Automatic Fault Detection Device for Surface Mount Varistors Sintering Furnaces
An automatic fault detection device that monitors sintering furnace parameters in real time and uses a PLC controller for fault logic analysis solves the problem of low efficiency in traditional detection methods, achieves accurate fault identification and improves system reliability, and ensures equipment safety and remote response.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- RUDONG BAOLIAN ELECTRONIC TECH CO LTD
- Filing Date
- 2025-06-26
- Publication Date
- 2026-05-26
AI Technical Summary
Traditional gas pressure sintering furnace fault detection requires shutting down the furnace and checking each component one by one, which is inefficient and makes it difficult for maintenance personnel to accurately identify the cause of the fault. It also cannot meet the needs of multiple sintering furnaces working simultaneously.
The system employs a signal acquisition module to monitor sintering furnace parameters in real time, utilizes a PLC controller for fault logic analysis, combines a backup power supply module to ensure stable system operation, and implements automatic fault detection and alarm through a multi-channel alarm module and a remote notification module.
It enables real-time and accurate fault identification of sintering furnaces, improves fault detection efficiency and system reliability, ensures that the device can still work normally when the main power is cut off, facilitates timely remote response and equipment safety.
Smart Images
Figure CN224285493U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of ceramic membrane production technology, and in particular to an automatic fault detection device for a chip varistor sintering furnace. Background Technology
[0002] A pneumatic pressure sintering furnace is a device used for sintering mineral powders. It uses high temperature and high pressure to bond mineral particles together to form a solid substance. The principle of a pneumatic pressure sintering furnace is to use high temperature and high pressure to promote the bonding between mineral particles. During the sintering process, thermal and chemical energy are input into the mineral particles, causing their surfaces to melt and recrystallize, ultimately forming a solid material. If a malfunction occurs during the operation of a pneumatic pressure sintering furnace, it will lead to poor final crystallization results. Therefore, fault detection has a significant impact on the operation of the pneumatic pressure sintering furnace. However, traditional fault detection methods require shutting down the furnace and checking each component individually, resulting in poor detection efficiency.
[0003] Chinese patent CN117168630B discloses a fault detection method and system for a pressure sintering furnace, relating to the field of fault detection technology. The method includes: obtaining a sequence of thermal images of the heating area in a first time zone; receiving desired temperature information for the first time zone; obtaining a first temperature anomaly area and a first temperature healthy area; performing temperature fluctuation analysis on the first temperature healthy area to generate a temperature fluctuation coefficient; generating a second temperature anomaly area when the temperature fluctuation coefficient is greater than or equal to a temperature fluctuation coefficient threshold; and marking the temperature control components in the first and second temperature anomaly areas with faults, sending the results to the pressure sintering furnace control terminal. This method solves the technical problem of traditional fault detection requiring shutdown and component-by-component troubleshooting, which results in poor detection efficiency. By performing temperature deviation analysis on the pressure sintering furnace and providing fault-marked temperature control components for troubleshooting, the method achieves the technical effect of improving fault detection efficiency.
[0004] Existing fault detection methods for sintering furnaces rely solely on detecting temperature anomalies. However, there are many causes of temperature anomalies, and maintenance personnel cannot accurately identify the specific cause of the fault. Furthermore, after transmitting the fault cause to the control terminal, staff need to physically go to the corresponding location to investigate the cause of the fault. This results in low fault diagnosis efficiency and cannot meet the needs of multiple sintering furnaces operating simultaneously. Utility Model Content
[0005] In order to overcome the problems existing in the prior art, this application provides an automatic fault detection device for chip varistor sintering furnace.
[0006] The automatic fault detection device for surface mount varistor sintering furnace provided in this application adopts the following technical solution:
[0007] An automatic fault detection device for a surface-mount varistor sintering furnace includes a signal acquisition module, a PLC controller, and an alarm module. The signal acquisition module includes a sensor group connected to the furnace body, which collects real-time operating parameters of the sintering furnace. The sensor group includes temperature, voltage, current, gas flow, and pressure sensors. The input terminal of the PLC controller is connected to the output terminal of the signal acquisition module to receive sensor signals. The PLC controller has an internal data processing unit configured to analyze the sensor signals based on preset fault logic and generate fault judgment results. The output terminal of the PLC controller is connected to the alarm module. The alarm module includes a communication unit and a voice alarm unit. A backup power supply module is also included, connected to the PLC controller and the alarm module, to provide power when the main power supply is interrupted.
[0008] By adopting the above technical solution, the sensor group in the signal acquisition module, including temperature, voltage, current, gas flow, and pressure sensors, collects parameters such as temperature, voltage, current, gas flow, and pressure in real time during the operation of the sintering furnace. The collected sensor signals are then transmitted to the PLC controller. After receiving the signals at the input end of the PLC controller, its internal data processing unit analyzes the sensor signals based on preset fault logic to generate a fault judgment result. The output end of the PLC controller transmits the fault judgment result to the alarm module, which then issues an alarm through the communication unit and voice alarm unit. In addition, a backup power supply module is connected to the PLC controller and the alarm module to provide power when the main power is cut off, ensuring the continuous operation of the fault detection device.
[0009] Preferably, the alarm module is a multi-channel cyclic alarm host, including: a communication sub-module with a built-in SIM card slot, a voice alarm sub-module with an integrated voice chip, and a dry contact alarm input interface for receiving signals from the PLC controller.
[0010] Preferably, the multi-channel cyclic alarm host is connected to the remote notification module via a data bus, and the remote notification module includes a mobile terminal or a monitoring center server.
[0011] Preferably, the communication submodule supports at least two protocols from SMS, voice calls, and mobile data networks.
[0012] By adopting the above technical solution, the sensor group of the signal acquisition module collects the operating parameters of the sintering furnace in real time and transmits the data to the PLC controller. Its data processing unit analyzes the signal according to the preset fault logic and generates a fault judgment result. When a fault is determined, the PLC controller transmits the signal to the multi-channel cyclic alarm host through the dry contact alarm input interface. The communication submodule in the host uses the built-in SIM card slot to send the fault information to the mobile terminal of the remote notification module or the monitoring center server using at least two protocols such as SMS, voice call or mobile data network. At the same time, the voice alarm submodule uses the integrated voice chip to perform voice alarm. The multi-channel cyclic alarm host also maintains data interaction with the remote notification module through the data bus.
[0013] Preferably, the backup power module includes: a main power monitoring unit connected to the sintering furnace power supply line to detect the power status; a lithium battery pack; and a switching control unit configured to automatically switch to the lithium battery pack for power supply when the main power fails.
[0014] By adopting the above technical solution, the main power monitoring unit of the backup power module monitors the power status of the sintering furnace power supply line in real time. Once the main power fails, the switching control unit automatically switches the power supply to the lithium battery pack to continuously power the PLC controller and alarm module, ensuring that the fault detection, alarm and data transmission process can still be carried out stably when the main power is abnormal.
[0015] Preferably, the fault logic executed by the data processing unit includes: comparing real-time sensor data with a preset threshold range, and triggering a primary alarm if the range is exceeded; performing trend analysis on sensor data within a continuous time window, and triggering a secondary alarm if the slope is abnormal, wherein the primary alarm and the secondary alarm are output to the alarm module via the PLC controller.
[0016] By adopting the above technical solution, the data processing unit in the PLC controller executes fault logic. First, it compares the real-time sensor data with the preset threshold range. Once the data exceeds the range, a primary alarm is triggered. At the same time, it performs trend analysis on the sensor data within the continuous time window. If the slope of the data change is abnormal, a secondary alarm is triggered. The primary alarm and secondary alarm signals are output to the multi-channel cyclic alarm host through the PLC controller.
[0017] Preferably, it also includes a human-machine interaction module, which includes a touch screen display for real-time display of sensor data, alarm records and fault diagnosis information.
[0018] By adopting the above technical solution, the touch screen display of the human-machine interaction module presents sensor data, alarm records and fault diagnosis information in real time, which makes it convenient for operators to intuitively understand the operating status and fault conditions of the sintering furnace and realize timely information interaction and feedback.
[0019] Preferably, it also includes an emergency braking module, comprising a safety valve installed on the sintering furnace power line and an inert gas supply pipe connecting to the sintering furnace cavity.
[0020] By adopting the above technical solution, when a serious fault is detected, the emergency braking module responds quickly. The safety valve installed on the power supply line of the sintering furnace immediately cuts off the power supply, and at the same time, it connects the inert gas supply pipeline in the sintering furnace cavity to transport inert gas into the furnace, quickly reducing the reactive reaction conditions in the furnace, avoiding dangerous situations, and ensuring the safety of the sintering furnace and the surrounding environment.
[0021] In summary, this application includes at least one of the following beneficial technical effects:
[0022] 1. This application utilizes a patch varistor sintering furnace automatic fault detection device to collect the operating parameters of the sintering furnace in real time through multiple sensors, which can comprehensively and accurately monitor the working status of the sintering furnace, overcoming the limitations of existing technologies that rely solely on temperature detection, and enabling maintenance personnel to more accurately identify the cause of the fault.
[0023] 2. The data processing unit of this application analyzes the sensor signals based on preset fault logic, can generate fault judgment results in a timely manner, and issue an alarm through the alarm module. At the same time, the backup power module can ensure that the device can still work normally when the main power is cut off, thus improving the reliability and stability of the system.
[0024] 3. This application, through the setting of a multi-channel cyclic alarm host and remote notification module, facilitates staff to receive fault information in a timely manner, enabling rapid response. The touch screen display of the human-machine interaction module can display relevant information in real time, helping staff to understand the equipment operation status and improve the efficiency of fault diagnosis. Attached Figure Description
[0025] Figure 1 This is a schematic diagram of the module structure of an automatic fault detection device for a surface mount varistor sintering furnace. Detailed Implementation
[0026] The following is in conjunction with the appendix Figure 1 This application will be described in further detail.
[0027] This application discloses an automatic fault detection device for a chip varistor sintering furnace.
[0028] Reference Figure 1An automatic fault detection device for a surface-mount varistor sintering furnace includes a signal acquisition module, a PLC controller, and an alarm module. The signal acquisition module includes a sensor group connected to the furnace body, which collects real-time operating parameters of the sintering furnace. The sensor group includes a temperature sensor, a voltage sensor, a current sensor, a gas flow sensor, and a pressure sensor. The input terminal of the PLC controller is connected to the output terminal of the signal acquisition module to receive sensor signals. The PLC controller has an internal data processing unit configured to analyze the sensor signals based on preset fault logic and generate fault judgment results. The output terminal of the PLC controller is connected to the alarm module. The alarm module includes a communication unit and a voice alarm unit. A backup power supply module is also included, connected to the PLC controller and the alarm module, to provide power when the main power supply is cut off. The signal acquisition module includes sensor groups such as temperature, voltage, current, gas flow, and pressure sensors, which collect parameters such as temperature, voltage, current, gas flow, and pressure in real time during the operation of the sintering furnace. The acquired sensor signals are transmitted to the PLC controller. After receiving the signals at its input, the PLC controller's internal data processing unit analyzes the sensor signals based on preset fault logic to generate a fault diagnosis result. The PLC controller's output transmits the fault diagnosis result to the alarm module, which then issues an alarm via a communication unit and a voice alarm unit. Furthermore, a backup power supply module is connected to the PLC controller and the alarm module, providing power when the main power is cut off to ensure the continuous operation of the fault detection device.
[0029] Reference Figure 1 The alarm module is a multi-channel cyclic alarm host, including: a communication submodule with a built-in SIM card slot, a voice alarm submodule with an integrated voice chip, and a dry contact alarm input interface for receiving signals from the PLC controller. The multi-channel cyclic alarm host is connected to a remote notification module via a data bus. The remote notification module includes a mobile terminal or a monitoring center server. The communication submodule supports both SMS and voice call protocols. The sensor group of the signal acquisition module collects the operating parameters of the sintering furnace in real time and transmits the data to the PLC controller. Its data processing unit analyzes the signals according to preset fault logic and generates fault judgment results. When a fault is detected, the PLC controller transmits the signal to the multi-channel cyclic alarm host through the dry contact alarm input interface. The communication submodule within the host, using the built-in SIM card slot, sends the fault information to the mobile terminal of the remote notification module via SMS and voice call. Simultaneously, the voice alarm submodule uses an integrated voice chip to provide voice alarms. The multi-channel cyclic alarm host also maintains data interaction with the remote notification module via the data bus.
[0030] Reference Figure 1The backup power module includes: a main power monitoring unit, connected to the sintering furnace power supply line to detect power status; a lithium battery pack; and a switching control unit, configured to automatically switch to lithium battery power supply when the main power supply fails. The main power monitoring unit of the backup power module monitors the power status of the sintering furnace power supply line in real time. Once the main power supply fails, the switching control unit automatically switches power to the lithium battery pack, providing continuous power to the PLC controller and alarm module, ensuring stable fault detection, alarm, and data transmission processes even when the main power supply is abnormal.
[0031] Reference Figure 1 The fault logic executed by the data processing unit includes: comparing real-time sensor data with a preset threshold range; triggering a primary alarm if the data exceeds the range; and performing trend analysis on sensor data within a continuous time window; triggering a secondary alarm if the slope of the data change is abnormal. Both the primary and secondary alarms are output to the alarm module via the PLC controller. The data processing unit within the PLC controller executes the fault logic by first comparing real-time sensor data with a preset threshold range; triggering a primary alarm if the data exceeds the range. Simultaneously, it performs trend analysis on sensor data within a continuous time window; triggering a secondary alarm if the slope of the data change is abnormal. Both the primary and secondary alarm signals are output to the multi-channel cyclic alarm host via the PLC controller.
[0032] Reference Figure 1 It also includes a human-machine interface (HMI) module, which includes a touchscreen display for real-time display of sensor data, alarm records, and fault diagnosis information. The touchscreen display of the HMI module presents sensor data, alarm records, and fault diagnosis information in real time, allowing operators to intuitively understand the operating status and fault conditions of the sintering furnace, and enabling timely information interaction and feedback.
[0033] Reference Figure 1 It also includes an emergency braking module, comprising a safety valve installed on the sintering furnace power line and an inert gas supply pipe connecting to the sintering furnace cavity. When a serious fault is detected, the emergency braking module responds quickly. The safety valve on the sintering furnace power line immediately cuts off the power supply, and at the same time, the inert gas supply pipe connecting to the sintering furnace cavity supplies inert gas into the furnace, rapidly reducing the reactive conditions inside the furnace, preventing dangerous situations, and ensuring the safety of the sintering furnace and its surrounding environment.
[0034] Working Principle: The sensor group in the signal acquisition module is connected to the sintering furnace body. Temperature, voltage, current, gas flow, and pressure sensors collect various operating parameters of the sintering furnace in real time. These parameter signals are transmitted to the input terminal of the PLC controller. The data processing unit within the PLC controller processes the sensor signals according to preset fault logic. First, the real-time sensor data is compared with a preset threshold range. If it exceeds the range, a primary alarm is triggered. Then, trend analysis is performed on the sensor data within a continuous time window. If the slope is abnormal, a secondary alarm is triggered. The primary and secondary alarm signals are output to alarm module 1 via the PLC controller. The multi-channel cyclic alarm host in the alarm module receives signals through the dry contact alarm input interface, uses the communication submodule for SMS and voice calls, and the voice alarm submodule to issue alarms. It can also transmit information to the mobile terminal in the remote notification module via the data bus. Simultaneously, the touch screen display of the human-machine interface module displays sensor data, alarm records, and fault diagnosis information in real time for easy viewing by staff. The backup power module's main power monitoring unit monitors the power status of the sintering furnace's power supply line. When the main power fails, the switching control unit automatically switches to the lithium battery pack to power the PLC controller and alarm module. In case of an emergency, the emergency braking module's safety valve will cut off the sintering furnace's power line, and the inert gas supply pipeline will introduce inert gas into the sintering furnace cavity to ensure the safety of equipment and personnel.
[0035] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. An automatic fault detection device for a surface mount varistor sintering furnace, characterized in that: Includes a signal acquisition module, a PLC controller, and an alarm module; The signal acquisition module includes a sensor group connected to the sintering furnace body. The sensor group collects the operating parameters of the sintering furnace in real time, and includes a temperature sensor, a voltage sensor, a current sensor, a gas flow sensor, and a pressure sensor. The input terminal of the PLC controller is connected to the output terminal of the signal acquisition module to receive sensor signals. It has a data processing unit inside, which is configured to analyze the sensor signals based on preset fault logic and generate fault judgment results. The output of the PLC controller is connected to the alarm module. The alarm module includes a communication unit and a voice alarm unit; It also includes a backup power module, which is connected to the PLC controller and the alarm module and is used to supply power when the main power is cut off.
2. The automatic fault detection device for surface mount varistors sintering furnace according to claim 1, characterized in that: The alarm module is a multi-channel cyclic alarm host, including: a communication sub-module with a built-in SIM card slot, a voice alarm sub-module with an integrated voice chip, and a dry contact alarm input interface for receiving signals from the PLC controller.
3. The automatic fault detection device for surface mount varistors sintering furnace according to claim 2, characterized in that: The multi-channel cyclic alarm host is connected to the remote notification module via a data bus. The remote notification module includes a mobile terminal or a monitoring center server.
4. The automatic fault detection device for surface mount varistors sintering furnace according to claim 2, characterized in that: The communication submodule supports at least two protocols from SMS, voice calls, and mobile data networks.
5. The automatic fault detection device for surface mount varistors sintering furnace according to claim 1, characterized in that: The backup power module includes: The main power monitoring unit is connected to the sintering furnace power supply line to detect the power status. Lithium battery pack; The switching control unit is configured to automatically switch to the lithium battery pack for power supply when the main power supply fails.
6. The automatic fault detection device for surface mount varistors sintering furnace according to claim 1, characterized in that: The fault logic executed by the data processing unit includes: comparing real-time sensor data with a preset threshold range; if the range is exceeded, a primary alarm is triggered; performing trend analysis on sensor data within a continuous time window; if the slope is abnormal, a secondary alarm is triggered, wherein the primary alarm and the secondary alarm are output to the alarm module via the PLC controller.
7. The automatic fault detection device for surface mount varistors sintering furnace according to claim 1, characterized in that: It also includes a human-machine interaction module, which includes a touch screen display for real-time display of sensor data, alarm records and fault diagnosis information.
8. The automatic fault detection device for surface mount varistors sintering furnace according to claim 1, characterized in that: It also includes an emergency braking module, which includes a safety valve installed on the sintering furnace power line and an inert gas supply pipe connecting to the sintering furnace cavity.