Heating control system

Abstract

This application belongs to the field of industrial heating technology, and particularly relates to a heating control system for controlling the heating of multiple heating zones of an electromagnetic heating roller. The system includes: a power supply that converts AC power to DC power for output; a main controller electrically connected to the power supply; and multiple power control modules, each corresponding to a heating zone of the electromagnetic heating roller. Each power control module includes: an inverter circuit electrically connected to the power supply and used to adjust the heating power of the heating zone; and a temperature acquisition unit used to acquire the actual temperature of the heating zone and electrically connected to the main controller. The main controller is electrically connected to the multiple inverter circuits and independently controls the output power of each inverter circuit based on the target temperature and the actual temperatures acquired by each temperature acquisition unit, thereby adjusting the heating power of each heating zone. The heating control system achieves high-precision, high-uniformity, fast-response, and reliable temperature control of the electromagnetic heating roller.

Description

Technical Field

[0001] This application belongs to the field of industrial electromagnetic heating technology, and in particular relates to a heating control system. Background Technology

[0002] Electromagnetic induction heating rollers, with their advantages of non-contact heating, fast thermal response, and high thermal efficiency, have been widely used in textiles, papermaking, printing, and film processing. Currently, the control of electromagnetic induction heating rollers often employs existing high-power control cabinets. However, these cabinets only focus on heat dissipation and their control systems operate in a single power output mode, heating the entire roller uniformly without the ability to independently adjust different areas. This leads to the following problems in practical applications: First, poor roller surface temperature uniformity, with temperature differences between different areas of a long roller often exceeding ±1.5℃, making it difficult to meet high-precision process requirements; second, insufficient temperature control flexibility, unable to adapt to changes in material width or the need for temperature differences in different areas; third, severe heat generation of high-power IGBT modules (30-100kW) during continuous high-load operation, with insufficient heat dissipation from air cooling or simple water cooling, affecting equipment lifespan; fourth, slow response speed of traditional PID control methods, with significant lag during temperature surges, affecting process stability; and fifth, low system integration, lacking intelligent functions such as remote monitoring, fault self-diagnosis, and automatic recording, making maintenance and management inconvenient. Summary of the Invention

[0003] This application aims to provide a heating control system that achieves high uniformity and fast response closed-loop temperature control of electromagnetic heating rollers through multi-segment independent power control and real-time temperature feedback.

[0004] The first aspect of this application provides a heating control system for heating multiple heating zones of an electromagnetic heating roller, comprising: a power supply for converting alternating current (AC) to direct current (DC) for power output; a main controller electrically connected to the power supply; and multiple power control modules, each power control module corresponding to one heating zone of the electromagnetic heating roller, and each power control module comprising: an inverter circuit electrically connected to the power supply and used to adjust the heating power of the heating zone; and a temperature acquisition unit used to acquire the actual temperature of the heating zone and electrically connected to the main controller; wherein the main controller is electrically connected to the multiple inverter circuits and independently controls the output power of each inverter circuit according to the target temperature and the actual temperature acquired by each temperature acquisition unit to adjust the heating power of each heating zone.

[0005] In an optional embodiment of this application, each power control module further includes a digital PID controller, which is electrically connected to the main controller. The digital PID controller calculates and generates a control quantity based on the deviation between the actual temperature and the target temperature collected by the corresponding temperature acquisition unit, and outputs the control quantity to the main controller to adjust the output power of the inverter circuit.

[0006] In an optional embodiment of this application, each inverter circuit includes multiple IGBT devices, and each power control module further includes an IGBT driver module. The input terminal of the IGBT driver module is electrically connected to the main controller, and the output terminal of the IGBT driver module is electrically connected to the multiple IGBT devices. The IGBT driver module is used to receive signals from the main controller and drive the multiple IGBT devices to switch on and off.

[0007] In an optional embodiment of this application, each power control module further includes a protection circuit. The input terminal of the protection circuit is electrically connected to the inverter circuit, and the output terminal of the protection circuit is electrically connected to the fault signal input terminal of the main controller. The protection circuit is used to monitor the current abnormality and / or temperature abnormality of the inverter circuit, and outputs a protection signal to the main controller when an abnormality is detected.

[0008] In an optional embodiment of this application, the inverter circuit further includes a heat sink corresponding to each IGBT device, and the protection circuit includes an overcurrent protection circuit and an overtemperature protection circuit. The overcurrent protection circuit is connected to the inverter circuit and is used to sample the current of the inverter circuit. The overtemperature protection circuit is connected to the IGBT device or the heat sink and is used to sample the temperature of the IGBT device. The output terminals of the overcurrent protection circuit and the overtemperature protection circuit are respectively connected to the main controller through the IGBT drive module. When the current exceeds a threshold or the temperature exceeds a threshold, the protection circuit outputs the protection signal to the main controller, and the main controller shuts down the inverter circuit or shuts down the IGBT device through the IGBT drive module according to the protection signal.

[0009] In an optional embodiment of this application, the main controller further includes: a load adaptive module, used to detect the inductance and resistance values ​​of the heating load corresponding to each heating zone, and adjust the operating frequency and phase of the inverter circuit corresponding to each heating zone according to the detection results; and a power balance module, used to acquire the temperature deviation between each heating zone and its adjacent heating zone temperature acquisition unit, calculate the power compensation amount of each heating zone according to the temperature deviation, and output it to the inverter circuit corresponding to each heating zone to dynamically adjust the output power of each inverter circuit.

[0010] In an optional embodiment of this application, the heating control system further includes a control cabinet. The control cabinet is vertically divided into a power device heat dissipation area, a control circuit area, and a terminal block area, arranged sequentially from top to bottom. An air inlet is located at the bottom of the control cabinet, and an exhaust outlet is located at the top, forming a bottom-to-top heat dissipation airflow channel. This airflow channel is used to dissipate heat from the power device heat dissipation area, the control circuit area, and the terminal block area. And / or the power device heat dissipation area is equipped with a first heat dissipation device for dissipating heat from the IGBT device and the heat sink; and / or the control circuit area is equipped with a second heat dissipation device for dissipating heat from the main controller and the IGBT drive module.

[0011] In an optional embodiment of this application, the heating control system further includes a heat exchanger and a water pump; the radiator, the heat exchanger, and the water pump are connected in sequence for dissipating heat from the radiator.

[0012] In an optional embodiment of this application, the power supply includes a rectifier and filter unit, wherein the input terminal of the power supply is electrically connected to an AC power supply, the output terminal of the power supply is connected to a DC bus, the DC bus is electrically connected to multiple inverter circuits, the AC power output by the AC power supply is rectified and filtered into DC power by the rectifier and filter unit, and the rectified and filtered DC power is supplied to multiple power control modules via the DC bus.

[0013] In an optional embodiment of this application, the main controller is a 32-bit ARM processor.

[0014] A second aspect of this application provides a heating device, including an electromagnetic heating roller and the aforementioned heating control system; the electromagnetic heating roller includes: a roller body forming a first cavity and having multiple heating zones; multiple heating components disposed in the first cavity, each for heating a corresponding heating zone; and multiple temperature sensors disposed in a corresponding heating zone; wherein each inverter circuit is electrically connected to a corresponding heating component to adjust the heating power of each heating component through the main controller, and each temperature acquisition unit is electrically connected to a corresponding temperature sensor to acquire the actual temperature of the heating zone.

[0015] In summary, the solution provided in this application has at least the following beneficial effects: The heating control system provided in this application embodiment independently controls multiple heating zones of the electromagnetic heating roller, and equips each heating zone with an independent power control module and its corresponding inverter circuit and temperature acquisition unit. This system achieves decoupled control of the heating power of each zone. The power supply converts AC power into a stable DC voltage, providing a unified energy input to each inverter circuit. The main controller acquires the actual roller surface temperature fed back by the temperature acquisition unit of each heating zone in real time, compares it with the preset target temperature, and independently adjusts the output power of the corresponding inverter circuit. This distributed architecture, with one zone per control, fundamentally avoids the problem of uneven axial temperature distribution caused by differences in heat conduction and heat dissipation conditions in traditional single-zone heating. Each heating zone can independently adjust its heating power according to its own load characteristics and process requirements, thereby controlling the axial temperature difference of the roller surface within a very small range, significantly improving the uniformity of product processing quality. Simultaneously, since the main controller directly controls each inverter circuit independently without complex intermediate conversion, the response speed of temperature adjustment is greatly accelerated, and the influence of external disturbances on the corresponding zone can be quickly suppressed. Furthermore, each power control module operates independently, and a failure in a single power control module does not affect the normal operation of other sections, thus improving the system's fault tolerance and reliability. The heating control system provided in this application achieves high-precision, high-uniformity, fast-response, and highly reliable electromagnetic heating roller temperature control through a closed-loop architecture of multi-segment independent power control and real-time temperature feedback. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the specific embodiments of this application, the drawings used in the specific embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the heating control system provided according to an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a heating control system according to an embodiment of this application; Figure 3 This is a schematic diagram of the structure of a heating control system according to another embodiment of this application; Figure 4 This is a schematic diagram of the structure of a heating control system according to another embodiment of this application; Figure 5 This is a schematic diagram of the structure of a heating control system according to another embodiment of this application; Figure 6 This is a schematic diagram of the structure of a main controller according to an embodiment of this application; Figure 7 This is a schematic diagram of the structure of a control cabinet according to yet another embodiment of this application; Figure 8 This is a schematic diagram of the structure of a heating control system according to an embodiment of this application; Figure 9 This is a schematic diagram of the structure of a heating device according to an embodiment of this application; Figure 10 This is a schematic diagram of the structure of an electromagnetic heating roller according to an embodiment of this application; The attached icons are numbered as follows: 00. Heating equipment; 200. Heating control system; 100. Electromagnetic heating roller; 101. Heating assembly; 102. Temperature sensor; 103. Roller body; 104. First cavity; 110. Heating zone; 120. Central body; 130. Roller shaft; 140. Drive mechanism; 150. Resolver temperature transmitter; 151. Resolver rotor plate; 152. Resolver stator plate; 160. Heavy-duty connector; 10. Power supply; 20. Main controller; 21. Load adaptive module; 22. Power balancing module; 30. Power control module; 31. Inverter circuit; 311. IGBT device; 312. Heat sink; 32. Temperature acquisition unit; 33. Digital PID controller; 34. IGBT drive module; 35. Protection circuit; 351. Overcurrent protection circuit; 352. Overtemperature protection circuit; 40. Control cabinet; 41. Power device heat dissipation area; 411. First heat dissipation device; 42. Control circuit area; 421. Second heat dissipation device; 43. Terminal block area; 50. Heat exchanger; 60. Water pump. Detailed Implementation

[0018] To make the above and other features and advantages of this application clearer, the application is further described below with reference to the accompanying drawings. It should be understood that the specific embodiments given herein are for the purpose of explanation to those skilled in the art and are exemplary only, not restrictive.

[0019] The terms "first" and "second" in the specification and claims of this application may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0020] See Figure 1-2This application provides a heating control system 200 for segmented heating control of an electromagnetic heating roller 100. Specifically, the heating control system 200 controls the heating of multiple heating zones 110 of the electromagnetic heating roller 100. The heating control system 200 includes a power supply 10, a main controller 20, and multiple power control modules 30. The power supply 10 converts AC power to DC power for power output.

[0021] The main controller 20 is electrically connected to the power supply 10. Specifically, the main controller 20 can use an STM32 series processor with built-in FPU and DSP instruction sets. The main controller 20 can be implemented using the STM32 processor's hardware and software.

[0022] Multiple power control modules 30, each corresponding to an independent heating zone 110 of the electromagnetic heating roller 100; the power control modules 30 are electrically connected to the power supply 10 and the main controller 20. Specifically, as shown... Figure 2 As shown, the electromagnetic heating roller 100 may include multiple heating zones 110, such as 2, 4, 5, 6, 7, 8-12 or more heating zones 110.

[0023] The segmented heating method of the electromagnetic heating roller 100 can ensure and improve the heating power of each area, thereby improving the overall heating power of the heating roller 100; while the segmented temperature acquisition method can ensure the accuracy of temperature acquisition in each area, which is convenient for control and adjustment, thereby improving the uniformity of the roller surface temperature of the heating roller 100.

[0024] The heating control system 200 of this application embodiment controls a heating roller 100 that can meet the thermal energy requirements (such as heating power requirements of 100kW or more) and the surface temperature uniformity requirements of large heating rollers with a diameter ≥ 0.4m and a length ≥ 1m. It can also raise the surface temperature of the heating roller 100 to over 400℃, making it suitable for continuous production lines requiring precise temperature control, such as textiles (e.g., aramid, carbon fiber), papermaking, printing, and film processing. The heating roller 100 controlled by the heating control system 200 of this application embodiment can operate stably under extreme conditions of 400℃ high temperature and 9000rpm high speed. Furthermore, the temperature difference between the heating roller 100 in the axial and circumferential directions is less than or equal to ±1℃, meaning the surface temperature uniformity can reach and be maintained at an accuracy of ±1℃. Additionally, the temperature control accuracy of the heating roller 100 by the heating control system 200 can reach ±0.1℃.

[0025] The power control module 30 includes an inverter circuit 31 and a temperature acquisition unit 32. In some embodiments, each power control module 30 typically includes at least one inverter circuit 31. The power control module 30 may include one or more independent inverter circuits 31. In one example, the inverter circuit 31 may be, for example, a bridge inverter unit, such as a full-bridge inverter unit, which may include IGBT modules, drive modules, resonant capacitors, etc.

[0026] The inverter circuit 31 is electrically connected to the power supply 10 and is used to adjust the heating power of the heating zone 110. For example, the input terminal of the inverter circuit 31 is electrically connected to the power supply 10, and the output terminal of the inverter circuit 31 is electrically connected to the heating component 101 corresponding to the heating zone 110. The electromagnetic heating roller 100 is provided with the heating component 101 and the temperature sensor 102 corresponding to the heating zone 110.

[0027] Temperature acquisition unit 32 is electrically connected to main controller 20. Temperature acquisition unit 32 is used to acquire the actual temperature of the corresponding heating zone 110. For example, the input terminal of temperature acquisition unit 32 is electrically connected to temperature sensor 102 of the corresponding heating zone 110, and the output terminal of temperature acquisition unit 32 is electrically connected to main controller 20. In one example, each heating zone 110 can be equipped with at least one temperature acquisition unit 32, such as a temperature measuring resistor (e.g., PT100 platinum resistance thermometer), using a three-wire connection, with a measurement accuracy of ±0.1℃.

[0028] The temperature acquisition unit 32 is used to acquire the roller temperature of the heating zone 110 corresponding to the power control module 30 and transmit it to the main controller 20. For example, the main controller 20 can be connected to the control terminal of each inverter circuit 31 respectively, and independently control the output power of each inverter circuit 31 according to the target temperature and the actual temperature acquired by each temperature acquisition unit 32, so as to adjust the heating power of each heating zone 110.

[0029] See Figures 2-3 In some embodiments, the power control module 30 further includes a digital PID controller 33, which is electrically connected to the main controller 20. The digital PID controller 33 calculates a control quantity based on the deviation between the actual temperature and the target temperature of the heating zone 110 corresponding to the power control module 30, and outputs the control quantity to the inverter circuit 31 to adjust the output power of the inverter circuit 31. Specifically, the digital PID controller 33 can be disposed within the power control module 30. In some embodiments, the digital PID controller 33 can also be integrated into the main controller 20.

[0030] Specifically, control quantities are generated through proportional, integral, and derivative operations. For example, fuzzy self-tuning PID control technology is used to fuzzify the precise input of the PID control. Through fuzzy rules and fuzzy inference, fuzzy control quantities are obtained and converted into precise control quantities for online adaptive control of PID parameters. The main controller 20, based on the characteristics of the controlled object (i.e., the electromagnetic heating roller 100), and according to the system output response curve, combined with the effects and interactions of the three parameters P, I, and D, and corresponding to the precise input variable deviation e and deviation change ec at different time periods, performs online adaptive control of the parameters Kp, Ki, and Kd in the controlled process through fuzzy rules and fuzzy inference to obtain precise output control quantities. This satisfies the different requirements of control parameters for different e and ec values, achieving the desired control effect.

[0031] Optionally, the main controller 20 can perform the following functions: establish a thermal coupling model between adjacent segments, eliminate cross-interference between electromagnetic fields and thermal radiation through feedforward compensation, thereby performing multi-segment decoupling control; sample the zero-crossing points of coil current and voltage, calculate the phase difference, adjust the PWM frequency in real time, and ensure the ZCS (zero current switching) state.

[0032] In some embodiments, the inverter circuit 31 includes a plurality of IGBT devices 311, and the power control module 30 further includes an IGBT drive module 34. The input terminal of the IGBT drive module 34 is electrically connected to the main controller 20, and the output terminal of the IGBT drive module 34 is electrically connected to the plurality of IGBT devices 311. The IGBT drive module 34 is used to receive signals from the main controller 20 and drive the plurality of IGBT devices 311 to switch on and off.

[0033] See Figures 2-4 In some embodiments, the heating control system 200 further includes a protection circuit 35. The input terminal of the protection circuit 35 is electrically connected to the inverter circuit 31, and the output terminal of the protection circuit 35 is electrically connected to the fault signal input terminal of the main controller 20. The protection circuit 35 is used to monitor current and / or temperature abnormalities in the inverter circuit 31, and outputs a protection signal to the main controller 20 when an abnormality is detected. In some embodiments, the detection of abnormalities may include fault diagnosis through a self-diagnostic system set by the protection circuit 35, for example, identifying and recording 16 common fault types.

[0034] See Figures 2-5 In some embodiments, the inverter circuit 31 includes a heat sink 312 provided for each IGBT device 311, and the protection circuit 35 includes an overcurrent protection circuit 351 and an overtemperature protection circuit 352.

[0035] Specifically, the overcurrent protection circuit 351 is connected to the inverter circuit 31 to sample the current of the inverter circuit 31, and the overtemperature protection circuit 352 is connected to the IGBT device 311 or the heat sink 312 to sample the temperature of the IGBT device 311. The heating control system 200 may also include multiple electrical protections, such as overcurrent protection (response time ≤ 2μs), overvoltage protection, undervoltage protection, and phase loss protection. In some embodiments, the overtemperature protection circuit 352 may include IGBT overheat protection (85±5℃), coil temperature monitoring, and ambient temperature monitoring.

[0036] The outputs of the overcurrent protection circuit 351 and the overtemperature protection circuit 352 are respectively connected to the IGBT drive module 34, which is connected to the main controller 20 through the IGBT drive module 34. When the current or temperature exceeds the threshold, the protection circuit 35 outputs a protection signal to the main controller 20. The main controller 20 shuts down the inverter circuit 31 or shuts down the IGBT device 311 through the IGBT drive module 34 according to the protection signal.

[0037] In some embodiments, when an abnormal current or temperature occurs, the protection action triggered by the protection circuit 35 may further include: an overcurrent fault is caused by the IGBT drive module 34 shutting down the IGBT device 311; an overtemperature fault is determined by the main controller 20 (e.g., the main controller 20 software) and then the IGBT drive module 34 shuts down the IGBT device 311. The main controller 20 will receive the corresponding fault signal in both cases.

[0038] See Figures 2-6 In some embodiments, the main controller 20 further includes a load adaptation module 21 and a power balancing module 22.

[0039] The load adaptive module 21 is used to detect the inductance and resistance values ​​of the heating load corresponding to each heating zone 110, and adjust the operating frequency and phase of the inverter circuit 31 corresponding to each heating zone 110 according to the detection results. Specifically, the heating load can be a heating component 101, which may include an induction coil.

[0040] The power balancing module 22 is used to obtain the temperature deviation between each heating zone and its adjacent heating zone 110. For example, it obtains the temperature deviation between each heating zone 110 by collecting the temperature through the temperature acquisition unit 32 of each heating zone 110. Based on the temperature deviation, the power compensation amount of each heating zone 110 is calculated and output to the inverter circuit 31 corresponding to each heating zone 110 to dynamically adjust the power distribution, that is, to adjust the output power of each inverter circuit 31.

[0041] Specifically, in the main controller 20, each heating zone 110 corresponds to an independent digital PID controller. In an example calculation logic of the main controller 20, the PID controller is implemented through the following data structure: a PID_Param structure is defined, containing a proportional coefficient Kp, an integral coefficient Ki, a derivative coefficient Kd, an integral term (integral), and a previous error (prev_error). The digital PID controller receives the deviation between the actual temperature and the target temperature fed back by the temperature acquisition unit 32 of the corresponding heating zone 110, calculates the control quantity according to a positional or incremental PID algorithm, wherein the integral term and the derivative term are weighted by the cumulative error and the rate of change of error through the integral coefficient Ki and the derivative coefficient Kd, respectively, and finally output to the inverter circuit 31 to adjust the output power.

[0042] To address the thermal interaction between the multiple heating zones 110, the main controller 20 can further construct a multi-segment temperature control structure, MultiZone_Control. This structure stores the set temperature (set_temp), actual temperature (actual_temp), power output (power_output), and corresponding PID_Param parameters for each heating zone 110, and also includes a coupling gain (coupling_gain). The power balancing module 22 built into the main controller 20 calculates the power compensation amount based on the temperature deviation between adjacent heating zones 110, achieving feedforward compensation: when the actual temperature of a heating zone 110 is lower than the target temperature and the temperature of adjacent zones is higher, this module appropriately increases the power of its own zone and decreases the power of adjacent zones, thereby eliminating edge effects and improving the axial temperature uniformity of the roller surface.

[0043] Optionally, the load adaptive module 21 built into the main controller 20 can detect the inductance and resistance values ​​of the heating components 101 corresponding to each heating zone 110, and adjust the operating frequency (adjustable from 8-20kHz) and phase angle of the corresponding inverter circuit 31 according to the detection results, so that the system always operates in a resonant state. The adaptive PID parameters adjust the values ​​of Kp, Ki, and Kd online according to the load changes: when the temperature deviation is large, the proportional coefficient Kp is increased to speed up the response; when the deviation approaches zero, the integral coefficient Ki is enhanced to eliminate steady-state error; and the derivative coefficient Kd is dynamically adjusted according to the error change rate to suppress overshoot.

[0044] The aforementioned calculation logic is executed periodically in the main controller 20, with a PID calculation cycle of 10ms, a load adaptive update cycle of 100ms, a temperature acquisition cycle of 5ms, and a fault monitoring cycle of 1ms. Through the coordinated operation of these algorithms, independent closed-loop temperature control of each heating zone 110 and dynamic power balance distribution between adjacent heating zones 110 are achieved.

[0045] In a specific workflow example of the heating control system 200, after the heating control system 200 is powered on, the main controller 20 first performs self-tests on each power control module 30, inverter circuit 31, temperature acquisition unit 32, IGBT drive module 33 and protection circuit 34, and at the same time checks the load connection status of the heating components 101 corresponding to each heating zone 110. Only after confirming that all modules are normal and the load is connected can it enter the standby mode.

[0046] Subsequently, the operator sets parameters such as the target temperature, heating rate, and holding time for each heating zone 110 through the human-machine interface. These parameters are stored in the data storage unit and then parsed by the main controller 20 and distributed to the corresponding digital PID controller and power balance module 22. When heating is started, the main controller 20 gradually increases the output power of each inverter circuit 31 through the IGBT drive module 33 in a soft-start manner, so that each heating zone 110 smoothly increases its power according to the preset heating curve, avoiding current surges.

[0047] When the actual temperature fed back by the temperature acquisition unit 32 approaches the target temperature, the digital PID controller of each heating zone 110 continuously calculates the control quantity and adjusts the output power of the inverter circuit 31 based on the deviation between the actual temperature and the target temperature to maintain the roller surface temperature stable at the set value. During the constant temperature process, the load adaptive module 21 monitors the changes in the inductance and resistance values ​​of the heating component 101 in real time and optimizes the operating frequency and phase of the inverter circuit 31; at the same time, the power balance module 22 automatically distributes power according to the temperature deviation of adjacent heating zones 110, dynamically compensates for the thermal interaction effect, and ensures uniform axial temperature of the roller surface.

[0048] When the process ends or a stop command is received, the main controller 20 performs a soft stop, gradually reducing the output power of the inverter circuit 31 to zero. In case of an emergency, the protection signal output by the protection circuit 34 directly and quickly shuts down the IGBT device 311 through the IGBT drive module 33 to achieve an emergency stop, and saves the temperature, power, fault records and other data of this operation to the data storage unit for subsequent query and analysis.

[0049] See Figures 2-7 In some embodiments, the heating control system 200 further includes a control cabinet 40, the interior of which, vertically from top to bottom, is divided into a power device heat dissipation area 41, a control circuit area 42, and a terminal block area 43. Figure 7 The direction D shown indicates the direction from the bottom of the control cabinet 40 upwards to the top of the control cabinet 40. Specifically, the interior of the control cabinet 40 can be separated into a power device heat dissipation area 41, a control circuit area 42, and a terminal block area 43 by a metal heat sink.

[0050] In some embodiments, the control cabinet 40 has an air inlet at the bottom and an exhaust vent at the top, forming a bottom-up heat dissipation airflow channel for cooling the power device heat dissipation area 41, the control circuit area 42, and the terminal block area 43. Specifically, the control cabinet 40 has an air inlet 42 at the bottom with a filter 49 installed, and an exhaust vent 43 at the top with a dust filter 50 installed, thereby forming a bottom-up main heat dissipation airflow channel.

[0051] In some embodiments, the power device heat dissipation area 41 is provided with a first heat dissipation device 411 for dissipating heat from the IGBT device 311 and the heat sink 312. Specifically, the first heat dissipation device 411 may be an air-cooling device.

[0052] In some embodiments, a second heat dissipation device 421 is provided in the control circuit area 42 for dissipating heat from the main controller 20 and the IGBT drive module 34. Specifically, the second heat dissipation device 421 may be an air-cooled device.

[0053] See Figures 2-8 In some embodiments, the heating control system 200 further includes a heat exchanger 50 and a water pump 60. The radiator 312, heat exchanger 50, and water pump 60 are connected in sequence for heat dissipation of the radiator 312. The radiator 312, heat exchanger 50, and water pump 60 can form a water-cooled circulation loop. In some optional embodiments, a water-cooled pipeline can be provided within the power device heat dissipation area 41, forming a closed liquid-cooled loop with the radiator, heat exchanger, and water pump to achieve water cooling for heat dissipation of the IGBT device 311 and the radiator 312. Specifically, the water pump 60 can be a circulating water pump, for example, a 24V DC water pump with a flow rate of 8L / min. The water-cooled pipeline can be made of a copper substrate and has internal microchannels.

[0054] Specifically, the power device heat dissipation area 41 contains an IGBT device 311 and its corresponding heat sink 312, and is equipped with a forced air cooling device 411 (such as a fan) to draw air from the bottom to force air cooling of the IGBT device 311 and the heat sink 312; at the same time, water cooling pipelines are also provided in this area, forming a closed liquid cooling loop with the heat sink 312, heat exchanger 50 and water pump 60 to achieve water-cooled auxiliary heat dissipation.

[0055] Specifically, the control circuit area 42 houses the main controller 20 and multiple IGBT drive modules 33, and is equipped with multiple independent air-cooling devices 421 to independently cool the aforementioned electronic components. The terminal block area 43 contains terminals electrically connected to the power supply 10 and signal terminals electrically connected to the main controller 20. This area does not have a fan; heat dissipation relies on natural convection through the main heat dissipation airflow channel. Through this layered airflow design and composite cooling method, the heating control system 200 effectively reduces the operating temperature of key heat-generating components, ensuring long-term operational reliability, thereby achieving efficient heat dissipation for the heating control system 200.

[0056] In some embodiments, the power supply 10 includes a rectifier and filter unit. The input terminal of the power supply 10 is electrically connected to an AC power source, and the output terminal of the power supply 10 is connected to a DC bus. The DC bus is electrically connected to multiple inverter circuits 31. The AC power output from the AC power source is rectified and filtered into DC power by the rectifier and filter unit. The rectified and filtered DC power is then supplied to multiple power control modules 30 via the DC bus. Optionally, the rectifier and filter unit may include components such as a rectifier bridge, filter capacitors, and charging / discharging resistors, used to convert the input AC mains voltage into a DC voltage that provides power for the inverter operation.

[0057] In some embodiments, the main controller 20 may be a 32-bit ARM processor.

[0058] In some embodiments, the main controller 20 may also be connected to a human-machine interface (e.g., a touchscreen), a communication interface module (e.g., RS485, Ethernet, etc.), and a data storage unit. Specifically, the communication interface module supports the Modbus RTU / TCP protocol. It should be noted that the supported protocols may also include Profibus, EtherNet / IP, and other protocols, which are not limited here.

[0059] In some embodiments, the main controller 20 provides support for various industrial communication protocols through a communication interface module, including Modbus RTU, Modbus TCP, Profibus, and EtherNet / IP, allowing flexible access to host computers or factory automation networks from different manufacturers. For remote monitoring, the host computer software interacts with the main controller 20 in real time via the aforementioned communication protocols to obtain real-time temperatures fed back by the temperature acquisition units 32 of the heating zones 110 corresponding to each power control module 30, the output power of the inverter circuit 31, and the system operating status (such as operating frequency, fault flags, etc.), and supports remotely issuing target temperatures or start / stop commands. Data recording is achieved through a data storage unit (built-in memory card) connected to the main controller 20. The system automatically records the historical temperature curves, power output, total energy consumption, fault logs (including overcurrent / overtemperature events triggered by the protection circuit 34 and fault type identification codes), and equipment operating time for each heating zone 110. This recorded data can be viewed locally through a human-machine interface, exported via a USB interface, or uploaded to a monitoring center via remote communication for subsequent energy efficiency analysis, fault tracing, and predictive maintenance.

[0060] The main controller 20 may have a built-in self-diagnostic system for identifying and recording various fault types. Specifically, the main controller 20 may include multiple communication interface modules electrically connected to it, whose logical functions are managed and controlled by the main controller 20. In one embodiment, the communication interfaces include: an RS485 interface supporting the Modbus RTU protocol; an Ethernet interface, 10 / 100M adaptive, supporting Modbus TCP; and a USB interface for data export and software upgrades.

[0061] In one example of this application, the heating roller control system 00 uses the FreeRTOS real-time operating system for multi-task scheduling. The system is divided into five periodic tasks: the fault monitoring and protection task has the highest priority (level 7) and a cycle of 1ms, used for rapid response to anomalies such as overcurrent, overtemperature, phase loss, and coil open / short circuit; the PID calculation and power control task has the next highest priority (level 6), executed once every 10ms, calculating the 110 kWh power output of each heating zone based on the temperature deviation; the temperature acquisition and processing task has a cycle of 5ms (priority 5), responsible for reading and filtering the roller surface temperature of each zone; the communication processing task has a cycle of 20ms (priority 4), handling data export and software upgrades for RS485 (Modbus RTU, 115200bps) and Ethernet (Modbus TCP, 100Mbps) protocol stacks and USB interface; and the human-machine interface refresh task has a cycle of 50ms (priority 3), updating the touch screen display. The control algorithm employs a multi-segment independent PID controller coupled with an adjacent zone compensation structure: the PID_Param structure stores the proportional, integral, and derivative coefficients, the integral term, and the previous error; the MultiZone_Control structure manages the set temperature, actual temperature, power output, PID parameters, and coupling gain of the four heating zones (110). The system adjusts the power of each segment in real time based on the adaptive PID algorithm and dynamically compensates for the thermal interaction between adjacent zones using the coupling gain. Protection logic includes: overcurrent protection triggered when the current exceeds 120% of the rated value for 100ms; overtemperature protection activated when the IGBT temperature exceeds 85℃ or the ambient temperature exceeds 50℃; phase loss detection response time less than 10ms; and coil fault (open circuit / short circuit) detection every second. Based on the above hardware and software architecture, the system achieves excellent performance with a total power of 100kW (4×25kW), adjustable operating frequency of 8-20kHz, steady-state temperature control accuracy of ±0.1℃, and roller surface axial temperature difference ≤±1.5℃.

[0062] In another example of this application, the heating roller control system 00 can support eight independently controlled electromagnetic heating rollers 100, suitable for longer roller bodies. The heating roller control system 00 is equipped with eight independent power control units, each with a rated power of 20kW, for a total power of 160kW; each heating zone 110 is equipped with a PT100 temperature sensor, for a total of eight temperature measurement points. The control algorithm adds a fuzzy control compensation module to the original adaptive PID to handle more complex roller surface temperature field distributions and further improve axial temperature uniformity. In addition, this example also integrates several special functions: a production data statistics module automatically records output, energy consumption, and running time; a remote diagnostic function supports VPN connection, allowing manufacturer technicians to remotely access and diagnose system faults; and an energy efficiency analysis interface displays energy consumption data for each section in real time and provides energy-saving optimization suggestions based on historical operating trends. Through these extensions, this eight-segment control system achieves refined energy management and intelligent operation and maintenance support for electromagnetic heating rollers with large aspect ratios while maintaining high precision (±0.1℃) and high uniformity (axial temperature difference ≤±1.5℃).

[0063] The heating control system provided in this application adopts a multi-segment independent control architecture, which divides the electromagnetic heating roller into multiple independent heating zones 110 along the axial direction. Each heating zone 110 includes an independent power control module 30, an inverter circuit 31, and a temperature acquisition unit 32, which breaks through the limitations of traditional single-segment control and realizes independent and precise temperature control of multiple axial zones.

[0064] Based on this, the intelligent power distribution algorithm is based on adaptive PID control of temperature coupling between adjacent sections. The main controller 20 detects the inductance and resistance values ​​of the heating component 101 to optimize the operating frequency and phase, and dynamically adjusts the power of adjacent sections according to the temperature deviation to achieve optimal control of the temperature field.

[0065] The aforementioned heat dissipation structures within the control cabinet 40 of the heating control system 200 collectively constitute a highly efficient composite heat dissipation system: through the separately arranged power device heat dissipation area 41, control circuit area 42, and terminal area 43, bottom air intake and top air exhaust form a main heat dissipation airflow channel from bottom to top. The power device heat dissipation area 41 is equipped with air-cooling devices and water-cooling pipes, the control circuit area 42 is equipped with multiple independent air-cooling devices, and the terminal area 43 relies on natural convection, effectively solving the heat dissipation problem of high-power IGBT devices 311. The combination of layered air channels and water cooling effectively reduces the temperature rise.

[0066] Furthermore, the heating control system 200 provided in this application embodiment adopts a main controller 20 based on a 32-bit ARM processor, integrating a human-machine interface, a communication interface module (supporting protocols such as Modbus RTU / TCP, Profibus, and EtherNet / IP), and a data storage unit to achieve fully digital remote monitoring and intelligent diagnosis. In addition, each power control module adopts a modular design, allowing for independent replacement and significantly reducing maintenance costs and downtime. Multi-segment independent control results in a more uniform roller surface temperature distribution, with axial temperature difference controllable within ±1.5℃; the full-bridge topology offers high efficiency, and multi-segment control avoids overheating, achieving energy saving and high efficiency; the system integrates functions such as temperature monitoring, fault diagnosis, and remote control, exhibiting a high degree of intelligence; optimized heat dissipation design and overcurrent and overtemperature protection mechanisms further improve the reliability of the IGBT device 311 and the mean time between failures (MTBF) of the entire system. The heating control system provided in this application has significant advantages in temperature control accuracy, energy efficiency, and system reliability, and possesses good market prospects and promotional value.

[0067] See Figure 9-10 This application also provides a heating device 00, including an electromagnetic heating roller 100 and a heating control system 200 according to embodiments of this application.

[0068] Specifically, the electromagnetic heating roller 100 includes multiple heating components 101, multiple temperature sensors 102, a roller body 103, and a first cavity 104. The roller body 103 forms the first cavity 104 and has multiple heating zones 110; the multiple heating components 101 are disposed in the first cavity 104 and are used to heat a corresponding heating zone 110; the multiple temperature sensors 102 are respectively disposed in a corresponding heating zone 110; wherein, each inverter circuit 31 is electrically connected to a corresponding heating component 101 to adjust the heating power of each heating component 101 through the main controller 20, and each temperature acquisition unit 32 is electrically connected to a corresponding temperature sensor 102 to acquire the actual temperature of the heating zone 110.

[0069] In some embodiments, the electromagnetic heating roller 100 may further include a central body 120, a roller shaft 130, a drive mechanism 1400, a resolver temperature transmitter 150, and a heavy-duty connector 160. Specifically, the central body 120 is disposed within the roller body 103, and one end of the central body 120 in the axial direction of the roller body 103 is connected to the roller shell of the roller body 103 and together with the roller shell forms a first cavity 104. The first cavity 104 is provided with a heating assembly 101, which is used to heat the roller shell. Figure 10The heating assembly 101 shown is for illustrative purposes only and is not intended to limit the number of heating assemblies 101. Specifically, each independent heating zone 110 is provided with a heating assembly 101 and a temperature sensor 102. The heating assembly 101 heats the portion of the roller shell located in each heating zone 110, and the temperature sensor 102 obtains the roller shell temperature of the corresponding heating zone 110.

[0070] Specifically, the roller shaft 130 is connected to the center body 120. At least a portion of the drive mechanism 140 is disposed within the roller body 103 and connected to the roller shaft 130 to drive the roller body 103 to rotate via the roller shaft 130.

[0071] Specifically, the heating assembly 101 may include a frame, a heating core, and a heating coil. The frame is disposed within the first cavity 104 of the roller body 103, for mounting multiple heating assemblies 101 and providing support for them. The heating core is fixedly mounted (e.g., bolted) to the frame, and has a receiving groove formed therein, with the heating coil disposed within the receiving groove. Specifically, the heating core may be a U-shaped structure to form a U-shaped receiving groove, and a heating coil is formed by winding wire within the U-shaped receiving groove. In some embodiments, the heating core is a magnetic core (made of an inductive magnetic material). The heating coil is connected to an AC power source (e.g., 8~20kHz). When the high-frequency AC power supplied by the AC power source passes through the heating coil, a rapidly changing alternating magnetic field is generated inside and outside the heating coil. At this time, the heating core, utilizing its high magnetic permeability, can greatly increase the magnetic flux and allow the magnetic field to penetrate the metal roller shell, thereby generating strong eddy currents inside the roller shell. The eddy currents interact with the material resistance of the roller shell to generate Joule heating, thus achieving efficient heating of the roller shell. In some embodiments, the heating core can be formed by stacking multiple sheet-like structures (e.g., multiple thin sheets) with interlayer insulation, which can significantly block eddy current paths, reduce eddy current losses, and thus further improve heating efficiency. Optionally, the AC power supply connected to the heating coil can be provided by the power supply 10 of this embodiment, or by a separate other power supply device.

[0072] Specifically, the resolver temperature transmitter 150 may include a resolver rotor plate 151 and a resolver stator plate 152. The resolver rotor plate 151 is connected to the drive mechanism 140 and rotates at high speed with the roller 103 under the action of the drive mechanism 140. Optionally, the resolver rotor plate 151 is electrically connected to multiple temperature sensors 102, and the resolver stator plate 152 is electrically connected to the power supply 10 and the main controller 20.

[0073] Optionally, the resolver rotor plate 151 is equipped with a first coil and a processor. The processor is connected to multiple temperature sensors 102 to process the temperature signals collected by the temperature sensors 102. Specifically, the processor can be an STM32 processor. The resolver stator plate 152 is equipped with a second coil, which is connected to a power supply to power the resolver rotor plate 151 using the magnetic coupling between the first and second coils. The resolver stator plate 152 is configured to receive the temperature signal processed by the processor and output it externally. There is no physical contact between the first and second coils, resulting in no friction or wear during long-term use, ensuring long-term reliability and meeting the requirements for long-term stable operation of the electromagnetic heating roller 100, significantly reducing maintenance costs. Furthermore, powering the resolver rotor plate 151 through the magnetic coupling between the first and second coils is not limited by speed (stable power supply can be provided from tens of revolutions to tens of thousands of revolutions), making it particularly suitable for high-speed operating heating rollers. In addition, by embedding a high-performance processor on the resolver rotor plate 151 to process and transmit data collected by multiple temperature sensors 102, the coil power can be adjusted in real time, which helps to improve the temperature control accuracy of the roller shell and the temperature uniformity of the roller surface.

[0074] Specifically, the heavy-duty connector 160 is disposed on the outer cover of the electromagnetic heating roller 100 on the end side away from the roller body 103. In some embodiments, the main controller 20 and each power control module 30, as well as the power supply 10 and each power control module 30, can achieve the connection and separation of power and signals through the heavy-duty connector 160. For example, the heavy-duty connector 160 is mounted on the housing of the control cabinet 40 and has a first interface and a second interface; the first interface is electrically connected to the output terminal of the power supply 10, the communication terminal of the main controller 20, and the control terminal of each power control module 30; the second interface is used to plug into the corresponding socket on the electromagnetic heating roller 100 to transmit the DC bus voltage, auxiliary power supply voltage, PWM control signal, temperature feedback signal, and fault protection signal from the control cabinet to the heating component 101 (e.g., induction coil), temperature sensor 102, and protection circuit 35 on the side of the electromagnetic heating roller 100, so as to realize quick plugging and unplugging and reliable connection between the control cabinet 40 and the electromagnetic heating roller 100, and adapt to high temperature and high vibration industrial environments. In some embodiments, when the electromagnetic heating roller 100 needs to be repaired or replaced, the electromagnetic heating roller 100 can be completely separated from the control cabinet 40 simply by unplugging the heavy-duty connector 160, which greatly improves the convenience of equipment maintenance.

[0075] Furthermore, the heating device 00 provided in the above embodiments and the heating control system 200 embodiments belong to the same concept, and the specific implementation process can be found in the heating control system 200 embodiments, which will not be repeated here.

[0076] The heating device 00 provided in this embodiment includes a heating control system 200 and an electromagnetic heating roller 100. By independently controlling multiple heating zones of the electromagnetic heating roller and equipping each heating zone with an independent power control module and its corresponding inverter circuit and temperature acquisition unit, the system achieves decoupled control of the heating power of each zone. The power supply converts AC power into a stable DC voltage, providing a unified energy input to each inverter circuit. The main controller acquires the actual roller surface temperature fed back by the temperature acquisition unit of each heating zone in real time and compares it with the preset target temperature, independently adjusting the output power of the corresponding inverter circuit. This distributed architecture of one zone, one control, fundamentally avoids the problem of uneven axial temperature distribution caused by differences in heat conduction and heat dissipation conditions in traditional single-zone heating. Each heating zone can independently adjust its heating power according to its own load characteristics and process requirements, thereby controlling the axial temperature difference of the roller surface within a very small range, significantly improving the uniformity of product processing quality. Simultaneously, since the main controller directly controls each inverter circuit independently without complex intermediate conversion, the response speed of temperature adjustment is greatly accelerated, and the influence of external disturbances on the corresponding zone can be quickly suppressed. In addition, each power control module is independent of the others, and a failure in a single power control module does not affect the normal operation of other sections, thus improving the fault tolerance and reliability of the system.

[0077] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A heating control system (200) for heating control of a plurality of heating zones (110) of an electromagnetic heating roller (100), characterized in that, include: The power supply (10) converts AC power to DC power for power output; The main controller (20) is electrically connected to the power supply (10); as well as Multiple power control modules (30), each power control module (30) corresponding to one of the heating zones (110) of the electromagnetic heating roller (100), and each power control module (30) includes: An inverter circuit (31) is electrically connected to the power supply (10) and is used to adjust the heating power of the heating zone (110); Temperature acquisition unit (32) is used to acquire the actual temperature of the heating zone (110) and is electrically connected to the main controller (20); The main controller (20) is electrically connected to the plurality of inverter circuits (31) and independently controls the output power of each inverter circuit (31) according to the target temperature and the actual temperature collected by each temperature acquisition unit (32) to adjust the heating power of each heating zone (110).

2. The heating control system (200) according to claim 1, characterized in that, Each of the power control modules (30) further includes a digital PID controller (33), which is electrically connected to the main controller (20) and generates a control quantity based on the deviation between the actual temperature and the target temperature collected by the corresponding temperature acquisition unit (32), and outputs the control quantity to the main controller (20) to adjust the output power of the inverter circuit (31).

3. The heating control system (200) according to claim 1, characterized in that, Each of the inverter circuits (31) includes multiple IGBT devices (311); Each of the power control modules (30) further includes an IGBT drive module (34), the input terminal of which is electrically connected to the main controller (20), and the output terminal of which is electrically connected to the plurality of IGBT devices (311). The IGBT drive module (34) is used to receive signals from the main controller (20) and drive the plurality of IGBT devices (311) to switch on and off.

4. The heating control system (200) according to claim 3, characterized in that, Each of the power control modules (30) further includes a protection circuit (35), the input of which is electrically connected to the inverter circuit (31), and the output of which is electrically connected to the fault signal input of the main controller (20). The protection circuit (35) is used to monitor the current and / or temperature abnormalities of the inverter circuit (31) and output a protection signal to the main controller (20) when an abnormality is detected.

5. The heating control system (200) according to claim 4, characterized in that, The inverter circuit (31) also includes a heat sink (312) provided for each of the IGBT devices (311), and the protection circuit (35) includes an overcurrent protection circuit (351) and an overtemperature protection circuit (352). The overcurrent protection circuit (351) is connected to the inverter circuit (31) and is used to sample the current of the inverter circuit (31); The over-temperature protection circuit (352) is connected to the IGBT device (311) or the heat sink (312) and is used to sample the temperature of the IGBT device (311); The output terminals of the overcurrent protection circuit (351) and the overtemperature protection circuit (352) are respectively connected to the main controller (20) through the IGBT drive module (34). When the current exceeds the threshold or the temperature exceeds the threshold, the protection circuit (35) outputs the protection signal to the main controller (20). The main controller (20) shuts off the inverter circuit (31) or shuts off the IGBT device (311) through the IGBT drive module (34) according to the protection signal.

6. The heating control system (200) according to claim 1, characterized in that, The main controller (20) also includes: The load adaptive module (21) is used to detect the inductance and resistance values ​​of the heating load corresponding to each heating zone (110), and adjust the operating frequency and phase of the inverter circuit (31) corresponding to each heating zone (110) according to the detection results; The power balance module (22) is used to obtain the temperature deviation between each heating zone (110) and its adjacent heating zone (110), calculate the power compensation amount of each heating zone (110) according to the temperature deviation, and output it to the inverter circuit (31) corresponding to each heating zone (110) to dynamically adjust the output power of each inverter circuit (31).

7. The heating control system (200) according to claim 3, characterized in that, The heating control system (200) also includes a control cabinet (40), which is divided into a power device heat dissipation area (41), a control circuit area (42) and a wiring terminal area (43) in a vertical direction from top to bottom. The control cabinet (40) has an air inlet at the bottom and an exhaust vent at the top, forming a bottom-up heat dissipation airflow channel. This airflow channel is used to dissipate heat from the power device heat dissipation area (41), the control circuit area (42), and the terminal block area (43); and / or The power device heat dissipation area (41) is provided with a first heat dissipation device (411) for dissipating heat from the IGBT device (311) and the heat sink (312); and / or The control circuit area (42) is provided with a second heat dissipation device (421) for dissipating heat from the main controller (20) and the IGBT drive module (34).

8. The heating control system (200) according to claim 7, characterized in that, The heating control system (00) also includes a heat exchanger (50) and a water pump (60); The radiator (312), the heat exchanger (50) and the water pump (60) are connected in sequence to dissipate heat from the radiator (312).

9. The heating control system (200) according to claim 1, characterized in that, The power supply (10) includes a rectifier and filter unit. The input terminal of the power supply (10) is electrically connected to an AC power source. The output terminal of the power supply (10) is connected to a DC bus. The DC bus is electrically connected to multiple inverter circuits (31). The AC power output by the AC power source is rectified and filtered into DC power by the rectifier and filter unit. The rectified and filtered DC power is supplied to multiple power control modules (30) via the DC bus.

10. A heating device (00) comprising an electromagnetic heating roller (100) and a heating control system (200) as described in any one of claims 1-9; The electromagnetic heating roller (100) includes: The roller (103) has a first cavity (104) and multiple heating zones (110). Multiple heating components (101) are disposed in the first cavity (104) and are used to heat a corresponding heating zone (110). Multiple temperature sensors (102) are respectively disposed in one of the heating zones (110); Each inverter circuit (31) is electrically connected to a corresponding heating component (101) to adjust the heating power of each heating component (101) through the main controller (20), and each temperature acquisition unit (32) is electrically connected to a corresponding temperature sensor (102) to acquire the actual temperature of the heating zone (110).

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