A remote monitoring and temperature measurement system for the bottom of an aluminum alloy casting furnace

Abstract

This invention relates to the field of furnace bottom temperature monitoring technology and discloses a remote monitoring and temperature measurement system for the bottom of an aluminum alloy casting furnace. To address the shortcomings of existing technologies in terms of the limited continuous monitoring effect of single temperature measurement points on the furnace bottom, this invention utilizes a redundant layout of dual S-type thermocouples, combined with a graded difference judgment and adaptive correction algorithm. This ensures accuracy within the core temperature measurement range of 755-765℃, adapting to the melting and casting effect of molten metal in the preparation of 5-series aluminum alloy casting rods. Furthermore, it allows for rapid switching to a backup channel in case of single thermocouple failure, supporting maintenance and replacement without furnace shutdown, significantly improving temperature measurement continuity and increasing the efficiency of aluminum molten casting. By using sensor detection units with differentiated point distribution according to furnace bottom zones, coupled with customized extension depth of the silicon carbide protective sleeve for each zone, it adapts to the temperature differences in different zones of the aluminum molten casting furnace, providing data support for differentiated control.

Description

Technical Field

[0001] This invention relates to the field of temperature monitoring technology for the bottom of casting furnaces, and in particular to a remote monitoring and temperature measurement system for the bottom of aluminum alloy casting furnaces. Background Technology

[0002] The smelting and casting technology of the new 5-series aluminum alloy ingots is also one of the key technologies. Because aluminum alloys are easy to oxidize and easy to absorb gas, advanced smelting equipment and high-purity raw materials are required. Temperature is the core process parameter, and its precise control directly determines the quality of aluminum liquid, casting performance, production efficiency and equipment safety.

[0003] Chinese Patent Publication No. CN223649677U discloses an online measurement and real-time monitoring system for the bottom temperature of a smelting furnace, comprising: a temperature acquisition layer, a communication transmission layer, and an early warning monitoring layer, which are connected sequentially. The temperature acquisition layer is used to acquire the bottom temperature signal of the target smelting furnace; the communication transmission layer is used to transmit the bottom temperature signal to the early warning monitoring layer; and the early warning monitoring layer is used to receive, store, and display the temperature signal, and issue early warnings based on preset conditions. This solves the problems of traditional furnace bottom temperature measurement methods being time-consuming, labor-intensive for operators, having certain measurement data errors, and being untimely in manual temperature measurement.

[0004] Regarding the aforementioned and existing related technologies, the inventors believe that the following defects often exist: In this system, the temperature of the furnace bottom is detected by a temperature probe and a temperature compensation wire. However, since the probe and the temperature compensation wire are connected in series, there is no redundancy design for the temperature measurement point at a single location. Therefore, when the probe fails, the temperature measurement at that location fails. The temperature distribution of the furnace bottom is closely related to the damage state of the furnace lining. The failure of a single temperature measurement point will create a local temperature monitoring blind spot, which not only disrupts the continuity and integrity of the overall temperature data and affects the comprehensive judgment of the furnace bottom temperature status, but may also increase the risk of safety accidents such as aluminum leakage due to the inability to capture abnormal temperature changes in a timely manner. Therefore, there is room for improvement. Summary of the Invention

[0005] The technical problem to be solved by this invention is that the existing technology has the disadvantage of generally poor continuous monitoring effect of a single temperature measurement point at the bottom of the furnace. To address this, we propose a remote monitoring and temperature measurement system for the bottom of an aluminum alloy casting furnace.

[0006] To achieve the above objectives, this application adopts the following technical solution: a remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace, comprising a core control module, a sensing and detection unit, a data transmission module, a remote control module, and a linkage unit; The core control module includes a PLC main unit, which is connected to an expansion I / O module, a PID temperature control module, a redundancy determination module, and an adaptive control module. The sensing and detection unit includes a silicon carbide protective sleeve. Two parallel mounting slots are opened at the bottom of the silicon carbide protective sleeve. S-type thermocouples are inserted into the inside of each mounting slot. The bottom of the outer side of the S-type thermocouple is fixedly connected to the bottom of the inner wall of the mounting slot by external thread and internal spiral screw. The silicon carbide protective sleeve extends from the outer shell of the aluminum alloy melting and casting furnace bottom, and the top of the silicon carbide protective sleeve extends into the refractory layer of the aluminum alloy melting and casting furnace bottom. The data transmission module includes a data acquisition box, a twisted-pair anti-interference shielded cable, a gateway, and a 5G industrial module. The data acquisition box establishes wired communication connections with the S-type thermocouple and the core control module through the twisted-pair anti-interference shielded cable. At the same time, the data acquisition box establishes wireless communication connections with the gateway, the 5G industrial module, and the core control module. The data acquisition box has built-in EMC shielding module, signal filtering and amplification module, analog-to-digital conversion module, and edge preprocessing module. The remote control module and linkage unit are all connected to the core control module via signals.

[0007] Preferably, there are multiple sets of sensing and detection units, and each set of sensing and detection units is arranged in multiple zones according to the temperature measurement area of ​​the aluminum alloy casting furnace bottom. There are multiple data acquisition boxes according to the number of temperature measurement areas of the aluminum alloy casting furnace bottom, and each data acquisition box is connected to all the sensing and detection units of one zone.

[0008] Preferably, the S-type thermocouple is made of platinum-rhodium 10-platinum material, with a temperature measurement range of 0-1300℃ and a temperature measurement accuracy of ±1℃. Under normal operating conditions, the data of one S-type thermocouple is used as the reference, and the data of the other S-type thermocouple is used as the verification. The difference between the two signals is calculated in real time. When the difference is ≤3℃, the temperature measurement deviation is adaptively corrected. When 3℃ < difference ≤5℃, a drift warning is issued and data fusion calculation is started. When the difference is >5℃, it is determined that one S-type thermocouple has failed and the other side is automatically switched to operation within 500ms.

[0009] Preferably, the twisted pair anti-interference shielded cable is equipped with a metal braided shielding mesh, and the metal braided shielding mesh is wrapped with a fluoroplastic sheath. One end of the metal braided shielding mesh is connected to the grounding of the explosion-proof data acquisition box shell, and the other end is connected to the grounding terminal of the core control module.

[0010] Preferably, the remote control module includes a cloud server, which is connected to a visual monitoring platform. The visual monitoring platform has a data storage module and an early warning push module. The cloud server establishes two-way communication with the core control module.

[0011] Preferably, the visual monitoring platform supports dual access from both computer and mobile devices, and features functions such as furnace bottom temperature zone display, sensor status monitoring, historical data backtracking, curve analysis, and remote adjustment of control parameters. The early warning push module pushes early warning information in a tiered manner through three channels: SMS, APP pop-up, and platform pop-up. The two-way communication between the remote monitoring unit and the PLC main control module adopts an encrypted protocol, realizing seamless switching between remote management and local automatic control.

[0012] Preferably, the linkage unit includes an audible and visual alarm and a fault location module. The PLC host is connected to the audible and visual alarm and the fault location module via an expansion I / O module. The fault location module locates the temperature point exceeding the standard in the corresponding temperature measurement zone of the aluminum alloy casting furnace bottom.

[0013] Preferably, the PLC host, data acquisition box, and audible and visual alarm are all installed on the outside of the furnace bottom via heat-insulated protective brackets, 300-500mm away from the outer wall of the furnace bottom refractory layer.

[0014] Preferably, the core control module is connected to the heating control system and aluminum tapping control system of the aluminum alloy melting and casting furnace through the PID temperature control module, and realizes differentiated control based on the temperature measurement data of different zones of the aluminum alloy melting and casting furnace bottom. When the two S-type thermocouple signals in the sensing unit are abnormal, the PLC main control module triggers the warning step by step. If it is not handled within 10 minutes, the furnace cooling program is automatically executed.

[0015] Preferably, the temperature data of the S-type thermocouple is calculated in real time, and invalid data with temperature jumps >20℃ / s are removed. The temperature measurement deviation is automatically corrected based on the furnace bottom ambient temperature and the cumulative working time of the S-type thermocouple to compensate for the influence of high temperature drift. The PLC host locally caches more than 1 year of historical data and uploads it to the cloud server simultaneously, supporting fault tracing, process optimization analysis and control parameter self-iteration.

[0016] The technical effects and advantages of this invention are as follows: In this invention, a redundant dual S-type thermocouple layout, combined with a graded difference judgment and adaptive correction algorithm, ensures the accuracy of the core temperature measurement range of 755-765℃, adapting to the melting and casting effect of molten metal in the preparation of 5-series aluminum alloy casting rods. It also allows for rapid switching to a backup channel when a single thermocouple fails, supporting maintenance and replacement without furnace shutdown, significantly improving temperature measurement continuity and increasing the efficiency of aluminum molten casting. Furthermore, by utilizing a sensor detection unit with differentiated point distribution according to furnace bottom zones, coupled with customized extension depth of the silicon carbide protective sleeve, it adapts to the temperature differences in different zones of the aluminum molten casting furnace, providing data support for differentiated control.

[0017] The data transmission module employs a dual-link design with a wired main link and a 5G wireless backup link, combined with anti-interference measures such as metal shielding and signal filtering, to reduce the packet loss rate of temperature signal transmission and strengthen signal stability. A PID temperature control module enables zoned differentiated power regulation, coupled with edge computing algorithms for invalid data removal and drift compensation, precisely matching the stringent temperature requirements of the 5-series aluminum alloy casting process, effectively reducing aluminum oxidation and gas absorption issues. Through a remote visualization platform, a hierarchical early warning mechanism, and a fault location module, rapid response to abnormal situations is achieved. Seamless switching between local automatic control and remote encrypted management comprehensively improves the reliability, accuracy, and ease of maintenance of furnace bottom temperature monitoring, providing a solid technical guarantee for the optimization of aluminum alloy casting processes and safe production. Attached Figure Description

[0018] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts: Figure 1 This is a schematic diagram of the signal connection structure of the present invention; Figure 2 This is a schematic diagram of the internal module composition of the PLC main unit of the present invention; Figure 3 This is a schematic diagram of the internal module composition of the data acquisition box of the present invention; Figure 4 This is a schematic diagram of the internal module composition of the visualization monitoring platform of the present invention; Figure 5 This is a schematic diagram of the front view structure of the present invention; Figure 6 This is a three-dimensional structural diagram of the sensing and detection unit of the present invention.

[0019] Legend: 1. Core control module; 11. PLC host; 111. Expansion I / O module; 112. PID temperature control module; 113. Redundancy determination module; 114. Adaptive control module; 2. Sensing and detection unit; 21. S-type thermocouple; 3. Data transmission module; 31. Data acquisition box; 311. EMC shielding module; 312. Signal filtering and amplification module; 313. Analog-to-digital conversion module; 314. Edge preprocessing module; 32. Gateway; 33. 5G industrial module; 34. Twisted pair anti-interference shielded cable; 4. Remote control module; 41. Cloud server; 42. Visual monitoring platform; 421. Data storage module; 422. Early warning push module; 5. Linkage unit; 51. Audible and visual alarm; 52. Fault location module; 6. Heating control system; 7. Aluminum output control system; 8. Heat insulation and protection bracket; 9. Silicon carbide protective sleeve; 91. Mounting slot. Detailed Implementation

[0020] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0021] Example: Refer to Figures 1-6 As shown, the present invention provides a technical solution: a remote monitoring and temperature measurement system for the bottom of an aluminum alloy casting furnace, comprising a core control module 1, a sensing and detection unit 2, a data transmission module 3, a remote control module 4, and a linkage unit 5; The core control module 1 includes a PLC host 11. The PLC host 11 is connected to an extended I / O module 111, a PID temperature control module 112, a redundancy determination module 113, and an adaptive control module 114. The PLC host 11 has a built-in edge computing algorithm, which can realize data calculation, fault determination, instruction issuance, and parameter self-iteration through specific formulas. The sensing and detection unit 2 includes a silicon carbide protective sleeve 9. The bottom end of the silicon carbide protective sleeve 9 has two parallel mounting grooves 91. The inner wall of the mounting grooves 91 is coated with high-temperature thermal conductive paste. S-type thermocouples 21 are inserted into the inside of each mounting groove 91. The bottom end of the outer side of the S-type thermocouple 21 is fixedly connected to the bottom end of the inner wall of the mounting groove 91 by external thread and internal spiral screwing. The silicon carbide protective sleeve 9 extends from the outer shell of the aluminum alloy melting and casting furnace bottom. The top of the silicon carbide protective sleeve 9 extends into the refractory layer of the aluminum alloy melting and casting furnace bottom. The temperature measurement height is 180-220mm for the core erosion zone, 150-180mm for the high-temperature working zone, and 120-150mm for the edge low-temperature zone, according to the different temperature measurement zones of the aluminum alloy melting and casting furnace bottom. The data transmission module 3 includes a data acquisition box 31, a twisted-pair anti-interference shielded cable 34, a gateway 32, and a 5G industrial module 33. The data acquisition box 31 establishes wired communication connections with the S-type thermocouple 21 and the core control module 1 through the twisted-pair anti-interference shielded cable 34, which is the main communication link. At the same time, the data acquisition box 31 establishes wireless communication connections with the core control module 1 through the gateway 32, the 5G industrial module 33, and the core control module 1, which is the backup communication link. The data acquisition box 31 has built-in EMC shielding module 311, signal filtering and amplification module 312, analog-to-digital conversion module 313, and edge preprocessing module 314, which can realize signal noise reduction, amplification, digital-to-analog conversion, and preliminary removal of outliers. The remote control module 4 and the linkage unit 5 are both connected to the core control module 1 to achieve coordination between local control and remote management.

[0022] Using the PLC host 11 as the central hub, a redundant design is presented through the temperature signal acquisition of dual S-type thermocouples 21 at a single position. Combined with adaptive correction formulas, the accuracy of temperature data is optimized to clearly define the temperature conditions in different positions of the aluminum alloy casting furnace bottom. This allows it to adapt to the refining and casting needs of molten aluminum during the preparation of 5-series aluminum alloy casting rods, precisely control the casting temperature, and reduce oxidation during the casting process. At the same time, it can automatically switch to the normal S-type thermocouple 21 for temperature measurement based on the temperature difference between the two S-type thermocouples 21, avoiding temperature measurement gaps caused by the failure of a single S-type thermocouple 21. Furthermore, this redundant design allows for the repair and replacement of failed S-type thermocouples 21 without interrupting temperature measurement, improving the continuity of temperature measurement. In addition, the dual-link and anti-interference design of the data transmission module 3 further improves the stability of temperature signal transmission, enhancing the temperature measurement, control, and protection effects of the aluminum alloy casting furnace bottom.

[0023] like Figure 5 As shown: The sensor detection unit 2 is set in multiple groups, each group corresponding to a temperature measurement zone on the furnace bottom, which can be the core erosion zone, the high-temperature working zone, or the edge low-temperature zone. Each group of sensor detection units 2 is arranged in multiple ways according to the temperature measurement zone of the aluminum alloy casting furnace bottom. The core erosion zone is arranged with 8-10 points / m², the high-temperature working zone with 4-6 points / m², and the edge low-temperature zone with 2-3 points / m². The data acquisition box 31 is set in multiple ways according to the number of temperature measurement zones on the aluminum alloy casting furnace bottom. Each data acquisition box 31 is connected to all sensor detection units 2 in one zone. The core erosion zone is equipped with a 16-channel data acquisition box 31, and the other zones are equipped with an 8-channel data acquisition box 31. Each data acquisition box 31 is reserved with an expansion interface, which can add or remove sensor detection units 2 as needed to ensure that the temperature of each zone is within the detection range of 755-765℃.

[0024] like Figure 6As shown: The S-type thermocouple 21 is made of platinum-rhodium 10-platinum material, with a temperature range of 0-1300℃ and a temperature measurement accuracy of ±1℃. Two S-type thermocouple cores are encapsulated in parallel within the same silicon carbide protective sleeve 9, and are connected to two analog input channels of the data acquisition box 31 via independent cables. Under normal operating conditions, the data T1 from one S-type thermocouple 21 is used as the reference, and the data T2 from the other S-type thermocouple 21 is used for verification. The redundant judgment module 113 and the adaptive control module 114 work together to calculate the signal difference ΔT = |T1-T2| between the two S-type thermocouples 21 in real time. When ΔT ≤ 3℃, an adaptive correction formula is used. The temperature measurement deviation is corrected by formula Tα = αT1 + (1-α)T2, where α is the weighting coefficient, α = 0.6, determined based on the thermocouple accuracy calibration; when 3℃ < ΔT ≤ 5℃, the system issues a thermocouple drift warning and simultaneously starts data fusion calculation, the fused temperature Tfusion = (T1 + T2) / 2 + ΔT compensation, where ΔT compensation is a fixed correction value, taken as 0.2℃, based on laboratory calibration; when ΔT > 5℃, the preset reference side S-type thermocouple 21 is determined to be faulty, and the redundant judgment module 113 automatically switches to the other side thermocouple as the reference within 500ms, synchronously marking the fault status and uploading it.

[0025] like Figure 5 As shown: The twisted pair anti-interference shielded cable 34 has a metal braided shielding mesh inside, and the metal braided shielding mesh is wrapped with a fluoroplastic sheath. One end of the metal braided shielding mesh is connected to the grounding of the explosion-proof data acquisition box 31, and the other end is connected to the grounding terminal of the core control module 1. It is specifically designed to resist the low-frequency magnetic field interference generated by the electromagnetic stirrer at the bottom of the melting furnace, ensuring that the packet loss rate of temperature signal transmission in the 755-765℃ range is ≤0.1%.

[0026] like Figure 1 , Figure 4 As shown: The remote control module 4 includes a cloud server 41, which is connected to a visual monitoring platform 42. The visual monitoring platform 42 is equipped with a data storage module 421 and an early warning push module 422. The cloud server 41 and the core control module 1 establish bidirectional communication through a 5G / LoRa link. On the one hand, it receives real-time temperature data, equipment status data and fault information in the 755-765℃ range uploaded by the PLC host 11. On the other hand, it can forward the parameter adjustment, calibration, manual intervention and other instructions issued by the operation and maintenance personnel to the PLC host 11.

[0027] like Figure 1As shown: The visualization monitoring platform 42 supports dual-terminal access on both computers and mobile devices. It features functions such as furnace bottom temperature zone display, sensor status monitoring, historical data backtracking, curve analysis, and remote adjustment of control parameters. The early warning push module 422 pushes early warning information in three channels—SMS, APP pop-up, and platform pop-up—based on risk levels: Level 1: thermocouple drift, Level 2: sensor failure, and Level 3: above 765℃ / below 755℃. The two-way communication between the remote monitoring unit and the PLC main control module adopts the AES encryption protocol, realizing seamless switching between remote management and local automatic control.

[0028] like Figure 1 As shown: The linkage unit 5 includes an audible and visual alarm 51 and a fault location module 52. The PLC host 11 is connected to the audible and visual alarm 51 and the fault location module 52 via an expansion I / O module 111. The fault location module 52 locates the temperature points exceeding the standard in the corresponding temperature measurement zone of the aluminum alloy casting furnace bottom. The fault location module 52 has built-in zone measurement point mapping logic based on the formula L=∑(T i -T standard)², where T i For a single measurement point temperature, T standard = 760℃, quickly locate the temperature point in the corresponding temperature measurement zone that deviates from the 755-765℃ range and the faulty sensor number, and simultaneously mark the location on the visualization platform.

[0029] like Figure 5 As shown: The PLC host 11, data acquisition box 31, and audible and visual alarm 51 are all installed on the outside of the furnace bottom through the heat-insulating protective bracket 8, 300-500mm away from the outer wall of the furnace bottom refractory layer. The twisted pair anti-interference shielded cable 34 can be laid along the bracket and protected by the metal cable tray to avoid the impact of high temperature radiation and vibration on the operation of the equipment and ensure stable temperature monitoring in the range of 755-765℃.

[0030] like Figure 2 As shown: The core control module 1 is connected to the heating control system 6 and the aluminum tapping control system 7 of the aluminum alloy casting furnace via the PID temperature control module 112, and achieves differentiated regulation based on the temperature measurement data of different zones at the bottom of the aluminum alloy casting furnace. The PID control formula here is: u(t)=Kp[e(t)+(1 / T)] i )∫e(t)dt+T d [(de / dt)], where u(t) is the output control quantity, i.e., the heating power adjustment value, Kp is the proportional coefficient, e(t) = Tactual - TStandard, where TStandard = 760℃, Tactual is the corrected average temperature of the zone, T i Let T be the integration time constant. dThe time constant is the differential; the specific control logic is as follows: when the temperature in the core erosion zone exceeds 765℃, the heating power of the corresponding area is reduced by 2% for every 1℃ of over-temperature; when the temperature is below 755℃, the heating power is increased, with an additional 1.5% increase for every 1℃ of low temperature; when the signals of the two S-type thermocouples 21 in the sensing unit 2 are abnormal, the PLC main control module triggers warnings step by step. If the problem is not resolved within 10 minutes, the furnace gradient cooling program is automatically executed to minimize safety risks.

[0031] like Figure 1 , Figure 3 As shown: Real-time calculations are performed on the temperature data of the S-type thermocouple 21. Here, the edge computing algorithm built into the PLC host 11 is used for calculation, eliminating invalid data with temperature jumps > 20℃ / s. The temperature measurement deviation is automatically corrected based on the furnace bottom ambient temperature and the cumulative working time of the S-type thermocouple 21. The jump determination formula is ΔT / Δt > 20℃ / s, where Δt is the sampling interval, taken as 0.1s. Simultaneously, based on the furnace bottom ambient temperature Tring, acquired by the built-in sensor in the data acquisition box 31, and the cumulative working time t of the S-type thermocouple 21, the temperature measurement deviation is automatically corrected using a high-temperature drift compensation formula. The drift compensation formula is: T_correction = T_measured - K × t × (T_ring - 25℃); where K is the drift coefficient, taken as 0.0003℃ / (h·℃), based on the high-temperature characteristics calibration of the S-type thermocouple 21, and 25℃ is the standard ambient temperature; the PLC locally caches more than 1 year of historical data and synchronously uploads it to the cloud server 41, supporting fault tracing, process optimization analysis and control parameter self-iteration, where the iteration logic is Kn+1 = Kn + 0.00005 × (T_correction - T_actual), ensuring compensation accuracy and adapting to different melting and casting conditions in the 755-765℃ range.

[0032] Working Principle: For the manufacturing process of 5-series aluminum alloy casting rods, a specialized casting furnace is used during the aluminum molten casting stage. Due to the easy oxidation and gas absorption characteristics of aluminum, precise control of the casting temperature is required. The refining temperature, between 755-765°C, requires stirring. Temperature control at this stage is crucial to the purity of the aluminum molten metal. The S-type thermocouple 21 in the sensing unit 2 collects the temperature signal of the refractory layer at the bottom of the aluminum alloy casting furnace. The temperature signal is output as a mV-level voltage signal and transmitted to the data acquisition box 31 via a twisted-pair anti-interference shielded cable 34. The voltage signal is received, filtered, amplified, and converted from analog to digital, after which invalid data is removed. The signal is then preferentially transmitted to the PLC main control module via the wired main link (twisted-pair anti-interference shielded cable 34). In case of wired link failure, it automatically switches to a wireless backup link, i.e., via a 5G industrial mode. In the block conveying process, the PLC main control module performs redundancy judgment and adaptive compensation calculation on the received data. If the temperature is in the range of 755-765℃, the current process parameters are maintained. If the temperature exceeds the threshold, the heating power adjustment value is calculated by the PID formula, and the process parameters are adjusted in conjunction with the melting furnace heating control system 6 and the aluminum tapping control system 7. The PLC host 11 uploads real-time data and equipment status to the cloud server 41 and displays the data through the visualization monitoring platform 42. In case of abnormality, early warning information is pushed according to the corresponding first, second and third levels. Among them, maintenance personnel can remotely issue instructions to adjust system parameters. At the same time, the fault location module 52 locks the abnormal location, and the audible and visual alarm 51 is activated to warn. Maintenance personnel can directly replace the S-type thermocouple 21 without shutting down the furnace through the silicon carbide protective sleeve 9 preset at the bottom of the furnace.

[0033] The technical scope of this invention is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the protection scope of this invention.

Claims

1. A remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace, characterized in that, It includes a core control module, a sensing and detection unit, a data transmission module, a remote control module, and a linkage unit; The core control module includes a PLC host, which is signal-connected to an extended I / O module, a PID temperature control module, a redundancy determination module, and an adaptive control module. The sensing and detection unit includes a silicon carbide protective sleeve. Two parallel mounting slots are opened at the bottom of the silicon carbide protective sleeve. An S-type thermocouple is inserted into the inside of each mounting slot. The bottom of the outer side of the S-type thermocouple is fixedly connected to the bottom of the inner wall of the mounting slot by an external thread and an internal spiral screw. The silicon carbide protective sleeve extends from the outer shell of the aluminum alloy casting furnace bottom and the top of the silicon carbide protective sleeve extends into the refractory layer of the aluminum alloy casting furnace bottom. The data transmission module includes a data acquisition box, a twisted-pair anti-interference shielded cable, a gateway, and a 5G industrial module. The data acquisition box establishes wired communication connections with the S-type thermocouple and the core control module through the twisted-pair anti-interference shielded cable. At the same time, the data acquisition box establishes wireless communication connections with the gateway, the 5G industrial module, and the core control module. The data acquisition box has a built-in EMC shielding module, a signal filtering and amplification module, an analog-to-digital conversion module, and an edge preprocessing module. The remote control module and linkage unit are both signal-connected to the core control module.

2. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 1, characterized in that: The sensing and detection unit is configured in multiple groups, and each group of sensing and detection units is arranged in multiple sections according to the temperature measurement zone of the aluminum alloy casting furnace bottom. The data acquisition box is configured in multiple sections according to the number of temperature measurement zones of the aluminum alloy casting furnace bottom, and each data acquisition box is connected to all the sensing and detection units of one section.

3. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 1, characterized in that: The S-type thermocouple is made of platinum-rhodium 10-platinum material, with a temperature range of 0-1300℃ and a temperature measurement accuracy of ±1℃. Under normal operating conditions, the data of one S-type thermocouple is used as the reference, and the data of the other S-type thermocouple is used as the verification. The difference between the two signals is calculated in real time. When the difference is ≤3℃, the temperature measurement deviation is adaptively corrected. When 3℃ < difference ≤5℃, a drift warning is issued and data fusion calculation is started. When the difference is >5℃, it is determined that one S-type thermocouple has failed and the other side is automatically switched to operation within 500ms.

4. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 1, characterized in that: The twisted pair anti-interference shielded cable is equipped with a metal braided shielding mesh, and the metal braided shielding mesh is wrapped with a fluoroplastic sheath. One end of the metal braided shielding mesh is connected to the grounding of the explosion-proof data acquisition box shell, and the other end is connected to the grounding terminal of the core control module.

5. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 1, characterized in that: The remote control module includes a cloud server, which is connected to a visual monitoring platform. The visual monitoring platform is equipped with a data storage module and an early warning push module. The cloud server establishes bidirectional communication with the core control module.

6. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 5, characterized in that: The visualization monitoring platform supports access from both computer and mobile devices, and features functions such as furnace bottom temperature zone display, sensor status monitoring, historical data backtracking, curve analysis, and remote adjustment of control parameters. The early warning push module pushes early warning information in a tiered manner through three channels: SMS, APP pop-up, and platform pop-up. The two-way communication between the remote monitoring unit and the PLC main control module adopts an encrypted protocol, enabling seamless switching between remote management and local automatic control.

7. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 1, characterized in that: The linkage unit includes an audible and visual alarm and a fault location module. The PLC host is connected to the audible and visual alarm and the fault location module via an expansion I / O module. The fault location module locates the temperature point exceeding the standard in the corresponding temperature measurement zone of the aluminum alloy casting furnace bottom.

8. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 7, characterized in that: The PLC host, data acquisition box, and audible and visual alarm are all installed on the outside of the furnace bottom via heat-insulated protective brackets, 300-500mm away from the outer wall of the furnace bottom refractory layer.

9. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 1, characterized in that: The core control module is connected to the heating control system and aluminum tapping control system of the aluminum alloy melting furnace through the PID temperature control module. It achieves differentiated control based on the temperature measurement data of different zones of the aluminum alloy melting furnace bottom. When the two S-type thermocouple signals in the sensing unit are abnormal, the PLC main control module triggers the warning step by step. If it is not handled within 10 minutes, the furnace cooling program is automatically executed.

10. The remote monitoring and temperature measurement system for the bottom of an aluminum alloy melting and casting furnace according to claim 9, characterized in that: The temperature data of the S-type thermocouple is calculated in real time, and invalid data with temperature jumps >20℃ / s are removed. The temperature measurement deviation is automatically corrected based on the furnace bottom ambient temperature and the cumulative working time of the S-type thermocouple to compensate for the influence of high temperature drift. The PLC host locally caches more than 1 year of historical data and uploads it to the cloud server simultaneously, supporting fault tracing, process optimization analysis and control parameter self-iteration.

Images