A smart monitoring and control system for energy consumption throughout the entire hot stamping steel production process

Abstract

This invention discloses an intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process. Belonging to the field of energy consumption control in hot stamping manufacturing, it uses the continuous evolution of the sheet metal enthalpy throughout the entire process as a unified tracking carrier. It integrates three unique physical effects of the hot stamping process—the coupled influence of furnace thermal field distortion and heat conversion ratio, the attenuation effect of high-temperature transfer time on the mold entry temperature, and the thermodynamic conservation relationship between latent heat release of phase transformation and cooling water heat load—into a closed-loop energy accounting system based on thermodynamic laws. This is transformed into calculable parameters such as the furnace thermal field distortion coefficient, the gas-sheet heat conversion ratio, the Stefan radiation heat dissipation, and the martensitic transformation progress factor. Based on these parameters, and using the output thermal resistance tag as the criterion, a closed-loop control system with enthalpy adjustment feedforward as the execution logic is implemented. This achieves segmented quantification of thermal resistance links causing abnormal energy consumption throughout the entire process and precise location of their physical roots.

Description

Technical Field

[0001] This invention relates to the field of energy consumption management in hot stamping manufacturing, and more specifically, to an intelligent monitoring and management system for energy consumption throughout the entire process of hot stamping steel production. Background Technology

[0002] Hot stamping is a key process that involves heating steel sheets to their austenitizing temperature and then rapidly transferring them into a die for stamping and quenching to obtain ultra-high-strength martensitic structures. This process is energy-intensive and tightly coupled: the heating furnace accounts for 50%-70% of the total energy consumption of the production line; high-temperature heat transfer and radiative heat dissipation are significant; and the latent heat of phase transformation released within the die (approximately 335 kJ / kg) needs to be promptly removed by the cooling system. Therefore, energy consumption control throughout the hot stamping process essentially involves tracking and balancing the enthalpy of the sheet metal (from heat absorption in the heating furnace and heat transfer to heat release during phase transformation and heat dissipation during cooling). However, conventional energy consumption monitoring and control schemes have the following technical shortcomings: Firstly, there is a lack of closed-loop energy accounting for the entire process based on the first law of thermodynamics. Energy consumption anomalies cannot be located at specific thermal resistance links. Traditional methods often treat each process as an independent accounting unit. For example, the intelligent monitoring and energy efficiency improvement method and system for bus production line energy consumption disclosed in patent number CN118393962A is essentially a data-driven general industrial energy consumption management method. It identifies energy consumption anomalies and inefficiency patterns through clustering and regression analysis, but does not incorporate the physical mechanism of the process. That is, it does not establish cross-process energy tracking based on the enthalpy of the sheet metal. As a result, when downstream cooling energy consumption is abnormal, it is impossible to distinguish whether it is caused by insufficient heating or excessive heat transfer from upstream, resulting in a "molding enthalpy deficit", or by "heat exchange efficiency reduction" caused by blockage of the cooling channel in this process. The energy consumption attribution is general.

[0003] Secondly, the energy efficiency evaluation index of the heating furnace is too simplistic, the heat loss due to heat transfer is not quantified and decomposed, and the latent heat of phase change is not calculated in real time. Specifically, the heating furnace only monitors the ratio of total gas consumption to output, and cannot distinguish the thermal field distortion caused by local slagging in the furnace / burner blockage and the global parameter deviation such as air-fuel ratio imbalance. In addition, the high-temperature transfer process only records the transfer time and does not decouple the total heat dissipation into radiation and convection components, so it is impossible to identify the specific causes of heat dissipation anomalies (such as oxide scale thickening, heat insulation cover damage or robotic arm movement delay). Furthermore, the difference between the heat load of cooling water and the change in enthalpy of the sheet metal is not used to infer the degree of martensitic phase transformation during the in-mold quenching stage. As a result, the abnormal cooling energy consumption cannot be quantitatively mapped to the upstream process deviation, and feedforward control based on the phase transformation progress cannot be achieved.

[0004] In summary, existing technologies lack an energy consumption monitoring and tracing method based on the physical mechanism of hot stamping that can use the enthalpy of the sheet metal as the tracking line, close the energy balance of the entire process in real time, quantitatively decouple the effects of thermal field distortion, heat dissipation transfer path and phase change completion on energy consumption, and accurately locate energy consumption anomalies to specific thermal resistance links. Therefore, this invention is proposed to address this technical need. Summary of the Invention

[0005] The purpose of this invention is to address the aforementioned technical deficiencies, and a smart monitoring and control system for energy consumption throughout the entire hot stamping steel production process is provided.

[0006] The objective of this invention can be achieved through the following technical solution: an intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process, comprising: The sheet metal enthalpy tracking module is used to build a sheet metal enthalpy tracking link along the entire hot stamping process, and to collect in real time the gas consumption of the heating furnace, the temperature of continuous measuring points in the furnace, the sheet metal conveying speed in the furnace, the sheet metal temperature when entering and exiting the furnace, the temperature at the end of the sheet metal transfer, the cooling water flow rate and inlet and outlet temperatures, and the steel extrusion temperature. The heating furnace thermal field-energy efficiency conversion module is used to calculate the furnace thermal field distortion coefficient parameter based on the temperature of continuous measuring points in the furnace, and to calculate the gas-to-sheet heat conversion ratio parameter based on the gas consumption, the sheet conveying speed and the preset sheet width and thickness converted into sheet mass flow rate, and the sheet entering and exiting temperatures. The energy consumption analysis module is used to calculate the total heat dissipation during the transfer process based on the furnace exit temperature and the end temperature of the sheet material. It uses a radiation heat transfer model to decompose the total heat dissipation into radiation heat dissipation components and convection heat dissipation components, and calculates the ratio of radiation heat dissipation to convection heat dissipation. The latent heat of phase transformation calculation module is used to calculate the heat carried away by the cooling circuit based on the cooling water flow rate and inlet and outlet temperatures, obtain the sheet mass, calculate the enthalpy of entry into the mold based on the temperature at the end of the sheet transfer, calculate the enthalpy of exit from the mold based on the temperature of the steel exiting the mold, and back-calculate the actual latent heat of martensitic phase transformation by using the enthalpy of entry into the mold, the enthalpy of exit from the mold, and the heat carried away by the cooling circuit, and calculate the ratio of it to the theoretical latent heat as a parameter of martensitic transformation progress factor. The module is used to receive the above-mentioned multidimensional parameters, identify deviation patterns of the multidimensional parameters based on the thermodynamic calibration baseline, and output thermal resistance link tags that characterize the physical causes of abnormal energy consumption; the thermal resistance link feedforward adjustment module is used to generate enthalpy adjustment command sequences based on the thermal resistance link tags.

[0007] As a preferred embodiment of the present invention, the calculation process of the furnace thermal field distortion coefficient and the gas-plate heat conversion ratio parameter is as follows: obtain the temperature of continuous measuring points in the furnace, calculate the average value of the absolute deviation between the measuring point temperature and the average temperature, and obtain the furnace thermal field distortion coefficient parameter. The gas consumption and the preset gas calorific value constant are obtained, and their product is calculated to obtain the chemical energy input to the heating furnace per unit time. The conveying speed of the sheet metal in the furnace, the preset sheet metal width and thickness, and the material density are obtained, and the product of these four parameters is calculated to obtain the sheet metal mass flow rate passing through the heating furnace per unit time. The difference between the sheet metal temperature at the furnace entrance and exit is calculated and marked as the sheet metal absorption temperature. Then, based on the product of the sheet metal mass flow rate, the sheet metal specific heat capacity, and the sheet metal absorption temperature, the heat energy absorbed by the sheet metal per unit time is obtained. This is divided by the chemical energy input to the heating furnace to obtain the gas-sheet metal heat conversion ratio parameter.

[0008] As a preferred embodiment of the present invention, the calculation process for the total heat dissipation and the proportion of radiative heat dissipation during the transfer process is as follows: Obtain the furnace exit temperature and the end temperature of the sheet material during transfer, calculate the difference between the two, and mark it as the transfer temperature difference. Also obtain the sheet material mass and specific heat capacity, calculate the product of the transfer temperature difference, sheet material mass, and specific heat capacity, and mark it as the total heat dissipation during the transfer process. Based on the sheet material's furnace exit temperature, ambient temperature, sheet material surface area, sheet material surface emissivity, and sheet material transfer time, the Stefan-Boltzmann radiative heat transfer model is used to decompose the radiative heat dissipation component and the convective heat dissipation component, and the ratio of these components to the total heat dissipation during the transfer process is calculated to obtain the radiative heat dissipation proportional parameter and the convective heat dissipation proportional parameter, respectively.

[0009] In a preferred embodiment of the present invention, the Stefan-Boltzmann radiative heat transfer model is used to calculate the radiative heat dissipation component Q. rad : Q rad =σ×ε×A(T 4 出炉 -T 4 环境 )t, where σ is the Stefan-Boltzmann constant, ε is the surface emissivity, A is the surface area of ​​the sheet, and T 出炉 T is the furnace exit temperature of the sheet metal. 环境 Here, t represents the ambient temperature, and t represents the transfer time of the board material. The convective heat dissipation component is obtained by calculating the difference between the total heat dissipation during the transfer process and the radiative heat dissipation component.

[0010] As a preferred embodiment of the present invention, the calculation process for the latent heat of martensitic phase transformation is as follows: The cooling water flow rate, cooling water inlet and outlet temperatures, and sampling time interval are obtained. The cooling circuit temperature difference is obtained based on the difference between the cooling water inlet and outlet temperatures, and is denoted as m. 水 Calculate the heat Q removed by the cooling circuit using ΔT and Δt. m Q m =m 水 ×c pw ×ΔT×Δt, where cpw This refers to the specific heat capacity of the cooling water. The end temperature and mass of the sheet metal during transfer are obtained and labeled as T. 转移 , m, calculate the enthalpy of heat H entering the model in H in =m×c p ×(T 转移 -T 环境 ), T 环境 For ambient temperature, c p Specific heat capacity of the material; Obtain the demolding temperature of the steel and mark it as T. 出模 Calculate the modulus enthalpy H out H out =m×c p ×(T 出模 -T 环境 And calculate the actual latent heat of martensitic phase transformation Q released at present according to the following formula. p Q p =H in -H out -Q m .

[0011] In a preferred embodiment of the present invention, the heat-energy deviation mode arbitration module has a built-in set of thermal balance deviation criteria, which is based on the association rules of thermodynamic calibration baseline and multidimensional parameter combination.

[0012] In a preferred embodiment of the present invention, the deviation pattern identification specifically involves: comparing each received feature value with its corresponding thermodynamic calibration baseline, determining the abnormal mode to which the current energy consumption deviation belongs based on the association rule, and mapping the abnormal mode to a thermal resistance link label with physical orientation.

[0013] In a preferred embodiment of the present invention, the thermal resistance link feedforward adjustment module has a built-in abnormal mode-adjustment operation mapping table. The enthalpy adjustment command sequence is as follows: based on the received thermal resistance link tag, the abnormal mode-adjustment operation mapping table is queried to obtain the corresponding adjustment operation type and parameters, and the adjustment operation type and parameters are encapsulated into a scalable enthalpy adjustment command sequence.

[0014] Compared with the prior art, the advantages of this invention are: Using the continuous phase change of sheet metal enthalpy throughout the entire process as a unified tracking carrier, the coupling effects of the unique physical effects of hot stamping process—the furnace thermal field distortion coefficient and the gas-sheet heat conversion ratio parameter, the attenuation effect of heat dissipation transfer time on the mold entry temperature, and the thermodynamic conservation relationship between the latent heat release of phase change and the cooling water heat load—are integrated into the whole-process energy closed-loop accounting system. This system is transformed into a series of energy consumption diagnostic parameters that can quantify the energy conversion state of each physical link. Based on these parameters, thermal resistance links are labeled, and the thermal resistance links with abnormal energy consumption throughout the entire process are quantified segment by segment and the physical root cause is accurately located by the enthalpy adjustment command sequence. This provides a decision basis with clear thermodynamic interpretation for process optimization and equipment maintenance.

[0015] Decoupling the linkage between thermal field distortion and energy efficiency degradation in heating furnaces: By calculating the thermal field distortion coefficient parameter of the furnace through multi-point temperature measurement in the heating furnace, and calculating the instantaneous thermal efficiency based on the chemical energy input of fuel gas and the enthalpy increment of the plate, a coupled judgment mechanism for thermal field distortion and energy efficiency degradation in heating furnaces is established. This mechanism can distinguish between thermal field distortion caused by local slagging in the furnace or burner blockage and global parameter shifts caused by air-fuel ratio imbalance, attributing abnormal energy efficiency of the heating furnace to specific physical parts, thus solving the problem that traditional single energy consumption parameters cannot distinguish between local furnace degradation and global parameter shifts.

[0016] Quantitative decoupling of the heat dissipation path during high-temperature transfer: The total heat dissipation during the transfer process is calculated based on the difference between the furnace exit temperature and the end temperature of the transfer. The Stefan-Boltzmann radiation model is used to decouple the radiation heat dissipation component and the convection heat dissipation component. By identifying abnormal changes in the radiation ratio or convection component, specific causes such as thickening of oxide scale on the sheet surface, damage to the heat insulation cover, or delay in the movement of the robotic arm are identified. This allows the heat dissipation path of the high-temperature transfer process to be quantified independently, providing a physical basis for targeted replacement of the heat insulation cover, optimization of the robotic arm speed, or descaling process.

[0017] Proactive energy consumption control based on phase transformation completion: The actual latent heat of martensitic phase transformation is inferred by the difference between the enthalpy of entry into the mold, the enthalpy of exit from the mold, and the heat carried away by the cooling water. The martensitic transformation progress factor parameter is inverted in real time. Based on the direction and degree of deviation of this factor, the enthalpy deficit of entry into the mold or the overheating and coarsening of austenite is determined. A quantitative mapping is established between the abnormal energy consumption of the cooling system and the process deviation of the upstream heating and transfer links, so as to realize proactive energy consumption control based on phase transformation completion. Attached Figure Description

[0018] Figure 1 This is a block diagram showing the data flow of each module in this invention; Figure 2 This is a flowchart illustrating how the furnace thermal field distortion coefficient and the gas-plate heat conversion ratio parameters are obtained by the heating furnace thermal field-energy efficiency conversion module of the present invention. Figure 3A flowchart illustrating how the energy transfer analysis module of this invention obtains the radiative heat dissipation ratio and the convective heat dissipation ratio. Figure 4 This is a flowchart illustrating how the phase transformation latent heat calculation module of the present invention obtains the martensitic transformation progress factor parameter. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] This invention discloses an intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process. Please refer to [link / reference]. Figures 1-4 It includes a sheet metal enthalpy tracking module, a furnace thermal field-energy efficiency conversion module, a transfer energy consumption analysis module, a phase change latent heat calculation module, a heat-energy deviation mode arbitration module, and a thermal resistance link feedforward adjustment module: The sheet metal enthalpy tracking module is used to construct a sheet metal enthalpy tracking link along the entire hot stamping process. Sensors are deployed on the sheet metal enthalpy tracking link, including: rhodium-iron thermocouples at the furnace inlet and outlet, multiple infrared temperature probes arranged along the length of the furnace, a laser velocimeter or encoder for measuring the sheet metal conveying speed, a dual-band infrared thermal imager arranged at a 45-degree angle to the horizontal direction above the transfer track, ultrasonic flow meters and platinum resistance thermometers at the inlet and outlet of the stamping die cooling water circuit, and a thin-film thermocouple array embedded in the stamping die. Real-time data collection of energy consumption datasets for the hot furnace section, transfer section, and cooling circuit section is performed. Specifically, this includes the gas consumption of the heating furnace, the temperature at continuous measuring points inside the furnace, the conveying speed of the sheet metal inside the furnace, the temperature of the sheet metal entering and exiting the furnace, the temperature at the end of the sheet metal transfer, the flow rate and inlet and outlet temperatures of the cooling water, and the temperature of the steel exiting the mold. All sensors collect data synchronously at a sampling frequency of not less than 20Hz, and the sampling trigger signal is synchronized with the angle encoder of the stamping press.

[0021] The heating furnace thermal field-energy efficiency conversion module is used to receive the energy consumption data of the transfer section, calculate the furnace thermal field distortion coefficient parameter based on the temperature of continuous measuring points in the furnace, and calculate the gas-to-sheet heat conversion ratio parameter based on the gas consumption, the sheet conveying speed and the preset sheet width and thickness converted into sheet mass flow rate, and the sheet entering and exiting temperatures. The calculation process for the furnace thermal field distortion coefficient and the gas-to-sheet heat conversion ratio is as follows: The temperature values ​​of N temperature measuring points arranged at equal intervals along the length of the furnace are obtained from the energy consumption data of the heating furnace section and marked as measuring point temperatures. The average value of the absolute deviation between the measuring point temperature and the average temperature is calculated to obtain the furnace thermal field distortion coefficient parameter. This parameter quantifies the degree of non-uniformity of temperature distribution along the length of the heating furnace and reflects the thermal field distortion conditions such as local slagging in the furnace, burner blockage, or radiant tube damage. The gas consumption and the preset gas calorific value constant are obtained, and their product is calculated to obtain the chemical energy input to the heating furnace per unit time. The conveying speed of the sheet metal in the furnace, the preset sheet metal width and thickness, and the material density are obtained, and the product of these four parameters is calculated to obtain the sheet metal mass flow rate through the heating furnace per unit time. The difference between the sheet metal temperature at the furnace entrance and exit is calculated and marked as the sheet metal absorption temperature. Then, based on the product of the sheet metal mass flow rate, the sheet metal specific heat capacity, and the sheet metal absorption temperature, the heat energy absorbed by the sheet metal per unit time is obtained. The heat energy absorbed by the sheet metal is divided by the chemical energy input to the heating furnace to obtain the gas-sheet metal heat conversion ratio parameter, which characterizes the efficiency of converting the chemical energy of the gas into the enthalpy increment of the sheet metal and reflects the overall energy efficiency level of the heating furnace. By decoupling the diagnosis of furnace thermal field distortion and gas-to-sheet heat conversion ratio, and by interpreting the two parameters together, it can distinguish whether the energy efficiency decline is caused by "local furnace thermal field distortion" or "global parameter shift such as air-fuel ratio imbalance". This allows the energy efficiency degradation of the heating furnace to be attributed to specific physical parts, solving the problem that traditional single energy consumption parameters cannot distinguish between local furnace degradation and global parameter shift.

[0022] The energy consumption analysis module is used to receive the energy consumption dataset of the transfer section, calculate the total heat dissipation during the transfer process based on the furnace exit temperature and the end temperature of the transfer section, decompose the total heat dissipation into radiation heat dissipation component and convection heat dissipation component using a radiation heat transfer model, and calculate the ratio of radiation heat dissipation to convection heat dissipation. The calculation process for the total heat dissipation and the proportion of radiative heat dissipation during the transfer process is as follows: Obtain the furnace exit temperature and the end temperature of the sheet material during transfer, calculate the difference between the two, and mark it as the transfer temperature difference. Also obtain the sheet material mass and specific heat capacity, calculate the product of the transfer temperature difference, sheet material mass, and specific heat capacity, and mark it as the total heat dissipation during the transfer process. Based on the sheet material exit temperature, ambient temperature, sheet material surface area, sheet material surface emissivity, and sheet material transfer time, the Stefan-Boltzmann radiative heat transfer model is used to decompose the radiative heat dissipation component and the convective heat dissipation component. Calculate the ratio of the radiative heat dissipation component to the total heat dissipation during the transfer process, and label it as the radiative heat dissipation proportional parameter. Similarly, calculate the convective heat dissipation proportional parameter. It should be added here that the principle mechanism of using the Stefan-Boltzmann radiative heat transfer model to calculate the radiative heat dissipation component is as follows: during the high-temperature transfer process of the sheet material, the heat exchange between it and the environment mainly consists of radiative heat dissipation and convective heat dissipation. At a high temperature of around 950℃, radiative heat dissipation is absolutely dominant (proportional to the fourth power of the temperature), while convective heat dissipation is relatively small. Stefan-Boltzmann law: The energy radiated by a blackbody per unit area per unit time is E=σT 4 Where σ is the Stefan-Boltzmann constant, the radiation capacity of a real object needs to be multiplied by the emissivity ε (0-1), therefore, for a sheet metal, its radiative heat dissipation component is: Q rad =σ×ε×A(T 4 出炉 -T 4 环境 )t, where A is the surface area of ​​the sheet metal, T 出炉 T is the furnace exit temperature of the sheet metal. 环境 Here, t represents the ambient temperature, and t represents the transfer time of the board material. The convective heat dissipation component is obtained by calculating the difference between the total heat dissipation during the transfer process and the radiative heat dissipation component. This module calculates the total heat dissipation based on the difference between the sheet material's exit temperature from the furnace and the final transfer temperature. It then uses the Stefan-Boltzmann radiation model to calculate the radiative heat dissipation component, thereby separating the radiative and convective heat dissipation ratios. This quantitatively decouples the contributions of radiative and convective heat dissipation during the high-temperature transfer process. When the radiative ratio suddenly increases, it indicates that the oxide scale on the sheet material surface has thickened (a change in radiation characteristics). When the convective component increases abnormally, it indicates that the heat shield is damaged or the robotic arm's movement is delayed (enhanced convection). This decoupling allows each heat dissipation path in the high-temperature transfer process to be quantified independently, providing a physical basis for targeted replacement of heat shields, optimization of robotic arm speed, or descaling processes.

[0023] The latent heat of phase transformation calculation module receives energy consumption data from the cooling loop section, calculates the heat carried away by the cooling loop based on the cooling water flow rate and inlet / outlet temperatures, obtains the sheet mass, calculates the enthalpy of entry into the mold based on the sheet transfer end temperature, and calculates the enthalpy of exit from the mold based on the steel exit temperature. The actual latent heat of martensitic phase transformation is then calculated by back-calculating the enthalpy of entry into the mold, the enthalpy of exit from the mold, and the heat carried away by the cooling loop. The specific back-calculation process is as follows: The cooling water flow rate, cooling water inlet and outlet temperatures, and sampling time interval are obtained. The cooling circuit temperature difference is obtained based on the difference between the cooling water inlet and outlet temperatures, and is denoted as m. 水 Calculate the heat Q removed by the cooling circuit using ΔT and Δt. m Q m =m 水 ×c pw ×ΔT×Δt, where c pw This refers to the specific heat capacity of the cooling water. The end temperature and mass of the sheet metal during transfer are obtained and labeled as T. 转移 , m, calculate the enthalpy of heat H entering the model in H in =m×c p ×(T 转移 -T 环境 ), T 环境 For ambient temperature, c p Specific heat capacity of the material; Obtain the demolding temperature of the steel and mark it as T. 出模 Calculate the modulus enthalpy H out H out =m×c p ×(T 出模 -T 环境 ); And calculate the actual latent heat of martensitic phase transformation Q released at present according to the following formula. p Q p =H in -H out -Q m ; Finally, the ratio of the actual latent heat of martensitic phase transformation to the theoretical latent heat is calculated and used as a parameter of martensitic transformation progress factor. By inverting the martensitic transformation progress factor parameter in real time, the upstream enthalpy of abnormal cooling energy consumption can be traced. Feedforward adjustment is performed based on the traceability basis to invert the actual proportion of martensitic phase transformation during the in-mold quenching stage in real time, reflecting whether the enthalpy of the sheet entering the mold meets the requirements for complete phase transformation. When the factor is below the lower limit, it is judged as "enthalpy deficit in mold entry" (insufficient upstream heating or excessive heat transfer); when it is above the upper limit, it is judged as "austenite overheating and coarsening". By establishing a quantitative mapping between abnormal energy consumption in the cooling system and process deviations in upstream heating and transfer stages, we can achieve forward-looking energy consumption control based on the degree of phase change completion.

[0024] The heat-energy deviation mode arbitration module, connected to the heating furnace thermal field-energy efficiency conversion module, the phase change latent heat calculation module, and the transferred energy consumption analysis module, is used to compare the gas-plate heat conversion ratio parameter, furnace thermal field distortion coefficient, martensitic transformation progress factor parameter, radiation heat dissipation ratio, and convection heat dissipation ratio with their respective thermodynamic calibration baselines, and outputs thermal resistance link tags according to the preset thermal balance deviation criterion set; the thermal resistance link feedforward adjustment module, connected to the heat-energy deviation mode arbitration module, is used to generate an enthalpy adjustment command sequence according to the thermal resistance link tags and send it to the heating furnace combustion controller, robotic arm motion controller, or maintenance work order system; The thermal-energy deviation mode arbitration module has a built-in thermal balance deviation criterion set, which is based on the association rules of thermodynamic calibration baseline and multi-dimensional parameter combination. The deviation mode identification is specifically as follows: each received feature value is compared with its corresponding thermodynamic calibration baseline, the abnormal mode to which the current energy consumption deviation belongs is determined according to the association rules, and the abnormal mode is mapped to a thermal resistance link label with physical orientation. The thermal resistance link feedforward adjustment module has a built-in abnormal mode-adjustment operation mapping table. According to the received thermal resistance link label, the abnormal mode-adjustment operation mapping table is queried to obtain the corresponding adjustment operation type and parameters, and the adjustment operation type and parameters are encapsulated into a scalable enthalpy adjustment command sequence. Specifically as follows: When the gas-plate heat conversion ratio parameter is less than the heat conversion calibration baseline and continues to decrease, and the furnace thermal field distortion coefficient is greater than the exponential baseline and continues to increase, it is judged as a thermal resistance link label of "heating furnace burner blockage or furnace slag accumulation", and a burner purging or furnace cleaning work order is generated. When the gas-to-plate heat conversion ratio parameter is less than the heat conversion calibration baseline and continues to decrease, while the furnace thermal field distortion coefficient is normal, it is judged as a "gas-fuel ratio imbalance" thermal resistance link label, and an air-fuel ratio self-tuning command is generated. When the martensitic transformation progress factor parameter is lower than the lower limit of the standard baseline and the total heat dissipation during the transfer process is within the heat dissipation baseline range, it is judged as "insufficient enthalpy of sheet metal entering the mold" thermal resistance link label, and an instruction is generated to increase the set value of the heating furnace outlet temperature or shorten the high-temperature transfer time. When the martensitic transformation progress factor parameter is lower than the lower limit of the standard baseline and the total heat dissipation during the transfer process is higher than the upper limit of the heat dissipation baseline, it is judged as a thermal resistance link label of "transfer time too long or heat shield damaged", and a robotic arm speed increase command or heat shield maintenance alarm command is generated. When the martensite transformation progress factor parameter is higher than the upper limit of the standard baseline, it is judged as "the temperature of the sheet material at the outlet of the heating furnace is too high, causing austenite coarsening" thermal resistance link label, and an automatic lowering command for the set temperature of the heating furnace insulation section is generated. When the radiative heat dissipation ratio is greater than the standard radiative ratio, it is judged as a thermal resistance link label of "thickened oxide scale on the surface of the sheet", and a descaling equipment inspection instruction is generated. When the convective heat dissipation ratio is greater than the standard convective ratio, it is judged as a thermal resistance link tag of "heat shield damage or robotic arm movement delay", and a heat shield maintenance alarm or robotic arm speed optimization command is generated. The output of thermal resistance links with clear thermodynamic interpretation directly points to the thermal resistance location that needs intervention, providing a precise decision basis for feedforward regulation operations. The thermal resistance link feedforward regulation module sends instructions to the actuator to achieve closed-loop feedforward control. It should be added that in the thermal-energy deviation mode arbitration module, the thermodynamic calibration baseline refers to the ideal value, standard range or dynamic baseline that each energy consumption diagnostic parameter should follow when the hot stamping production line is in a normal, stable and efficient operating state. It is not a fixed constant, but a set of reference boundaries pre-established based on the first law of thermodynamics, equipment design parameters and optimal process practices, used to determine whether the current measured energy consumption diagnostic parameters deviate from the normal energy conversion path.

[0025] In summary, this system uses the continuous evolution of sheet metal enthalpy throughout the entire process (heat absorption increment in the heating furnace, heat dissipation attenuation during high-temperature transfer, latent heat release during in-mold phase change, and heat dissipation by cooling water) as a unified tracking carrier. It integrates three unique physical effects of hot stamping process—the coupled influence of furnace thermal field distortion and heat conversion ratio, the attenuation effect of high-temperature transfer time on mold entry temperature, and the thermodynamic conservation relationship between latent heat release during phase change and heat load of cooling water—into a closed-loop energy accounting system based on thermodynamic laws. Specifically, this enthalpy tracking architecture collaboratively utilizes three physical characteristics: Firstly, the furnace thermal field distortion coefficient and instantaneous thermal efficiency are linked for analysis. The nonlinear amplification effect of furnace temperature distortion on the heat absorption consistency of the sheet material is used to distinguish between furnace slagging and burner blockage or air-fuel ratio imbalance. Secondly, the degree of completion of martensitic phase transformation is inverted in real time by the difference between the heat load of cooling water and the enthalpy of the sheet entering and exiting the mold. The thermodynamic constraint that the latent heat release of phase transformation must be equal to the difference between the enthalpy of entering and exiting the mold minus the heat load of cooling is used to establish a quantitative mapping between the energy consumption fluctuation of the cooling system and the process deviation of the upstream heating and transfer links. Third, Stefan-Boltzmann radiation decomposition is introduced. By utilizing the strong nonlinear characteristic that the heat transfer rate is proportional to the fourth power of the temperature, the thickening of the oxide scale on the surface of the plate is identified by the sudden increase in the radiation ratio, and the damage to the heat insulation cover or the delay in the movement of the robotic arm is located by radiation-convection decoupling.

[0026] This invention enables the segmented quantification of thermal resistance links and precise location of physical causes of abnormal energy consumption throughout the entire process, providing a clear thermodynamic interpretation for decision-making in process optimization and equipment maintenance, independent of black-box statistical models.

[0027] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto; any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in the present invention, based on the technical solution and its improved concept, should be covered within the scope of protection of the present invention.

Claims

1. A smart monitoring and control system for energy consumption throughout the entire hot stamping steel production process, characterized in that: include: The sheet metal enthalpy tracking module is used to build a sheet metal enthalpy tracking link along the entire hot stamping process, and to collect energy consumption datasets of the heating furnace section, the transfer section, and the cooling circuit section in real time. The heating furnace thermal field-energy efficiency conversion module is used to receive the energy consumption data of the heating furnace section, decouple the furnace thermal field distortion coefficient parameter based on the temperature of continuous measuring points in the furnace, and decouple the gas-to-sheet heat conversion ratio parameter based on the gas consumption, sheet conveying speed, and sheet temperature at the furnace inlet and outlet. The energy consumption analysis module is used to receive the energy consumption dataset of the transfer section, calculate the total heat dissipation during the transfer process based on the furnace exit temperature and the end temperature of the plate transfer, decompose the total heat dissipation into radiation heat dissipation component and convection heat dissipation component using the radiation heat transfer model, and calculate the ratio parameter of radiation heat dissipation and convection heat dissipation. The latent heat of phase transformation calculation module is used to receive the energy consumption data of the cooling loop section, calculate the heat carried away by the cooling loop based on the cooling water flow rate and inlet and outlet temperatures, obtain the sheet mass, calculate the enthalpy of entry into the mold based on the temperature at the end of the sheet transfer, calculate the enthalpy of exit from the mold based on the temperature of the steel exiting the mold, and back-calculate the actual latent heat of martensitic phase transformation by using the enthalpy of entry into the mold, the enthalpy of exit from the mold, and the heat carried away by the cooling loop, and calculate the ratio of it to the theoretical latent heat as a parameter of martensitic transformation progress factor. The thermal-energy deviation mode arbitration module is used to receive the above-mentioned multidimensional parameters, identify the deviation mode of the multidimensional parameters according to the thermodynamic calibration baseline, and output the thermal resistance link label characterizing the physical cause of energy consumption anomalies; the thermal resistance link feedforward adjustment module is used to generate a thermal enthalpy adjustment command sequence based on the thermal resistance link label.

2. The intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process according to claim 1, characterized in that: The calculation process for the furnace thermal field distortion coefficient and the gas-plate heat conversion ratio parameter is as follows: obtain the temperature of continuous measuring points in the furnace, calculate the average value of the absolute deviation between the measuring point temperature and the average temperature, and obtain the furnace thermal field distortion coefficient parameter. The gas consumption and the preset gas calorific value constant are obtained, and their product is calculated to obtain the chemical energy input to the heating furnace per unit time. The conveying speed of the sheet metal in the furnace is obtained and multiplied with the preset sheet metal width, thickness and material density to obtain the sheet metal mass flow rate through the heating furnace per unit time. The difference between the sheet metal temperature at the furnace entrance and exit is calculated and marked as the sheet metal absorption temperature. Then, based on the product of the sheet metal mass flow rate, the sheet metal specific heat capacity and the sheet metal absorption temperature, the heat energy absorbed by the sheet metal per unit time is obtained. This is divided by the chemical energy input to the heating furnace to obtain the gas-sheet metal heat conversion ratio parameter.

3. The intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process according to claim 2, characterized in that: The calculation process for the total heat dissipation and the proportion of radiative heat dissipation during the transfer process is as follows: Obtain the furnace exit temperature and the end temperature of the sheet material during transfer, calculate the difference between the two, and mark it as the transfer temperature difference. Also obtain the sheet material mass and specific heat capacity, calculate the product of the transfer temperature difference, sheet material mass, and specific heat capacity, and mark it as the total heat dissipation during the transfer process. Based on the sheet material's furnace exit temperature, ambient temperature, sheet material surface area, sheet material surface emissivity, and sheet material transfer time, the Stefan-Boltzmann radiative heat transfer model is used to decompose the radiative heat dissipation component and the convective heat dissipation component. The ratios of these components to the total heat dissipation during the transfer process are calculated to obtain the radiative heat dissipation proportional parameters and the convective heat dissipation proportional parameters.

4. The intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process according to claim 3, characterized in that: The radiative heat dissipation component Q is calculated using the Stefan-Boltzmann radiative heat transfer model. rad : Q rad =σ×ε×A(T 4 出炉 -T 4 环境 )t, where σ is the Stefan-Boltzmann constant, ε is the surface emissivity, A is the surface area of ​​the sheet, and T 出炉 T is the furnace exit temperature of the sheet metal. 环境 Here, t represents the ambient temperature, and t represents the transfer time of the board material. The convective heat dissipation component is obtained by calculating the difference between the total heat dissipation during the transfer process and the radiative heat dissipation component.

5. The intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process according to claim 4, characterized in that: The calculation process for the latent heat of martensitic phase transformation is as follows: The cooling water flow rate, cooling water inlet and outlet temperatures, and sampling time interval are obtained. The cooling circuit temperature difference ΔT is obtained based on the difference between the cooling water inlet and outlet temperatures. The cooling water flow rate and sampling time interval are labeled as m. 水 Δt, calculate the heat Q removed by the cooling circuit. m Q m =m 水 ×c pw ×ΔT×Δt, where c pw This refers to the specific heat capacity of the cooling water. The end temperature and mass of the sheet metal during transfer are obtained and labeled as T. 转移 , m, calculate the enthalpy of heat H entering the model in H in =m×c p ×(T 转移 -T 环境 ), T 环境 For ambient temperature, c p Specific heat capacity of the material; Obtain the demolding temperature of the steel and mark it as T. 出模 Calculate the modulus enthalpy H out H out =m×c p ×(T 出模 -T 环境 And calculate the actual latent heat of martensitic phase transformation Q released at present according to the following formula. p Q p =H in -H out -Q m .

6. The intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process according to claim 5, characterized in that: The heat-energy deviation mode arbitration module has a built-in set of thermal balance deviation criteria, which is based on the association rules of thermodynamic calibration baseline and multidimensional parameter combination.

7. The intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process according to claim 6, characterized in that: The deviation pattern identification specifically involves comparing each received feature value with its corresponding thermodynamic calibration baseline, determining the abnormal pattern to which the current energy consumption deviation belongs based on the association rules, and mapping the abnormal pattern to a thermal resistance link label with physical orientation.

8. The intelligent monitoring and control system for energy consumption throughout the entire hot stamping steel production process according to claim 7, characterized in that: The thermal resistance link feedforward adjustment module has a built-in abnormal mode-adjustment operation mapping table. The enthalpy adjustment command sequence is as follows: based on the received thermal resistance link tag, the abnormal mode-adjustment operation mapping table is queried to obtain the corresponding adjustment operation type and parameters, and the adjustment operation type and parameters are encapsulated into a scalable enthalpy adjustment command sequence.

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