CN105624374B - A kind of air-cushion type quenching system and automatic control system - Google Patents
A kind of air-cushion type quenching system and automatic control system Download PDFInfo
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- CN105624374B CN105624374B CN201610080833.2A CN201610080833A CN105624374B CN 105624374 B CN105624374 B CN 105624374B CN 201610080833 A CN201610080833 A CN 201610080833A CN 105624374 B CN105624374 B CN 105624374B
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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
Abstract
The invention discloses a kind of air-cushion type quenching system and automatic control system, wherein, a kind of air-cushion type quenches system, including air cushion heater and air-cushion type quenching unit, material is entered in the air cushion heater by the first transfer unit to be heated, and is then entered in the air-cushion type quenching unit and is quenched, and finally transferring out the air-cushion type through the second transfer unit quenches system, the air cushion heater front end is additionally provided with sensing element, and the sensing element can sense to the material；The air-cushion type quenching unit includes upper blasting unit, lower blasting unit and recognition unit.The present invention realizes the intellectuality of air-cushion type quenching unit production process, realizes the intellectuality and material automation vibration suppression control of air-cushion type quenching unit, it is ensured that air-cushion type quenching unit is efficient, the production of high level.
Description
Technical field
The present invention relates to heat treatment process automatic control technology field, more particularly to a kind of air-cushion type quenching system and its
Automatic control system.
Background technology
Air-cushion type quenching unit has the spy that production process is complicated, design difficulty is high and automation process control difficulty is big
Point.Current air-cushion type quenching unit is monopolized by external several big companies, and the country is not yet by air-cushion type quenching unit successful Application
In industry spot.The production process of air-cushion type quenching unit is related to the complexity between fluid mass, solid area and temperature field
Coupling process.Crucial control and forecast parameter in import air-cushion type quenching apparatus production process frequently rely upon artificial setting, people
Work is intervened and manual record, the quality and technology stability of influence air-cushion type quenching product, limits air-cushion type quenching unit high
Effect and stable operation, therefore the Based Intelligent Control of air-cushion type quenching unit is that a key for restricting air-cushion type quenching unit is asked
Topic.
In process of production, material easily produces vibration in air-cushion type quenching unit, when vibrating violent, can cause material with
The wall of nozzle is contacted and is scratched up and down, and material fracture is resulted even in when serious.And aluminium alloy is in heat treatment process
Temperature accuracy require it is higher, the vibration amplitude for making material be in rational scope material reach setting technological temperature one
Individual premise condition.But Gu the heat treatment coupling process of material is related to stream-- temperature THM coupling process, therefore, quenching dress
The standby suppression function to material vibrating is the important prerequisite and key difficulties that air-cushion type quenching unit is normally produced.
The content of the invention
The purpose of this part is to summarize some aspects of embodiments of the invention and briefly introduce some preferably to implement
Example.It may do a little simplified or be omitted to avoid making our department in this part and the description of the present application summary and denomination of invention
Point, the purpose of specification digest and denomination of invention obscure, and this simplification or omit and cannot be used for limiting the scope of the present invention.
In view of above-mentioned and/or existing air-cushion type quenches system and quenches what system was automatically controlled to the air-cushion type
Problem present in system, it is proposed that the present invention.
Therefore, one of purpose of the invention is to provide a kind of system that air-cushion type quenching can be carried out to material.
In order to solve the above technical problems, the present invention provides following technical scheme：A kind of air-cushion type quenches system, including air cushion
Heater and air-cushion type quenching unit, material is entered in the air cushion heater by the first transfer unit to be heated, then
Quenched in into the air-cushion type quenching unit, finally transferring out the air-cushion type through the second transfer unit quenches system, described
Air cushion heater front end is additionally provided with sensing element, and the sensing element can sense to the material；The air cushion
Formula quenching unit includes upper blasting unit, lower blasting unit and recognition unit, wherein, the upper blasting unit includes upper return air
Road, upper air blast part, upper blast channel and upper injecting-unit, cold air are flowed through air blast part, are admitted to drum by upper air -return duct
It is finally spouting by upper injecting-unit in air channel, form once the circulation of cold air in upper blasting unit；The lower air blast list
Member includes lower air -return duct, lower air blast part, lower blast channel and lower injecting-unit, and cold air flows through lower air blast portion by lower air -return duct
Part, is admitted in lower blast channel, finally spouting by lower injecting-unit, is formed and once descends following for cold air in blasting unit
The upper and lower surface of material, makes material described in the cool air impingement that ring, the upper injecting-unit and the lower injecting-unit are ejected
Suspend in the air, so as to be cooled to desired technological temperature；And, recognition unit is arranged at the air-cushion type quenching unit
It is interior, material suspended state and hoverheight in the air-cushion type quenching unit can be recognized, the floating shape of the material is detected
State.
A kind of preferred scheme of system is quenched as air-cushion type of the present invention, wherein：The upper injecting-unit includes,
Upper shell, the upper accommodating groove being arranged in the upper shell, the upper load cell and difference for being arranged at the upper shell front end
Shape and percent opening are different, multiple upper homogenizing plates so as to produce influence on flow of cooled air, during normal work, according to setting
Fixed pressure value, adjustment meets the operating position in upper homogenizing plate to the upper shell of the pressure value, if the upper ejection section
The cold air flows of part change, and the upper load cell determines pressure oscillation and pressure loss exceeds setting value, then by institute
The upper homogenizing plate for stating the corresponding pressure value in accommodating groove is adjusted to operating position, and original place is flowed in the upper of operating position
Plate is played back in accommodating groove, so as to adjust the undulating value and pressure loss of pressure in the upper injecting-unit to the scope of setting
It is interior.
A kind of preferred scheme of system is quenched as air-cushion type of the present invention, wherein：The lower injecting-unit includes,
Lower house, the lower accommodating groove being arranged in the lower house, the lower load cell and difference for being arranged at the lower house front end
Shape and percent opening are different, multiple lower homogenizing plates so as to produce influence on flow of cooled air, during normal work, according to setting
Fixed pressure value, adjustment meets the operating position in lower homogenizing plate to the lower house of the pressure value, if the lower ejection section
The cold air flows of part change, and the lower load cell determines pressure oscillation and pressure loss exceeds setting value, then by institute
The lower homogenizing plate for stating the corresponding pressure value in lower accommodating groove is adjusted to operating position, and original place is flowed in the lower of operating position
Plate is played back in lower accommodating groove, so as to adjust the undulating value and pressure loss of pressure in the lower injecting-unit to the scope of setting
It is interior.
Automatic control system is quenched it is a further object to provide a kind of air-cushion type, the system can be realized to gas
Cushion quenches the Automated condtrol of system.
In order to solve the above technical problems, the present invention provides following technical scheme：A kind of air-cushion type quenches automatic control system,
It includes, data acquisition module, picture recognition module, PLC control and communication module, process control module, interface module and
Optimizing forecast module, wherein, data collecting module collected is surveyed by the load cell including upper load cell or lower load cell
Pressure value in the fixed air-cushion type quenching unit everywhere, and the air cushion that collection is determined by temperature element heat dress
Temperature value in putting everywhere, and feed back to the PLC controls and communication module；The recognition unit that picture recognition module passes through is determined
Material amount of deflection, and feed back to the process control module；PLC is controlled and communication module feeds back the pressure value of acquisition and temperature value
To the process control module；The pressure value of acquisition, temperature value and material amount of deflection are fed back to institute by process control module
State in interface module and optimizing forecast module, carry out interactive operation respectively and obtain the technological parameter of optimization.
A kind of preferred scheme of automatic control system is quenched as air-cushion type of the present invention, wherein：Also include data
Library module, the process control module can extract type, composition, model parameter and the acquiescence of material from database module
Value, and being sent to the optimizing forecast module, the optimizing forecast module include temperature prediction model, amount of deflection forecasting model,
Energy consumption model and Optimized model, the Optimized model start the technological parameter of output optimization, and subsequent temperature prediction model, amount of deflection are pre-
Report model and energy consumption model start to predict temperature, amount of deflection predicted value and the power consumption values of material, and then Optimized model is surveyed according to actual
The output technological parameter of value amendment Optimized model, until the Optimizing Process Parameters that Optimized model is provided can make the temperature of material
The temperature forecast value and amount of deflection predicted value of forecasting model and amount of deflection forecasting model meet the energy of actual production demand and energy consumption model
Consumption is minimum, that is, obtains the technological parameter of optimization.
A kind of preferred scheme of automatic control system is quenched as air-cushion type of the present invention, wherein：It is described excessively program control
Molding block includes process control unit, jitter suppression controller and safety interlocking unit, and the process control module can connect
The feedback of the interface module and optimizing forecast module is received, and described image identification module and PLC controls and communication module are sent out
Go out instruction.
A kind of preferred scheme of automatic control system is quenched as air-cushion type of the present invention, wherein：It is described excessively program control
Unit processed include pressure controller, temperature controller, tension force and speed control and, become spray box adjuster；Wherein, the pressure
Force controller input variable is pressure divergence and pressure divergence rate of change, and pressure is divided into high pressure, three sections of areas of middle pressure and low pressure by it
Between, different pressures interval uses different upper homogenizing plate or lower homogenizing plate, so that the pressure obtained in air-cushion type quenching unit reaches
Setting value；The temperature controller is used for the control to temperature, when the temperature of air-cushion type quenching unit is higher or lower than certain
When temperature, heater, increase or reduction heating power are adjusted, the temperature of hot gas is increased or is reduced；Institute
The frequency converter of the technological parameter of tension force and speed control according to setting, the first transfer unit of adjustment or the second transfer unit is stated,
Material is set to be in rational tension force and velocity interval；And, the change spray box adjuster be used for the upper homogenizing plate or under
Homogenizing plate is adjusted.
A kind of preferred scheme of automatic control system is quenched as air-cushion type of the present invention, wherein：The shake suppression
Shake of the controller processed to adjust material, when the floating state stabilization or smaller Oscillation Amplitude of material, jitter suppression control
Device processed does not work, and when material carries out low amplitude vibrations, jitter suppression controller passes through the pressure controller and the tension force
With speed control start adjust air-cushion type quenching unit in pressure, the tension force of the first transfer unit or the second transfer unit and
Speed, reduces the dither amplitude of material, untill the vibration of material returns to the acceptable amplitude of setting；When shaking for material
When dynamic amplitude is larger, the change spray box adjuster adjusts homogenizing plate or lower homogenizing plate first, then passes through the pressure control again
Device processed and the tension force and speed control start to adjust pressure in air-cushion type quenching unit, the first transfer unit or second defeated
The tension force and speed of part are sent, untill the vibration amplitude of material is returned to the acceptable degree of setting.
A kind of preferred scheme of automatic control system is quenched as air-cushion type of the present invention, wherein：The safety connects
The security of the lock unit protection equipment course of work and equipment running process, it is to avoid cause great production accident or equipment serious
Damage, when homogenizing plate in upper air blast part or lower air blast component speed, heater power, material tension force, material speed, regulation or
When lower homogenizing plate process has influence on the safe operation of equipment, triggering alarm limits the certain operations in production process, or directly
Shut down.
A kind of preferred scheme of automatic control system is quenched as air-cushion type of the present invention, wherein：Also include learning by oneself
Module is practised, when there are low amplitude vibrations in air-cushion type quenching automatic control system, the adjustment of Optimized model output adaptive
Technical process control parameter, the execution equipment of control workshop level mechanical floor performs corresponding control action, so that equipment
Operational factor is met after process goal, the technological parameter of the Optimized model output optimization, and equipment detects the vibrational state of material,
Detected value is fed back in optimizing forecast module, so as to correct the parameter of optimizing forecast module, makes optimizing forecast module in self-study
During habit, the effect of optimization and forecast is improved.
Beneficial effects of the present invention：The present invention proposes a kind of air-cushion type quenching system and automatic control system, and the system is filled
Divide and consider current big data and technology of Internet of things, realize the intellectuality of air-cushion type quenching unit production process, realize that air-cushion type is quenched
The intellectuality of fiery device and material automation vibration suppression control, it is ensured that air-cushion type quenching unit is efficient, the production of high level.
Brief description of the drawings
Technical scheme in order to illustrate more clearly the embodiments of the present invention, below will be to that will use needed for embodiment description
Accompanying drawing be briefly described, it should be apparent that, drawings in the following description are only some embodiments of the present invention, for this
For the those of ordinary skill of field, without having to pay creative labor, it can also obtain other according to these accompanying drawings
Accompanying drawing.Wherein：
Fig. 1 is the overall structure diagram that air-cushion type quenches system 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 that air-cushion type quenches automatic control system described in one embodiment of the invention；
Fig. 5 is each model operation method 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.
Embodiment
To enable the above objects, features and advantages of the present invention more obvious understandable, with reference to Figure of description pair
The embodiment of the present invention is described in detail.
Many details are elaborated in the following description to fully understand the present invention, but the present invention can be with
It is different from other manner described here using other to implement, those skilled in the art can be without prejudice to intension of the present invention
In the case of do similar popularization, therefore the present invention is not limited by following public specific embodiment.
Secondly, " one embodiment " or " embodiment " referred to herein refers to may be included at least one realization side of the invention
Special characteristic, structure or characteristic in formula." in one embodiment " that different places occur in this manual not refers both to
Same embodiment, nor the single or selective embodiment mutually exclusive with other embodiment.
Fig. 1 shows the overall structure 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, and material is entered by the first transfer unit 100 '
Heated, then quenched into air-cushion type quenching unit 200 is interior, finally through the second conveying in air cushion heater 100
Part 200 ' transfers out air-cushion type quenching system, and the front end of air cushion heater 100 is additionally provided with sensing element 101, sensing element
101 can sense to material, judge the position that material is carried out；And air-cushion type quenching unit 200 includes upper blasting unit
201st, lower blasting unit 202 and recognition unit 203, wherein, upper blasting unit 201 includes upper air -return duct 201a, upper air blast part
201b, upper blast channel 201c and upper injecting-unit 201d, cold air flow through air blast part 201b, quilt by upper air -return duct 201a
Cold sky finally spouting by upper injecting-unit 201d in feeding in blast channel 201c, being formed once in upper blasting unit 201
The circulation of gas；Lower blasting unit 202 includes lower air -return duct 202a, lower air blast part 202b, lower blast channel 202c and lower ejection section
Part 202d, cold air flows through lower air blast part 202b by lower air -return duct 202a, is admitted in lower blast channel 202c, finally under
Injecting-unit 202d is spouting, forms the circulation of the cold air once descended in blasting unit 202, in this embodiment,
The upper and lower surface for the cool air impingement material that upper injecting-unit 201d and lower injecting-unit 202d are ejected, makes material suspended in sky
In, so as to be cooled to desired technological temperature.Recognition unit 203 is arranged in air-cushion type quenching unit 200, can recognize gas
The suspended state and hoverheight of material, detect the floating state of material in cushion quenching unit 200.
It is preferred that as shown in Fig. 2 upper injecting-unit 201d includes, upper shell 201d-1, it is arranged in upper shell 201d-1
Upper accommodating groove 201d-2, be arranged at the upper load cell 201d-3 and different shape and percent opening of upper shell 201d-1 front ends
Multiple upper homogenizing plate 201d-4 different, so as to produce influence on flow of cooled air, during normal work, according to the pressure of setting
Force value, adjustment meets the operating position in the upper homogenizing plate 201d-4 to upper shell 201d-1 of the pressure value, if upper injecting-unit
201d cold air flows change, and upper load cell 201d-3 determines pressure oscillation and pressure loss exceeds setting value, then
The upper homogenizing plate 201d-4 of corresponding pressure value in upper accommodating groove 201d-2 is adjusted to operating position, and by original place in work
The upper homogenizing plate 201d-4 of position is played back in accommodating groove 201d-2, so as to adjust the fluctuation of pressure in injecting-unit 201d
Value and pressure loss are in the range of setting.
Lower injecting-unit 202d is arranged on below injecting-unit 201d, can be formed relatively with upper injecting-unit 201d
The general layout of injection.Herein, lower injecting-unit 202d includes, lower house 202d-1, the lower storage being arranged in lower house 202d-1
Groove 202d-2, the lower load cell 202d-3 and different shape that are arranged at lower house 202d-1 front ends and percent opening be different, from
And multiple lower homogenizing plate 202d-4 of influence can be produced on flow of cooled air, during normal work, according to the pressure value of setting, adjust
Operating position in the whole lower homogenizing plate 202d-4 to lower house 202d-1 for meeting the pressure value, if lower injecting-unit 202d's is cold
Air mass flow changes, and lower load cell 202d-3 determines pressure oscillation and pressure loss exceeds setting value, then is stored lower
The lower homogenizing plate 202d-4 of corresponding pressure value in groove 202d-2 is adjusted to operating position, and by original place under operating position
Homogenizing plate 202d-4 is played back in lower accommodating groove 202d-2, so as to adjust the undulating value and pressure of pressure in lower injecting-unit 202d
It is lost in the range of setting.
Fig. 4 shows the structural representation of air-cushion type quenching automatic control system in one embodiment of the invention.Referring to figure
4, air-cushion type quenching automatic control system, which includes, can gather by upper load cell 201d-3 or lower load cells 202d-3
Pressure value in the air-cushion type quenching unit 200 that load cell 301 inside is determined everywhere, and can gather by thermometric member
Temperature value everywhere in the air cushion heater 100 that part 302 is determined, and feed back to the data of PLC controls and communication module 500 and adopt
Collect module (300)；Material amount of deflection is determined by recognition unit 203, and feeds back to the picture recognition module of process control module 600
400；The pressure value and temperature value of acquisition are fed back to PLC controls and the communication module 500 of process control module 600；And, will
Pressure value, temperature value and the material amount of deflection of acquisition are fed back in interface module 700 and optimizing forecast module 800, are carried out respectively
Interactive operation and the process control module 600 for obtaining the technological parameter optimized.
Specifically, interface module 700 is responsible for monitoring production process or carries out manufacturing parameter setting.The interface mould of operating room
Block 700 by operating room man-machine interaction industrial computer be responsible for monitoring production process or carry out manufacturing parameter setting, operating room it is excellent
Change setting and optimization operation that forecast module 800 is responsible for operating personnel, it is in another embodiment, also standby with operating room
Industrial computer, to Emergency use when operating room other industrial computers go wrong, the operating personnel of operating room pass through operation
Room remote console carries out production operation.The standby industrial computer of electric panel room is made when electric panel room other industrial computers go wrong
With the optimizing forecast module 800 of electric panel room is that electric panel room personnel use when debugging to model parameter or program, electricity
The interface module 700 of air chamber is that electric personnel carry out man-machine interface and write use when monitoring with electric state.Interface module
700 can be set with implementation process, process monitoring, alarm and state setting etc. function.Referring to Fig. 6, process setting includes：At each heat
Manage area desired temperature, each thermal treatment unit safety interlocking state setting (temperature it is chain setting, pressure interlock setting,
Chain setting of pressure oscillation etc.), the hypertension setting value of the first transfer unit 100 ' or the second transfer unit 200 ', before material
Enter speed setting value, the homogenizing plate setting for becoming spray box, the design of pressure of injecting-unit, the pressure value of air-cushion type quenching unit 200
Setting, the heter temperature setting value of each thermal treatment unit, air temperature settings value；Process detection includes：Each heat-treatment zone
Temperature, the safety interlocking state (temperature is chain, pressure interlock, pressure oscillation are chain etc.) of each thermal treatment unit, the first conveying
The hypertension value of part 100 ' or the second transfer unit 200 ', material pace process values, change spray box orifice plate, injecting-unit
Press process value, the press process value of air-cushion type quenching unit 200, the heter temperature process values of each thermal treatment unit, gas temperature
Spend process values；Warning function includes alarm indication and alarm logging (pressure alarm of air-cushion type quenching unit 200, temperature alarming, pressure
Fluctuation alarm, tension force alarm, threading acceleration alert, instrument air pressure alarm, fault alarm)；State set-up function, including it is automatic
The functions such as change/manual switching.
PLC control and communication module 500 be for realize workshop level monitoring layer and mechanical floor between communication and control.Image
Identification module 400 can be with collection site material vibrating signal.Executing agency includes becoming spray box executing agency, air bleed valve, stove
Regulating valve etc. is pressed, can perform in execute-in-place action, realization in injecting-unit 201d or lower injecting-units 202d upper flows
Plate 201d-4 or lower homogenizing plates 202d-4 adjustment, the production such as the action of air bleed valve and the pressure of air-cushion type quenching unit 200
During control action.Safe spacing refers to limit switch, the alarm set in production process for protection equipment safety
Device is the equipment of the output alarm signal when occurring influence equipment safety situation in production process.
Referring to Fig. 5, in this embodiment, air-cushion type quenching automatic control system also includes database module, receives
Production process information is (for example：In yield, name of product, product specification, Product Process parameter, product quantity and production process
Special circumstances remark information), enterprise-level server stores production process information in database module by ODBC modes, should
Database module can realize the functions such as modification, increase, timing renewal, deletion, inquiry, the historical record of production process information.
Enterprise process production information is based on ICP/IP protocol and is sent to by interchanger in workshop level monitoring layer.Meanwhile, physical parameter number
According to unit (material composition, convection transfer rate, specific heat), production information data cell (stock number, name of material, material
Can, yield), process pre-set parameter and process values, the setting value of process control parameters unit and process values, process status
Multivariable process value, safety interlocking state, warning message.Database module have recorded real time information and the history letter of above-mentioned variable
Breath, can realize the functions such as increase, modification, deletion and the inquiry of information and data.Process control module 600 can be from database
Type, composition, model parameter and the default value of material are extracted in module, and is 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 start the technological parameter of output optimization, and subsequent temperature prediction model 801, amount of deflection forecasting model 802 and energy consumption model 803 are opened
Temperature, amount of deflection predicted value and the power consumption values of beginning prediction material, then Optimized model 804 is according to actual measured value amendment Optimized model
804 output technological parameter, until the Optimizing Process Parameters that Optimized model 804 is provided can make the temperature prediction model of material
801 and the temperature forecast value and amount of deflection predicted value of amount of deflection forecasting model 802 meet the energy of actual production demand and energy consumption model 803
Consumption is minimum, that is, obtains the technological parameter of optimization.
Specifically, the course of work of temperature prediction model 801 is：First, based on the excessively program control of air-cushion type quenching unit 200
The physical parameter of data processed and material, according to two dimensional unsteady heat transfer mechanism principle, predicts material in air-cushion type quenching unit
Temperature.Then the thermometer collection of the end of air-cushion type quenching unit 200 is come out of the stove the temperature of material, obtain surface of material measured value with
Difference between the predicted value of temperature prediction model 801, finally sets up air-cushion type hardening heat intelligence using automating Integrated Algorithm
Energy compensation model, with the error between compensatory michanism model predication value and measured value.
The course of work of amount of deflection forecasting model 802 is first, material to be set up according to beam conservation equation and wall jet theory
Amount of deflection forecasting model 802, predicts the deflection value of material under material stable state and vibrational state respectively.Secondly, image recognition mould
Block 400 gathers material Floating Height image, and the image pick-up card of optimization, forecast and Controlling model industrial computer is sent to by optical fiber
In, then the image processing software of industrial computer is filtered to image, denoising, correction, extracts and do not descend the floating of material in the same time
Height and floating state.So as to obtain material Floating Height and material floating state.Material amount of deflection measured value is obtained to scratch with material
The difference spent between predicted value, finally sets up the error of the amount of deflection forecasting model 802 of material using automation neural network algorithm
Value, so as to set up the amount of deflection forecasting model 802 of material.
Energy consumption model 803 be based on usually test data and instrumented data fit come energy consumption model 803, can forecast
The information such as energy consumption and energy consumption cost under the conditions of the technique productions.The material temperature of the Kernel-based methods control module 600 of Optimized model 804
Predicted value, the predicted value of amount of deflection forecasting model 802 of forecasting model 801 are spent, energy consumption model 803 optimizes air-cushion type quenching process
Technological parameter (tension force, threading speed, heating-up temperature etc.), export one optimization technological parameter.
In one embodiment, temperature prediction model 801, amount of deflection forecasting model 802, energy consumption model 803 and optimization mould
Type 804 is read and data storage by ODBC modes, temperature prediction model 801, amount of deflection forecasting model 802, the and of energy consumption model 803
Optimized model 804 sends and transmitted each other data by message, passes through between workshop level monitoring layer and workshop level mechanical floor
TCP/IP is communicated, and picture recognition module 400 is communicated by coaxial cable with process control module 600.
In another embodiment, referring to Fig. 7, process control module 600 includes process control unit 601, shake suppression
Controller 602 and safety interlocking unit 603 processed, process control module 600 being capable of reception interface module 700 and optimizing forecast moulds
The feedback of block 800, and instruction is sent to described image identification module 400 and PLC controls and communication module 500.Process control mould
Block 600 ensure that whole self-regulating process has good dynamic characteristic, it is ensured that technique of the equipment in dynamic adjustment phase
Variable is in safe operation interval, and when ensureing that system is stable, target process parameter can accurately reach that technological parameter is set
Definite value.Wherein, process control unit 601 includes pressure controller 601a, temperature controller 601b, tension force and speed control
601c and, become spray box adjuster 601d；Wherein, pressure controller 601a input variables are that pressure divergence and pressure divergence change
Rate, pressure is divided into high pressure, three sections of intervals of middle pressure and low pressure by it, different pressures interval using different upper homogenizing plate 201d-4 or
Lower homogenizing plate 202d-4, so that the pressure obtained in air-cushion type quenching unit 200 reaches setting value.
Temperature controller 601b is used for the control to temperature, when the temperature of air-cushion type quenching unit 200 is higher or lower than
When uniform temperature, heater, increase or reduction heating power are adjusted, making the temperature of hot gas increases or subtract
It is small；Tension force and speed control 601c adjust the first transfer unit 100 ' or the second transfer unit according to the technological parameter of setting
200 ' frequency converter, makes material be in rational tension force and velocity interval；And, become spray box adjuster 601d and flowed with to upper
Plate 201d-4 or lower homogenizing plates 202d-4 is adjusted.
Shake of the jitter suppression controller 602 to adjust material, when the floating state of material is stable or Oscillation Amplitude
When smaller (being approximately stable state), jitter suppression controller 602 does not work, when material carries out low amplitude vibrations, shake suppression
Controller 602 processed starts to adjust air-cushion type quenching unit by the pressure controller 601a and tension force and speed control 601c
The tension force and speed of pressure, the first transfer unit 100 ' or the second transfer unit 200 ' in 200, reduce the shake width of material
Value, untill the vibration of material returns to the acceptable amplitude of setting；When the vibration amplitude of material is larger, becomes spray box and adjust
Section device 601d adjusts homogenizing plate 201d-4 or lower homogenizing plate 202d-4 first, then passes through pressure controller 601a and tension force again
Start to adjust pressure, the first transfer unit 100 ' or the second conveying in air-cushion type quenching unit 200 with speed control 601c
The tension force and speed of part 200 ', untill the vibration amplitude of material is returned to the acceptable degree of setting.
The security of the protection equipment course of work of safety interlocking unit 603 and equipment running process, it is to avoid cause great life
Production accident or equipment are badly damaged, when upper air blast part 201b or lower air blast parts 202b (in this collectively blower fan) rotating speed, add
Hot device power, material tension force, material speed, homogenizing plate 201d-4 or lower homogenizing plate 202d-4 processes have influence on equipment in regulation
During safe operation, triggering alarm limits the certain operations in production process, or directly shut down.
In one embodiment, air-cushion type quenching automatic control system also includes self-learning module, when the air-cushion type
When there are low amplitude vibrations in quenching automatic control system, the technical process control ginseng of the output adaptive of Optimized model 804 adjustment
Number, the execution equipment of control workshop level mechanical floor performs corresponding control action, so that the operational factor of equipment meets technique
After target, the technological parameter of the output optimization of Optimized model 804, equipment detects the vibrational state of material, detected value is fed back to excellent
Change in forecast module 800, so as to correct the parameter of optimizing forecast module 800, make optimizing forecast module 800 in the process of self study
In, improve the effect of optimization and forecast.
Embodiment 1
When air-cushion type quenching automatic control system material vibrating is smaller exemplified by control process：
Step 1：The collection air outlet of load cell 301 pressure, air inlet pressure, upper injecting-unit 201d or lower injecting-units
202d pressure and the pressure of air-cushion type quenching unit 200.The temperature of the collection air-cushion type of temperature element 302 quenching unit 200, upper injection
Part 201d or lower injecting-units 202d temperature signal.The signal of load cell 301 and temperature element 302 is assisted by Modbus
View is sent to PLC controls and communication module 500, and then the collection of picture recognition module 400 material amount of deflection image was sent to program control
Molding block 600, then state of a control signal is sent to interface module 700 and shown by process control module 600, and will be optimized pre-
The report status signal of module 800 is sent to amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804.
Step 2：Optimizing forecast module 800 extracts material type, alloying component, the model ginseng of material from database module
Number and default value.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 of output optimization, then temperature prediction model 801, material amount of deflection forecasting model 802 and energy
Consumption model starts to predict temperature, amount of deflection predicted value and the power consumption values of material, and then Optimized model 804 is according to actual measured value amendment
The output technological parameter of Optimized model, until the Optimizing Process Parameters that Optimized model 804 is provided can make the temperature forecast of material
The temperature forecast value and amount of deflection predicted value of model 801 and amount of deflection forecasting model 802 meet actual production demand and energy consumption model 803
Energy consumption it is minimum, that is, obtain the technological parameter of optimization.
Step 3：Optimal procedure parameters are output to workshop level mechanical floor, process control unit 601 by MODBUS agreements
Output signal (Stress control output signal, tension force output signal and speed control letter are controlled according to target process data
Number).Pressure control procedure gives upper air blast part 201b or lower air blast portion by PLC controls and the output control signal of communication module 500
Part 202b frequency converter, upper air blast part 201b or lower air blast parts 202b frequency converter is with the suitable upper air blast portion of increment regulation
Part 201b or lower air blast parts 202b rotating speed, to ensure that pressure is steady and accurately reach the setting value of pressure.Tension force and
Speed control, the first transfer unit 100 ' or the second transfer unit are given by PLC controls and the output control signal of communication module 500
200 ' frequency converter, clipping operation is carried out in frequency converter to current signal, so that steadily adjustment tension force or rate signal.
Step 4：After each state-variable is stable, step 1 and step 2 are repeated, the excellent of optimizing forecast module 800 is corrected
Change technological parameter, then performing above-mentioned steps 3, the whole heat treatment process of system is reached optimization.
Embodiment 2
When air-cushion type quenching automatic control system material vibrating is smaller exemplified by control process：
Step 1：The collection air outlet of load cell 301 pressure, air inlet pressure, upper injecting-unit 201d or lower injecting-units
202d pressure and the pressure of air-cushion type quenching unit 200.The temperature of the collection air-cushion type of temperature element 302 quenching unit 200, upper ejection section
Part 201d or lower injecting-unit 202d temperature signals.The signal of load cell 301 and temperature element 302 is sent out by Modbus agreements
PLC controls and communication module 500 are given, then the collection of picture recognition module 400 material amount of deflection image is sent to process control mould
Block 600, then process control module 600 state of a control signal is sent to interface module 700 and shown, and by optimizing forecast mould
The status signal of block 800 is sent to amount of deflection forecasting model 802, energy consumption model 803 and Optimized model 804.And pressure sensor is surveyed
Pressure value in amount in injecting-unit 201d or lower injecting-units 202d, is sent in optimizing forecast module 800, PLC control and
Communication module 500 according to the numerical computations of pressure signal go out upper injecting-unit 201d or lower injecting-unit 202d pressure losses, on
Injecting-unit 201d or lower injecting-unit 202d pressure oscillation situations.
Step 2：Optimizing forecast module 800 extracts material type, alloying component, the model ginseng of material from database module
Number and default value.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 of output optimization, subsequent temperature prediction model 801, material amount of deflection forecasting model 802 and energy
Consumption model 803 starts to predict temperature, amount of deflection predicted value and the power consumption values of material, and then Optimized model 804 is according to actual measured value
The output technological parameter of Optimized model 804 is corrected, until the Optimizing Process Parameters that Optimized model 804 is provided can make the temperature of material
The temperature forecast value and amount of deflection predicted value of degree forecasting model 801 and amount of deflection forecasting model 802 meet actual production demand and energy consumption
The energy consumption of model 803 is minimum, that is, obtains the technological parameter of optimization.
Step 3：Optimal procedure parameters are output to workshop level mechanical floor, process control unit 601 by MODBUS agreements
Output signal (Stress control output signal, tension force output signal and speed control letter are controlled according to target process data
Number).Pressure control procedure gives upper air blast part 201b or lower air blast portion by PLC controls and the output control signal of communication module 500
Part 202b frequency converter, upper air blast part 201b or lower air blast parts 202b frequency converter is turned with suitable increment regulation blower fan
Speed, to ensure that pressure is steady and accurately reach the setting value of pressure.Tension force and speed control, by PLC controls and communication mould
The output control signal of block 500 is to the first transfer unit 100 ' or the frequency converter of the second transfer unit 200 ', to electricity in frequency converter
Flow signal and carry out clipping operation, so that steadily adjustment tension force or rate signal.Upper injecting-unit 201d or lower injecting-units
202d is according to the control instruction for becoming spray box adjuster 601d, to the upper homogenizing plate 201d-4 or lower homogenizing plates of a upper working condition
202d-4 carries out rotation control, and upper one upper homogenizing plate 201d-4 or lower homogenizing plates 202d-4 is turned into its corresponding upper receipts
Receive in groove 201d-2 or lower accommodating grooves 202d-2.Then the upper homogenizing plate 201d-4 or lower that will be opened according to control instruction flows
Plate 202d-4 opens out of corresponding upper accommodating groove 201d-2 or lower accommodating grooves 202d-2, injecting-unit 201d or lower sprays in change
The pressure loss and flow distribution penetrated in part 202d.
Step 4：After each state-variable is stable, step 1 and step 2 are repeated, the excellent of optimizing forecast module 800 is corrected
Change technological parameter, then performing above-mentioned steps 3, the whole heat treatment process of system is reached optimization.
It should be noted that the above embodiments are merely illustrative of the technical solutions of the present invention and it is unrestricted, although with reference to preferable
The present invention is described in detail embodiment, it will be understood by those within the art that, can be to technology of the invention
Scheme is modified or equivalent, and without departing from the spirit and scope of technical solution of the present invention, it all should cover in this hair
Among bright right.
Claims (7)
1. a kind of air-cushion type quenches system, including air cushion heater（100）With air-cushion type quenching unit（200）, material passes through
First transfer unit（100’）Into the air cushion heater（100）Interior heating, then into the air-cushion type quenching unit
（200）Interior quenching, finally through the second transfer unit（200’）Transfer out the air-cushion type quenching system, it is characterised in that：
The air cushion heater（100）Front end is additionally provided with sensing element（101）, the sensing element（101）Can to institute
Material is stated to be sensed；
The air-cushion type quenching unit（200）Including upper blasting unit（201）, lower blasting unit（202）And recognition unit
（203）, wherein,
The upper blasting unit（201）Including upper air -return duct（201a）, upper air blast part（201b）, upper blast channel（201c）With it is upper
Injecting-unit（201d）, cold air is by upper air -return duct（201a）, flow through air blast part（201b）, it is admitted to blast channel
（201c）In, finally by upper injecting-unit（201d）It is spouting, form once upper blasting unit（201）Interior cold air is followed
Ring；
The lower blasting unit（202）Including lower air -return duct（202a）, lower air blast part（202b）, lower blast channel（202c）With under
Injecting-unit（202d）, cold air is by lower air -return duct（202a）, flow through lower air blast part（202b）, it is admitted to lower blast channel
（202c）In, finally by lower injecting-unit（202d）Spouting, blasting unit is once descended in formation（202）Interior cold air is followed
Ring, the upper injecting-unit（201d）With the lower injecting-unit（202d）Described in the cool air impingement ejected above and below material
Surface, make it is material suspended in the air, so as to be cooled to desired technological temperature；And,
Recognition unit（203）It is arranged at the air-cushion type quenching unit（200）It is interior, the air-cushion type quenching unit can be recognized
（200）Interior material suspended state and hoverheight, detect the floating state of the material；
The upper injecting-unit（201d）Including upper shell（201d-1）, be arranged at the upper shell（201d-1）Interior upper receipts
Receive groove（201d-2）, be arranged at the upper shell（201d-1）The upper load cell of front end（201d-3）And different shape and open
Porosity is different, multiple upper homogenizing plates so as to produce influence on flow of cooled air（201d-4）, during normal work, according to setting
Fixed pressure value, adjustment meets the upper homogenizing plate of the pressure value（201d-4）To the upper shell（201d-1）Interior working position
Put, if the upper injecting-unit（201d）Cold air flows change, the upper load cell（201d-3）Determine pressure
Fluctuation and pressure loss exceed setting value, then by the upper accommodating groove（201d-2）In corresponding pressure value upper homogenizing plate
（201d-4）Adjust to operating position, and by original place in the upper homogenizing plate of operating position（201d-4）Play back to accommodating groove
（201d-2）In, so as to adjust the upper injecting-unit（201d）Scope of the undulating value and pressure loss of interior pressure to setting
It is interior；
The lower injecting-unit（202d）Including lower house（202d-1）, be arranged at the lower house（202d-1）Interior lower receipts
Receive groove（202d-2）, be arranged at the lower house（202d-1）The lower load cell of front end（202d-3）And different shape and open
Porosity is different, multiple lower homogenizing plates so as to produce influence on flow of cooled air（202d-4）, during normal work, according to setting
Fixed pressure value, adjustment meets the lower homogenizing plate of the pressure value（202d-4）To the lower house（202d-1）Interior working position
Put, if the lower injecting-unit（202d）Cold air flows change, the lower load cell（202d-3）Determine pressure
Fluctuation and pressure loss exceed setting value, then by the lower accommodating groove（202d-2）In corresponding pressure value lower homogenizing plate
（202d-4）Adjust to operating position, and by original place in the lower homogenizing plate of operating position（202d-4）Play back to lower accommodating groove
（202d-2）In, so as to adjust the lower injecting-unit（202d）Scope of the undulating value and pressure loss of interior pressure to setting
It is interior；
Lower injecting-unit（202d）It is arranged on injecting-unit（201d）Below, can be with upper injecting-unit（201d）Form phase
To the general layout of injection.
2. a kind of air-cushion type quenches automatic control system, it is characterised in that：Including data acquisition module（300）, image recognition mould
Block（400）, PLC control and communication module（500）, process control module（600）, interface module（700）And optimizing forecast mould
Block（800）, wherein,
Data acquisition module（300）Collection passes through including upper load cell as claimed in claim 1（201d-3）Or lower pressure measurement
Element（202d-3）Load cell inside（301）The air-cushion type quenching unit determined（200）Interior pressure value everywhere, with
And collection passes through temperature element（302）The air cushion heater determined（100）Inside temperature value everywhere, and feeding back to described
PLC is controlled and communication module（500）；
Picture recognition module（400）Pass through recognition unit as claimed in claim 1（203）Material amount of deflection is determined, and is fed back to
The process control module（600）；
PLC is controlled and communication module（500）The pressure value and temperature value of acquisition are fed back into the process control module（600）；
Process control module（600）The pressure value of acquisition, temperature value and material amount of deflection are fed back into the interface module
（700）With optimizing forecast module（800）In, carry out interactive operation respectively and obtain the technological parameter of optimization；
Also include database module, the process control module（600）Can be extracted from database module material type, into
Point, model parameter and default value, and be sent to the optimizing forecast module（800）, the optimizing forecast module（800）Including
Temperature prediction model（801）, amount of deflection forecasting model（802）, energy consumption model（803）And Optimized model（804）, the Optimized model
（804）Start the technological parameter of output optimization, subsequent temperature prediction model（801）, amount of deflection forecasting model（802）And energy consumption model
（803）Start temperature, amount of deflection predicted value and the power consumption values of prediction material, then Optimized model（804）Repaiied according to actual measured value
Positive Optimized model（804）Output technological parameter, until Optimized model（804）The Optimizing Process Parameters provided can make material
Temperature prediction model（801）With amount of deflection forecasting model（802）Temperature forecast value and amount of deflection predicted value meet actual production demand
And energy consumption model（803）Energy consumption it is minimum, that is, obtain the technological parameter of optimization.
3. air-cushion type as claimed in claim 2 quenches automatic control system, it is characterised in that：The process control module
（600）Including process control unit（601）, jitter suppression controller（602）And safety interlocking unit（603）, the process
Control module（600）The interface module can be received（700）With optimizing forecast module（800）Feedback, and to described image
Identification module（400）With PLC controls and communication module（500）Send instruction.
4. air-cushion type as claimed in claim 3 quenches automatic control system, it is characterised in that：The process control unit
（601）Including pressure controller（601a）, temperature controller（601b）, tension force and speed control（601c）And, become spray box
Adjuster（601d）；Wherein,
The pressure controller（601a）Input variable be pressure divergence and pressure divergence rate of change, its by pressure be divided into high pressure,
Middle pressure and three sections of intervals of low pressure, different pressures interval use different homogenizing plates upper as claimed in claim 1（201d-4）Or
Lower homogenizing plate（202d-4）, so as to obtain air-cushion type quenching unit（200）Interior pressure reaches setting value；
The temperature controller（601b）For the control to temperature, when air-cushion type quenching unit（200）Temperature be higher than or
When less than uniform temperature, adjust heater, increase or reduce heating power, make hot gas temperature increase or
Reduce；
The tension force and speed control（601c）According to the technological parameter of setting, the first transfer unit is adjusted（100’）Or second
Transfer unit（200’）Frequency converter, make material be in rational tension force and velocity interval in；And,
The change spray box adjuster（601d）For to the upper homogenizing plate（201d-4）Or lower homogenizing plate（202d-4）Adjusted
It is whole.
5. air-cushion type as claimed in claim 4 quenches automatic control system, it is characterised in that：The jitter suppression controller
（602）Shake to adjust material, when the floating state stabilization or smaller Oscillation Amplitude of material, jitter suppression controller
（602）Do not work, when material carries out low amplitude vibrations, jitter suppression controller（602）Pass through the pressure controller
（601a）With the tension force and speed control（601c）Start to adjust air-cushion type quenching unit（200）It is interior pressure, first defeated
Send part（100’）Or second transfer unit（200’）Tension force and speed, reduce material dither amplitude, until shaking for material
Untill the dynamic acceptable amplitude for returning to setting；
When the vibration amplitude of material is larger, the change spray box adjuster（601d）Upper homogenizing plate is adjusted first（201d-4）Or under
Homogenizing plate（202d-4）, then pass through the pressure controller again（601a）With the tension force and speed control（601c）Start
Adjust air-cushion type quenching unit（200）Interior pressure, the first transfer unit（100’）Or second transfer unit（200’）Tension force
And speed, untill the vibration amplitude of material is returned to the acceptable degree of setting.
6. the air-cushion type quenching automatic control system as described in claim 4 or 5, it is characterised in that：The safety interlocking unit
（603）The security of the protection equipment course of work and equipment running process, it is to avoid cause great production accident or equipment serious
Damage, when upper air blast part（201b）Or lower air blast part（202b）Rotating speed, heater power, material tension force, material speed, tune
Homogenizing plate on section（201d-4）Or lower homogenizing plate（202d-4）When process has influence on the safe operation of equipment, triggering alarm, limitation
Certain operations in production process, or directly shut down.
7. the air-cushion type quenching automatic control system as described in claim 2 ~ 5 is any, it is characterised in that：Also include self study mould
Block, when there are low amplitude vibrations in air-cushion type quenching automatic control system, Optimized model（804）Output adaptive is adjusted
Technical process control parameter, the execution equipment of control workshop level mechanical floor performs corresponding control action, so that equipment
Operational factor meets process goal, the Optimized model（804）After the technological parameter for exporting optimization, equipment detects the vibration of material
State, optimizing forecast module is fed back to by detected value（800）In, so as to correct optimizing forecast module（800）Parameter, make optimization
Forecast module（800）During self study, the effect of optimization and forecast is improved.
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| CN114561513A (en) * | 2022-02-21 | 2022-05-31 | 郑州科创电子有限公司 | Quenching induction heating system and method |
Citations (4)
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|---|---|---|---|---|
| CN2273838Y (en) * | 1996-08-06 | 1998-02-04 | 机械工业部西安重型机械研究所 | Air cushion type belt products drying oven |
| CN102703676A (en) * | 2012-06-27 | 2012-10-03 | 艾伯纳工业炉(太仓)有限公司 | Air cushion furnace quenching system for heat treatment of aluminum coil materials and aluminum foil materials |
| CN203498431U (en) * | 2013-08-23 | 2014-03-26 | 南京苏星冶金科技有限公司 | Nozzle of air cushion furnace |
| CN104878188A (en) * | 2015-05-20 | 2015-09-02 | 东北大学 | Experimental facility and experiment method for realizing air cushion type heat treatment of aluminum strips |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH06207226A (en) * | 1993-01-08 | 1994-07-26 | Sumitomo Metal Ind Ltd | Directly firing continuous annealing furnace |
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2016
- 2016-02-04 CN CN201610080833.2A patent/CN105624374B/en not_active Expired - Fee Related
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN2273838Y (en) * | 1996-08-06 | 1998-02-04 | 机械工业部西安重型机械研究所 | Air cushion type belt products drying oven |
| CN102703676A (en) * | 2012-06-27 | 2012-10-03 | 艾伯纳工业炉(太仓)有限公司 | Air cushion furnace quenching system for heat treatment of aluminum coil materials and aluminum foil materials |
| CN203498431U (en) * | 2013-08-23 | 2014-03-26 | 南京苏星冶金科技有限公司 | Nozzle of air cushion furnace |
| CN104878188A (en) * | 2015-05-20 | 2015-09-02 | 东北大学 | Experimental facility and experiment method for realizing air cushion type heat treatment of aluminum strips |
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