CN105624374A - Air cushion type quenching system and automatic control system - Google Patents
Air cushion type quenching system and automatic control system Download PDFInfo
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- CN105624374A CN105624374A CN201610080833.2A CN201610080833A CN105624374A CN 105624374 A CN105624374 A CN 105624374A CN 201610080833 A CN201610080833 A CN 201610080833A CN 105624374 A CN105624374 A CN 105624374A
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/62—Quenching devices
- C21D1/667—Quenching devices for spray quenching
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/56—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering characterised by the quenching agents
- C21D1/613—Gases; Liquefied or solidified normally gaseous material
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D11/00—Process control or regulation for heat treatments
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Abstract
The invention discloses an air cushion type quenching system and an automatic control system. The air cushion type quenching system comprises an air cushion heating device and an air cushion type quenching device. Materials enter the air cushion heating device through a first conveying component to be heated, then enters the air cushion type quenching device to be quenched, and finally are conveyed out of the air cushion type quenching system through a second conveying component. A sensing component is further arranged at the front end of the air cushion heating device and can sense the materials. The air cushion type quenching device comprises an upper blowing unit, a lower blowing unit and a recognition unit. By the adoption of the air cushion type quenching system and the automatic control system, the intelligence of the production process of the air cushion type quenching device is achieved, the intelligence of the air cushion type quenching device and automatic vibration suppression control over the materials are achieved, and efficient and high-value production of the air cushion type quenching device is guaranteed.
Description
Technical field
The present invention relates to heat treatment process automatic control technology field, particularly relate to a kind of air-cushion type quenching system and automatic control system thereof.
Background technology
The feature that air-cushion type quenching unit has production process complexity, design difficulty is high and automation process control difficulty is big. Current air-cushion type quenching unit is monopolized by external several big companies, domestic is not yet successfully applied in industry spot by air-cushion type quenching unit. The production process of air-cushion type quenching unit relates to the complicated coupling process between fluid mass, solid area and temperature field. Pass key control and forecast parameter in inlet gas cushion quenching apparatus production process frequently rely upon artificial setting, manual intervention and manual record, affect quality and the technology stability of air-cushion type quenching product, limiting the operation that air-cushion type quenching unit is efficient and stable, therefore the Based Intelligent Control of air-cushion type quenching unit is a key issue of restriction air-cushion type quenching unit.
In process of production, in air-cushion type quenching unit, material easily produces vibration, when vibrating violent, can cause that material contacts with the wall of upper and lower nozzle and is scratched, and results even in material fracture time serious. And the temperature accuracy in heat treatment process is required higher by aluminium alloy, the vibration amplitude making material is the premise condition that material reaches to set technological temperature in rational scope. Gu but the heat treatment coupling process of material relates to stream--temperature THM coupling process, therefore, the suppression function of material vibrating is an important prerequisite normally producing of air-cushion type quenching unit and key difficulties by quenching equipment.
Summary of the invention
The purpose of this part is in that some aspects of general introduction embodiments of the invention and briefly introduces some preferred embodiments. Make a summary in this part and the description of the present application and denomination of invention may be done a little simplification or omit to avoid making the purpose of this part, specification digest and denomination of invention to obscure, and this simplification or omission cannot be used for restriction the scope of the present invention.
In view of Problems existing in the system that above-mentioned and/or existing air-cushion type quenching system and system that described air-cushion type is quenched automatically control, it is proposed that the present invention.
Therefore, one of them purpose of the present invention is to provide a kind of system that material can carry out air-cushion type quenching.
For solving above-mentioned technical problem, the present invention provides following technical scheme: a kind of air-cushion type quenching system, including air cushion heater and air-cushion type quenching unit, material enters heating in described air cushion heater by the first transfer unit, then enter quenching in described air-cushion type quenching unit, finally transferring out described air-cushion type quenching system through the second transfer unit, described air cushion heater front end is additionally provided with sensing element, and described material can be sensed by described sensing element; Described air-cushion type quenching unit includes blasting unit, lower blasting unit and recognition unit, wherein, described upper blasting unit includes air-return duct, upper air blast parts, upper blast channel and upper injecting-unit, cold air is by upper air-return duct, flow through air blast parts, it is admitted in blast channel, finally spouting by upper injecting-unit, formed and once go up the circulation of cold air in blasting unit; Described lower blasting unit includes lower air-return duct, lower air blast parts, lower blast channel and lower injecting-unit, cold air is by lower air-return duct, flow through lower air blast parts, it is admitted in lower blast channel, final spouting by lower injecting-unit, form the upper and lower surface of material described in the cool air impingement once descending the circulation of cold air in blasting unit, described upper injecting-unit and described lower injecting-unit to eject, make material suspended aloft, thus being cooled to desired technological temperature; And, recognition unit is arranged in described air-cushion type quenching unit, it is possible to identifies material suspended state and hoverheight in described air-cushion type quenching unit, detects the floating state of described material.
A kind of preferred version of system of quenching as air-cushion type of the present invention, wherein: described upper injecting-unit includes, upper shell, it is arranged at the upper accommodating groove in described upper shell, it is arranged at the upper load cell of described upper shell front end and difformity and percent opening is different, it is thus possible to flow of cooled air to be produced the multiple upper homogenizing plate of impact, during normal operation, according to the force value set, adjust the operating position in the upper homogenizing plate extremely described upper shell meeting this force value, if the cold air flows of described upper injecting-unit changes, described upper load cell measures pressure oscillation and pressure loss beyond setting value, then the upper homogenizing plate of the corresponding force value in described upper accommodating groove is adjusted to operating position, and the original place upper homogenizing plate in operating position is played back in upper accommodating groove, thus adjusting the undulating value of pressure in described upper injecting-unit and pressure loss in the scope set.
A kind of preferred version of system of quenching as air-cushion type of the present invention, wherein: described lower injecting-unit includes, lower house, it is arranged at the lower accommodating groove in described lower house, it is arranged at the lower load cell of described lower house front end and difformity and percent opening is different, it is thus possible to flow of cooled air to be produced the multiple lower homogenizing plate of impact, during normal operation, according to the force value set, adjust the operating position in the lower homogenizing plate extremely described lower house meeting this force value, if the cold air flows of described lower injecting-unit changes, described lower load cell measures pressure oscillation and pressure loss beyond setting value, then the lower homogenizing plate of the corresponding force value in described lower accommodating groove is adjusted to operating position, and the original place lower homogenizing plate in operating position is played back in lower accommodating groove, thus adjusting the undulating value of pressure in described lower injecting-unit and pressure loss in the scope set.
It is a further object to provide a kind of air-cushion type quenching automatic control system, this system is capable of the Automated condtrol to air-cushion type quenching system.
For solving above-mentioned technical problem, the present invention provides following technical scheme: a kind of air-cushion type quenching automatic control system, it includes, data acquisition module, picture recognition module, PLC controls and communication module, process control module, interface module and optimizing forecast module, wherein, data collecting module collected is by upper load cell or lower load cell force value everywhere in the described air-cushion type quenching unit that interior load cell measures, and gather in the described air cushion heater measured by temperature element temperature value everywhere, and feed back to described PLC control and communication module, the recognition unit that picture recognition module is passed through measures material amount of deflection, and feeds back to described process control module, PLC controls and force value and the temperature value of acquisition are fed back to described process control module by communication module, the described force value obtained, temperature value and material amount of deflection are fed back in described interface module and optimizing forecast module by process control module, carry out interactive operation respectively and obtain the technological parameter optimized.
A kind of preferred version as air-cushion type of the present invention quenching automatic control system, wherein: also include DBM, described process control module can extract the type of material from DBM, composition, model parameter and default value, and be sent to described optimizing forecast module, described optimizing forecast module includes temperature prediction model, amount of deflection forecasting model, energy consumption model and Optimized model, described Optimized model starts the technological parameter that output optimizes, temperature prediction model subsequently, amount of deflection forecasting model and energy consumption model start to predict the temperature of material, amount of deflection predictive value and power consumption values, then Optimized model is according to the output technological parameter of actual measured value correction Optimized model, until the Optimizing Process Parameters that provides of Optimized model that the temperature prediction model of material and the temperature forecast value of amount of deflection forecasting model and amount of deflection predicted value can be made to meet the energy consumption of actual production demand and energy consumption model is minimum, namely the technological parameter of optimization is obtained.
A kind of preferred version as air-cushion type of the present invention quenching automatic control system, wherein: described process control module includes process control unit, jitter suppression controller and safety interlocking unit, described process control module is able to receive that described interface module and the feedback of optimizing forecast module, and described picture recognition module and PLC is controlled and communication module sends instruction.
As air-cushion type of the present invention quench automatic control system a kind of preferred version, wherein: described process control unit include pressure controller, temperature controller, tension force and speed control and, become spray box actuator; Wherein, described pressure controller input variable is pressure divergence and pressure divergence rate of change, pressure is divided into high pressure, middle pressure and three sections of intervals of low pressure by it, and different pressures interval uses different upper homogenizing plates or lower homogenizing plate, so that the pressure in air-cushion type quenching unit reaches setting value; Described temperature controller for control to temperature, when the temperature of air-cushion type quenching unit higher or lower than uniform temperature time, regulate heater, increase or reduce heating power, make the temperature of heated air increase or reduce; Described tension force and speed control, according to the technological parameter set, adjust the first transfer unit or the converter of the second transfer unit, make material be in rational tension force and velocity interval; And, described change spray box actuator is for being adjusted described upper homogenizing plate or lower homogenizing plate.
A kind of preferred version as air-cushion type of the present invention quenching automatic control system, wherein: described jitter suppression controller is in order to adjust the shake of material, when the floating state of material is stable or Oscillation Amplitude is less, jitter suppression controller does not work, when material carries out low amplitude vibrations, jitter suppression controller starts to regulate the pressure in air-cushion type quenching unit by described pressure controller and described tension force and speed control, the tension force of the first transfer unit or the second transfer unit and speed, reduce the dither amplitude of material, until the vibration of material returns to the amplitude that can accept of setting, when the vibration amplitude of material is bigger, first described change spray box actuator adjusts homogenizing plate or lower homogenizing plate, the tension force of the pressure, the first transfer unit or the second transfer unit that then start again through described pressure controller and described tension force and speed control to regulate in air-cushion type quenching unit and speed, until the vibration amplitude of material is returned to the degree that can accept of setting.
A kind of preferred version as air-cushion type of the present invention quenching automatic control system; wherein: the safety of described safety interlocking cell protection equipment work process and equipment running process; avoid causing great production accident or equipment badly damaged; when on upper air blast parts or lower air blast component speed, heater power, material tension force, material speed, adjustment, homogenizing plate or lower homogenizing plate process influence are to the safe operation of equipment; trigger and report to the police; certain operations in restriction production process, or directly shut down.
A kind of preferred version as air-cushion type of the present invention quenching automatic control system, wherein: also include self-learning module, when low amplitude vibrations occurs in described air-cushion type quenching automatic control system time, the technical process control parameter that Optimized model output adaptive adjusts, the execution equipment controlling workshop level mechanical floor performs corresponding control action, so that the operational factor of equipment meets process goal, after the technological parameter that the output of described Optimized model optimizes, the vibrational state of equipment Inspection material, detected value is fed back in optimizing forecast module, thus revising the parameter of optimizing forecast module, make optimizing forecast module in the process of self study, improve the effect optimizing and forecasting.
Beneficial effects of the present invention: the present invention proposes a kind of air-cushion type quenching system and automatic control system, this system takes into full account current big data and technology of Internet of things, realize the intellectuality of air-cushion type quenching unit production process, the intellectuality and the material automatization that realize air-cushion type quenching unit press down control of shaking, it is ensured that air-cushion type quenching unit is efficient, the production of high level.
Accompanying drawing explanation
In order to be illustrated more clearly that the technical scheme of the embodiment of the present invention, below the accompanying drawing used required during embodiment is described is briefly described, apparently, accompanying drawing in the following describes is only some embodiments of the present invention, for those of ordinary skill in the art, under the premise not paying creative work, it is also possible to obtain other accompanying drawing according to these accompanying drawings. Wherein:
Fig. 1 is the overall structure schematic diagram of the quenching system of air-cushion type described in one embodiment of the invention;
Fig. 2 is the structural representation of upper injecting-unit described in embodiment illustrated in fig. 1 of the present invention;
Fig. 3 is the structural representation of lower injecting-unit described in embodiment illustrated in fig. 1 of the present invention.
Fig. 4 is the structural representation of the quenching automatic control system of air-cushion type described in one embodiment of the invention;
Fig. 5 is each model How It Works schematic diagram in process control module described in embodiment illustrated in fig. 4 of the present invention;
Fig. 6 is the structural representation of interface module described in embodiment illustrated in fig. 4 of the present invention;
Fig. 7 is the structural representation of process control module described in embodiment illustrated in fig. 4 of the present invention.
Detailed description of the invention
Understandable for enabling the above-mentioned purpose of the present invention, feature and advantage to become apparent from, below in conjunction with Figure of description, the specific embodiment of the present invention is described in detail.
Elaborate a lot of detail in the following description so that fully understanding the present invention, but the present invention can also adopt other to be different from alternate manner described here to be implemented, those skilled in the art can do similar popularization when without prejudice to intension of the present invention, and therefore the present invention is not by the restriction of following public specific embodiment.
Secondly, " embodiment " or " embodiment " referred to herein refers to the special characteristic, structure or the characteristic that may be included at least one implementation of the present invention. Different local in this manual " in one embodiment " occurred not refer both to same embodiment, neither be independent or selective and that other embodiments are mutually exclusive embodiment.
Fig. 1 illustrates the overall structure schematic diagram of air-cushion type quenching system in one embodiment of the invention. In figure, air-cushion type quenching system includes air cushion heater 100 and air-cushion type quenching unit 200, material is entered in air cushion heater 100 by the first transfer unit 100 ' and is heated, then enter in air-cushion type quenching unit 200 and quench, finally transfer out air-cushion type quenching system through the second transfer unit 200 ', air cushion heater 100 front end is additionally provided with sensing element 101, and material can be sensed by sensing element 101, it is determined that the position that material carries out; And air-cushion type quenching unit 200 includes blasting unit 201, lower blasting unit 202 and recognition unit 203, wherein, upper blasting unit 201 includes air-return duct 201a, upper air blast parts 201b, upper blast channel 201c and upper injecting-unit 201d, cold air is by upper air-return duct 201a, flow through air blast parts 201b, it is admitted in blast channel 201c, finally spouting by upper injecting-unit 201d, form the circulation of the cold air once gone up in blasting unit 201; Lower blasting unit 202 includes lower air-return duct 202a, lower air blast parts 202b, lower blast channel 202c and lower injecting-unit 202d, cold air is by lower air-return duct 202a, flow through lower air blast parts 202b, it is admitted in lower blast channel 202c, final spouting by lower injecting-unit 202d, form the circulation of the cold air once descended in blasting unit 202, in this embodiment, the upper and lower surface of the cool air impingement material that upper injecting-unit 201d and lower injecting-unit 202d ejects, make material suspended aloft, thus being cooled to desired technological temperature. Recognition unit 203 is arranged in air-cushion type quenching unit 200, it is possible to identifies suspended state and the hoverheight of material in air-cushion type quenching unit 200, detects the floating state of material.
Preferably, as shown in Figure 2, upper injecting-unit 201d includes, upper shell 201d-1, it is arranged at the upper accommodating groove 201d-2 in upper shell 201d-1, it is arranged at the upper load cell 201d-3 of upper shell 201d-1 front end and difformity and percent opening is different, it is thus possible to flow of cooled air to be produced the multiple upper homogenizing plate 201d-4 of impact, during normal operation, according to the force value set, adjust the operating position in the upper homogenizing plate 201d-4 to upper shell 201d-1 meeting this force value, if the cold air flows of upper injecting-unit 201d changes, upper load cell 201d-3 measures pressure oscillation and pressure loss beyond setting value, then the upper homogenizing plate 201d-4 of the corresponding force value in upper accommodating groove 201d-2 is adjusted to operating position, and original place is played back in upper accommodating groove 201d-2 in the upper homogenizing plate 201d-4 of operating position, thus adjusting the undulating value going up pressure in injecting-unit 201d and pressure loss in the scope set.
Lower injecting-unit 202d is arranged on below injecting-unit 201d, it is possible to the general layout that upper injecting-unit 201d forms relative injection. herein, lower injecting-unit 202d includes, lower house 202d-1, it is arranged at the lower accommodating groove 202d-2 in lower house 202d-1, it is arranged at the lower load cell 202d-3 of lower house 202d-1 front end and difformity and percent opening is different, it is thus possible to flow of cooled air to be produced the multiple lower homogenizing plate 202d-4 of impact, during normal operation, according to the force value set, adjust the operating position in the lower homogenizing plate 202d-4 to lower house 202d-1 meeting this force value, if the cold air flows of lower injecting-unit 202d changes, lower load cell 202d-3 measures pressure oscillation and pressure loss beyond setting value, then the lower homogenizing plate 202d-4 of the corresponding force value in lower accommodating groove 202d-2 is adjusted to operating position, and original place is played back in lower accommodating groove 202d-2 in the lower homogenizing plate 202d-4 of operating position, thus adjusting the undulating value of pressure in lower injecting-unit 202d and pressure loss in the scope of setting.
Fig. 4 illustrates the structural representation of air-cushion type quenching automatic control system in one embodiment of the invention. Referring to Fig. 4, air-cushion type quenching automatic control system includes and can gather by upper load cell 201d-3 or lower load cell 202d-3 force value everywhere in the air-cushion type quenching unit 200 that interior load cell 301 measures, and temperature value everywhere can be gathered in the air cushion heater 100 measured by temperature element 302, and feed back to the data acquisition module (300) of PLC control and communication module 500; Measure material amount of deflection by recognition unit 203, and feed back to the picture recognition module 400 of process control module 600; The PLC that the force value of acquisition and temperature value feed back to process control module 600 controls and communication module 500; And, the force value of acquisition, temperature value and material amount of deflection are fed back in interface module 700 and optimizing forecast module 800, carry out interactive operation respectively and obtain the process control module 600 of the technological parameter optimized.
Specifically, interface module 700 charge of overseeing production process or carry out manufacturing parameter setting. The interface module 700 of operating room is operated by room man-machine interaction industrial computer charge of overseeing production process or carries out manufacturing parameter setting, the optimizing forecast module 800 of operating room is responsible for setting and the Optimum Operation of operator, in another embodiment, also there is the standby industrial computer of operating room, in order to Emergency use when going wrong at other industrial computers of operating room, the operator of operating room are operated by room remote console and carry out production operation. The standby industrial computer of electric panel room is to use when other industrial computers of electric panel room go wrong, the optimizing forecast module 800 of electric panel room is that electric panel room personnel use when model parameter or program are debugged, and the interface module 700 of electric panel room is that electric personnel carry out man machine interface and write use when monitor with electric state. Interface module 700 can realize the functions such as process setting, process monitoring, warning and state setting. Referring to Fig. 6, process setting includes: the desired temperature of each heat-treatment zone, and the safety interlocking state of each thermal treatment unit sets (the chain setting of temperature, pressure interlock setting, the chain setting of pressure oscillation etc.), the first transfer unit 100 ' or the hypertension setting value of the second transfer unit 200 ', material pace setting value, becomes the homogenizing plate setting of spray box, the design of pressure of injecting-unit, air-cushion type quenching unit 200 design of pressure, the heter temperature setting value of each thermal treatment unit, air temperature settings value; Process detection includes: the temperature of each heat-treatment zone, the safety interlocking state of each thermal treatment unit (temperature is chain, pressure interlock, pressure oscillation are chain), the first transfer unit 100 ' or the hypertension value of the second transfer unit 200 ', material pace process values, becomes spray box orifice plate, injecting-unit press process value, air-cushion type quenching unit 200 press process value, the heter temperature process values of each thermal treatment unit, gas temperature process values; Warning function includes alarm indicator and alarm logging (air-cushion type quenching unit 200 pressure alarm, temperature alarming, pressure oscillation warning, tension force warning, threading acceleration alert, instrument air pressure alarm, fault alarm); State set-up function, the function such as including automatization/manual switching.
PLC controls and communication module 500 is the communication for realizing between workshop level supervision layer and mechanical floor and control. Picture recognition module 400 can collection site material vibrating signal. Actuator includes becoming spray box actuator, air bleed valve, furnace pressure adjustment valve etc., execute-in-place action can be performed, the adjustment of the upper homogenizing plate 201d-4 in injecting-unit 201d or lower injecting-unit 202d or lower homogenizing plate 202d-4 in realization, the control action in the production process such as the action of air bleed valve and air-cushion type quenching unit 200 pressure. Safe spacing refers to that the limit switch, the alarm device that arrange to protect equipment safety in production process are the equipment of output alarm signal when occurring affecting equipment security situation in production process.
Referring to Fig. 5, in this embodiment, air-cushion type quenching automatic control system also includes DBM, accept production process information (such as: the special circumstances remark information in yield, name of product, product specification, Product Process parameter, product quantity and production process), production process information is stored in DBM by ODBC mode by enterprise-level server, and this DBM can realize the functions such as the amendment of production process information, increase, timing renewal, deletion, inquiry, historical record. enterprise process production information is sent to workshop level based on ICP/IP protocol by switch and monitors in layer. meanwhile, physical parameter data cell (material composition, convection transfer rate, specific heat), production information data cell (stock number, name of material, material performance, yield), process pre-set parameter and process values, the setting value of process control parameters unit and process values, process state variables process values, safety interlocking state, warning message. DBM have recorded real time information and the historical information of above-mentioned variable, it is possible to realizes the function such as information and the increase of data, amendment, deletion and inquiry. process control module 600 can extract the type of material from DBM, composition, model parameter and default value, and be sent to optimizing forecast module 800, optimizing forecast module 800 includes temperature prediction model 801, amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804, Optimized model 804 starts the technological parameter that output optimizes, temperature prediction model 801 subsequently, amount of deflection forecasting model 802 and energy consumption model 803 start to predict the temperature of material, amount of deflection predictive value and power consumption values, then Optimized model 804 is according to the output technological parameter of actual measured value correction Optimized model 804, until the Optimizing Process Parameters that provides of Optimized model 804 that the temperature prediction model 801 of material and the temperature forecast value of amount of deflection forecasting model 802 and amount of deflection predicted value can be made to meet the energy consumption of actual production demand and energy consumption model 803 is minimum, namely the technological parameter of optimization is obtained.
Specifically, the work process of temperature prediction model 801 is: first, based on the physical parameter of the process control data of air-cushion type quenching unit 200 and material, according to two dimensional unsteady heat transfer mechanism principle, it was predicted that the temperature of material in air-cushion type quenching unit. Then the thermometer collection of air-cushion type quenching unit 200 end is come out of the stove the temperature of material, obtain the difference between material surface measured value and the predicted value of temperature prediction model 801, automatization's Integrated Algorithm is finally utilized to set up air-cushion type hardening heat intelligent compensation model, with the error between compensatory michanism model predication value and measured value.
The work process of amount of deflection forecasting model 802 is, first, sets up material amount of deflection forecasting model 802 according to beam conservation equation and wall jet theory, predicts the deflection value of material under material steady statue and vibrational state respectively. Secondly, picture recognition module 400 gathers material Floating Height image, being sent in the image pick-up card of optimization, forecast and Controlling model industrial computer by optical fiber, then image is filtered by the image processing software of industrial computer, Floating Height and the floating state of material are not descended in denoising, correction, extraction in the same time. Thus obtaining material Floating Height and material floating state. Obtaining the difference between material amount of deflection measured value and material amount of deflection predicted value, finally employing automatization neural network algorithm sets up the error amount of the amount of deflection forecasting model 802 of material, thus setting up the amount of deflection forecasting model 802 of material.
Energy consumption model 803 is based on test data and instrumented data matching energy consumption model 803 out at ordinary times, it is possible to forecast the information such as energy consumption and energy consumption cost when this explained hereafter. Optimized model 804 Kernel-based methods controls the predictive value of the predictive value of temperature of charge forecasting model 801 of module 600, amount of deflection forecasting model 802, energy consumption model 803, optimize the technological parameter (tension force, threading speed, heating-up temperature etc.) of air-cushion type quenching process, export a technological parameter optimized.
In one embodiment, temperature prediction model 801, amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804 are read by ODBC mode and store data, temperature prediction model 801, amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804 are sent by message each other and transmit data, workshop level monitors by TCP/IP communication between layer and workshop level mechanical floor, and picture recognition module 400 is by coaxial cable and process control module 600 communication.
In another embodiment, referring to Fig. 7, process control module 600 includes process control unit 601, jitter suppression controller 602 and safety interlocking unit 603, process control module 600 is able to receive that interface module 700 and the feedback of optimizing forecast module 800, and described picture recognition module 400 and PLC is controlled and communication module 500 sends instruction. Process control module 600 ensure that whole self-regulating process has good dynamic characteristic, guarantee equipment is in safe operation interval at the state-variable of dynamic adjustment phase, and when ensureing system stability, target process parameter can accurately reach processing parameter setting value. Wherein, process control unit 601 include pressure controller 601a, temperature controller 601b, tension force and speed control 601c and, become spray box actuator 601d; Wherein, pressure controller 601a input variable is pressure divergence and pressure divergence rate of change, pressure is divided into high pressure, middle pressure and three sections of intervals of low pressure by it, different pressures interval uses different upper homogenizing plate 201d-4 or lower homogenizing plate 202d-4, so that the pressure in air-cushion type quenching unit 200 reaches setting value.
Temperature controller 601b for control to temperature, when the temperature of air-cushion type quenching unit 200 higher or lower than uniform temperature time, regulate heater, increase or reduce heating power, make the temperature of heated air increase or reduce; Tension force and speed control 601c, according to the technological parameter set, adjust the first transfer unit 100 ' or the converter of the second transfer unit 200 ', make material be in rational tension force and velocity interval; And, become spray box actuator 601d and be adjusted with to upper homogenizing plate 201d-4 or lower homogenizing plate 202d-4.
Jitter suppression controller 602 is in order to adjust the shake of material, when the floating state of material is stable or during Oscillation Amplitude less (being approximately steady statue), jitter suppression controller 602 does not work, when material carries out low amplitude vibrations, jitter suppression controller 602 starts to regulate the pressure in air-cushion type quenching unit 200 by described pressure controller 601a and tension force and speed control 601c, the tension force of the first transfer unit 100 ' or the second transfer unit 200 ' and speed, reduce the dither amplitude of material, until the vibration of material returns to the amplitude that can accept of setting, when the vibration amplitude of material is bigger, become spray box actuator 601d and first adjust homogenizing plate 201d-4 or lower homogenizing plate 202d-4, the tension force of the pressure, the first transfer unit 100 ' or the second transfer unit 200 ' that then start again through pressure controller 601a and tension force and speed control 601c to regulate in air-cushion type quenching unit 200 and speed, until the vibration amplitude of material is returned to the degree that can accept of setting.
Safety interlocking unit 603 protects the safety of equipment work process and equipment running process; avoid causing great production accident or equipment badly damaged; when on upper air blast parts 201b or lower air blast parts 202b (in this collectively blower fan) rotating speed, heater power, material tension force, material speed, adjustment, homogenizing plate 201d-4 or lower homogenizing plate 202d-4 process influence are to the safe operation of equipment; trigger and report to the police; certain operations in restriction production process, or directly shut down.
In one embodiment, air-cushion type quenching automatic control system also includes self-learning module, when low amplitude vibrations occurs in described air-cushion type quenching automatic control system time, the technical process control parameter that Optimized model 804 output adaptive adjusts, the execution equipment controlling workshop level mechanical floor performs corresponding control action, so that the operational factor of equipment meets process goal, after the technological parameter that Optimized model 804 output optimizes, the vibrational state of equipment Inspection material, detected value is fed back in optimizing forecast module 800, thus revising the parameter of optimizing forecast module 800, make optimizing forecast module 800 in the process of self study, improve the effect optimizing and forecasting.
Embodiment 1
For air-cushion type quench automatic control system material vibrating less time control process:
Step 1: load cell 301 gathers air outlet pressure, air inlet pressure, upper injecting-unit 201d or lower injecting-unit 202d pressure and air-cushion type quenching unit 200 pressure. Temperature element 302 gathers the temperature signal of the temperature of air-cushion type quenching unit 200, upper injecting-unit 201d or lower injecting-unit 202d. The signal of load cell 301 and temperature element 302 is sent to PLC control and communication module 500 by Modbus agreement, then picture recognition module 400 gathers material amount of deflection image and is sent to process control module 600, then controlled state signal is sent to interface module 700 and shows by process control module 600, and optimizing forecast module 800 status signal is sent to amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804.
Step 2: optimizing forecast module 800 extracts the material type of material, alloying component, model parameter and default value from DBM. And it is sent to temperature prediction model 801, amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804. Optimized model 804 starts the technological parameter that output optimizes, then temperature prediction model 801, material amount of deflection forecasting model 802 and energy consumption model start to predict the temperature of material, amount of deflection predictive value and power consumption values, then Optimized model 804 is according to the output technological parameter of actual measured value correction Optimized model, until the Optimizing Process Parameters that provides of Optimized model 804 that the temperature prediction model 801 of material and the temperature forecast value of amount of deflection forecasting model 802 and amount of deflection predicted value can be made to meet the energy consumption of actual production demand and energy consumption model 803 is minimum, namely obtain the technological parameter of optimization.
Step 3: by MODBUS agreement, optimal procedure parameters is exported workshop level mechanical floor, process control unit 601 controls output signal (Stress control output signal, tension force control output signal and speed control signal) according to target process data. Pressure control procedure is exported the control signal converter to upper air blast parts 201b or lower air blast parts 202b by PLC control and communication module 500, the converter of upper air blast parts 201b or lower air blast parts 202b is with the rotating speed of air blast parts 201b in suitable up regulation or lower air blast parts 202b, to ensure that pressure steadily and accurately reaches the setting value of pressure. Tension force and speed controlling, exported the control signal converter to the first transfer unit 100 ' or the second transfer unit 200 ' by PLC control and communication module 500, in converter, current signal carried out clipping operation, thus steadily adjusting tension force or rate signal.
Step 4: after each state-variable is stable, repeats step 1 and step 2, revises the Optimizing Process Parameters of optimizing forecast module 800, is then performing above-mentioned steps 3, makes the whole heat treatment process of system reach to optimize.
Embodiment 2
For air-cushion type quench automatic control system material vibrating less time control process:
Step 1: load cell 301 gathers air outlet pressure, air inlet pressure, upper injecting-unit 201d or lower injecting-unit 202d pressure and air-cushion type quenching unit 200 pressure. Temperature element 302 gathers air-cushion type quenching unit 200 temperature, upper injecting-unit 201d or lower injecting-unit 202d temperature signal. The signal of load cell 301 and temperature element 302 is sent to PLC control and communication module 500 by Modbus agreement, then picture recognition module 400 gathers material amount of deflection image and is sent to process control module 600, then controlled state signal is sent to interface module 700 and shows by process control module 600, and optimizing forecast module 800 status signal is sent to amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804. And pressure transducer measures the force value in upper injecting-unit 201d or lower injecting-unit 202d, being sent in optimizing forecast module 800, PLC controls and communication module 500 goes out upper injecting-unit 201d or lower injecting-unit 202d pressure loss, upper injecting-unit 201d or lower injecting-unit 202d pressure oscillation situation according to the numerical computations of pressure signal.
Step 2: optimizing forecast module 800 extracts the material type of material, alloying component, model parameter and default value from DBM. and it is sent to temperature prediction model 801, amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804. Optimized model 804 starts the technological parameter that output optimizes, temperature prediction model 801 subsequently, material amount of deflection forecasting model 802 and energy consumption model 803 start to predict the temperature of material, amount of deflection predictive value and power consumption values, then Optimized model 804 is according to the output technological parameter of actual measured value correction Optimized model 804, until the Optimizing Process Parameters that provides of Optimized model 804 that the temperature prediction model 801 of material and the temperature forecast value of amount of deflection forecasting model 802 and amount of deflection predicted value can be made to meet the energy consumption of actual production demand and energy consumption model 803 is minimum, namely the technological parameter of optimization is obtained.
Step 3: by MODBUS agreement, optimal procedure parameters is exported workshop level mechanical floor, process control unit 601 controls output signal (Stress control output signal, tension force control output signal and speed control signal) according to target process data. Pressure control procedure is exported the control signal converter to upper air blast parts 201b or lower air blast parts 202b by PLC control and communication module 500, the converter of upper air blast parts 201b or lower air blast parts 202b is with suitable up regulation rotation speed of fan, to ensure that pressure steadily and accurately reaches the setting value of pressure. Tension force and speed controlling, exported the control signal converter to the first transfer unit 100 ' or the second transfer unit 200 ' by PLC control and communication module 500, in converter, current signal carried out clipping operation, thus steadily adjusting tension force or rate signal. Upper injecting-unit 201d or lower injecting-unit 202d is according to the control instruction becoming spray box actuator 601d, carry out rotating control to the upper homogenizing plate 201d-4 or lower homogenizing plate 202d-4 of a upper duty, a upper upper homogenizing plate 201d-4 or lower homogenizing plate 202d-4 is turned in its corresponding upper accommodating groove 201d-2 or lower accommodating groove 202d-2. Then the upper homogenizing plate 201d-4 that will open according to control instruction or lower homogenizing plate 202d-4 opens in accommodating groove 201d-2 or lower accommodating groove 202d-2 corresponding, the pressure loss in injecting-unit 201d or lower injecting-unit 202d and flow distribution in change.
Step 4: after each state-variable is stable, repeats step 1 and step 2, revises the Optimizing Process Parameters of optimizing forecast module 800, is then performing above-mentioned steps 3, makes the whole heat treatment process of system reach to optimize.
It should be noted that, above example is only in order to illustrate technical scheme and unrestricted, although the present invention being described in detail with reference to preferred embodiment, it will be understood by those within the art that, technical scheme can be modified or equivalent replacement, without deviating from the spirit and scope of technical solution of the present invention, it all should be encompassed in the middle of scope of the presently claimed invention.
Claims (10)
1. an air-cushion type quenching system, including air cushion heater (100) and air-cushion type quenching unit (200), material enters heating in described air cushion heater (100) by the first transfer unit (100 '), then enter quenching in described air-cushion type quenching unit (200), finally transfer out described air-cushion type quenching system through the second transfer unit (200 '), it is characterised in that:
Described air cushion heater (100) front end is additionally provided with sensing element (101), and described material can be sensed by described sensing element (101);
Described air-cushion type quenching unit (200) includes blasting unit (201), lower blasting unit (202) and recognition unit (203), wherein,
Described upper blasting unit (201) includes air-return duct (201a), upper air blast parts (201b), upper blast channel (201c) and upper injecting-unit (201d), cold air is by upper air-return duct (201a), flow through air blast parts (201b), it is admitted in blast channel (201c), final spouting by upper injecting-unit (201d), form the circulation once going up blasting unit (201) interior cold air;
Described lower blasting unit (202) includes lower air-return duct (202a), lower air blast parts (202b), lower blast channel (202c) and lower injecting-unit (202d), cold air is by lower air-return duct (202a), flow through lower air blast parts (202b), it is admitted in lower blast channel (202c), final spouting by lower injecting-unit (202d), form the circulation once descending blasting unit (202) interior cold air, the upper and lower surface of material described in the cool air impingement that described upper injecting-unit (201d) and described lower injecting-unit (202d) eject, make material suspended aloft, thus being cooled to desired technological temperature, and,
Recognition unit (203) is arranged in described air-cushion type quenching unit (200), it is possible to identifies material suspended state and hoverheight in described air-cushion type quenching unit (200), detects the floating state of described material.
2. air-cushion type quenching system as claimed in claim 1, it is characterized in that: described upper injecting-unit (201d) includes, upper shell (201d-1), it is arranged at the upper accommodating groove (201d-2) in described upper shell (201d-1), it is arranged at the upper load cell (201d-3) of described upper shell (201d-1) front end and difformity and percent opening is different, it is thus possible to flow of cooled air to be produced the multiple upper homogenizing plate (201d-4) of impact, during normal operation, according to the force value set, adjust the operating position in upper homogenizing plate (201d-4) the extremely described upper shell (201d-1) meeting this force value, if the cold air flows of described upper injecting-unit (201d) changes, described upper load cell (201d-3) measures pressure oscillation and pressure loss beyond setting value, then the upper homogenizing plate (201d-4) of the corresponding force value in described upper accommodating groove (201d-2) is adjusted to operating position, and the original place upper homogenizing plate (201d-4) in operating position is played back in upper accommodating groove (201d-2), thus adjusting the undulating value of the interior pressure of described upper injecting-unit (201d) and pressure loss in the scope set.
3. air-cushion type quenching system as claimed in claim 1 or 2, it is characterized in that: described lower injecting-unit (202d) includes, lower house (202d-1), it is arranged at the lower accommodating groove (202d-2) in described lower house (202d-1), it is arranged at the lower load cell (202d-3) of described lower house (202d-1) front end and difformity and percent opening is different, it is thus possible to flow of cooled air to be produced the multiple lower homogenizing plate (202d-4) of impact, during normal operation, according to the force value set, adjust the operating position in lower homogenizing plate (202d-4) the extremely described lower house (202d-1) meeting this force value, if the cold air flows of described lower injecting-unit (202d) changes, described lower load cell (202d-3) measures pressure oscillation and pressure loss beyond setting value, then the lower homogenizing plate (202d-4) of the corresponding force value in described lower accommodating groove (202d-2) is adjusted to operating position, and the original place lower homogenizing plate (202d-4) in operating position is played back in lower accommodating groove (202d-2), thus adjusting the undulating value of the interior pressure of described lower injecting-unit (202d) and pressure loss in the scope set.
4. an air-cushion type quenching automatic control system, it is characterized in that: include, data acquisition module (300), picture recognition module (400), PLC control and communication module (500), process control module (600), interface module (700) and optimizing forecast module (800), wherein
Data acquisition module (300) gathers by including going up as claimed in claim 3 in the described air-cushion type quenching unit (200) that the load cell (301) of load cell (201d-3) or lower load cell (202d-3) measures force value everywhere, and gather in the described air cushion heater (100) measured by temperature element (302) temperature value everywhere, and feed back to described PLC and control and communication module (500);
Picture recognition module (400) measures material amount of deflection by recognition unit as claimed in claim 1 (203), and feeds back to described process control module (600);
PLC controls and force value and the temperature value of acquisition are fed back to described process control module (600) by communication module (500);
The described force value obtained, temperature value and material amount of deflection are fed back in described interface module (700) and optimizing forecast module (800) by process control module (600), carry out interactive operation respectively and obtain the technological parameter optimized.
5. air-cushion type quenching automatic control system as claimed in claim 4, it is characterized in that: also include DBM, described process control module (600) can extract the type of material from DBM, composition, model parameter and default value, and be sent to described optimizing forecast module (800), described optimizing forecast module (800) includes temperature prediction model (801), amount of deflection forecasting model (802), energy consumption model (803) and Optimized model (804), described Optimized model (804) starts the technological parameter that output optimizes, temperature prediction model (801) subsequently, amount of deflection forecasting model (802) and energy consumption model (803) start to predict the temperature of material, amount of deflection predictive value and power consumption values, then Optimized model (804) is according to the output technological parameter of actual measured value correction Optimized model (804), until the Optimizing Process Parameters that provides of Optimized model (804) that the temperature prediction model (801) of material and the temperature forecast value of amount of deflection forecasting model (802) and amount of deflection predicted value can be made to meet the energy consumption of actual production demand and energy consumption model (803) is minimum, namely the technological parameter of optimization is obtained.
6. the air-cushion type quenching automatic control system as described in claim 4 or 5, it is characterized in that: described process control module (600) includes process control unit (601), jitter suppression controller (602) and safety interlocking unit (603), described process control module (600) is able to receive that described interface module (700) and the feedback of optimizing forecast module (800), and described picture recognition module (400) and PLC is controlled and communication module (500) sends instruction.
7. air-cushion type quenching automatic control system as claimed in claim 6, it is characterized in that: described process control unit (601) include pressure controller (601a), temperature controller (601b), tension force and speed control (601c) and, become spray box actuator (601d); Wherein,
Described pressure controller (601a) input variable is pressure divergence and pressure divergence rate of change, pressure is divided into high pressure, middle pressure and three sections of intervals of low pressure by it, different pressures interval uses different as claimed in claim 3 upper homogenizing plates (201d-4) or lower homogenizing plate (202d-4), so that the pressure in air-cushion type quenching unit (200) reaches setting value;
Described temperature controller (601b) is for the control to temperature, when the temperature of air-cushion type quenching unit (200) higher or lower than uniform temperature time, regulate heater, increase or reduce heating power, make the temperature of heated air increase or reduce;
Described tension force and speed control (601c), according to the technological parameter set, adjust the first transfer unit (100 ') or the converter of the second transfer unit (200 '), make material be in rational tension force and velocity interval; And,
Described change spray box actuator (601d) is for being adjusted described upper homogenizing plate (201d-4) or lower homogenizing plate (202d-4).
8. air-cushion type quenching automatic control system as claimed in claim 7, it is characterized in that: described jitter suppression controller (602) is in order to adjust the shake of material, when the floating state of material is stable or Oscillation Amplitude is less, jitter suppression controller (602) does not work, when material carries out low amplitude vibrations, jitter suppression controller (602) starts to regulate the pressure in air-cushion type quenching unit (200) by described pressure controller (601a) and described tension force and speed control (601c), the tension force of the first transfer unit (100 ') or the second transfer unit (200 ') and speed, reduce the dither amplitude of material, until the vibration of material returns to the amplitude that can accept of setting,
When the vibration amplitude of material is bigger, described change spray box actuator (601d) first adjusts homogenizing plate (201d-4) or lower homogenizing plate (202d-4), the tension force of the pressure, the first transfer unit (100 ') or the second transfer unit (200 ') that then start again through described pressure controller (601a) and described tension force and speed control (601c) to regulate in air-cushion type quenching unit (200) and speed, until the vibration amplitude of material is returned to the degree that can accept of setting.
9. air-cushion type quenching automatic control system as claimed in claim 7 or 8, it is characterized in that: the safety of described safety interlocking unit (603) protection equipment work process and equipment running process, avoid causing great production accident or equipment badly damaged, when upper air blast parts (201b) or lower air blast parts (202b) rotating speed, heater power, material tension force, material speed, when in adjustment, homogenizing plate (201d-4) or lower homogenizing plate (202d-4) process influence are to the safe operation of equipment, trigger and report to the police, certain operations in restriction production process, or directly shut down.
10. air-cushion type quenching automatic control system as claimed in claim 5, it is characterized in that: also include self-learning module, when low amplitude vibrations occurs in described air-cushion type quenching automatic control system time, the technical process control parameter that Optimized model (804) output adaptive adjusts, the execution equipment controlling workshop level mechanical floor performs corresponding control action, so that the operational factor of equipment meets process goal, after the technological parameter that described Optimized model (804) output optimizes, the vibrational state of equipment Inspection material, detected value is fed back in optimizing forecast module (800), thus revising the parameter of optimizing forecast module (800), make optimizing forecast module (800) in the process of self study, improve the effect optimizing and forecasting.
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| CN110669912A (en) * | 2019-10-18 | 2020-01-10 | 甘肃酒钢集团宏兴钢铁股份有限公司 | Operation method of nitrogen interlocking control system of hot galvanizing vertical annealing furnace |
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