CN110191519B - Double-station resistance heating process and system thereof - Google Patents
Double-station resistance heating process and system thereof Download PDFInfo
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- CN110191519B CN110191519B CN201910441202.2A CN201910441202A CN110191519B CN 110191519 B CN110191519 B CN 110191519B CN 201910441202 A CN201910441202 A CN 201910441202A CN 110191519 B CN110191519 B CN 110191519B
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Abstract
The invention relates to the technical field of electric heating processing, in particular to a double-station resistance heating process and a system thereof, wherein the double-station resistance heating process sequentially comprises the following steps: the first station is heated at full power, and the second station waits for heating; gradually reducing the power of the first station to zero, applying the residual power to the second station, and gradually increasing the power of the second station to full power for heating; before the full-power heating of the second station is finished, the first station finishes the replacement of the workpiece; the second station is heated at full power, and the first station waits for heating; the second station gradually reduces the power to zero, the rest power is applied to the first station, and the first station gradually increases the power to full power for heating. The double-station resistance heating process enables the utilization rate of all power at any moment to be maximum, more electric energy is converted into the internal energy of the workpiece, and the production efficiency is greatly improved; when the same number of workpieces are produced, the double-station resistance heating process saves energy compared with the conventional single-station resistance heating process.
Description
Technical Field
The invention relates to the technical field of electric heating processing, in particular to a double-station resistance heating process and a system thereof.
Background
Resistance heating refers to a method of electrically heating a material using thermal energy generated by joule effect of current flowing through a conductor. Resistance heating is the simplest (and oldest) heating method based on electricity, and can heat metal, molten metal or nonmetal with the efficiency almost reaching 100%, and meanwhile, the working temperature can reach 2000 ℃, so that the method can be applied to high-temperature heating and low-temperature heating. Because of its controllability and rapid warming properties, resistance heating is used in all aspects from heating molten metal to heating food.
Resistance heating has the characteristics that: the heating temperature of the material can be selected according to the process requirement in a wide range from room temperature to about 3000 ℃, and can be accurately controlled; optionally heating the material in a specific environment, such as in a vacuum, controlled atmosphere, liquid medium; heating uniformly; the thermal efficiency is high; has little pollution to the environment.
In the prior art, conventional single-station resistance heating is performed, and referring to fig. 1, the process flow is as follows:
at time T0, the workpiece starts to be heated by 100% power;
in the time of T1-T2, the power is reduced and the temperature is kept after the workpiece is heated to the process temperature;
the time is T2-T3, and the workpiece is in a heat preservation state;
stopping heating within T3-T4 time;
at T4-T5 time, replacing the workpiece and stopping the power supply;
time T5, repeat T0, continue the next process cycle.
In the time period from T1 to T3, when the workpiece is subjected to heat preservation, the utilization rate of the total power of the power supply is gradually reduced until the total power is zero; and in the time period from T3 to T5, when the workpiece is replaced by stopping the machine, the utilization rate of the total power of the power supply is zero, and when a new workpiece is heated, the utilization rate of the total power of the power supply is gradually increased from zero to the maximum.
From the above analysis, it can be known that the utilization rate of the total power of the power supply in each time period from T1 to T5 is not high, even zero, which results in low production efficiency and low yield. And the power (P1) used for heating the workpiece is obtained by reducing the total power (Ptotal) of the power supply through the power converter, and the power (Ptotal-P1) not used for heating the workpiece is not saved or stored, but is wasted, thereby causing the waste of energy.
Disclosure of Invention
The invention aims to provide a double-station resistance heating process and a system thereof, which have the advantages of greatly improving the production efficiency and saving energy.
The above object of the present invention is achieved by the following technical solutions: a double-station resistance heating process comprises the following steps:
s1, heating at full power at a first station, and waiting for heating at a second station;
s2, gradually reducing the power of the first station to zero, applying the residual power to a second station, and gradually increasing the power of the second station to full power for heating;
s3, the first station finishes the replacement of the workpiece before the full-power heating of the second station is finished;
s4, heating the second station at full power, and waiting for heating the first station;
s5, gradually reducing the power of the second station to zero, applying the residual power to the first station, and gradually increasing the power of the first station to full power for heating;
s6, the second station finishes the replacement of the workpiece before the full-power heating of the first station is finished;
and S7, repeating S1 and continuing the next process cycle.
By adopting the technical scheme, the workpiece of the second station is preheated by utilizing the residual power during the temperature reduction and heat preservation of the first station, then the power of the second station is gradually increased until the workpiece is heated at full power (at the moment, the power distributed by the first station is gradually reduced until the power is zero, and the workpiece of the first station can be gradually cooled until the workpiece is stopped to be heated), and the time for heating at full power of another station is utilized for replacing the workpiece, so that the utilization rate of all power at any moment is maximum, more electric energy is converted into the internal energy of the workpiece, and the production efficiency is greatly improved.
Due to the fact that production efficiency is improved (compared with the conventional single-station resistance heating process, time required for producing the same number of workpieces is reduced), time t1 required by the double-station resistance heating process for producing the M workpieces is smaller than time t2 required by the conventional single-station resistance heating process for producing the M workpieces, and the longer the power supply time of the power supply equipment is, the more electric energy is supplied, so that when the same number of workpieces are produced, the energy can be saved by the double-station resistance heating process compared with the conventional single-station resistance heating process.
Preferably, in step S2, the power of the first station is reduced to P1, and then the temperature is maintained for t time and then reduced from P1 to zero; the second station is powered up to P2, and then is powered up to full power from P2 after t time of heat preservation.
By adopting the technical scheme, the full power of the first station is reduced to P1, the workpiece is annealed for the first time, the first station is annealed from P1 to zero, the workpiece is annealed for the second time, and the first annealing, the second annealing and the heat preservation time t between two annealing are carried out, so that the internal metal structure of the workpiece reaches or approaches to a balance state, a thinner structure is obtained, and the cutting performance of the workpiece material is improved.
When the workpiece at the first station is annealed for the first time, the workpiece at the second station is preheated primarily by using the residual power, and when the workpiece at the first station is annealed for the second time, the workpiece at the second station is preheated secondarily by using the residual power, so that the power utilization rate is improved, and the production speed is accelerated.
Preferably, the step S2 is performed in the time sequence of T1, T2, T3 and T4, and when T1-T2, the first station is decreased from full power to P1, and the second station is increased from zero power to P2; at T2-T3, the first station is kept at the temperature of P1, and the second station is kept at the temperature of P2; T3-T4, the first station is powered down to zero at P1, and the second station is powered up to full power at P2.
By adopting the technical scheme, the process is implemented step by step according to the time period sequence, so that the process flow of each step is convenient to control.
Preferably, in step S5, the power of the second station is reduced to P1, and then the temperature is maintained for t time and then reduced from P1 to zero; the first station is increased to P2, and then is kept for t time and increased from P2 to full power.
By adopting the technical scheme, the second station is heated at full power for a certain time after being preheated for two times, then the full power of the second station is reduced to P1, the workpiece is annealed for the first time, the second station is reduced to zero from P1, the workpiece is annealed for the second time, and the temperature of the workpiece is kept for t time between the first annealing, the second annealing and the two annealing, so that the internal metal structure of the workpiece reaches or approaches to a balanced state, a thinner structure is obtained, and the cutting performance of the workpiece material is improved.
When the workpiece at the second station is annealed for the first time, the workpiece at the first station is preheated primarily by using the residual power, and when the workpiece at the second station is annealed for the second time, the workpiece at the first station is preheated secondarily by using the residual power, so that the power utilization rate is improved, and the production speed is accelerated.
Preferably, the step S5 is carried out in the time sequence of T5, T6, T7 and T8, when T5-T6, the second station is decreased from full power to P1, and the first station is increased from zero power to P2; at T6-T7, the second station is kept at the temperature of P1, and the first station is kept at the temperature of P2; T7-T8, the second station is powered down to zero at P1 and the first station is powered up to full power at P2.
By adopting the technical scheme, the process is implemented step by step according to the time period sequence, so that the process flow of each step is convenient to control.
Preferably, the power is gradually increased before the step S1 is started.
By adopting the technical scheme, the production quality of the workpiece on the first station can be ensured when the production is started.
Preferably, P1 is less than P2.
By adopting the technical scheme, the first annealing time of the workpiece and the preliminary preheating time of the workpiece can be prolonged.
The above object of the present invention is also achieved by the following technical solutions: a system of a double-station resistance heating process comprises a power output unit, wherein the power output unit is electrically connected with two heating furnaces or one heating furnace with two heating stations.
By adopting the technical scheme, the heating power of the two heating stations is distributed through the power output unit, so that the high-efficiency processing and the energy-saving processing of the double-station resistance heating process are realized.
In conclusion, the beneficial technical effects of the invention are as follows:
1. the double-station resistance heating process enables the utilization rate of all power at any moment to be maximum, more electric energy is converted into the internal energy of the workpiece, and the production efficiency is greatly improved;
2. when the same number of workpieces are produced, the double-station resistance heating process saves energy compared with the conventional single-station resistance heating process.
Drawings
FIG. 1 is a power-time table of a conventional single-station resistance heating process of the background art;
fig. 2 is a power-time table for a dual-station resistance heating process in an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
Example (b): fig. 2 is a power-time table of a double-station resistance heating process disclosed by the invention, the double-station resistance heating process is sequentially processed according to the time sequence of T0, T1, T2, T3, T4, T5, T6, T7 and T8, and T0-T8 is a process cycle.
Referring to FIG. 2, at T0-T1, the first station heats up at full power, the second station waits to heat up;
at T1, the first station begins to reduce power, and the rest power is applied to the second station;
at T2, the power of the first station is reduced to P1, the power of the second station is increased to P2, and the sum of P1 and P2 is total power;
at T2-T3, the first station is insulated with P1 power, and the second station is insulated with P2 power;
at T3, the first station begins to reduce power, and the rest power is applied to the second station;
at T4-T5, the first station stops heating and replaces the workpiece to wait for heating, and the second station heats at full power;
at T5, the second station begins to reduce power, and the rest power is applied to the first station;
at T6, the power of the second station is reduced to P1, the power of the first station is increased to P2, and the sum of P1 and P2 is total power;
at T6-T7, the second station is insulated with P1 power, and the first station is insulated with P2 power;
at T7, the second station begins to reduce power, and the rest power is applied to the first station;
at T8, the first station stops heating and replaces the workpiece to wait for heating, and the second station heats at full power;
after T8, the process cycle is restarted by repeating the above-mentioned T1.
The workpiece of the second station is preheated by using the residual power during the temperature reduction and heat preservation of the first station, then the power of the second station is gradually increased until the workpiece is heated at full power (at the moment, the power distributed by the first station is gradually reduced until the power is zero, and the workpiece of the first station can be gradually cooled until the heating is stopped), and the time for heating at full power of the other station is used for replacing the workpiece, so that the utilization rate of all power at any moment is maximized, more electric energy is converted into the internal energy of the workpiece, and the production efficiency is greatly improved.
Due to the fact that production efficiency is improved (compared with the conventional single-station resistance heating process, time required for producing the same number of workpieces is reduced), time t1 required by the double-station resistance heating process for producing the M workpieces is smaller than time t2 required by the conventional single-station resistance heating process for producing the M workpieces, and the longer the power supply time of the power supply equipment is, the more electric energy is supplied, so that when the same number of workpieces are produced, the energy can be saved by the double-station resistance heating process compared with the conventional single-station resistance heating process.
The first station is reduced from full power to P1, the workpiece is annealed for the first time, the first station is reduced from P1 to zero, the workpiece is annealed for the second time, and the first annealing, the second annealing and the heat preservation time t between the two anneals are carried out, so that the internal metal structure of the workpiece reaches or approaches to a balanced state, a thinner structure is obtained, and the cutting performance of the workpiece material is improved.
When the workpiece at the first station is annealed for the first time, the workpiece at the second station is preheated primarily by using the residual power, and when the workpiece at the first station is annealed for the second time, the workpiece at the second station is preheated secondarily by using the residual power, so that the power utilization rate is improved, and the production speed is accelerated.
It should be noted that: 1. the workpiece replacement of one station must be completed before the full-power heating of the other station is finished, and the condition that the full-power surplus cannot be utilized cannot occur; p1 being less than P2, the first anneal time of the workpiece and the preliminary preheat time of the workpiece are extended.
The system of the double-station resistance heating process comprises a power output unit, wherein the power output unit is electrically connected with two heating furnaces or one heating furnace with two heating stations, and the heating power of the two heating stations is distributed through the power output unit, so that the high-efficiency processing and the energy-saving processing of the double-station resistance heating process are realized.
The embodiments of the present invention are preferred embodiments of the present invention, and the scope of the present invention is not limited by these embodiments, so: all equivalent changes made according to the structure, shape and principle of the invention are covered by the protection scope of the invention.
Claims (8)
1. A double-station resistance heating process is characterized by comprising the following steps:
s1, heating at full power at a first station, and waiting for heating at a second station;
s2, gradually reducing the power of the first station to zero, applying the residual power to a second station, and gradually increasing the power of the second station to full power for heating;
s3, the first station finishes the replacement of the workpiece before the full-power heating of the second station is finished;
s4, heating the second station at full power, and waiting for heating the first station;
s5, gradually reducing the power of the second station to zero, applying the residual power to the first station, and gradually increasing the power of the first station to full power for heating;
s6, the second station finishes the replacement of the workpiece before the full-power heating of the first station is finished;
and S7, repeating S1 and continuing the next process cycle.
2. The double-station resistance heating process according to claim 1, wherein: in step S2, the power of the first station is reduced to P1, and then the power is reduced to zero from P1 after the temperature is kept for t time; the second station is powered up to P2, and then is powered up to full power from P2 after t time of heat preservation.
3. The double-station resistance heating process according to claim 2, characterized in that: step S2 is carried out according to the time sequence of T1, T2, T3 and T4, when T1-T2, the first station is decreased from full power to P1, and the second station is increased from zero power to P2; at T2-T3, the first station is kept at the temperature of P1, and the second station is kept at the temperature of P2; T3-T4, the first station is powered down to zero at P1, and the second station is powered up to full power at P2.
4. The double-station resistance heating process according to claim 1, wherein: in step S5, the power of the second station is reduced to P1, and then the power is reduced to zero from P1 after the temperature is kept for t time; the first station is increased to P2, and then is kept for t time and increased from P2 to full power.
5. The double-station resistive heating process of claim 4, wherein: step S5 is carried out according to the time sequence of T5, T6, T7 and T8, when T5-T6, the second station is decreased from full power to P1, and the first station is increased from zero power to P2; at T6-T7, the second station is kept at the temperature of P1, and the first station is kept at the temperature of P2; T7-T8, the second station is powered down to zero at P1 and the first station is powered up to full power at P2.
6. The double-station resistance heating process according to claim 1, wherein: the power is gradually increased before step S1 is started.
7. The double-station resistance heating process according to claim 2, characterized in that: p1 is less than P2.
8. A system for a double-station resistance heating process according to any one of claims 1 to 7, wherein: the device comprises a power output unit, wherein the power output unit is electrically connected with two heating furnaces or one heating furnace with two heating stations.
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| US6262400B1 (en) * | 2000-10-03 | 2001-07-17 | Delphi Technologies, Inc. | Control method for a resistance heater in a vehicle heating system |
| CN104228051B (en) * | 2014-09-05 | 2017-04-19 | 上海金日冷却设备有限公司 | Infrared heating dual-station vacuum plastic-absorbing forming machine |
| CN107178803A (en) * | 2017-05-31 | 2017-09-19 | 中山市奥斯精工机械科技有限公司 | Multistation automatic cycle makes steamed rice in clay pot equipment |
| CN207162632U (en) * | 2017-05-31 | 2018-03-30 | 中山市奥斯精工机械科技有限公司 | Multistation automatic cycle makes steamed rice in clay pot equipment |
| CN208629893U (en) * | 2018-08-15 | 2019-03-22 | 南京特尔驰电子科技有限公司 | A kind of multistation machine thermal control plate |
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