A metal wire homogenization heat treatment temperature control system and control method

Abstract

This invention relates to the field of heat treatment and industrial control technology for metallic materials, specifically to a temperature control system and method for homogenizing heat treatment of metal wire. The temperature control system includes a multi-dimensional state sensing module, a distributed main control unit, and a high-frequency execution module. The multi-dimensional state sensing module is used to collect multi-source characteristic data such as wire speed, temperature, and specifications. The distributed main control unit is internally configured with a feedforward prediction model, a decoupled control matrix, and a phase change latent heat correction algorithm to generate comprehensive control commands. The high-frequency execution module includes a thyristor power regulator to execute control commands to adjust the heating or cooling of each temperature zone. This invention effectively overcomes thermal inertia lag and cross-zone interference, actively compensates for phase change latent heat, eliminates temperature oscillations and overshoot, and significantly improves the uniformity of the mechanical properties of the wire after heat treatment.

Description

Technical Field

[0001] This invention relates to the field of heat treatment and industrial control technology for metal materials, specifically to a temperature control system and method for homogenizing heat treatment of metal wires. Background Technology

[0002] Current continuous heat treatment of metal wires mainly adopts an independent PID closed-loop control method based on local temperature deviations, using single-point thermocouple temperature measurement to drive the actuators of each temperature zone for feedback control. This passive response to a single temperature error cannot predict the dynamic load demand of the material in advance, nor can it achieve heat decoupling between different temperature zones. The large heat capacity of multi-zone continuous furnaces will generate severe thermal inertia lag, and strong cross-zone thermodynamic coupling interference will also occur between adjacent temperature zones. At the same time, the nonlinear latent heat fluctuations of phase transition during the microstructure transformation of metal materials will cause transient concentrated enthalpy changes. Existing control methods are prone to control lag and dynamic mismatch, and it is difficult to eliminate temperature oscillations at the temperature zone boundaries and temperature overshoot during the phase transition stage, ultimately resulting in the finished wire's mechanical properties being difficult to maintain uniformity. Summary of the Invention

[0003] The purpose of this invention is to provide a temperature control system and method for homogenizing heat treatment of metal wires. Existing passive feedback control suffers from drawbacks such as thermal inertia hysteresis, cross-regional thermodynamic interference, and temperature overshoot caused by latent heat of phase change. There is an urgent need to propose a composite temperature control system and method that integrates feedforward enthalpy prediction, matrix decoupling compensation, and latent heat of phase change correction algorithms to accurately match dynamic heat loads, eliminate temperature oscillations and overshoot, and significantly improve the uniformity of the mechanical properties of metal wires. This is achieved through the following technical solution: On the one hand, the present invention provides a temperature control system for homogenization heat treatment of metal wires. The core architecture of the system mainly includes a multi-dimensional state perception module, a distributed main control unit, and a high-frequency execution module. The multi-dimensional state perception module is used to comprehensively collect the kinematic characteristics (such as travel speed), physical parameters, and dynamic temperature field data inside and outside the multi-zone continuous heat treatment system of the metal wire. The distributed main control unit, as the core decision-making layer of the system, has built-in feedforward prediction model, decoupled control matrix, closed-loop control loop, and phase change latent heat correction algorithm. This unit can calculate the basic heat demand power based on the multi-source real-time data collected by the perception module, decouple and calculate the cross-zone thermal interference compensation power, and adaptively generate the phase change latent heat correction coefficient to dynamically adjust the closed-loop feedback regulation power when the wire enters the microstructure phase change stage. The high-frequency execution module receives the comprehensive control command after the above multi-dimensional fusion and precisely drives the heating or cooling mechanism of each temperature zone through the thyristor power regulator to achieve millisecond-level precise heat distribution.

[0004] On the other hand, the present invention provides a method for controlling the homogenization heat treatment of metal wire based on the temperature control system. The control method collects the operating status of the wire and the thermal parameters of the furnace in real time, and combines the specific heat capacity-temperature curve of the metal wire with the feedforward prediction model to dynamically track the enthalpy in order to calculate the basic heat demand power. Based on the heat transfer characteristics of thermal radiation and thermal convection in adjacent temperature ranges, a decoupling control matrix is ​​used to calculate the cross-regional parasitic heat flux in real time and generate decoupling compensation power. The target temperature of the temperature zone and the actual surface temperature of the wire are fed into the closed-loop control loop to generate feedback adjustment power. When the actual surface temperature of the wire is detected to enter the preset phase change temperature range, the phase change latent heat correction algorithm is automatically called to add the correction coefficient. By comprehensively processing the aforementioned multi-dimensional power parameters, a comprehensive control command is output to drive the high-frequency execution module, thereby achieving in-situ decoupling and precise temperature control of the multi-temperature zone continuous furnace.

[0005] The beneficial effects of this invention are as follows: Addressing the problems of furnace thermal inertia lag, cross-zone coupling interference between adjacent temperature zones, and temperature overshoot caused by phase change latent heat fluctuations in existing control methods, this system uses a multi-dimensional state perception module to collect multi-source characteristic data in real time, and a distributed main control unit to achieve multi-dimensional collaborative regulation; it utilizes a feedforward prediction model combined with the pre-acquired specific heat capacity temperature curve of the metal wire to dynamically track enthalpy, generating the basic heat demand power in advance, achieving in-situ matching of heat energy supply and dynamic load, and effectively overcoming thermal inertia lag; The decoupling compensation power calculated by the decoupling control matrix cuts off the cross-regional thermodynamic interference. When the actual surface temperature of the wire reaches the preset phase transition temperature range, the feedback regulation power of the closed-loop control loop is adjusted by superimposing the correction coefficient through the phase transition latent heat correction algorithm, actively compensating for the phase transition endothermic or exothermic phase transitions that accompany the microstructure transformation. After the above power is fused, it drives the thyristor power regulator to perform high-frequency precise regulation, eliminating temperature oscillations at the temperature zone boundary and temperature overshoot during the phase transition stage, significantly improving the uniformity of the mechanical properties of the metal wire after heat treatment. Attached Figure Description

[0006] The invention will now be further described with reference to the accompanying drawings.

[0007] Figure 1This is a schematic diagram of the module structure of a temperature control system for homogenizing heat treatment of metal wire provided in an embodiment of the present invention. The temperature control system includes a multi-dimensional state sensing module, a distributed main control unit, and a high-frequency execution module connected in sequence. The multi-dimensional state sensing module includes a photoelectric encoder, a multi-point dual-color infrared temperature measurement array, and a furnace thermocouple array, used to input the collected data to the distributed main control unit. The distributed main control unit is configured with a feedforward prediction model, a decoupling control matrix, and a phase change latent heat correction algorithm. The output results from multiple modules are comprehensively processed to generate control commands and sent to the high-frequency execution module. The high-frequency execution module includes a phase-shifted triggered thyristor power regulator, used to receive commands and drive the heating / cooling mechanisms of each temperature zone. Figure 2 This invention provides a flowchart of a method for controlling the homogenization heat treatment of metal wires. The flowchart shows the complete control logic chain, specifically including: Step S1, real-time synchronous acquisition of various multi-source data; Step S2, calculation of basic heat demand power by dynamically tracking enthalpy using a feedforward prediction model; Step S3, calculation of heat transfer influence by decoupling control matrix to generate decoupling compensation power; Step S4, importing temperature data into closed-loop circuit to generate feedback adjustment power, and calling the latent heat correction coefficient of phase change for adjustment when the actual surface temperature of the wire is determined to be within the phase change temperature range; Step S5, integrating the above power and correction coefficient to output a comprehensive control command, which ultimately drives the thyristor power regulator to adjust the heating and / or cooling mechanism of the corresponding temperature zone. Detailed Implementation

[0008] 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.

[0009] Example 1: like Figure 1 As shown, this embodiment provides a temperature control system for homogenization heat treatment of metal wires, including: The multi-dimensional state sensing module is used to collect the traveling speed of the metal wire, the initial temperature of the wire, the wire parameters, and the real-time furnace temperature and actual surface temperature of the wire in each temperature zone of the multi-zone continuous heat treatment system. The distributed master control unit communicates with the multi-dimensional state perception module and is internally configured with a feedforward prediction model, a decoupled control matrix, a closed-loop control loop, and a phase change latent heat correction algorithm. The high-frequency execution module is connected to the distributed main control unit. The high-frequency execution module includes a thyristor power regulator that connects the heating mechanism and / or cooling mechanism of each temperature zone. The distributed master control unit is used to generate basic heat demand power through a feedforward prediction model based on the data collected by the multi-dimensional state perception module, generate decoupling compensation power through a decoupling control matrix, generate phase change latent heat correction coefficient through a phase change latent heat correction algorithm, adjust the feedback regulation power of the closed-loop control loop, and send the integrated control command to the high-frequency execution module to control the heating and / or cooling process of each temperature zone.

[0010] In this embodiment, the multi-dimensional state perception module not only undertakes the basic data acquisition task, but also provides multi-source feature data for subsequent system calculations through the state data of the metal wire during its movement. The feedforward prediction model configured inside the distributed master control unit aims to reduce the thermal inertia lag effect caused by the large heat capacity of the furnace body and overcome the inherent delay defects of conventional feedback control; the decoupling control matrix is ​​used to separate the unavoidable strong thermodynamic coupling phenomenon between adjacent temperature zones in the continuous furnace in situ and cut off the heat cross-interference path; the phase change latent heat correction algorithm is specifically designed to deal with the drastic enthalpy change fluctuations that accompany the microstructure transformation of metal materials, and deeply integrates the metallurgical phase transformation characteristics into the thermal control closed loop. After receiving the integrated control command, the high-frequency execution module uses a thyristor power regulator to achieve millisecond-level precise energy injection or extraction, ensuring that the deviation between the thermal history trajectory along the metal wire and the preset process curve is within the preset threshold range. The multi-dimensional state perception module includes: a photoelectric encoder installed at the inlet end for measuring the traveling speed of the metal wire; a multi-point dual-color infrared temperature measurement array installed at each temperature zone node in the multi-zone continuous heat treatment system for measuring the actual surface temperature of the metal wire; and a furnace thermocouple array installed in the multi-zone continuous heat treatment system for measuring the real-time furnace temperature of each temperature zone.

[0011] The high-frequency pulse signal of the photoelectric encoder is directly mapped to the real-time kinematic vector of the metal wire, providing a benchmark for dynamic tracking of heat load. The multi-point dual-color infrared thermometry array effectively eliminates the measurement noise caused by complex dust aerosol scattering in the furnace and time-varying emissivity fluctuations of the oxide scale on the wire surface through colorimetric thermometry, obtaining the actual surface temperature of the wire that approximates the true thermal state of the wire body. This indicator marks the real-time sensible heat absorption or latent heat release process of the metal wire. The furnace thermocouple array constructs the macroscopic profile of the ambient temperature field, providing key environmental parameters for the calculation of radiation and convection heat flux density. The thyristor power regulator in the high-frequency execution module is a phase-shift triggered thyristor power regulator.

[0012] Phase-shift triggered thyristor power regulators achieve continuous, stepless, and smooth adjustment of output power by frequently adjusting the conduction angle of AC voltage. Compared with zero-crossing triggering, phase-shift triggering is more suitable for heat treatment scenarios requiring rapid and continuous power adjustment, reducing furnace temperature fluctuations caused by power cycle switching and thus improving temperature control resolution. For grid harmonics that may be introduced by phase-shift triggering, conventional input reactors, filters, or harmonic suppression measures in this field can be used for control to ensure stable system operation and meet the control requirements of sensitive metal materials for internal temperature gradients. like Figure 2 As shown, the present invention also provides a method for controlling the homogenization heat treatment of metal wire based on a temperature control system, the control method comprising: Step S1: Real-time synchronous acquisition of the metal wire's traveling speed, initial wire temperature, wire parameters, and the real-time furnace temperature and corresponding actual wire surface temperature of each temperature zone in the multi-zone continuous heat treatment system. Step S2: Based on the traveling speed, initial temperature upon entry, and wire parameters, combined with the pre-acquired specific heat capacity-temperature curve of the metal wire, the enthalpy is dynamically tracked using a feedforward prediction model to calculate the enthalpy required to move the metal wire from the point of entry into the first... The basic heat demand power required to heat the initial temperature of the temperature zone to the preset target temperature; Step S3: Based on the heat transfer characteristics between adjacent temperature zones, the first step is calculated in real time using the decoupling control matrix. Temperature zone and the first Temperature zone and the first The real-time furnace temperature difference between temperature zones is important for the first... The net heat inflow or net heat outflow generated in the temperature zone generates decoupling compensation power; among which... This refers to the current temperature zone number in a multi-zone continuous heat treatment system; when the... When the temperature zone is the first or last temperature zone in a multi-zone continuous heat treatment system, the corresponding missing adjacent temperature zones are ignored. The influence of heat transfer in the temperature zone; Temperature zone and the first Temperature zones respectively represent the first The preceding and following adjacent temperature zones; Step S4, will the first The preset target temperature of the temperature zone and the actual temperature of the wire surface are fed into the closed-loop control loop to generate feedback adjustment power; when the actual temperature of the wire surface reaches the preset phase change temperature range, the phase change latent heat correction coefficient is superimposed through the phase change latent heat correction algorithm. And in step S5, the basic thermal demand power, decoupling compensation power, feedback regulation power, and phase change latent heat correction coefficient are integrated, and a control command is output to the high-frequency execution module to drive the thyristor power regulator to adjust the first Heating and / or cooling mechanisms for the temperature zone.

[0013] During the execution of the control method, multi-stream data is synchronized, aligned, and injected into the control core in step S1; In step S2, the feedforward prediction model is based on the first law of thermodynamics. It treats the metal wire as a continuously moving energy absorber and performs integral calculations on the nonlinear heat capacity characteristics of the material in a specific temperature range through the specific heat capacity-temperature curve. It calculates in advance the basic heat demand power required to maintain thermal balance, so that the corresponding heat energy supply is matched the moment the metal wire enters the temperature range, effectively avoiding the risk of temperature underload or overshoot. The decoupling control matrix in step S3 is built upon a spatially discretized heat transfer model, quantifying the parasitic heat flow driven by temperature differences between adjacent temperature zones. The generated decoupling compensation power serves as an inverse cancellation vector, ensuring the first... The temperature zone becomes an independent space in a thermodynamic sense; The closed-loop control loop introduced in step S4 processes the residual error of the system. In particular, within the tissue phase change temperature range, the intervention of the phase change latent heat correction algorithm compensates for the adjustment lag of conventional PID control in the phase change latent heat stage and actively compensates for the large temperature fluctuations caused by phase change heat absorption or release. The instruction fusion process in step S5 achieves multi-dimensional coordination of macroscopic feedforward, spatial decoupling, and microscopic phase transition compensation, and the output control instructions are directly mapped to the actions of the physical actuators. The calculations show that the metal wire will enter the first... The specific methods for determining the basic heat demand power required to heat the initial temperature of the temperature zone to the preset target temperature include: The metal wire is calculated based on its travel speed and wire parameters in the [number]th [phase / time]. The mass flow rate in the temperature range; where wire parameters include diameter and material density; based on the mass flow rate and specific heat capacity-temperature curve, the mass flow rate of the metal wire in the first temperature range is calculated. The enthalpy increment within the temperature range; converting the enthalpy increment into the basic heat demand power, and issuing the basic heat demand power as a feedforward command.

[0014] The calculation of mass flow rate transforms the one-dimensional travel velocity and three-dimensional wire parameters into the mass flux per unit time, forming the material basis of energy balance; specifically, mass flow rate is obtained by multiplying the cross-sectional area of ​​the wire, travel velocity, and density. The process of solving the enthalpy increment deeply integrates the intrinsic thermophysical properties of metallic materials, accurately reflecting the total energy required for internal lattice vibration and electronic transitions when the material crosses a specific temperature difference. Its value is accurately obtained by integrating the specific heat capacity-temperature curve function of the metallic material within the initial temperature and target temperature range. The specific heat capacity-temperature curve function of the 72A high-carbon steel wire used in this invention can be obtained by consulting the "Handbook of Thermophysical Properties of Metallic Materials" or by experimental fitting using differential scanning calorimetry, for example, at 500... 1000 Within the interval, empirical constants can be used for polynomial fitting calculations, which can be obtained through experimental measurement or fitting calculations in existing technologies. The system multiplies the calculated mass flow rate by the enthalpy increment, converts it into basic heat demand power, and issues it as a feedforward command. This enables the heat source output and load demand to maintain real-time correspondence on the time axis. The heat transfer characteristics include heat radiation transfer characteristics and heat convection transfer characteristics. The specific process of converting radiative and convective heat transfer into decoupling compensation power involves the system's equivalent emissivity. With convective heat transfer coefficient The fundamental thermodynamic parameters mentioned above can all be obtained through conventional experimental calibration; in this embodiment, the system's equivalent emissivity is directly taken as... The convective heat transfer coefficient is taken as The system directly calculates the first temperature range based on the above parameters and the temperature difference between adjacent temperature zones using a decoupled control matrix. The total amount of parasitic heat flow across the temperature zone is converted into the decoupling compensation power of the temperature zone as a reverse cancellation vector, thereby achieving in-situ thermodynamic isolation between adjacent temperature zones and significantly reducing the temperature oscillation amplitude at the interface.

[0015] The closed-loop control loop is a fuzzy PID control loop; the specific method of superimposing the latent heat correction coefficient of phase change includes: judging whether the actual temperature of the wire surface is within the preset phase change temperature range based on the continuous cooling transformation curve or isothermal transformation curve of the metal wire; if it is within the phase change temperature range, it is determined that the phase change has absorbed or released heat, and the corresponding latent heat correction coefficient of phase change is called to adjust the feedback regulation power.

[0016] The fuzzy PID control loop uses fuzzy logic reasoning to dynamically adjust the proportional-integral-derivative gain to adapt to dynamic changes in operating conditions; specifically, the fuzzy PID control loop will adjust the temperature deviation... and rate of change of deviation As input, the universe of discourse is set as It is divided into seven fuzzy subsets: negative large, negative medium, negative small, zero, positive small, positive medium, and positive large, and the triangular membership function is used. The fuzzy rule table is constructed based on the following principles: when When the data is in a negative or positive fuzzy subset, a larger proportional gain correction should be used. and a smaller differential gain correction amount To expedite the response; when When the subset is in the negative small, positive small, or zero fuzzy subset, a larger integral gain correction should be used. To eliminate static error; when the actual surface temperature of the wire falls into the microstructure phase transition temperature range pre-calibrated based on the continuous cooling transformation curve, the system accurately detects the latent heat signal released or absorbed by the reconstruction of the microcrystalline structure. At this point, the system dynamically calculates and generates a latent heat correction coefficient based on parameters such as wire mass flow rate, basic heat demand power, the relative position of the actual temperature within the phase change range, and the latent heat of phase change of the material, combined with empirical adjustment factors. Among them, the latent heat of phase change With empirical moderating factors It can be obtained through conventional thermal analysis experiments and on-site calibration; for the 72A high-carbon steel wire used in this embodiment, it can be directly taken... , In terms of control logic, when a phase change occurs that releases heat, the system determines and executes power reduction; when a phase change occurs that absorbs heat, the system executes power increase. The system directly calls the calculated... The value corrects the feedback regulation power, effectively offsetting the impact of latent heat of phase change on the macroscopic temperature field; The system calls the phase transformation latent heat correction coefficient to multiply or add to correct the feedback regulation power, which can suppress or increase the heat source power in advance, effectively offset the impact of phase transformation latent heat on the macroscopic temperature field, and ensure the dynamic stability of supercooling during the transformation of austenite to pearlite or sorbite. The specific method for outputting control commands is as follows: the basic thermal demand power, the decoupling compensation power, and the feedback regulation power adjusted by the phase change latent heat correction coefficient are superimposed to obtain the comprehensive command output power; the comprehensive command output power is converted into a trigger signal and sent to the thyristor power regulator.

[0017] The power superposition process realizes the comprehensive calculation of control components in different dimensions. The comprehensive command output power fully includes the control intentions of load prediction, spatial decoupling and micro-phase change compensation. It is converted into a trigger signal to drive the thyristor power regulator, and a complete control link from the underlying physical algorithm to the actuator is constructed, realizing the digital and precise control of complex metallurgical heat treatment processes. The multi-zone continuous heat treatment system includes a heating zone, a holding zone, a slow cooling zone, and an isothermal quenching zone arranged sequentially. The control method, applied to the heat treatment of carbon steel wire or alloy steel wire, preferably high-carbon steel wire, sets the target austenitizing temperature of 910°C. The isothermal transition temperature is 530°C. The speed of travel is 75. ; When high-carbon steel wire enters the isothermal quenching zone, the initial trigger temperature of the phase transformation temperature range is 530°C. When the actual surface temperature of the wire shows an upward trend, the latent heat correction coefficient of the phase change is triggered, and the latent heat correction coefficient of the phase change is 0.85; at the same time, the cooling mechanism of the isothermal quenching zone is linked to increase the cooling airflow output.

[0018] For the continuous transfer process of high-carbon steel wire from the heating zone to the isothermal quenching zone, 910 is set. The target austenitizing temperature is designed to ensure sufficient dissolution of cementite and prevent abnormal grain growth, while 530°C... The isothermal transformation temperature setting can induce the supercooled austenite to undergo an isothermal transformation, generating a sorbite structure with extremely fine lamellar spacing; 75 The travel speed was matched to the low-temperature phase transformation kinetics time window of the material under this temperature field; in the early stage of the isothermal transformation, the high-carbon steel wire released a large amount of latent heat of phase transformation, causing local temperature rise, which the system accurately captured at 530°C. The trigger threshold for the phase transition temperature range of the tissue; Specifically, the phase transition temperature range for the tissue is set at 530°C. 550 The aforementioned 530 This is the starting trigger temperature for that range; for 72A high-carbon steel wire with a diameter of 5.5mm, at 75... At the travel speed, the mass flow rate is calculated. When entering the isothermal quenching zone, the basic heat demand power calculated by the feedforward prediction model... 41 ; When the actual surface temperature of the wire reaches At that time, the system calculates the ratio of the theoretical maximum latent heat power of phase change to the basic heat demand power based on the mass flow rate and the latent heat value of phase change, which is 0.5. Combined with the set empirical adjustment factor, the latent heat correction coefficient of phase change at this time is 0.85 through the latent heat correction algorithm.

[0019] The system calls this coefficient to forcibly reduce the heating power output and simultaneously links the cooling mechanism to increase the wind speed to 18m / s as a fixed constant for strong convection heat transfer; this coordinated control mechanism of cold and heat eliminates the temperature overshoot phenomenon in the isothermal quenching stage, ensures that the sorbite transformation process is carried out under strict isothermal conditions, and guarantees the uniformity of the mechanical toughness of the finished wire.

[0020] Example 2: When the control method is applied to the heat treatment of high-carbon steel wire, the target austenitizing temperature of the high-carbon steel wire is 920°C. The isothermal transition temperature is 540°C. The speed of travel is 78. When high-carbon steel wire enters the isothermal quenching zone, the initial trigger temperature of the phase transformation temperature range is 544°C. When the actual surface temperature of the wire shows an upward trend, the latent heat correction factor for phase change is triggered, and the latent heat correction factor for phase change is 0.90.

[0021] This embodiment is a specific verification of the core control parameters under normal operating conditions; the target austenitizing temperature is set to 920°C. 78 The travel speed is designed to balance the heat treatment running rate with the uniformity of austenitization; When the wire enters the isothermal quenching zone and reaches 545... Within the phase transformation temperature range of the microstructure, the austenite decomposition rate accelerates, and the latent heat release intensity is moderate; under this condition, an empirical adjustment factor is set. The latent heat of phase transformation of 72A high carbon steel wire The phase transition start and end temperatures of the tissue are 540°C. 560 The above 545 This refers to a specific trigger temperature point within the phase transition temperature range of the organization. For 72A high-carbon steel wire with a diameter of 5.5mm, the travel speed is 78. The mass flow rate was calculated. The feedforward prediction model calculates the basic heat demand power. It is 43.5 When the actual surface temperature of the wire reaches 544°C At that time, the system calculated the theoretical maximum latent heat power of phase change to be approximately 21.78. The algebraic ratio of the theoretical maximum latent heat power of phase change to the basic heat demand power is 0.5; substituting into the algorithm formula and combining the empirical adjustment factor (1.0), the latent heat correction coefficient of phase change at this time is 0.90. Based on this, the system calls a phase change latent heat correction coefficient of 0.90 to perform negative compensation and attenuation suppression of the feedback regulation power; this parameter configuration strategy demonstrates the system's ability to accurately suppress the micro phase change exothermic effect under normal industrial production load, and verifies the robustness of the feedforward and latent heat compensation coupling mechanism in the median range. Example 3: When the control method is applied to the heat treatment of high-carbon steel wire, the target austenitizing temperature of the high-carbon steel wire is 930°C. The isothermal transition temperature is 550°C. The speed of travel is 80. When high-carbon steel wire enters the isothermal quenching zone, the initial trigger temperature of the phase transformation temperature range is 555°C. When the actual surface temperature of the wire shows an upward trend, the latent heat correction factor for phase change is triggered, and the latent heat correction factor for phase change is 0.95.

[0022] This embodiment aims to explore the system at an online speed of 80. With temperature setting 930 The control effect and parameter applicability are up to 80. The significantly reduced travel speed of the wires necessitates that the feedforward prediction model possess extremely high dynamic response bandwidth; a setting of 930... The target austenitizing temperature was set at 550 °C to accelerate the diffusion and dissolution of carbon atoms. Phase transition occurs at the isothermal transition temperature; Because the driving force of phase transition is relatively weakened at high temperatures, the release of latent heat is more gradual, thus triggering 555 The latent heat correction factor for the phase transition temperature range of the tissue is set to 0.95, and a slight power adjustment is performed. In the specific calculation process, an empirical adjustment factor is taken. Phase change latent heat value The phase transition start and end temperatures are 550°C. 570 The above 555 This is a specific operating temperature point for the actual latent heat correction coefficient of phase change within this temperature range; When the actual surface temperature of the wire is 555 Furthermore, when the ratio of the theoretical maximum latent heat power of phase change to the basic heat demand power is calculated to be 0.25, the system combines the empirical adjustment factor (0.8) to accurately calculate the latent heat correction coefficient of phase change to be 0.95; and performs slight power attenuation compensation accordingly. Test data shows that even under extreme conditions of high-speed operation, the decoupling control matrix effectively isolates the high-intensity thermal radiation interference from adjacent temperature zones, ensuring the dynamic response capability and stability of the heat treatment process. Example 4: When the control method is applied to the heat treatment of high-carbon steel wire, the target austenitizing temperature of the high-carbon steel wire is 915°C. The isothermal transition temperature is 535°C. The speed of travel is 76. When high-carbon steel wire enters the isothermal quenching zone, the initial trigger temperature of the phase transformation temperature range is 538°C. When the actual surface temperature of the wire shows an upward trend, the latent heat correction factor for phase change is triggered, and the latent heat correction factor for phase change is 0.88.

[0023] This embodiment selects a conservative combination of process parameters to address the extreme sensitivity of certain high-purity alloy wires to temperature fluctuations; 76 The increased travel speed enhances the time margin for heat conduction within the wire, effectively reducing the radial temperature gradient; at 535 At the isothermal transition temperature, the supercooling is relatively large, and the release of latent heat of phase change is relatively concentrated; the system at 538 The phase transition temperature range of the tissue is precisely intervened, and a phase transition latent heat correction coefficient of 0.88 is applied. With the timely activation of the cooling mechanism, the phase transition temperature rise is strictly limited within the allowable safety threshold. This embodiment further confirms the rapid convergence characteristics of the phase transition latent heat correction algorithm when dealing with concentrated exothermic abrupt changes. Example 5: When the control method is applied to the heat treatment of high-carbon steel wire, the target austenitizing temperature of the high-carbon steel wire is 925°C. The isothermal transition temperature is 545°C. The speed of travel is 79. When high-carbon steel wire enters the isothermal quenching zone, the initial trigger temperature of the phase transformation temperature range is 550°C. When the actual surface temperature of the wire shows an upward trend, the latent heat correction factor for phase change is triggered, and the latent heat correction factor for phase change is 0.92.

[0024] This embodiment focuses on high-throughput production scenarios for large-diameter high-carbon steel wire; 925 The target austenitizing temperature is 79. The speed of travel significantly increases the mass throughput of metal passing through the furnace per unit time, thereby increasing the basic heat demand power of the metal wire. The feedforward prediction model implements feedforward compensation for high-power thermal energy by accurately calculating the mass flow rate and enthalpy increment under large wire diameters; at 550 Within the phase transition temperature range of the tissue, the theoretical maximum latent heat power of the phase transition increases to approximately 118. The ratio of its power to the basic heat demand is approximately 0.49; the system accurately calculates and applies a phase change latent heat correction coefficient of 0.92 based on this ratio, and dynamically adjusts the conduction angle of the thyristor power regulator. This operation not only offsets the large-scale release of latent heat of phase change inside the material, but also eliminates the convective heat disturbance caused by high-throughput material movement in a coordinated manner with the decoupling matrix. Comparative Example 1: This comparative example uses traditional independent PID control technology to construct a heat treatment temperature control system. The system relies solely on single-point thermocouple temperature measurement and does not include a feedforward prediction model, decoupled control matrix, or phase change latent heat correction algorithm. Each temperature zone is independently set and closed-loop control is performed. The process parameters are selected from the same median values ​​as in Example 2: the target austenitizing temperature is set to 920°C. The isothermal transition temperature is set to 540°C. The travel speed is set to 78. ; Comparative Example 2: This comparative model introduces a feedforward predictive model for initial heat load tracking based on traditional PID control, but it does not include a decoupled control matrix or a correction algorithm for latent heat of phase transformation; its process parameters are also selected from median values: the target austenitizing temperature is 920°C. The isothermal transition temperature is 540°C. The speed of travel is 78 ; Comparative Example 3: This comparative example serves as a control group for Example 5; the system employs traditional independent PID closed-loop control technology, without a feedforward prediction model, decoupled control matrix, or phase transformation latent heat correction algorithm; the process parameters are selected exactly as in Example 5: the target austenitizing temperature of the high-carbon steel wire is set to 925°C. The isothermal transition temperature is set to 545°C. The travel speed is set to 79. ; Verification Experiment: To verify the actual control performance of the temperature control system for homogenization heat treatment of metal wire proposed in this invention, a comparative verification experiment was conducted on the continuous isothermal quenching process of high carbon steel wire. The experiment aims to quantitatively evaluate the comprehensive impact of multiple mechanisms, including feedforward, decoupling, and latent heat compensation for phase change, on the macroscopic temperature field control accuracy and the consistency of microscopic mechanical properties. Testing standards: Mechanical property testing strictly follows the GB / T4354-2008 standard "High-quality carbon steel hot-rolled wire rod", and also refers to the strict acceptance standards in the high carbon steel wire industry regarding the extreme fluctuation of tensile strength. Specific testing process: The temperature control systems of Examples 1 to 5 and Comparative Examples 1 to 2 were used to continuously heat treat 72A high-carbon steel wires smelted in the same furnace number. During the production process, a high-precision infrared thermal imager and a high-speed data acquisition card are used to record the temperature fluctuation amplitude at the junction of the heat preservation zone and the slow cooling zone in real time, as well as the maximum temperature overshoot value when the phase transformation occurs in the isothermal quenching zone. After the heat treatment process is completed, destructive sampling is performed every 100 meters along the length of the finished steel wire, with 30 samples taken continuously from each coil. Tensile tests are then performed on all samples using an electronic universal testing machine, and the yield strength and tensile strength are recorded. Special attention is paid to calculating the range of tensile strength fluctuations within the same batch of wire. ; Table 1 Performance test data of Examples 1-5 and Comparative Examples 1-3 Test data shows that Examples 1 to 5 all achieved the set control precision under different parameter gradients, and the temperature fluctuation amplitude at the interface was suppressed to within 2. Within this range, the maximum overshoot value in the isothermal region does not exceed 2.5. This fully demonstrates the effectiveness of the decoupling control matrix in cutting off the thermodynamic coupling path and the phase change latent heat correction algorithm in suppressing internal enthalpy fluctuations; reflected in mechanical properties, the tensile strength fluctuations of each embodiment are extremely poor. All remained stable at 20 Within this range, a high degree of uniformity in microstructure was achieved; In addition, a control experiment was conducted with a single variable controlled based on Example 1, targeting the system's equivalent emissivity ε, convective heat transfer coefficient h, and empirical adjustment factor α. A comparison of the data from Example 1 and its variant AF in Table 1 shows that when the parameters are taken at the lower limit of the interval, the temperature oscillation amplitude and tensile strength fluctuation range at the interface increase due to the relatively weak decoupling compensation and latent heat correction. However, when the parameters are taken at the upper limit of the interval, all indicators are further reduced. A detailed comparison of the specific optimization effects of different constant values ​​within the interval on temperature oscillation and mechanical properties at the interface and phase transition zone is provided. In contrast, Comparative Example 1, lacking prediction and decoupling mechanisms, suffers from severe temperature fluctuations due to cross-regional thermal interference at the interface, leading to uncontrolled temperature in the phase transition zone and extremely high dispersion in mechanical properties. Comparative Example 2, although incorporating feedforward prediction, still experiences severe kinetic mismatch when faced with thermal radiation interference from adjacent temperature zones and concentrated release of latent heat from the phase transition, with a maximum overshoot value reaching 25.0. The tensile strength fluctuation remains as high as 48. ; Furthermore, to verify the universality of the system of the present invention for multi-specification wires, Comparative Example 3 was set up under the large-diameter wire condition of Example 5; the comparison results in Table 1 show that the temperature fluctuation amplitude at the junction of the large-diameter wire in Example 5 is only 1.6. The maximum overshoot value in the isothermal region is 2.2. In contrast, the large-diameter wire in Comparative Example 3, due to its enormous latent heat release and lack of a multi-dimensional control architecture, exhibited a maximum overshoot value as high as 35.0. The range of tensile strength fluctuation is as high as 62. The above comparative data and the control effect of conventional small wire diameter in Examples 1-4 form a complete verification, which fully verifies the universality of the feedforward prediction model and the phase change latent heat correction algorithm for large and small wire diameters and multiple specifications, and demonstrates the synergistic control role of the multi-dimensional composite control architecture under complex and high load conditions. The above comparison directly confirms the significant synergistic technical effect of the multidimensional composite control architecture and the optimized key parameter range of the present invention in eliminating temperature gradients and ensuring the uniformity of material properties. The foregoing has provided a detailed description of one embodiment of the present invention, but this description is merely a preferred embodiment and should not be construed as limiting the scope of the invention. All equivalent variations and modifications made within the scope of the claims of this invention should still fall within the patent coverage of this invention.

Claims

1. A temperature control system for homogenization heat treatment of metal wire, characterized in that, The temperature control system includes: A multi-dimensional state sensing module is used to collect the traveling speed of the metal wire, the initial temperature of the wire, the wire parameters, and the real-time furnace temperature and actual surface temperature of the wire in each temperature zone of the multi-zone continuous heat treatment system; wherein, the material of the metal wire includes carbon steel wire or alloy steel wire; the multi-zone continuous heat treatment system is divided into at least four continuous temperature zones; The distributed master control unit is communicatively connected to the multi-dimensional state perception module. The distributed master control unit is internally configured with a feedforward prediction model based on the heat treatment process, a decoupled control matrix, a closed-loop control loop, and a phase change latent heat correction algorithm. A high-frequency execution module is communicatively connected to the distributed main control unit. The high-frequency execution module includes a thyristor power regulator that connects the heating mechanism and / or cooling mechanism of each temperature zone. The heating mechanism includes an electric heater or a radiant heating tube, and the cooling mechanism includes an air-cooled nozzle or a water-cooled jacket. The distributed master control unit is used to generate basic heat demand power through the feedforward prediction model based on the data collected by the multi-dimensional state perception module, generate decoupling compensation power through the decoupling control matrix, generate phase change latent heat correction coefficient through the phase change latent heat correction algorithm, adjust the feedback regulation power of the closed-loop control loop, and send the comprehensive processed control command to the high-frequency execution module to control the heating and / or cooling process of each temperature zone.

2. The temperature control system according to claim 1, characterized in that, The multi-dimensional state perception module includes: An optical encoder installed at the inlet end is used to measure the travel speed of the metal wire. The multi-point dual-color infrared temperature measuring array installed at each temperature zone node in the multi-zone continuous heat treatment system is used to measure the actual surface temperature of the metal wire; and the furnace thermocouple array installed in the multi-zone continuous heat treatment system is used to measure the real-time furnace temperature of each temperature zone.

3. The temperature control system according to claim 1, characterized in that, The thyristor power regulator in the high-frequency execution module is a phase-shift triggered thyristor power regulator.

4. A method for controlling the homogenization of metal wire heat treatment based on the temperature control system according to any one of claims 1 to 3, characterized in that, The control method includes: Step S1: Real-time synchronous acquisition of the metal wire's traveling speed, initial wire temperature, wire parameters, and the real-time furnace temperature and corresponding actual wire surface temperature of each temperature zone in the multi-zone continuous heat treatment system. Step S2: Based on the traveling speed, the initial temperature of the incoming wire, and the wire parameters, combined with the pre-acquired specific heat capacity-temperature curve of the metal wire, the enthalpy is dynamically tracked using the feedforward prediction model to calculate the enthalpy of the metal wire from its entry point into the first... The basic heat demand power required to heat the initial temperature of the temperature zone to the preset target temperature; Step S3: Based on the heat transfer characteristics between adjacent temperature zones, the first step is calculated in real time using the decoupling control matrix. Temperature zone and the first Temperature zone and the first The real-time furnace temperature difference between the temperature zones is related to the first... The net heat inflow or net heat outflow generated in the temperature zone generates decoupling compensation power; among which... Let i be the current temperature zone number in the multi-zone continuous heat treatment system. When the i-th temperature zone is the first or last temperature zone in the multi-zone continuous heat treatment system, the heat transfer effect of the corresponding missing adjacent temperature zone on the i-th temperature zone is ignored; Temperature zone and the first Temperature zones respectively represent the first The preceding and following adjacent temperature zones; Step S4, the first The preset target temperature of the temperature zone and the actual temperature of the wire surface are fed into a closed-loop control loop to generate feedback adjustment power; when the actual temperature of the wire surface reaches the preset phase transition temperature range, the phase transition latent heat correction coefficient is superimposed through the phase transition latent heat correction algorithm; when the actual temperature of the wire surface is not in the phase transition temperature range, the phase transition latent heat correction coefficient is set to 1. Step S5: The basic heat demand power, the decoupling compensation power, the feedback adjustment power, and the phase change latent heat correction coefficient are fused together, and a control command is output to the high-frequency execution module to drive the thyristor power regulator to adjust the first... Heating and / or cooling mechanisms for the temperature zone.

5. The control method according to claim 4, characterized in that, In step S2, the calculation is performed to determine the metal wire entering the first... The specific methods for determining the basic heat demand power required to heat the initial temperature of the temperature zone to the preset target temperature include: Based on the travel speed and the wire parameters, the metal wire is calculated in the [number]th [phase]. Mass flow rate in the temperature zone; wherein the wire parameters include diameter and density; Based on the mass flow rate and the specific heat capacity-temperature curve, the metal wire at the [missing information] in the [missing information]... Enthalpy increment within the temperature range; The enthalpy increment is converted into the basic heat demand power, and the basic heat demand power is issued as a feedforward command.

6. The control method according to claim 5, characterized in that, In step S3, the heat transfer characteristics include heat radiation transfer characteristics and heat convection transfer characteristics; the specific methods for generating decoupling compensation power include: Obtain the first Temperature zone and the first Temperature zone and the first The real-time furnace temperature difference between temperature zones; wherein the calculation of the radiative heat transfer and the convective heat transfer is based on the system's equivalent emissivity, convective heat transfer coefficient, and the real-time furnace temperature difference; the radiative heat transfer and the convective heat transfer are converted into the decoupling compensation power.

7. The control method according to claim 6, characterized in that, In step S4, the closed-loop control loop is a fuzzy PID control loop or a model predictive control loop; the specific method for superimposing the latent heat correction coefficient of phase change includes: Determine whether the actual surface temperature of the wire is within the microstructure phase transition temperature range preset based on the continuous cooling transformation curve or isothermal transformation curve of the metal wire; If the temperature is within the tissue phase transition temperature range, it is determined that a phase transition has occurred with endothermic or exothermic heat, and the corresponding latent heat correction coefficient for the phase transition is used to adjust the feedback regulation power.

8. The control method according to claim 7, characterized in that, In step S5, the specific manner of the output control command is as follows: The basic thermal demand power, the decoupling compensation power, and the feedback regulation power adjusted by the phase change latent heat correction coefficient are superimposed to obtain the comprehensive command output power. The output power of the integrated command is converted into a trigger signal and sent to the thyristor power regulator.

9. The control method according to claim 8, characterized in that, The multi-zone continuous heat treatment system includes a heating zone, a heat preservation zone, a slow cooling zone, and an isothermal quenching zone arranged sequentially. When the control method is applied to the above-mentioned carbon steel wire or alloy steel wire, preferably high carbon steel wire, the target austenitizing temperature of the high carbon steel wire is 910-930℃ and the isothermal transformation temperature is 530-550℃. When the diameter of the high-carbon steel wire is 5.5 mm, the traveling speed is 75-80 m / min.

10. The control method according to claim 9, characterized in that, When the high-carbon steel wire enters the isothermal quenching zone, the phase transformation temperature range of the microstructure is 530-560℃. When the actual surface temperature of the wire shows an upward trend, the latent heat correction coefficient of the phase change is triggered, and the latent heat correction coefficient of the phase change is less than 1; at the same time, the cooling mechanism of the isothermal quenching zone is linked to increase the cooling airflow output.

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