Temperature precision control system and method for mechanical component heat treatment energy efficiency optimization

Abstract

This invention discloses a precise temperature control system and method for optimizing the energy efficiency of heat treatment of mechanical components, relating to the field of heat treatment of mechanical components. The method includes: constructing a basic database for heat treatment temperature control; dividing the heat treatment process into a heating section, a holding section, and a cooling section, and setting upper and lower temperature limits for each section; acquiring parameters such as furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristics; setting the maximum allowable heating rate for the heating section and the maximum allowable cooling rate for the cooling section, and establishing smooth transition rules between sections; generating a continuous temperature control curve without overshoot; performing small-step closed-loop correction using a single-adjustment limiting method, and dynamically compensating for the cooling medium; and updating the database based on the quality inspection data of the component after heat treatment for subsequent control of similar components. This method ensures qualified heat treatment quality while improving temperature control accuracy, preventing component cracking and deformation, effectively reducing energy consumption, and achieving a balance between precise temperature control and high energy efficiency.

Description

Technical Field

[0001] This invention relates to the field of heat treatment of mechanical components, and more specifically to a precise temperature control system and method for optimizing the energy efficiency of heat treatment of mechanical components. Background Technology

[0002] Mechanical components are core structural parts in various equipment that bear loads and transmit power. Their strength, hardness, toughness, wear resistance, and dimensional stability directly determine the reliability and service life of the entire machine. Heat treatment refers to a key thermal processing technology that alters the internal metallographic structure of metal components through the orderly control of heating, holding, and cooling, thereby obtaining the desired mechanical and performance characteristics. During heat treatment, temperature is the core process parameter determining the microstructure transformation. Whether the temperature is precise, stable, and controllable directly affects the component's hardness compliance rate, microstructure uniformity, deformation amount, and cracking risk. Therefore, strict and precise temperature control must be implemented throughout the entire heating, holding, and cooling process.

[0003] Currently, with the increasing demands for component precision, performance consistency, and production energy efficiency in high-end equipment manufacturing, the drawbacks of traditional heat treatment temperature control methods are becoming increasingly prominent. Industrial heat treatment furnaces generally suffer from problems such as large thermal inertia, significant temperature lag, easy overshoot during temperature rise, and difficulty in stabilizing cooling rates. Traditional control often relies on manual experience setting, fixed temperature control curves, or conventional PID regulation, without fully considering differences in component materials, cross-sectional dimensions, wall thickness, and furnace thermal response characteristics. This easily leads to phenomena such as temperature overshoot, inter-stage switching shocks, and cooling rate fluctuations. At the same time, the component undergoes a microstructure transformation during the cooling stage, releasing latent heat of phase change, causing the actual cooling curve to deviate from the target. Traditional systems cannot automatically identify and dynamically compensate for this, easily causing microstructure abnormalities, deformation, or even cracking. Furthermore, existing equipment generally lacks mechanisms for thermal inertia identification based on historical data, smooth temperature control curve generation, and iterative energy efficiency optimization. Control parameters are rigid and adjustments are coarse, resulting in high ineffective energy consumption and large fluctuations in the quality of products within the same batch, making it difficult to simultaneously meet the comprehensive production requirements of precise temperature control, reliable quality, low energy consumption, and high stability. Summary of the Invention

[0004] To address the aforementioned technical problems, a precise temperature control system and method for optimizing the energy efficiency of heat treatment of mechanical components are provided. This technical solution solves the problems mentioned in the background art, such as deviation of the component's heating state, overshoot phenomenon leading to increased ineffective energy consumption, and lack of smooth transition mechanism between process stages caused by the furnace gas being the controlled object in traditional heat treatment temperature control.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components includes: Based on the geometric characteristics and material properties of mechanical components, and combined with the thermal response characteristics of the furnace body, a basic database for heat treatment temperature control is constructed. The heat treatment process is divided into a heating section, a heat preservation section, and a cooling section. The target temperature and allowable fluctuation range of each section are determined, and the upper and lower limits of the temperature of each section are set with quality qualification as a hard constraint. Based on historical operating data, obtain parameters such as furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristics; Based on the component material and cross-sectional dimensions, the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section are set respectively, and smooth connection rules between sections are established. Based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates, a continuous temperature control curve without overshoot is generated. Real-time acquisition of furnace and component temperatures; small-step closed-loop correction using single-adjustment limiting method; and dynamic compensation of cooling medium by identifying phase change heat release based on temperature change rate during cooling. Based on the quality inspection data after heat treatment of the components, the temperature control parameters are optimized with the goal of minimizing energy consumption, provided that the quality is qualified, and the database is updated for subsequent control of similar components.

[0006] Preferably, the step of obtaining the furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristic parameters based on historical operating data specifically includes: Extract multiple sets of heating process data from historical operating data. Each set of data needs to record the heating rate before the heating power stops and the actual magnitude and duration of the temperature continuing to rise due to thermal inertia after the heating power stops. Using the heating rate as the independent variable and the inertial rise amplitude as the dependent variable, a mapping relationship is established through linear regression fitting, and the slope obtained from the fitting is defined as the thermal inertia overshoot coefficient. The duration for which the temperature continues to rise after the heating power is stopped is defined as the thermal inertia response duration, and the average value of multiple sets of data is taken as the final value. Cooling process data is extracted from historical operating data to obtain the temperature decay rate under natural cooling and forced cooling conditions, and a temperature decay characteristic curve is established. The thermal inertia overshoot coefficient, thermal inertia response time, and temperature decay characteristic curve are stored in the heat treatment temperature control basic database, and corresponding parameter values ​​are output for different furnace conditions.

[0007] Preferably, the step of setting the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section according to the component material and cross-sectional dimensions, and establishing smooth connection rules between sections specifically includes: The maximum allowable internal and external temperature difference during the heating process is determined based on the thermal conductivity and cross-sectional dimensions of the component material. Calculate the maximum allowable heating rate based on the maximum internal and external temperature difference and the component thickness; Based on the martensitic transformation characteristics and cracking sensitivity of the component material, the maximum allowable cooling rate of the cooling section is set. Establish smooth transition rules between segments, wherein the smooth transition rules between segments include: When the process stage switches from the heating section to the heat preservation section, it is forbidden to directly jump the set value. A linear transition method is adopted. The transition time is equal to the absolute value of the difference between the current actual temperature and the heat preservation target temperature at the time of switching, divided by the maximum heating rate allowed in the heating section. When the process stage switches from the heat preservation section to the cooling section, the same linear transition rule is adopted. The transition time is equal to the absolute value of the difference between the current actual temperature and the target cooling temperature at the time of switching, divided by the maximum allowable cooling rate of the cooling section.

[0008] Preferably, the step of generating a continuous temperature control curve without overshoot based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates specifically includes: Based on the segmented control results, the heating section termination temperature, the heat preservation section target temperature, and the cooling section termination temperature are obtained as key trajectory points of the continuous temperature control curve. During the heating phase, the target temperature sequence of the heating section components is generated by interpolation point by point, starting from the initial temperature, with the end temperature of the heating section as the endpoint and the maximum allowable heating rate of the heating section as the slope constraint. When the difference between the actual temperature of the component and the target temperature of the insulation section is equal to the preset threshold, the product of the current heating rate and the thermal inertia overshoot coefficient is calculated to obtain the estimated inertial rise. When the difference between the actual temperature of the component and the target temperature of the insulation section is less than the estimated inertial rise, the heating rate begins to decrease linearly. During the insulation stage, the target temperature of the component is always equal to the target temperature of the insulation section, and the duration is equal to the insulation time. During the cooling stage, starting from the target temperature of the insulation section and using the maximum allowable cooling rate of the cooling section as the slope constraint, the target temperature sequence of the cooling section components is generated point by point through interpolation until the end temperature of the cooling section. The target temperature sequences of components at each stage are spliced ​​together in chronological order to form a continuous temperature control curve that includes the target temperature of components at each time point throughout the entire process.

[0009] Preferably, the real-time acquisition of furnace and component temperatures, the small-step closed-loop correction using a single-adjustment limiting method, and the dynamic compensation of the cooling medium based on the temperature change rate to identify phase change heat release during cooling specifically include: Collect multiple temperatures in the furnace and temperatures at characteristic points of components at fixed sampling intervals; Calculate the average temperature and temperature uniformity at multiple points in the furnace, where the temperature uniformity is the maximum deviation between the temperature at each measuring point and the average temperature. Calculate the real-time deviation between the average temperature at multiple points in the furnace and the target temperature of the component at the corresponding time point in the continuous temperature control curve; When the absolute value of the real-time deviation is less than the first deviation threshold, the current power output remains unchanged; when the absolute value of the real-time deviation is greater than or equal to the first deviation threshold and less than the second deviation threshold, a small step correction method is adopted, and the single power adjustment amount does not exceed the set percentage of the total power; when the absolute value of the real-time deviation is greater than or equal to the second deviation threshold, it is determined to be an abnormal operating condition and an alarm is triggered. During the cooling process, the real-time temperature change rate of the component is obtained, and the real-time temperature change rate is compared with the preset standard cooling change rate to calculate the deviation of the change rate. Calculate the moving average of the rate of change deviation. When the moving average shows a phased slowdown and the slowdown magnitude continuously exceeds the preset exothermic identification threshold, the component is determined to have entered the tissue transformation exothermic stage. During the exothermic phase of tissue transformation, the dynamic incremental supply of cooling medium is calculated based on the magnitude of the rate of change deviation, and the dynamic incremental supply is positively correlated with the magnitude of the rate of change deviation. After the heat release phase of the tissue transformation is completed, restore the cooling medium to the baseline supply.

[0010] Furthermore, this solution proposes a precise temperature control system for optimizing the energy efficiency of heat treatment of mechanical components, used to achieve the precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components as described above, including: The database module is used to construct a basic database for heat treatment temperature control based on the geometric features and material properties of mechanical components, combined with the thermal response characteristics of the furnace body. The limiting and optimization module is used to divide the heat treatment process into a heating section, a holding section, and a cooling section, determine the target temperature and allowable fluctuation range for each section, and set the upper and lower limits of the temperature for each section with quality qualification as a hard constraint; based on historical operating data, it obtains the furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristic parameters; based on the component material and cross-sectional dimensions, it sets the maximum allowable heating rate for the heating section and the maximum allowable cooling rate for the cooling section, and establishes smooth connection rules between sections; based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates, it generates a continuous temperature control curve without overshoot; it collects the furnace and component temperatures in real time, performs small-step closed-loop correction using a single adjustment amplitude limiting method, and identifies phase change heat release based on the temperature change rate during cooling, dynamically compensating for the cooling medium; The module for saving and updating is used to optimize temperature control parameters based on the quality inspection data of the component after heat treatment, with the goal of minimizing energy consumption while ensuring that the quality is qualified, and to update the database for subsequent control of similar components.

[0011] Preferably, the limiting and optimizing module includes: The phased unit is used to divide the heat treatment process into a heating section, a heat preservation section and a cooling section, determine the target temperature and allowable fluctuation range of each section, and set the upper and lower limits of the temperature of each section with quality qualification as a hard constraint. The parameter extraction unit is used to obtain parameters such as furnace body heating lag time, thermal inertia overshoot coefficient and temperature decay characteristics based on historical operating data. The smooth connection rule unit is used to set the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section according to the component material and cross-sectional dimensions, and to establish smooth connection rules between sections. Temperature control curve unit, which is used to generate a continuous temperature control curve without overshoot based on the segmented target temperature, thermal inertia overshoot coefficient and maximum allowable heating and cooling rates; The control and optimization unit is used to collect the furnace and component temperatures in real time, perform small-step closed-loop correction in a single adjustment limiting manner, and identify phase change heat release based on the temperature change rate during cooling to dynamically compensate the cooling medium.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention provides a precise temperature control system and method for optimizing the energy efficiency of heat treatment of mechanical components. By using the actual heating state of the component as the control core, combined with furnace thermal inertia identification and overshoot-free curve generation mechanism, it achieves smooth and precise temperature control throughout the heat treatment process. This effectively solves the problems of traditional processes that use furnace gas as the control object, such as component temperature deviation, high ineffective energy consumption caused by overshoot and correction oscillation, and thermal shock and component deformation and cracking caused by abrupt inter-stage switching. At the same time, through segmented rate constraints, dynamic compensation for phase change heat release, and iterative optimization of energy efficiency under the premise of quality compliance, it significantly reduces overall energy consumption, improves temperature control stability and product consistency, and makes the heat treatment process more precise, efficient, energy-saving, and reliable, while ensuring that the component hardness, metallographic structure and other quality indicators meet the standards. Attached Figure Description

[0013] Figure 1 This is a flowchart of a precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to the present invention. Figure 2 The flowchart for obtaining furnace body heating lag time, thermal inertia overshoot coefficient and temperature decay characteristic parameters of the present invention is shown below. Figure 3 This is a flowchart illustrating the rules for establishing smooth transitions between segments in this invention. Figure 4 The flowchart for generating a continuous temperature control curve without overshoot according to the present invention is shown below. Figure 5 This invention collects furnace and component temperatures in real time, performs small-step closed-loop correction using a single-adjustment-limiting method, and identifies phase change heat release based on the temperature change rate during cooling, dynamically compensating for the cooling medium flow chart. Detailed Implementation

[0014] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0015] Reference Figure 1 As shown, a precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components includes: Based on the geometric characteristics and material properties of mechanical components, and combined with the thermal response characteristics of the furnace body, a basic database for heat treatment temperature control is constructed. The heat treatment process is divided into a heating section, a heat preservation section, and a cooling section. The target temperature and allowable fluctuation range of each section are determined, and the upper and lower limits of the temperature of each section are set with quality qualification as a hard constraint. Based on historical operating data, obtain parameters such as furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristics; Based on the component material and cross-sectional dimensions, the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section are set respectively, and smooth connection rules between sections are established. Based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates, a continuous temperature control curve without overshoot is generated. Real-time acquisition of furnace and component temperatures; small-step closed-loop correction using single-adjustment limiting method; and dynamic compensation of cooling medium by identifying phase change heat release based on temperature change rate during cooling. Based on the quality inspection data after heat treatment of the components, the temperature control parameters are optimized with the goal of minimizing energy consumption, provided that the quality is qualified, and the database is updated for subsequent control of similar components.

[0016] The construction of a basic database for heat treatment temperature control based on the geometric characteristics and material properties of mechanical components, combined with the thermal response characteristics of the furnace body, specifically includes: Obtain component geometric features and material property data. The geometric features include: structural form, cross-sectional dimensions and maximum wall thickness. The material properties include: material grade, density, specific heat capacity and thermal conductivity. Acquire furnace body thermal response characteristic data, including: effective furnace volume, heating element layout, number and location of temperature measuring points, power adjustment range, and hysteresis time from power output to temperature response; The temperature measuring points include multiple temperature measuring points on the upper, middle, lower, left, and right sides of the furnace, as well as feature points on the surface and core of the components; Obtain process requirements and quality constraints data, including: target heating temperature, holding time, cooling method, and allowable temperature difference; The quality constraints include: hardness requirements after heat treatment, metallographic structure requirements, and allowable deformation. Acquire historical operating data, which includes: temperature curves for each furnace run, power output records, cooling medium flow rate, pressure records, energy consumption data, and quality inspection results; The multi-source data is aligned and normalized according to the time axis to eliminate dimensional differences and form a basic database for heat treatment temperature control.

[0017] This can be explained by the fact that the geometric characteristics and material properties of the components directly determine the temperature distribution, temperature rise rate, and thermal stress level during the heating process, which are the core basis for determining the temperature control strategy; the thermal response characteristics of the furnace body reflect the inertia, hysteresis, and adjustment capability of the heating system, which are key constraints for achieving precise power output and avoiding overshoot and sudden changes; process requirements and quality constraints clearly define the hard indicators that the temperature control process must meet, ensuring that all control actions take the quality of component heat treatment as the primary premise; historical operating data includes temperature trajectories, energy consumption levels, and quality results under actual operating conditions, which are used for subsequent model parameter calibration and control effect verification; by uniformly aligning and normalizing component data, furnace body data, process data, and energy consumption data according to the time axis, calculation deviations caused by different acquisition cycles, different dimensions, and different ranges are eliminated, so that all types of data participate in model calculations and decision-making under the same spatiotemporal reference, ensuring the accuracy and stability of subsequent precise temperature control and energy efficiency optimization.

[0018] The process of dividing the heat treatment process into a heating section, a holding section, and a cooling section, determining the target temperature and allowable fluctuation range for each section, and setting the upper and lower temperature limits for each section with quality qualification as a hard constraint, specifically includes: Based on the phase transformation characteristics of the material, the entire heat treatment process is clearly divided into three independent control zones: the heating zone, the heat preservation zone, and the cooling zone. Based on the material and performance requirements of the components, set the heating section termination temperature, the insulation section constant temperature, and the cooling section target termination temperature. Based on the component's precision level and quality requirements, the upper limit of the allowable temperature fluctuation for the heating section, the insulation section, and the cooling section, as well as the upper limit of the absolute temperature and the lower limit of the absolute temperature for each section, are set respectively.

[0019] It can be explained that after data acquisition and integration, segmented constraints and boundary limits were not applied to the entire heating, insulation, and cooling process. Directly entering the control phase would result in unclear objectives, ambiguous ranges, and unrestricted fluctuations, failing to guarantee quality and energy efficiency. Therefore, specific segmented constraints and boundary limits need to be set based on the component's geometric characteristics and material property data. Specifically: Since the temperature control targets for heating, heat preservation, and cooling are completely different from thermal behavior, strategies must be developed in stages to accurately match the laws of microstructure transformation. It is necessary to divide the control intervals into three stages according to the phase transformation characteristics of the material. Setting target temperatures in stages allows the control system to clearly define the core tasks of each stage, avoiding insufficient heating, excessive heat preservation, or cooling deviation caused by using a single temperature setting throughout the process. The upper limit of allowable fluctuation is set according to the accuracy and quality requirements of the components to distinguish between normal process fluctuations and abnormal deviations, and to prevent malfunctions and ineffective adjustments caused by small temperature fluctuations. Setting absolute temperature upper and lower limits based on overheating temperature and phase transformation critical temperature is to set an inviolable safety red line for component quality: temperatures below the lower limit will lead to insufficient phase transformation and substandard performance; temperatures above the upper limit will cause irreversible defects such as coarse grains, overheating, and cracking; among them, the absolute lower limit of the cooling section is determined based on the material's martensitic transformation initiation temperature or the critical temperature to avoid cold cracking. By transforming the materials, processes, and quality requirements in the database into clear temperature ranges, strict boundary constraints, and segmented control objectives, accurate execution basis is provided for subsequent smooth heating, inertia compensation, stage transitions, and precise cooling, ensuring that all control actions are carried out within the quality and safety range. The cooling section is mainly controlled by the cooling rate, and the target termination temperature is the final temperature requirement at the end of cooling. The allowable fluctuation range is mainly used to constrain the deviation of the cooling endpoint temperature.

[0020] Reference Figure 2 As shown, the acquisition of furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristic parameters specifically includes: Extract multiple sets of heating process data from historical operating data. Each set of data needs to record the heating rate before the heating power stops and the actual magnitude and duration of the temperature continuing to rise due to thermal inertia after the heating power stops. Using the heating rate as the independent variable and the inertial rise amplitude as the dependent variable, a mapping relationship is established through linear regression fitting, and the slope obtained from the fitting is defined as the thermal inertia overshoot coefficient. The duration for which the temperature continues to rise after the heating power is stopped is defined as the thermal inertia response duration, and the average value of multiple sets of data is taken as the final value. Cooling process data is extracted from historical operating data to obtain the temperature decay rate under natural cooling and forced cooling conditions, and a temperature decay characteristic curve is established. The thermal inertia overshoot coefficient, thermal inertia response time, and temperature decay characteristic curve are stored in the heat treatment temperature control basic database, and corresponding parameter values ​​are output for different furnace conditions.

[0021] The explanation is that thermal inertia is the root cause of temperature overshoot: when the temperature reaches the set value, even if heating is stopped immediately, the input heat will continue to be transferred, causing the temperature to continue to rise. By identifying the relationship between the inertial rise and the heating rate through historical data, the inertial rise can be predicted in advance before the temperature reaches the set value, thereby determining the timing of power attenuation. Specifically: Multiple sets of complete heating process data were extracted, and the heating rate, the inertial rise amplitude and duration after the power stopped were recorded to eliminate the randomness of a single experiment and obtain statistical samples that can represent the true thermal behavior of the furnace. Among them, the heating rate was taken as the average rate of the last stable heating stage before the heating power stopped, to avoid the influence of instantaneous fluctuations on the fitting accuracy. Linear regression fitting is performed with heating rate as independent variable and inertial rise amplitude as dependent variable. The fitting slope is defined as thermal inertia overshoot coefficient, which is used to predict the inertial rise amplitude when the temperature is close to the set value, and provides a quantitative calculation basis for the early decay of heating power. For cases with strong nonlinearity, polynomial regression or piecewise linear fitting can be used to improve accuracy. The duration of temperature continuing to rise after heating stops is defined as the thermal inertia response duration. Multiple average values ​​are taken to determine the timing for early overshoot suppression, ensuring that the temperature approaches the set value smoothly in an asymptotic manner. Extract data from natural cooling and forced cooling processes, obtain temperature decay rates under different cooling conditions, and establish temperature decay characteristic curves in the form of fitting function parameters or discrete sampling points to accurately predict cooling trends and provide support for subsequent phase change cooling compensation and stage switching balance. The identified thermal inertia overshoot coefficient, thermal inertia response time, and temperature decay characteristic curve are stored in the database and associated with the furnace status. The furnace status includes empty furnace status, full load status, and different load distribution status, so that matching parameters can be called up under different furnace conditions and different load conditions. By transforming fuzzy empirical judgments into quantified thermal response parameters, temperature overshoot, backtracking oscillations, and ineffective energy consumption are suppressed at the source. At the same time, component deformation and cracking caused by thermal shock are avoided, laying the foundation for smooth temperature control and energy efficiency optimization throughout the process.

[0022] Reference Figure 3 As shown, the rules for establishing smooth transitions between segments specifically include: The maximum allowable internal and external temperature difference during the heating process is determined based on the thermal conductivity and cross-sectional dimensions of the component material. Calculate the maximum allowable heating rate based on the maximum internal and external temperature difference and the component thickness; Based on the martensitic transformation characteristics and cracking sensitivity of the component material, the maximum allowable cooling rate of the cooling section is set. Establish smooth transition rules between segments, wherein the smooth transition rules between segments include: When the process stage switches from the heating section to the heat preservation section, it is forbidden to directly jump the set value. A linear transition method is adopted. The transition time is equal to the absolute value of the difference between the current actual temperature and the heat preservation target temperature at the time of switching, divided by the maximum heating rate allowed in the heating section. When the process stage switches from the heat preservation section to the cooling section, the same linear transition rule is adopted. The transition time is equal to the absolute value of the difference between the current actual temperature and the target cooling temperature at the time of switching, divided by the maximum allowable cooling rate of the cooling section.

[0023] This can be explained by the fact that temperature jumps simultaneously cause excessive thermal stress and increased ineffective energy consumption in components: on the one hand, rapid temperature changes generate thermal stress inside and outside the component, increasing the risk of deformation and cracking; on the other hand, after a sudden temperature change, a reverse adjustment is needed to restore stability, resulting in energy loss during oscillating adjustment. By using rate constraints and smooth transitions, the temperature can change along a gradual curve, ensuring uniform transformation of the component's microstructure while significantly reducing energy waste caused by repeated heating. Specifically: During the heating process, a temperature difference forms between the surface and core of the component due to the lag in heat conduction. When this temperature difference exceeds the material's allowable critical value, thermal stress will cause cracking or deformation. Based on the component's thermal conductivity and cross-sectional dimensions, the maximum allowable internal and external temperature difference during the heating process is determined. This temperature difference represents the safe upper limit of the internal and external temperature difference during the heating process. Exceeding this value will generate excessive thermal stress, leading to quality defects such as deformation and cracking. Based on this, and combining the maximum allowable internal and external temperature difference, component thickness, and material thermal diffusivity, the maximum allowable heating rate is calculated. The physical principle is: the faster the heating rate, the greater the temperature difference between the core and the surface. The specific calculation formula is as follows: In the formula, For the maximum allowable heating rate, To the maximum permissible internal and external temperature difference, The thermal conductivity of the material. The effective thickness of the component is usually taken as half of the maximum wall thickness. For material density, Specific heat capacity; During the cooling process, excessively rapid cooling rates can lead to uncontrolled martensitic transformation, stress concentration in the microstructure, or quenching cracks. The maximum allowable cooling rate is determined based on the martensitic transformation characteristics and cracking sensitivity of the component material: the critical cooling rate to prevent cracking is obtained through the continuous cooling transformation curve of the material, and a safety factor is introduced considering the complexity of the component shape and the cross-sectional dimensions to finally determine the allowable value. For commonly used materials, the recommended cooling rate range is obtained by referring to tables in material handbooks or process specifications; for special materials or complex components, the critical cooling rate is obtained through the continuous cooling transformation curve, and a safety factor is introduced considering the complexity of the component shape and the cross-sectional dimensions (the value is generally between 1.2 and 2.0, and the more complex the shape and the larger the cross-sectional dimensions, the higher the safety factor value). Smooth transition rules between heating and cooling stages: When the process switches from the heating stage to the holding stage, direct jumps in the setpoint are prohibited. A linear transition method is adopted. The transition time is calculated by dividing the absolute value of the difference between the current actual temperature and the holding target temperature at the time of switching by the maximum allowable heating rate of the heating stage. The control system updates the setpoint linearly during the transition time, ensuring that the actual temperature smoothly approaches the holding target temperature at a rate within limits, avoiding thermal shock. After the transition is complete, the system enters steady-state holding control. When the process switches from the holding stage to the cooling stage, the same linear transition rule is adopted. The transition time is calculated by dividing the absolute value of the difference between the current actual temperature and the cooling target temperature at the time of switching by the maximum allowable cooling rate of the cooling stage, ensuring that the temperature smoothly enters the cooling control range. By employing rate constraints and a smooth transition mechanism, a stable and shock-free transition is achieved between the three stages of heating, heat preservation, and cooling. This ensures the uniformity of component microstructure transformation and avoids thermal stress and energy loss caused by sudden temperature changes, laying the foundation for subsequent precise cooling and energy efficiency optimization.

[0024] Reference Figure 4 As shown, the generation of a continuous temperature control curve without overshoot specifically includes: Based on the segmented control results, the heating section termination temperature, the heat preservation section target temperature, and the cooling section termination temperature are obtained as key trajectory points of the continuous temperature control curve. During the heating phase, the target temperature sequence of the heating section components is generated by interpolation point by point, starting from the initial temperature, with the end temperature of the heating section as the endpoint and the maximum allowable heating rate of the heating section as the slope constraint. When the difference between the actual temperature of the component and the target temperature of the insulation section is equal to the preset threshold, the product of the current heating rate and the thermal inertia overshoot coefficient is calculated to obtain the estimated inertial rise. When the difference between the actual temperature of the component and the target temperature of the insulation section is less than the estimated inertial rise, the heating rate begins to decrease linearly. During the insulation stage, the target temperature of the component is always equal to the target temperature of the insulation section, and the duration is equal to the insulation time. During the cooling stage, starting from the target temperature of the insulation section and using the maximum allowable cooling rate of the cooling section as the slope constraint, the target temperature sequence of the cooling section components is generated point by point through interpolation until the end temperature of the cooling section. The target temperature sequences of components at each stage are spliced ​​together in chronological order to form a continuous temperature control curve that includes the target temperature of components at each time point throughout the entire process.

[0025] It can be explained that although the upper limit of the heating process is constrained by the maximum allowable heating rate, and smooth transitions between stages are achieved through inter-stage linear transition rules, the thermal inertia problem is not completely solved: when the actual temperature of the component approaches the insulation target, even if the heating rate is controlled within the allowable range, the heat already input will continue to be transferred after the heating power stops, causing the temperature to continue to rise and resulting in overshoot; after overshoot, reverse adjustment to cool down is required, which again triggers a correction oscillation, causing not only energy loss but also potential component deformation or cracking due to thermal shock. Therefore, this solution introduces an inertia prediction and early deceleration mechanism, specifically: The heating section termination temperature, the heat preservation section target temperature, and the cooling section termination temperature are used as the necessary nodes of the control curve to ensure that the temperature control process strictly follows the process requirements. Using the maximum allowable heating rate as the upper limit of the slope, a series of heating segment setpoints are generated by interpolation point by point, so that the heating rate is always controlled within a safe range. During the heating process, the actual temperature of the component is monitored in real time. When the actual temperature approaches the target temperature, the product of the current heating rate and the thermal inertia overshoot coefficient is calculated to obtain the estimated inertia rise. At this point, heating is stopped, and the temperature will continue to rise. When the difference between the actual temperature and the target temperature is less than the estimated inertia rise, the heating rate is linearly reduced to allow the temperature to approach the target value in a smooth manner. This is achieved by controlling the rate in advance. By predicting the inertia surge amplitude in advance, the rate is actively reduced before the temperature reaches the target, allowing the thermal inertia to be naturally consumed during the approach process, thus achieving a smooth transition without overshoot. During the heat preservation period, the set value is kept constant at the target temperature, and the duration is equal to the heat preservation time required by the process, to ensure that the temperature of the core and surface of the component is uniform and to complete the microstructure transformation; Using the maximum allowable cooling rate as the upper limit of the slope, point-by-point interpolation is used to generate a sequence of cooling section setpoints to prevent uncontrolled martensitic transformation or quenching cracks caused by excessively rapid cooling. By splicing the setpoint sequences of each stage in chronological order, a complete and continuous temperature control curve is formed from heating to heat preservation to cooling, ensuring smooth transitions between stages. By transforming fuzzy empirical judgments into quantitative control based on thermal inertia characteristics, temperature overshoot, backtracking oscillations, and ineffective energy consumption are suppressed at the source. At the same time, component deformation and cracking caused by thermal shock are avoided, laying the foundation for subsequent precise cooling and energy efficiency optimization.

[0026] Reference Figure 5As shown, the real-time acquisition of furnace and component temperatures, the small-step closed-loop correction using a single-adjustment limiting method, and the dynamic compensation of the cooling medium based on the temperature change rate to identify phase change heat release during cooling specifically include: Collect multiple temperatures in the furnace and temperatures at characteristic points of components at fixed sampling intervals; Calculate the average temperature and temperature uniformity at multiple points in the furnace, where the temperature uniformity is the maximum deviation between the temperature at each measuring point and the average temperature. Calculate the real-time deviation between the average temperature at multiple points in the furnace and the target temperature of the component at the corresponding time point in the continuous temperature control curve; When the absolute value of the real-time deviation is less than the first deviation threshold, the current power output remains unchanged; when the absolute value of the real-time deviation is greater than or equal to the first deviation threshold and less than the second deviation threshold, a small step correction method is adopted, and the single power adjustment amount does not exceed the set percentage of the total power; when the absolute value of the real-time deviation is greater than or equal to the second deviation threshold, it is determined to be an abnormal operating condition and an alarm is triggered. During the cooling process, the real-time temperature change rate of the component is obtained, and the real-time temperature change rate is compared with the preset standard cooling change rate to calculate the deviation of the change rate. Calculate the moving average of the rate of change deviation. When the moving average shows a phased slowdown and the slowdown magnitude continuously exceeds the preset exothermic identification threshold, the component is determined to have entered the tissue transformation exothermic stage. During the exothermic phase of tissue transformation, the dynamic incremental supply of cooling medium is calculated based on the magnitude of the rate of change deviation, and the dynamic incremental supply is positively correlated with the magnitude of the rate of change deviation. After the heat release phase of the tissue transformation is completed, restore the cooling medium to the baseline supply.

[0027] This solution is designed to achieve precise temperature tracking and dynamic compensation of the cooling path throughout the entire process, ensuring that the actual temperature strictly follows the continuous temperature control curve while eliminating the interference of phase change heat release on the cooling process. Temperature uniformity is used to evaluate the furnace temperature field distribution. When the uniformity exceeds the limit, it can trigger independent adjustment of the heating power of multiple zones. The temperature closed-loop system employs a small-step limiting correction strategy: if the single power adjustment is too large, it can easily lead to temperature overshoot and system oscillation; if the adjustment is too small, the response will be slow and the temperature control will lag. By setting a first deviation threshold and a second deviation threshold, graded adjustment is achieved: when the deviation is small, the output remains stable to avoid frequent actions; when the deviation is moderate, a small-step smooth correction is used, and the single power adjustment does not exceed the set percentage of the total power; when the deviation is too large, it is judged as an abnormal operating condition and an alarm is triggered, thus ensuring temperature control accuracy while avoiding over-adjustment. During the cooling process, the component undergoes a microstructure transformation, releasing latent heat of phase change. This causes the temperature change rate to slow down in stages and the cooling curve to deviate from the target. This solution identifies the heat release characteristics of phase change by calculating the temperature change rate and its moving average in real time. When the slowdown continuously exceeds the heat release identification threshold, it is determined that the microstructure transformation heat release stage has begun. The supply of cooling medium is then linearly increased according to the deviation to offset the effect of latent heat. After the heat release is completed, the baseline supply is restored to ensure that the actual cooling curve is consistent with the target cooling curve. Taking specific values ​​as an example: the first deviation threshold is set to 3℃, the second deviation threshold is set to 8℃, the upper limit of a single power adjustment is set to 5% of the total power; the heat release identification threshold is set to 20% of the standard cooling change rate. When the change rate deviation exceeds this threshold for 10 consecutive seconds, it is determined that the phase change heat release stage has begun, and the dynamic incremental supply of cooling medium increases linearly according to the deviation amplitude.

[0028] The step of optimizing temperature control parameters based on the quality inspection data of components after heat treatment, with the goal of minimizing energy consumption while ensuring quality compliance, and updating the database for subsequent control of similar components specifically includes: Obtain hardness test data, metallographic structure rating results and deformation test data of components after heat treatment, and compare them with target requirements; The following quality acceptance criteria are set: hardness is within the target range, metallographic structure level is not lower than the target level, deformation does not exceed the allowable deformation and there is no cracking. All of the above criteria must be met. For furnaces that meet quality standards, calculate the energy consumption per unit product and compare it with the minimum energy consumption per unit product of the same type of component in history. If the energy consumption of the current furnace is lower, then the temperature control parameters of the current furnace are selected as the candidate optimal parameters. For batches of furnaces that fail to meet quality standards, the cumulative temperature deviation during the process is calculated by using the deviation reverse propagation algorithm, the key control links that cause quality problems are identified, and the control parameter boundaries of the corresponding links are corrected. The optimized temperature control parameters are stored in the database for subsequent temperature control of similar components.

[0029] This can be explained by the fact that, under the premise of absolutely ensuring the quality of heat treatment, this scheme iteratively optimizes the temperature control parameters with the lowest energy consumption, and achieves self-correction of the control model by tracing back the deviations of unqualified components, so that the heat treatment process of similar components continues to become more precise and efficient. Specifically: We obtain four types of quality test results: hardness, metallographic structure, deformation amount, and whether cracking occurs. We set a strict judgment condition that all four indicators must be met to be considered qualified, and strictly adhere to the principle of quality first. We only conduct energy efficiency comparisons on the batches that meet the quality standards, calculate the energy consumption per unit product, and compare it with the best energy consumption record of the same type of component in history. We retain the temperature control parameters with lower energy consumption as the candidate optimal solution, and achieve continuous optimization of energy efficiency on the basis of meeting quality standards. For batches of furnaces that fail to meet quality standards, the deviation reverse propagation algorithm is used to reverse-engineer the cumulative temperature deviation throughout the entire process, locate the out-of-control links in heating, holding, and cooling, and make targeted corrections to the temperature range, heating rate, holding time, or cooling flow rate of the corresponding stage to prevent the recurrence of the same defects. Finally, the optimized temperature control parameters are updated to the heat treatment temperature control database for subsequent batch production control of components of the same material, structure, and size, forming a complete closed loop of acquisition, control, detection, optimization, and iteration, continuously improving temperature control accuracy and energy efficiency. The deviation reverse propagation algorithm is a quantitative attribution method that calculates the cumulative deviation between the actual parameters and the target parameters of each stage from back to front, based on the contribution weight of each stage of heat treatment to the quality, thereby locating the out-of-control link and determining the correction direction. The contribution weights are obtained through orthogonal experiments: Select components of the same type from the same batch, adjust parameters such as heating temperature, holding time, and cooling rate within the allowable range of the process, record the quality results of each batch, and determine the influence weight of each process parameter on the final quality through orthogonal analysis.

[0030] Furthermore, based on the same inventive concept as the aforementioned precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components, this solution proposes a precise temperature control system for optimizing the energy efficiency of heat treatment of mechanical components, comprising: The database module is used to construct a basic database for heat treatment temperature control based on the geometric features and material properties of mechanical components, combined with the thermal response characteristics of the furnace body. The limiting and optimization module is used to divide the heat treatment process into a heating section, a holding section, and a cooling section, determine the target temperature and allowable fluctuation range for each section, and set the upper and lower limits of the temperature for each section with quality qualification as a hard constraint; based on historical operating data, it obtains the furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristic parameters; based on the component material and cross-sectional dimensions, it sets the maximum allowable heating rate for the heating section and the maximum allowable cooling rate for the cooling section, and establishes smooth connection rules between sections; based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates, it generates a continuous temperature control curve without overshoot; it collects the furnace and component temperatures in real time, performs small-step closed-loop correction using a single adjustment amplitude limiting method, and identifies phase change heat release based on the temperature change rate during cooling, dynamically compensating for the cooling medium; The module for saving and updating is used to optimize temperature control parameters with the goal of minimizing energy consumption based on the quality inspection data of the component after heat treatment, under the premise of qualified quality, and update the database for subsequent control of the same type of component. The limiting and optimization module includes: The phased unit is used to divide the heat treatment process into a heating section, a heat preservation section and a cooling section, determine the target temperature and allowable fluctuation range of each section, and set the upper and lower limits of the temperature of each section with quality qualification as a hard constraint. The parameter extraction unit is used to obtain parameters such as furnace body heating lag time, thermal inertia overshoot coefficient and temperature decay characteristics based on historical operating data. The smooth connection rule unit is used to set the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section according to the component material and cross-sectional dimensions, and to establish smooth connection rules between sections. Temperature control curve unit, which is used to generate a continuous temperature control curve without overshoot based on the segmented target temperature, thermal inertia overshoot coefficient and maximum allowable heating and cooling rates; The control and optimization unit is used to collect the furnace and component temperatures in real time, perform small-step closed-loop correction in a single adjustment limiting manner, and identify phase change heat release based on the temperature change rate during cooling to dynamically compensate the cooling medium.

[0031] In summary, the advantages of this invention are as follows: by segmented temperature control, thermal inertia prediction, overshoot-free curve, small step size closed loop, phase change compensation, and energy efficiency iteration under quality priority, it can improve temperature control accuracy, avoid component cracking and deformation, and effectively reduce energy consumption while ensuring qualified heat treatment quality, thus achieving a balance between precise temperature control and high-efficiency energy saving.

[0032] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components, characterized in that, include: Based on the geometric characteristics and material properties of mechanical components, and combined with the thermal response characteristics of the furnace body, a basic database for heat treatment temperature control is constructed. The heat treatment process is divided into a heating section, a heat preservation section, and a cooling section. The target temperature and allowable fluctuation range of each section are determined, and the upper and lower limits of the temperature of each section are set with quality qualification as a hard constraint. Based on historical operating data, obtain parameters such as furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristics; Based on the component material and cross-sectional dimensions, the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section are set respectively, and smooth connection rules between sections are established. Based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates, a continuous temperature control curve without overshoot is generated. Real-time acquisition of furnace and component temperatures; small-step closed-loop correction using single-adjustment limiting method; and dynamic compensation of cooling medium by identifying phase change heat release based on temperature change rate during cooling. Based on the quality inspection data after heat treatment of the components, the temperature control parameters are optimized with the goal of minimizing energy consumption, provided that the quality is qualified, and the database is updated for subsequent control of similar components.

2. The precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to claim 1, characterized in that, The construction of a basic database for heat treatment temperature control based on the geometric characteristics and material properties of mechanical components, combined with the thermal response characteristics of the furnace body, specifically includes: Obtain component geometric features and material property data. The geometric features include: structural form, cross-sectional dimensions and maximum wall thickness. The material properties include: material grade, density, specific heat capacity and thermal conductivity. Acquire furnace body thermal response characteristic data, including: effective furnace volume, heating element layout, number and location of temperature measuring points, power adjustment range, and hysteresis time from power output to temperature response; The temperature measuring points include multiple temperature measuring points on the upper, middle, lower, left, and right sides of the furnace, as well as feature points on the surface and core of the components; Obtain process requirements and quality constraints data, including: target heating temperature, holding time, cooling method, and allowable temperature difference; The quality constraints include: hardness requirements after heat treatment, metallographic structure requirements, and allowable deformation. Acquire historical operating data, which includes: temperature curves for each furnace run, power output records, cooling medium flow rate, pressure records, energy consumption data, and quality inspection results; The multi-source data is aligned and normalized according to the time axis to eliminate dimensional differences and form a basic database for heat treatment temperature control.

3. The precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to claim 2, characterized in that, The process of dividing the heat treatment process into a heating section, a holding section, and a cooling section, determining the target temperature and allowable fluctuation range for each section, and setting the upper and lower temperature limits for each section with quality qualification as a hard constraint, specifically includes: Based on the phase transformation characteristics of the material, the entire heat treatment process is clearly divided into three independent control zones: the heating zone, the heat preservation zone, and the cooling zone. Based on the material and performance requirements of the components, set the heating section termination temperature, the insulation section constant temperature, and the cooling section target termination temperature. Based on the component's precision level and quality requirements, the upper limit of the allowable temperature fluctuation for the heating section, the insulation section, and the cooling section, as well as the upper limit of the absolute temperature and the lower limit of the absolute temperature for each section, are set respectively.

4. The precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to claim 3, characterized in that, The specific steps for obtaining furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristic parameters based on historical operating data include: Extract multiple sets of heating process data from historical operating data. Each set of data needs to record the heating rate before the heating power stops and the actual magnitude and duration of the temperature continuing to rise due to thermal inertia after the heating power stops. Using the heating rate as the independent variable and the inertial rise amplitude as the dependent variable, a mapping relationship is established through linear regression fitting, and the slope obtained from the fitting is defined as the thermal inertia overshoot coefficient. The duration for which the temperature continues to rise after the heating power is stopped is defined as the thermal inertia response duration, and the average value of multiple sets of data is taken as the final value. Cooling process data is extracted from historical operating data to obtain the temperature decay rate under natural cooling and forced cooling conditions, and a temperature decay characteristic curve is established. The thermal inertia overshoot coefficient, thermal inertia response time, and temperature decay characteristic curve are stored in the heat treatment temperature control basic database, and corresponding parameter values ​​are output for different furnace conditions.

5. The precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to claim 4, characterized in that, The specific steps include setting the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section based on the component material and cross-sectional dimensions, and establishing smooth connection rules between sections. The maximum allowable internal and external temperature difference during the heating process is determined based on the thermal conductivity and cross-sectional dimensions of the component material. Calculate the maximum allowable heating rate based on the maximum internal and external temperature difference and the component thickness; Based on the martensitic transformation characteristics and cracking sensitivity of the component material, the maximum allowable cooling rate of the cooling section is set. Establish smooth transition rules between segments, wherein the smooth transition rules between segments include: When the process stage switches from the heating section to the heat preservation section, it is forbidden to directly jump the set value. A linear transition method is adopted. The transition time is equal to the absolute value of the difference between the current actual temperature and the heat preservation target temperature at the time of switching, divided by the maximum heating rate allowed in the heating section. When the process stage switches from the heat preservation section to the cooling section, the same linear transition rule is adopted. The transition time is equal to the absolute value of the difference between the current actual temperature and the target cooling temperature at the time of switching, divided by the maximum allowable cooling rate of the cooling section.

6. The precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to claim 5, characterized in that, The generation of a continuous temperature control curve without overshoot based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates specifically includes: Based on the segmented control results, the heating section termination temperature, the heat preservation section target temperature, and the cooling section termination temperature are obtained as key trajectory points of the continuous temperature control curve. During the heating phase, the target temperature sequence of the heating section components is generated by interpolation point by point, starting from the initial temperature, with the end temperature of the heating section as the endpoint and the maximum allowable heating rate of the heating section as the slope constraint. When the difference between the actual temperature of the component and the target temperature of the insulation section is equal to the preset threshold, the product of the current heating rate and the thermal inertia overshoot coefficient is calculated to obtain the estimated inertial rise. When the difference between the actual temperature of the component and the target temperature of the insulation section is less than the estimated inertial rise, the heating rate begins to decrease linearly. During the insulation stage, the target temperature of the component is always equal to the target temperature of the insulation section, and the duration is equal to the insulation time. During the cooling stage, starting from the target temperature of the insulation section and using the maximum allowable cooling rate of the cooling section as the slope constraint, the target temperature sequence of the cooling section components is generated point by point through interpolation until the end temperature of the cooling section. The target temperature sequences of components at each stage are spliced ​​together in chronological order to form a continuous temperature control curve that includes the target temperature of components at each time point throughout the entire process.

7. A precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to claim 6, characterized in that, The real-time acquisition of furnace and component temperatures, the small-step closed-loop correction using a single-adjustment limiting method, and the dynamic compensation of the cooling medium based on the temperature change rate to identify phase change heat release during cooling specifically include: Collect multiple temperatures in the furnace and temperatures at characteristic points of components at fixed sampling intervals; Calculate the average temperature and temperature uniformity at multiple points in the furnace, where the temperature uniformity is the maximum deviation between the temperature at each measuring point and the average temperature. Calculate the real-time deviation between the average temperature at multiple points in the furnace and the target temperature of the component at the corresponding time point in the continuous temperature control curve; When the absolute value of the real-time deviation is less than the first deviation threshold, the current power output remains unchanged; when the absolute value of the real-time deviation is greater than or equal to the first deviation threshold and less than the second deviation threshold, a small step correction method is adopted, and the single power adjustment amount does not exceed the set percentage of the total power; when the absolute value of the real-time deviation is greater than or equal to the second deviation threshold, it is determined to be an abnormal operating condition and an alarm is triggered. During the cooling process, the real-time temperature change rate of the component is obtained, and the real-time temperature change rate is compared with the preset standard cooling change rate to calculate the deviation of the change rate. Calculate the moving average of the rate of change deviation. When the moving average shows a phased slowdown and the slowdown magnitude continuously exceeds the preset exothermic identification threshold, the component is determined to have entered the tissue transformation exothermic stage. During the exothermic phase of tissue transformation, the dynamic incremental supply of cooling medium is calculated based on the magnitude of the rate of change deviation, and the dynamic incremental supply is positively correlated with the magnitude of the rate of change deviation. After the heat release phase of the tissue transformation is completed, restore the cooling medium to the baseline supply.

8. The precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components according to claim 7, characterized in that, The step of optimizing temperature control parameters based on the quality inspection data of components after heat treatment, with the goal of minimizing energy consumption while ensuring quality compliance, and updating the database for subsequent control of similar components specifically includes: Obtain hardness test data, metallographic structure rating results and deformation test data of components after heat treatment, and compare them with target requirements; The following quality acceptance criteria are set: hardness is within the target range, metallographic structure level is not lower than the target level, deformation does not exceed the allowable deformation and there is no cracking. All of the above criteria must be met. For furnaces that meet quality standards, calculate the energy consumption per unit product and compare it with the minimum energy consumption per unit product of the same type of component in history. If the energy consumption of the current furnace is lower, then the temperature control parameters of the current furnace are selected as the candidate optimal parameters. For batches of furnaces that fail to meet quality standards, the cumulative temperature deviation during the process is calculated by using the deviation reverse propagation algorithm, the key control links that cause quality problems are identified, and the control parameter boundaries of the corresponding links are corrected. The optimized temperature control parameters are stored in the database for subsequent temperature control of similar components.

9. A precise temperature control system for optimizing the energy efficiency of heat treatment of mechanical components, characterized in that, A precise temperature control method for optimizing the energy efficiency of heat treatment of mechanical components as described in any one of claims 1-8, comprising: The database module is used to construct a basic database for heat treatment temperature control based on the geometric features and material properties of mechanical components, combined with the thermal response characteristics of the furnace body. The limiting and optimization module is used to divide the heat treatment process into a heating section, a holding section, and a cooling section, determine the target temperature and allowable fluctuation range for each section, and set the upper and lower limits of the temperature for each section with quality qualification as a hard constraint; based on historical operating data, it obtains the furnace body heating lag time, thermal inertia overshoot coefficient, and temperature decay characteristic parameters; based on the component material and cross-sectional dimensions, it sets the maximum allowable heating rate for the heating section and the maximum allowable cooling rate for the cooling section, and establishes smooth connection rules between sections; based on the segmented target temperature, thermal inertia overshoot coefficient, and maximum allowable heating and cooling rates, it generates a continuous temperature control curve without overshoot; it collects the furnace and component temperatures in real time, performs small-step closed-loop correction using a single adjustment amplitude limiting method, and identifies phase change heat release based on the temperature change rate during cooling, dynamically compensating for the cooling medium; The module for saving and updating is used to optimize temperature control parameters based on the quality inspection data of the component after heat treatment, with the goal of minimizing energy consumption while ensuring that the quality is qualified, and to update the database for subsequent control of similar components.

10. A precise temperature control system for optimizing the energy efficiency of heat treatment of mechanical components according to claim 9, characterized in that, The limiting and optimization module includes: The phased unit is used to divide the heat treatment process into a heating section, a heat preservation section and a cooling section, determine the target temperature and allowable fluctuation range of each section, and set the upper and lower limits of the temperature of each section with quality qualification as a hard constraint. The parameter extraction unit is used to obtain parameters such as furnace body heating lag time, thermal inertia overshoot coefficient and temperature decay characteristics based on historical operating data. The smooth connection rule unit is used to set the maximum allowable heating rate of the heating section and the maximum allowable cooling rate of the cooling section according to the component material and cross-sectional dimensions, and to establish smooth connection rules between sections. Temperature control curve unit, which is used to generate a continuous temperature control curve without overshoot based on the segmented target temperature, thermal inertia overshoot coefficient and maximum allowable heating and cooling rates; The control and optimization unit is used to collect the furnace and component temperatures in real time, perform small-step closed-loop correction in a single adjustment limiting manner, and identify phase change heat release based on the temperature change rate during cooling to dynamically compensate the cooling medium.

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