equipment is immediately cut off to isolate the fault circuit and ensure the normal operation of the main power supply and other equipment.

[0108] 8. Data Traceability Module:

[0109] It adopts industrial-grade local storage + cloud storage, with a storage period of no less than 1 year.

[0110] Stored data includes: main power supply operation data, equipment current distribution data, operating condition change records, load trend analysis results, alarm information, and maintenance records.

[0111] Function support: Users can query historical data, export Excel files, and view historical current / load trend curves through the human-computer interaction module, which facilitates fault location and system optimization.

[0112] The following describes the system operation process.

[0113] S1. Parameter initialization:

[0114] The system allows users to set the maximum rated current of the main power supply, equipment priority, current distribution ratio for each operating condition, and alarm threshold through the human-machine interaction module. The system defaults to "allocate according to startup order" mode and loads historical operating data of the equipment for load trend analysis.

[0115] S2. Data Acquisition and Operating Condition Identification:

[0116] The main power supply monitoring module collects total current, residual current, voltage, and harmonic data in real time.

[0117] The device-side execution module collects real-time current, temperature, and load parameters of the device, and the operating condition identification unit automatically identifies the operating condition type and transmits it synchronously to the central control unit.

[0118] S3. Load Trend Analysis:

[0119] The load trend analysis unit outputs the subsequent load change trend and reference current demand range of the device based on real-time data and historical records.

[0120] S4. Intelligent Current Distribution:

[0121] The central control unit allocates the remaining current according to the equipment startup sequence through a dynamic remaining current allocation algorithm; combined with the PID fuzzy control algorithm, operating condition type (sintering state is given priority allocation), equipment priority and load trend analysis results, it corrects the optimal allocation value and sends it to the intelligent current regulator.

[0122] S5. Command Execution and Feedback:

[0123] The intelligent current regulator performs adjustment operations, provides feedback on the execution status, and forms a closed-loop control.

[0124] S6. Safety Protection and Alarm:

[0125] The security protection module monitors in real time and triggers the corresponding level of protection mechanism and alarm prompts.

[0126] S7. Data Storage and Traceability:

[0127] The data traceability module continuously stores key data and supports historical queries and exports.

[0128] This method has at least the following beneficial effects:

[0129] 1. Improved utilization: The basic logic of allocating residual current according to the startup sequence improves the utilization of the main power supply;

[0130] 2. Significantly improved allocation accuracy: The combination of PID fuzzy control algorithm and operating condition perception adapts to different operating conditions and sudden load changes.

[0131] 3. Significantly enhanced safety and stability: Three-level graded protection + dual-mode communication backup, reducing main power supply tripping rate and communication interruption rate;

[0132] 4. Improved operational efficiency: Load trend analysis enables predictive maintenance, and data traceability and visualization functions quickly locate faults, shortening maintenance time;

[0133] 5. Wide adaptability: It is suitable for various high-power converter equipment such as resistance furnaces and electric arc furnaces. It can be adapted to different production scenarios through parameter adjustment, and its industrial application value is significant.

[0134] Example: Taking a centralized power supply scenario for 4 small sintering resistance furnaces (No. 1-4, each with a power of 20-40kW, compatible with 380V industrial voltage) as an example; the maximum rated current of the main power supply is 280A, and the system operation process is described in detail.

[0135] 1. System Configuration:

[0136] Central control unit: Siemens S7-1500 PLC + edge computing module;

[0137] Main power monitoring module: Hall effect current sensor (accuracy class 0.1), voltage sensor, harmonic detector;

[0138] Equipment-side execution module: intelligent current regulator, high-precision current sensor, operating condition identification unit (integrated temperature sensor and load detector).

[0139] Dual-mode communication module: Industrial Ethernet switch + Industrial 5G gateway;

[0140] Human-computer interaction module: 10-inch industrial touch screen;

[0141] Load trend analysis unit: Industrial-grade data processing module, pre-loaded with nearly 6 months of historical data of electric resistance furnace;

[0142] Data traceability module: 1TB industrial-grade local storage + cloud storage interface.

[0143] 2. Parameter settings:

[0144] Maximum rated current of main power supply: 280A (compatible with 4 small sintering resistance furnaces operating simultaneously, with redundancy reserved);

[0145] Equipment priority: Furnace No. 1 (critical production furnace) Level 3, Furnace No. 2 / No. 3 (regular production furnace) Level 2, Furnace No. 4 (standby furnace) Level 1;

[0146] Operating current distribution ratio: 100% in sintering state (threshold 35-70A per unit, corresponding to 20-40kW power, closely matching the peak value of the actual sintering furnace), 80% in normal state (threshold 25-35A per unit, corresponding to 14-20kW), 50% in heat preservation state (threshold 15-25A per unit, corresponding to 8.5-14kW), and 20% in maintenance state (≤10A per unit, corresponding to ≤5.7kW, only maintaining standby monitoring); consistent with the operating condition identification unit and algorithm constraint thresholds;

[0147] Alarm thresholds: Level 1 warning (threshold 90%), Level 2 flow restriction (threshold 95%), Level 3 disconnection (threshold exceeded).

[0148] 3. Operation process:

[0149] After initialization, the main power supply has a remaining current of 280A, the human-machine interface module displays "standby status", and the operating status identification units of each device are in a ready state.

[0150] 0:00:

[0151] Furnace No. 1 (critical production furnace, 40kW, level 3) is started. The operating condition identification unit detects its temperature at 1250℃ and identifies it as being in the sintering state. The high-precision current sensor collects the real-time current of 50A (within the sintering threshold range of 35-70A) and transmits it to the central control unit. The central control unit calculates the remaining current as 280-50=230A.

[0152] The load trend analysis unit initiates the prediction process:

[0153] ① Extract features (sintering conditions, stable temperature 1250℃, current current 50A, fluctuation range ±2A in the last 1 minute);

[0154] ②The LSTM module calls historical sintering condition data and matches it to a pattern in similar scenarios where the current is stable for about 30 minutes and fluctuates within a range of 50-65A;

[0155] ③ The linear regression module, combined with parameters such as real-time voltage stability (380V) and ambient temperature of 25℃, corrects the prediction range and finally outputs the result that "the sintering state of furnace No. 1 will be maintained for 30 minutes, the current demand will be stable at 50-65A, and the trend stability rating is A", providing a basis for subsequent current supplement allocation.

[0156] 0:35:

[0157] Furnace No. 2 (a conventional production furnace, 20kW, level 2) is started and the operating condition is identified as normal (temperature 900℃). The central control unit allocates 25A current according to the startup sequence (the normal threshold is 25-35A, which is in the low range). The remaining current is 230-25=205A. The PID fuzzy control algorithm, combined with the 380V industrial voltage data (stable and without fluctuation), corrects the allocated value to 30A (fully utilizing redundancy and not exceeding the threshold). The intelligent current regulator performs the adjustment, and the remaining current is updated to 230-30=200A.

[0158] 0:45:

[0159] Furnace No. 3 (conventional production furnace, 20kW, level 2) is started and the operating condition is identified as normal (temperature 900℃). The central control unit distributes 25A current in sequence, and the remaining current = 200-25=175A.

[0160] The load trend analysis unit performs predictions:

[0161] ① Extract features (normal operating conditions, temperature 900℃ rising at a rate of 5℃ / min, current current 25A, equipment cumulative operation 45min);

[0162] ②The LSTM module matched historical data and found that under the same heating rate, the temperature will rise to above 1220℃ (sintering threshold) after 10 minutes, and the corresponding current needs to be increased from the normal range (25-35A) to the sintering range (35-70A).

[0163] ③ The linear regression module corrects the incremental value. Considering that Furnace No. 3 is a level 2 priority and the load fluctuation is small, it is finally predicted that "Furnace No. 3 will switch to the sintering state in 10 minutes, and the current demand will increase from 25A to 35A. It will then gradually approach the upper limit of 70A. An incremental value of 20A needs to be reserved. The trend stability rating is B". This result is fed back to the central control unit to guide the allocation of reserved redundant current.

[0164] 1:00

[0165] The central control unit performs the allocation through the residual current dynamic allocation algorithm. At this time, the activated equipment is No. 1 (sintering, 50A), No. 2 (normal, 30A), and No. 3 (normal, 25A). Furnace No. 4 is waiting to be activated. The residual current = 280 - (50 + 30 + 25) = 175A.

[0166] First, the reserved current allocation is executed, reserving an incremental current of 20A for furnace No. 3 (predicted to switch to sintering in 10 minutes). The remaining allocable current = 175 - 20 = 155A; then, power is supplemented according to the dynamic adjustment rules:

[0167] ① Add power to furnace No. 1 (sintering + stage 3), increasing it from 50A to 65A (high level of sintering range, reserving 5A to 70A upper limit), consuming 15A of redundancy, leaving 155-15=140A of distributable current;

[0168] ② Add power to boiler No. 2 (normal + level 2), increasing it from 30A to 35A (the upper limit of the normal threshold, corresponding to a full load of 20kW), consuming 5A of redundant current, leaving 140-5=135A of distributable current;

[0169] ③ Add power to furnace No. 3 (normal + 2 levels), increasing it from 25A to 30A (with a 20A increment reserved, below the normal threshold limit), consuming 5A of redundant current, leaving 135-5=130A of distributable current;

[0170] ④Activate Furnace No. 4 (standby furnace, level 1, maintenance status), allocate a base current of 8A (below the maintenance threshold of 10A upper limit), consume 8A of redundancy, and the remaining allocable current = 130 - 8 = 122A;

[0171] ⑤ The remaining 122A is replenished according to priority. Furnace No. 1 is replenished to 70A (the upper limit of sintering, 40kW full load), consuming 5A of redundancy, leaving 117A. Furnaces No. 2 and No. 3 have reached the reasonable range of the current operating conditions. Finally, the redundancy is temporarily stored as an emergency. After fine-tuning through the PID fuzzy control algorithm, the total current = 70 + 35 + 30 + 8 = 143A, with 137A remaining as emergency redundancy. The current and power are perfectly matched, and the utilization rate is 51.1%.

[0172] 1:10:

[0173] When the temperature of furnace No. 3 rises to 1220℃ (exceeding the sintering temperature threshold of 1200℃), it automatically switches to sintering mode. The central control unit immediately activates the reserved 20A current increment, adjusting its current from 30A to 65A (high level of the sintering range, reserving 5A to the upper limit); simultaneously, the current of furnace No. 2 is finely adjusted from 35A to 30A (releasing 5A redundancy, still higher than the lower limit of the normal threshold), furnace No. 1 is maintained at 70A (the upper limit of sintering), and furnace No. 4 is maintained at 8A (maintenance mode). The total current = 70 + 30 + 65 + 8 = 173A.

[0174] The system calls up some emergency redundancy to raise the A of furnace No. 3 to 70A (sintering limit), consuming 5A of redundancy, with a total current of 70+30+70+8=178A; then it returns furnace No. 2 to 35A (normal limit), with a total current of 70+35+70+8=183A.

[0175] Corrected precise closed loop: The remaining emergency redundancy is 97A, and the total current is stable at 185A (utilization rate 66%), which is suitable for switching of operating conditions and does not exceed the threshold of each device, thus conforming to the actual production load.

[0176] 1:30:

[0177] Wired communication was interrupted due to electromagnetic interference. The dual-mode communication module switched to 5G wireless communication within 0.7 seconds, and the system operation was not affected. After communication was restored, it automatically switched back to wired communication, and current distribution and load monitoring continued normally.

[0178] 2:00

[0179] The current of Boiler No. 2 rose to 33.25A due to fluctuations in operating conditions (95% of the normal threshold of 35A), triggering the secondary current limiting of the safety protection module. The intelligent current regulator maintained the current at 33.25A (corresponding to 19kW).

[0180] The load trend analysis unit updates predictions in real time:

[0181] ① Extract features (normal operating conditions, temperature 980℃ and tending to be stable, current current 33.25A, fluctuation range of ±1A in the past 1 minute);

[0182] ②Based on historical data of similar fluctuations, it is predicted that the load of Boiler No. 2 will drop to 28A (the median of the normal range) after 10 minutes, releasing 5.25A of redundant current;

[0183] ③ Synchronously mark "redundant current allocation priority". Since furnaces No. 1 and No. 3 have reached the sintering limit, it is recommended to temporarily store the redundancy as an emergency and allocate it when the load of subsequent equipment fluctuates, so as to ensure the stability of the main power load and avoid redundancy waste.

[0184] Running result:

[0185] Main power utilization: up to 66% (185 / 280A), which is consistent with the actual production scenario of 4 devices not being at full load at the same time. There are no abnormal operating conditions caused by forced full load. The current and power are precisely matched (No. 1 70A / 40kW, No. 2 35A / 20kW, No. 3 70A / 40kW, No. 4 8A / ≤5.7kW), and there are no over-threshold operation situations.

[0186] Equipment overload rate: Based on the three-level protection and load prediction, only boiler No. 2 triggered the second-level current limiting (not overloaded), and no equipment was damaged due to current runaway;

[0187] Communication interruption rate: Only one wired communication interruption occurred at 1:30, and the dual-mode switching (0.7s) was seamless, without affecting current distribution and system operation;

[0188] Unplanned downtime: Due to load trend prediction, preventive adjustments are made and faults are quickly located through data tracing, which reduces downtime compared to traditional systems and significantly improves operation and maintenance efficiency.

[0189] This invention, with the core objective of "main power supply operating at full load," achieves the following goals by integrating multi-dimensional optimization functions: ① Basic logic: Remaining current is allocated according to the device startup sequence by default, ensuring that the main power supply is always operating at full load; ② Improved allocation accuracy: PID fuzzy control algorithm and operating condition perception are introduced to achieve precise matching of current allocation with the actual needs of the devices; ③ Enhanced safety protection: A three-level hierarchical protection mechanism is constructed to proactively address overload and faults and prevent main power supply tripping; ④ Stable communication is ensured: Dual-mode communication backup is adopted to adapt to the complex electromagnetic environment of industrial sites; ⑤ Reduced operation and maintenance difficulty: Predictive maintenance and efficient operation and maintenance are achieved through load trend analysis, data traceability, and visual monitoring.

[0190] The automatic current distribution system provided by this invention is suitable for centralized power supply scenarios of high-power converter equipment such as resistance furnaces and electric arc furnaces. Based on the logic of distributing residual current according to the startup sequence and ensuring full-load operation of the main power supply, it integrates operating condition perception, PID fuzzy control, load trend analysis, and hierarchical safety protection functions. It includes a central control unit, a main power supply monitoring module, an equipment-side execution module, a dual-mode communication module, a human-machine interaction module, a safety protection module, a load trend analysis unit, and a data traceability module. By collecting multi-dimensional data from the main power supply and equipment in real time, and combining equipment operating condition type, priority, and load trend, it dynamically optimizes current distribution. This ensures efficient full-load operation of the main power supply while preventing overload tripping and communication interruptions through three-level protection and dual-mode communication backup, significantly improving system stability and practicality. It solves the problems of rigid distribution, insufficient safety protection, and poor operating condition adaptability in traditional systems, making it suitable for complex production needs in industrial settings.

[0191] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

[0192] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0193] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. An automatic current distribution system, characterized in that, include: The system comprises a central control unit, a main power monitoring module, an equipment-side execution module, a dual-mode communication module, a human-machine interaction module, and a load trend analysis unit. The main power monitoring module collects the total current, residual current, voltage, and harmonic data of the main power supply. The equipment-side execution module monitors equipment parameters, identifies operating condition types, and executes current distribution commands. The load trend analysis unit analyzes load change trends. The central control unit integrates a residual current dynamic allocation algorithm and a PID fuzzy control algorithm to calculate the optimal current allocation value for each device.

2. The automatic current distribution system according to claim 1, characterized in that, The central control unit allocates current according to the device startup order by default. High-priority devices receive priority current supplementation. When the current demand of low-priority devices is insufficient, the redundant current is redistributed to high-priority devices.

3. The automatic current distribution system according to claim 1, characterized in that, The dual-mode communication module includes an industrial Ethernet wired communication unit and an industrial 5G / WiFi wireless communication unit, supporting automatic switching between the two modes; when one communication mode is interrupted, it automatically switches to the other communication mode.

4. The automatic current distribution system according to claim 1, characterized in that, Also includes: Safety protection module; used to implement graded protection and alarm for overload, short circuit, harmonic exceedance and equipment failure.

5. The automatic current distribution system according to claim 4, characterized in that, The safety protection module has a graded protection mechanism including: Level 1 protection: when the device current reaches 90% of the preset threshold, the human-machine interaction module issues an audible and visual warning; Level 2 protection: when the device current reaches 95% of the preset threshold, the intelligent current regulator automatically limits the current; Level 3 protection: when the device current exceeds the preset threshold, a short circuit occurs, or the main power supply harmonic content exceeds the standard, the power supply to the device is immediately cut off, and the fault circuit is isolated.

6. The automatic current distribution system according to claim 1, characterized in that, The central control unit adopts an integrated architecture of industrial-grade PLC and edge computing module; it localizes the processing of load trend analysis data and real-time allocation calculations, reducing data transmission latency.

7. The automatic current distribution system according to claim 1, characterized in that, The load trend analysis unit, based on historical operating data and real-time operating parameters of the equipment, can accurately predict the load trend in the short term and output a reference current demand range. This provides a basis for the central control unit to adjust the current distribution strategy in advance and avoid supply and demand imbalance caused by sudden load changes.

8. The automatic current distribution system according to claim 1, characterized in that, The human-computer interaction module is used to set system parameters, visualize operating data, and display alarm information.

9. The automatic current distribution system according to claim 1, characterized in that, Also includes: Data traceability module; Used to store critical data for system operation, supporting historical queries and exports.

10. The automatic current distribution system according to claim 9, characterized in that, The key data stored in the data traceability module includes main power supply operation data, equipment current distribution data, operating condition change records, load trend analysis results, alarm information, and maintenance records.

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