CN109596916B - Wire extruder barrel heating fault detection system and detection method thereof - Google Patents
Wire extruder barrel heating fault detection system and detection method thereof Download PDFInfo
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- CN109596916B CN109596916B CN201811485452.8A CN201811485452A CN109596916B CN 109596916 B CN109596916 B CN 109596916B CN 201811485452 A CN201811485452 A CN 201811485452A CN 109596916 B CN109596916 B CN 109596916B
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Abstract
The invention discloses a wire extruder barrel heating fault detection system and a detection method thereof, relating to the technical field of wire extruder barrel heating detection, wherein the system comprises: the heating control system comprises a plurality of sections of zone heating systems which all contain heating rings; the fault diagnosis system comprises a current transformer for detecting the current value of the heating coil; the master control module controls the starting and the closing of the fault diagnosis system and the heating control system; the PLC module compares the data measured by the current transformer with a preset alarm threshold value; and the alarm module is used for alarming according to the comparison result of the PLC module. The detection method comprises the following steps: after a certain time, the fault diagnosis system is used for quickly diagnosing whether the fault exists in each zone heating system, and if the fault exists in the zone heating system, the alarm module is used for immediately giving an alarm. The system and the method can quickly and accurately detect the heating element, save cost and space and reduce the generation of waste products in the production process.
Description
Technical Field
The invention relates to the technical field of heating of screw barrels of wire extruders, in particular to a heating fault detection system and a heating fault detection method for screw barrels of wire extruders.
Background
At present, in the wire and cable industry, the extruder main/auxiliary machine can be heated by heating coils, a parallel connection mode is generally adopted, four groups of coils are generally connected in parallel to form one section, and heating coils in a thread cylinder heating system of the whole wire extruder are generally more than four sections.
At present, a normal value (such as 20A) is marked on a heating mechanical ammeter, when the normal value is lower than the normal value (such as 16A), damage of a certain group of heating coils is suspected, the fault is discovered by manually looking at the ammeter, the uncertainty of a person is too high, and the heating fault cannot be discovered in time basically by manually looking at the ammeter, so that the phenomena of surface anesthesia, poor plasticization and the like of the produced electric wire are caused. It is difficult to take maintenance action when one group of four groups of heating rings in one section has faults, and generally, the maintenance action can be found only when the four heating rings in the section are totally damaged or the defective products cannot be produced due to debugging.
Disclosure of Invention
The invention aims to: the invention provides a wire extruder barrel heating fault detection system and a detection method thereof, aiming at solving the problems that the wire extruder barrel heating fault detection depends on manual detection, the detection efficiency is low, and the heating fault cannot be found in time.
The technical scheme adopted by the invention is as follows:
a wire extruder barrel heating fault detection system, comprising:
the heating control system comprises M sections of zone heating systems, and each section of zone heating system comprises N groups of heating rings;
the fault diagnosis system comprises a current transformer for detecting the current value of the heating coil;
the master control module is used for controlling the starting and the closing of the fault diagnosis system and the heating control system;
the PLC module is used for comparing the data measured by the current transformer with a preset alarm threshold value;
and the alarm module is used for giving an alarm according to the comparison result of the PLC module.
Further, the heating control system further includes:
the temperature acquisition module is used for acquiring the heating temperature of the screw cylinder;
the temperature control module is used for comparing the temperature data acquired by the temperature acquisition module with a preset temperature threshold value and controlling the heating module and the cooling module to be started and closed according to the comparison result;
the heating module is used for heating the screw cylinder when the acquired temperature data is lower than a temperature threshold value;
and the cooling module is used for cooling the screw cylinder when the acquired temperature data is higher than a temperature threshold value.
Further, the interval time delta T of the master control module starting the fault diagnosis system is 3 min.
Further, the wireless communication module is used for data transmission between the fault diagnosis system and the PLC module.
Furthermore, the device also comprises an electronic terminal used for displaying and storing the data measured by the current transformer.
A heating fault detection method for a screw barrel of a wire extruder comprises the following steps:
step 1, sequentially recording M sections of zone heating systems as 1, 2, 1, M-1 and M, and putting the sections into an array [ M ]]In the method, and find the array [ M ]]The middle value Md of (1), the array [ M [ ]]Divided into two sub-arrays1[1，Md]And array2[Md+1，M](ii) a Wherein, the intermediate value Md is a value obtained by rounding down after (1+ M)/2;
step 2, starting the M sections of zone heating systems, closing the whole section of zone heating systems after heating the M multiplied by N groups of heating rings for delta T time, and starting a fault diagnosis system;
and 3, starting the 1 st to Md section zone heating systems, diagnosing whether faults exist in the 1 st to Md section zone heating systems based on the current transformers, and if faults exist, closing the continuous interval [ a, b ] formed by the currently started zone heating systems]Entering step 5; if not, the sub array is closed1[1，Md]A zone heating system corresponding to the medium element enters the step 4; wherein a and b are both temporary variables;
step 4, starting the Md +1 to M sections of zone heating systems, diagnosing whether faults exist in the Md +1 to M sections of zone heating systems based on the current transformers, if so, closing a continuous interval [ a, b ] formed by the currently started zone heating systems, and entering the step 5; if not, ending the diagnosis;
step 5, judging whether the intermediate value i in the interval [ a, b ] of the continuous interval is equal to a, if so, ending the diagnosis; if not, entering step 6; wherein, the intermediate value i is a value obtained by rounding down after (a + b)/2;
step 6, obtaining the interval [ a, b ] of the continuous interval]Middle value i in (1), interval [ a, b ] of consecutive intervals]Divided into two sub-continuous intervals1[a，i]And interval2[i+1，b]；
Step 7, starting the section a to section i of the zone heating system, diagnosing whether faults exist in the section a to section i of the zone heating system based on the current transformers, if so, closing all currently started zone heating systems, and enabling b to be equal to i, and entering the step 5; if not, all the zone heating systems which are currently started are closed, and the step 5 is entered.
In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:
1. according to the invention, the system and the method can rapidly and accurately detect the heating element, save cost and space, accurately and timely give an alarm for a fault area, and reduce the generation of waste products in the production process.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a block diagram of the system of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present invention without making any creative effort, shall fall within the protection scope of the present invention.
It is noted that relational terms such as "first" and "second," and the like, may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. The term "comprising", without further limitation, means that the element so defined is not excluded from the group consisting of additional identical elements in the process, method, article, or apparatus that comprises the element.
The features and properties of the present invention are described in further detail below with reference to examples.
Example 1
A system for detecting heating fault of screw barrel of wire extruder provided in the preferred embodiment of the present invention, as shown in fig. 1, includes:
the heating control system comprises 16 sections of zone heating systems, and each section of zone heating system comprises 4 groups of heating rings which are mutually connected in parallel.
The fault diagnosis system comprises a current transformer for detecting the current value of the heating coil, wherein the current transformer converts the collected heating current into a voltage signal and transmits the voltage signal to the PLC module through the wireless communication module.
And the master control module is used for controlling the starting and the closing of the fault diagnosis system and the heating control system. And the master control module starts the fault diagnosis system every 3 min.
And the PLC module is used for comparing the received voltage signal with a preset alarm threshold value.
And the alarm module is used for giving an alarm according to the comparison result of the PLC module. If the comparison result is abnormal, alarming; if the comparison result is normal, no alarm is given.
And the wireless communication module is used for data transmission between the fault diagnosis system and the PLC module.
And the electronic terminal is used for displaying and storing the data measured by the current transformer.
Wherein, the heating control system still includes:
and the temperature acquisition module is used for acquiring the heating temperature of the screw cylinder.
And the temperature control module is used for comparing the temperature data acquired by the temperature acquisition module with a preset temperature threshold value and controlling the heating module and the cooling module to be started and closed according to a comparison result.
And the heating module is used for heating the screw when the acquired temperature data is lower than a temperature threshold value.
And the radiator is used for cooling the screw cylinder when the acquired temperature data is higher than a temperature threshold value.
A heating fault detection method for a screw barrel of a wire extruder comprises the following steps:
step 1, sequentially recording 16 sections of zone heating systems as 1, 2, 15 and 16, and putting the sections into an array [16 ]]In (1), and find the array [16 ]]The intermediate value Md of (1) is 8, and the array [16 ]]Divided into two sub-arrays1[1，8]And array2[9，16]。
And 2, starting the 16-section zone heating system to enable the heating control system to be in a normal working state, and heating the 64 groups of heating rings. When the heating control system is in a normal working state, if the acquired temperature is lower than a temperature threshold value, heating the heating control system through a heating module; and if the acquired temperature is higher than the temperature threshold value, cooling the heating control system through the radiator. And closing the whole-section zone heating system every 3min, enabling the heating control system to be in a detection state, and starting the fault diagnosis system. When the heating control system is in the detection state, steps 3 to 7 are performed.
Step 3, starting the 1 st to 8 th section zone heating system based on the current transformerDiagnosing whether faults exist in the 1 st to 8 th section zone heating systems, and if so, closing the continuous interval [ a, b ] formed by the currently started zone heating system]Entering step 5; if not, the sub array is closed1[1，8]And (4) entering a step 4 by the zone heating system corresponding to the element. Wherein a and b are both temporary variables, in which case a is 1 and b is 8.
Step 4, starting the 9 th to 16 th subarea heating systems, diagnosing whether faults exist in the 9 th to 16 th subarea heating systems based on the current transformers, if so, closing a continuous interval [ a, b ] formed by the currently started subarea heating system, and entering the step 5; if not, the diagnosis is ended. In this case, a is 1 and b is 8.
Step 5, judging whether the intermediate value i in the interval [ a, b ] of the continuous interval is equal to a, if so, ending the diagnosis; if not, go to step 6. Wherein, the intermediate value i is a value obtained by rounding down after (a + b)/2.
Step 6, obtaining the interval [ a, b ] of the continuous interval]Middle value i in (1), interval [ a, b ] of consecutive intervals]Divided into two sub-continuous intervals1[a，i]And interval2[i+1，b]。
Step 7, starting the section a to section i of the zone heating system, diagnosing whether faults exist in the section a to section i of the zone heating system based on the current transformers, if so, closing all currently started zone heating systems, and enabling b to be equal to i, and entering the step 5; if not, all the zone heating systems which are currently started are closed, and the step 5 is entered.
For example: when the 10 th stage zone heating system is in failure, after steps 1 to 4, the length of the interval [9, 16] is 8, and after steps 5 and 6 are sequentially carried out, the intermediate value i is equal to 12. After step 7, starting the 9 th to 12 th section zone heating systems, diagnosing whether a fault exists in the 9 th to 12 th section zone heating systems based on the current transformers, and if the 10 th section zone heating system has a fault, closing the currently started 9 th to 12 th section zone heating systems, and making b equal to 10. The length of the interval [9, 10] is 2, and after steps 5 and 6, the intermediate value i is equal to 9. And 7, starting the 9 th section of zone heating system, and diagnosing whether the 9 th section of zone heating system has faults or not based on the current transformer, wherein the 9 th section of zone heating system has no faults. And closing the 9 th section of zone heating system, starting the 10 th section of zone heating system, diagnosing that the 10 th section of zone heating system has faults based on the current transformer, alarming through an alarm module, displaying and storing the diagnosis result through an electronic terminal, and finishing detection.
Example 2
On the basis of the first embodiment, a method for detecting heating faults of a screw cylinder of a wire extruder comprises the following specific steps:
and starting the 16-section zone heating system to enable the heating control system to be in a normal working state, and heating the 64 groups of heating rings. When the heating control system is in a normal working state, if the acquired temperature is lower than a temperature threshold value, heating the heating control system through a heating module; and if the acquired temperature is higher than the temperature threshold value, cooling the heating control system through the radiator. And closing the whole-section zone heating system every 3min, enabling the heating control system to be in a detection state, and starting the fault diagnosis system. When the heating control system is in the detection state, the operation is as follows:
the heating system starts to heat the first section of the zone heating system, the current value of the heating ring is detected through the current transformer, the collected heating current is converted into a voltage signal, and the voltage signal is transmitted to the PLC module through the wireless communication module. And the PLC module compares the received voltage signal with a preset alarm threshold value. If the fault of the first section of the zone heating system at the diagnosis position is diagnosed based on the current transformer, the comparison result is displayed and stored on the electronic terminal, and the alarm module gives an alarm; if no fault exists, the first section zone heating system is closed, the second section zone heating system is heated, whether a fault exists in the second section zone heating system is diagnosed based on the current transformer, if the fault exists, the comparison result is displayed and stored on the electronic terminal, and an alarm module gives an alarm; if no fault exists, the second section of zone heating system is closed, the third section of zone heating system is heated, and the like.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (6)
1. A detection method of a wire extruder barrel heating fault detection system is characterized by comprising the following steps:
step 1, sequentially recording M sections of zone heating systems as 1, 2, 1, M-1 and M, and putting the sections into an array [ M ]]In the method, and find the array [ M ]]The middle value Md of (1), the array [ M [ ]]Divided into two sub-arrays1[1,Md]And array2[Md+1,M](ii) a Wherein, the intermediate value Md is a value obtained by rounding down after (1+ M)/2;
step 2, starting the M sections of zone heating systems, closing the whole section of zone heating systems after heating the M multiplied by N groups of heating rings for delta T time, and starting a fault diagnosis system;
and 3, starting the 1 st to Md section zone heating systems, diagnosing whether faults exist in the 1 st to Md section zone heating systems based on the current transformers, and if faults exist, closing the continuous interval [ a, b ] formed by the currently started zone heating systems]Entering step 5; if not, the sub array is closed1[1,Md]A zone heating system corresponding to the medium element enters the step 4; wherein a and b are both temporary variables;
step 4, starting the Md +1 to M sections of zone heating systems, diagnosing whether faults exist in the Md +1 to M sections of zone heating systems based on the current transformers, if so, closing a continuous interval [ a, b ] formed by the currently started zone heating systems, and entering the step 5; if not, ending the diagnosis;
step 5, judging whether the intermediate value i in the interval [ a, b ] of the continuous interval is equal to a, if so, ending the diagnosis; if not, entering step 6; wherein, the intermediate value i is a value obtained by rounding down after (a + b)/2;
step 6, obtaining the interval [ a, b ] of the continuous interval]Middle value i in (1), interval [ a, b ] of consecutive intervals]Divided into two sub-continuous intervals1[a,i]And interval2[i+1,b]；
Step 7, starting the section a to section i of the zone heating system, diagnosing whether faults exist in the section a to section i of the zone heating system based on the current transformers, if so, closing all currently started zone heating systems, and enabling b to be equal to i, and entering the step 5; if not, all the zone heating systems which are currently started are closed, and the step 5 is entered.
2. The method of claim 1, wherein each of said M zones heating system comprises N sets of heating coils; the fault diagnosis system comprises a current transformer for detecting the current value of the heating coil; the intelligent heating and fault diagnosis system is also provided with a master control module for controlling the starting and closing of the fault diagnosis system and the heating control system, a PLC module for comparing data measured by the current transformer with a preset alarm threshold value, and an alarm module for alarming according to the comparison result of the PLC module.
3. The method of claim 2, wherein the heating control system further comprises:
the temperature acquisition module is used for acquiring the heating temperature of the screw cylinder;
the temperature control module is used for comparing the temperature data acquired by the temperature acquisition module with a preset temperature threshold value and controlling the heating module and the cooling module to be started and closed according to the comparison result;
the heating module is used for heating the screw cylinder when the acquired temperature data is lower than a temperature threshold value;
and the cooling module is used for cooling the screw cylinder when the acquired temperature data is higher than a temperature threshold value.
4. The method for detecting the heating fault detection system of the screw barrel of the wire extruder as claimed in claim 2, wherein the time interval Δ T between the master control module and the start of the fault diagnosis system is 3 min.
5. The method of claim 2, further comprising a wireless communication module for data transmission between the fault diagnosis system and the PLC module.
6. The method of claim 2, further comprising an electronic terminal for displaying and storing data measured by the current transformer.
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| CN111830933B (en) * | 2020-07-16 | 2022-03-29 | 广东亨通光电科技有限公司 | Heating element detection system, method and device and storage medium |
| CN112497712B (en) * | 2020-11-14 | 2022-09-23 | 邓权塑业科技（湖南）有限公司 | Current induction alarm device for heating ring in extruder head |
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