CN110955208A - Material unfreezing intelligent analysis system based on three-dimensional unsteady heat transfer model - Google Patents
Material unfreezing intelligent analysis system based on three-dimensional unsteady heat transfer model Download PDFInfo
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Abstract
The invention belongs to the field of intelligent analysis of industrial thawing, and discloses a material thawing intelligent analysis system based on a three-dimensional unsteady heat transfer model, which comprises: first temperature detection means: the system is arranged at the door of the unfreezing warehouse and used for monitoring the temperature of a carriage and materials when the carrier loader enters and exits; the second temperature detection device: the method comprises the steps that a thawing warehouse is arranged and used for measuring key point temperature information of a carriage during thawing; third temperature detection means: the defrosting warehouse is arranged and used for measuring the temperature of the warehouse and the flue gas temperature in the defrosting room; an industrial personal computer: the system is used for receiving and storing temperature information obtained by monitoring of the first temperature detection device, the second temperature detection device and the third temperature detection device, and calculating by utilizing a product algorithm of three-dimensional unsteady heat conduction to obtain thawing time; a user side display: the method is used for displaying the human-computer interface. The method analyzes the thawing state of the material by establishing the three-dimensional unsteady heat transfer model, can accurately predict the thawing time, and can be widely applied to the field of industrial thawing.
Description
Technical Field
The invention belongs to the field of industrial unfreezing intelligent analysis, and particularly relates to a material unfreezing intelligent analysis system based on a three-dimensional unsteady heat transfer model.
Background
In the long-distance transportation process of coal, mineral powder and other materials used by industrial enterprises in winter, due to cold weather and high water content of the materials, the phenomenon of severe freezing between the materials and vehicles can be caused, so that unloading is extremely difficult, and heating and thawing are needed in a thawing warehouse.
Foreign research institutions, colleges and enterprises began to research related technologies of material thawing in the last 80 th century; the research in China starts a little later, and researchers pay attention to the problem in the last 90 th century, and the research mainly appears in northeast regions with cold weather and strong enterprise demands in winter. The research results are concentrated in the early 90 s and the early century, and the proposed solutions can be divided into a chemical reagent antifreezing method and a thawing warehouse heating method. The reagent antifreezing method is to add calcium chloride, glycol and other antifreezing agents and to take measures before shipment to avoid freezing of the transported material. The unfreezing method of the unfreezing warehouse is that after materials are transported to a destination, a carrying vehicle is integrally placed in the unfreezing warehouse, and the transported materials are separated from the carrying vehicle through heating and unfreezing, so that unloading conditions are achieved. The thawing warehouse can be divided into a natural convection thawing room, a forced convection thawing room and an electric infrared thawing room. The natural convection unfreezing chamber is provided with a steam exhaust pipe at the bottom, and the carrier loader is heated by the natural rising of steam. On the basis of the natural convection unfreezing chamber, the forced convection unfreezing chamber is additionally provided with an induced draft fan to suck down hot air at the top of the chamber to blow the hot air to the bottom and the side of the vehicle, so that heat exchange between the bottom and two ends of the vehicle is enhanced. The electric infrared unfreezing chamber unfreezes frozen materials in a heat radiation mode by utilizing infrared rays generated by the infrared radiators, heat insulation walls are arranged on two sides of a railway in a warehouse, and the side radiators are arranged on the heat insulation walls on the two sides for radiation unfreezing.
The existing technical scheme focuses on two aspects of preventing the material from freezing and optimizing the design of a thawing warehouse to improve the heat exchange efficiency, and does not research on the prediction of thawing duration. In the actual industrial production process, when the material is unfrozen, the heating time cannot be accurately grasped, and the operation is only carried out by manual experience. When the heating time is insufficient, the container cannot be completely thawed, so that unloading is difficult; when the heating time is too long, not only is time wasted, but also slag water is accumulated in the vehicle, so that the water content of the material is too high, and the material cannot be normally used. In addition, the thawing chamber is in a high-temperature and high-pressure closed state during thawing, so that personnel cannot enter the thawing chamber and know the internal conditions, and the temperature of the heating steam is difficult to control.
The material thawing warehouse is in a continuous operation state in winter, the internal temperature reaches 60-80 ℃, personnel are difficult to enter, and temperature acquisition needs to be carried out through temperature sensor equipment. Traditional temperature acquisition mainly goes on through thermocouple and thermal resistance, receives the restriction of sensor characteristic, can only arrange the part of keeping away from the carrier loader at storehouse top, side etc. of storehouse of unfreezing, can't gather the temperature of carriage surface or material, is difficult to accurate monitoring and calculates required temperature data. And the collected abnormal temperature data cannot be verified, so that it is difficult to judge whether the thermocouple and the thermal resistance sensor have faults or abnormal heating conditions occur in the thawing warehouse.
In conclusion, under the existing conditions, the problems of high warehouse return rate, high fuel consumption, low turnover efficiency of the train wagons and the like exist, and the overall production efficiency of enterprises is influenced.
Disclosure of Invention
Based on the above situation, the invention provides a material thawing duration prediction system based on a three-dimensional unsteady heat transfer model, which is characterized in that temperature data in a thawing warehouse are collected through a high-temperature-resistant and high-humidity-resistant temperature sensor, a three-dimensional unsteady heat transfer model is established, the thawing condition of materials in a carriage is analyzed in real time, and the material thawing duration is accurately predicted.
In order to solve the technical problems, the invention adopts the technical scheme that: a material unfreezing intelligent analysis system based on a three-dimensional unsteady heat transfer model comprises: first temperature detection means: the system is arranged at the door of the unfreezing warehouse and used for monitoring the temperature of a carriage and materials when the carrier loader enters and exits; the second temperature detection device: the method comprises the steps that a thawing warehouse is arranged and used for measuring key point temperature information of a carriage during thawing; third temperature detection means: the defrosting warehouse is arranged and used for measuring the temperature of the warehouse and the flue gas temperature in the defrosting room; an industrial personal computer: the system comprises a first temperature detection device, a second temperature detection device, a third temperature detection device and a control device, wherein the first temperature detection device is used for detecting the temperature of a user, the second temperature detection device is used for detecting the temperature of the user, the third temperature detection device is used for detecting the temperature of the user, and the control device is used for receiving and storing temperature information obtained by monitoring of the first temperature detection device; a user side display: the method is used for displaying the human-computer interface.
The first temperature detection device comprises a plurality of double-spectrum thermal infrared imagers which are respectively arranged at the outer door head of the thawing warehouse and two sides of the gate; the second temperature detection device comprises a plurality of temperature measurement type thermal infrared imagers which are respectively arranged on two sides of the rail inside the thawing warehouse and are aligned to the bottom and the side surface of the carriage, and a water cooling protective cover device is arranged on the outer side of each thermal infrared imager and is used for carrying out water circulation cooling on the temperature measurement type thermal infrared imagers; and the third temperature detection device comprises a thermal resistor and a thermocouple and is used for measuring the temperature of the storage temperature and the flue gas temperature in the thawing chamber.
The material thawing intelligent analysis system based on the three-dimensional unsteady heat transfer model further comprises a PLC, wherein the PLC is connected with the first temperature detection device, the second temperature detection device, the third temperature detection device and the industrial personal computer and is used for realizing data transmission and control between each temperature detection device and the industrial personal computer.
A data processing module and a model calculation module are arranged in the industrial personal computer; the data processing module is used for receiving and storing temperature information obtained by monitoring the first temperature detection device, the second temperature detection device and the third temperature detection device, and is also used for carrying out data fusion and consistency judgment on the temperature information obtained by measuring the three temperature detection devices, and the specific method for the data fusion and the consistency judgment comprises the following steps: calculating the mean value mu and the standard deviation sigma of different source data of the same monitoring point, and eliminating data outside the interval of (mu-3 sigma, mu +3 sigma) as noise data; the model calculation module is used for calculating the thawing time by using a product algorithm of three-dimensional unsteady heat conduction by taking the temperature information measured by the first temperature detection device as an initial condition and the temperature information measured by the second temperature detection device as a modeling parameter for calculating the thawing time.
The model calculation module is used for taking the temperature information measured by the first temperature detection device as an initial condition, taking the temperature information measured by the second temperature detection device as a modeling parameter for calculating the thawing duration, and obtaining a calculation formula of the thawing time tau by utilizing a product algorithm of three-dimensional unsteady heat conduction, wherein the calculation formula is as follows:
wherein x, y and z represent coordinate values of any point in the thawing chamber, α represents thermal diffusivity of the material, and deltax、δy、δzRespectively represent the thawing thickness in the x, y and z directions,
representing a dimensionless excess temperature in the x-direction,
representing a dimensionless excess temperature in the y-direction,
denotes the dimensionless excess temperature in the z direction, μx1Is that
Solution of (u), muy1Is that
Solution of (u), muz1Is that
Lambda denotes the thermal conductivity of the material.
The industrial personal computer is also provided with an abnormal data alarming module which is used for sending out an alarming signal when the noise data is obtained in the data processing module.
The industrial personal computer is also internally provided with a human-computer interaction module for visual display of unfreezing intelligent analysis information and configuration management functions of system parameters; the human-computer interaction module comprises an operation data visualization module and an operation notification reminding module; the operation data visualization module is used for displaying the basic state of the thawing library, the basic information of the carried materials, the thawing duration statistics, the positions of all monitoring points and the temperature change curve in a windowing and interfacing mode, and is also used for providing historical operation data query and chart statistics display; and system basic parameter configuration; the operation notification reminding module is used for pushing loading and unloading operation reminding and abnormal condition warning information to an operator; the loading and unloading operation reminding content comprises thawing time statistics and thawing completion notification; the abnormal alarm comprises an abnormal type, abnormal fault occurrence time and abnormal fault occurrence position.
Compared with the prior art, the invention has the following beneficial effects:
1. the invention can realize long-term stable and accurate collection of the internal temperature of the material thawing warehouse; and the integrated thermal infrared imager, the thermocouple and the thermal resistor are used for carrying out combined monitoring on temperature data in the thawing warehouse. The common thermal infrared imager is difficult to use for a long time in a high-temperature state, and the thermal infrared imager is subjected to water circulation cooling by additionally arranging a water-cooling heat dissipation protection cover device, so that the long-term stable operation of the thermal infrared imager is ensured.
2. In the invention, the thawing state of the material is analyzed by establishing a three-dimensional unsteady heat transfer model, and the thawing time is accurately predicted; the thermal infrared imagers are arranged above the warehousing gate and on two sides of rails in the warehouse, and the thermal infrared imagers above the warehousing gate scan the vehicle body when the carrier vehicle enters the thawing warehouse and acquire temperature information of each point of the carriage and materials as initial conditions for calculating thawing duration. And infrared thermal imagers on two sides of the rails in the warehouse are aligned to the bottom and the side faces of the carriage, and the temperature information of key points is monitored in the whole process of thawing as a modeling parameter for calculating thawing duration. The invention is based on the subject theory of heat transfer science, a mathematical model is established according to the actual conditions of the material thawing process, variables comprise hot air temperature, air pressure, size of a carrying vehicle body, material heat conduction properties and vehicle body key point temperature, and various factors are comprehensively considered. In the model calculation process, the performance of the computer is fully exerted, the difference differential is efficiently solved by using a numerical simulation method, and the unfreezing time is accurately calculated. Under the condition that the temperature variable, the material type and the property of the carrier vehicle body change, the heat transfer model can be automatically adjusted to follow the environmental change in time; meanwhile, real-time temperature information returned by the sensor monitoring points is utilized to correct the model calculation result, a feedback closed loop is formed, and the thawing time is accurately predicted.
3. The calculation result is displayed through a human-computer interaction layer visual interface, and one-line operators can acquire simple and clear operation prompts without concerning model details and can acquire temperature data of the carrying vehicle body and the material surface through the thermal infrared imager, so that the accuracy of calculating the freezing duration is greatly improved.
4. Due to the fact that the monitoring range is overlapped, data of the thermocouple and the thermal resistor can be cross-verified with the thermal infrared imager, source tracing is conducted on abnormal data, remote fault detection of the temperature sensor device is achieved, and reliability of data collection is improved.
Drawings
Fig. 1 is a schematic structural diagram of a material thawing intelligent analysis system based on a three-dimensional unsteady heat transfer model according to an embodiment of the present invention;
FIG. 2 is a system framework diagram of an intelligent analysis system for material thawing based on a three-dimensional unsteady heat transfer model according to an embodiment of the present invention;
in the figure: the system comprises a double-spectrum thermal infrared imager 1, a temperature measurement type thermal infrared imager 2, a thermocouple and a thermal resistor 3, a PLC controller 4, an industrial personal computer 5, a user side display 6, a coal car 7 and a database 8.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments; all other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The embodiment of the invention provides a material thawing intelligent analysis system based on a three-dimensional unsteady heat transfer model, which comprises a hardware part and a software part.
As shown in fig. 1, the hardware part comprises a plurality of dual-spectrum thermal infrared imagers, has thermal infrared and visible light imaging functions, is respectively installed at the external door head and two sides of the gate of the thawing warehouse, and is used for monitoring the temperature of the carriage and the material when the carrier loader comes in and goes out; the system comprises a plurality of temperature measuring thermal infrared imagers; the thermal resistors and the thermocouples are used for measuring the temperature of the reservoir temperature and the flue gas temperature in the thawing chamber; the PLC is used for controlling and monitoring data transmission between the equipment and the industrial personal computer by the sensor; the industrial personal computer is arranged in the control room, is the core of the intelligent analysis system, is used for data processing, model calculation and instruction sending, and stores data uploaded by the monitoring equipment and processed and calculated in the database for report generation and data backtracking; and the user side display is used for displaying a human-computer interface of the system.
Specifically, in this embodiment, the thermal infrared imager, the PLC, the thermocouple, the thermal resistor, and the like are connected to the upper layer through the wireless communication and the optical fiber to transmit data back. The thermal infrared imagers are arranged above the warehousing gate and on two sides of the rails in the warehouse. And scanning the vehicle body by an infrared thermal imager above the warehouse entry gate when the carrier vehicle enters the thawing warehouse, and acquiring temperature information of each point of the carriage and the material as an initial condition for calculating thawing duration. The thermal infrared imagers on the two sides of the rails in the warehouse are aligned to the bottom and the side faces of the carriage, the temperature information of key points is monitored in the whole process of thawing, the temperature information is used as a modeling parameter for calculating thawing duration, and the function of preventing high-temperature steam from damaging the train body is achieved.
A PLC control system (Programmable Logic Controller) is an electronic device designed for industrial production and operated by digital operation, which employs a Programmable memory for storing therein programs, executing Logic operation, sequence control, timing, counting, arithmetic operation, and other user-oriented instructions, and controls various types of machinery or production processes by digital or analog input/output, and is a core part of industrial control. In the intelligent thawing analysis system, the PLC is mainly responsible for carrying out analog-to-digital conversion on temperature information acquired by the temperature sensor and transmitting the temperature information back to the client computer for data storage and calculation through a communication function.
The thermal resistor and the thermocouple are mainly used for measuring the temperature of a specific point, a numerical measurement result is directly obtained, the arrangement cost is low, the thermal resistor and the thermocouple can be cross-verified with monitoring data of the thermal infrared imager, and the coverage range is enlarged. The common thermal infrared imager is difficult to use for a long time in a high-temperature state, and in the embodiment of the invention, the water-cooling heat-dissipation protection cover device is additionally arranged on the outer side of the thermal infrared imager to carry out water circulation cooling on the thermal infrared imager, so that the long-term stable operation of the thermal infrared imager can be ensured.
As shown in fig. 2, in the present embodiment, in the system architecture design, a layering concept is adopted, which is divided into four layers, and the four layers are a hardware monitoring layer, a data processing layer, a model calculation layer, and a human-computer interaction layer from bottom to top in sequence. The lower layer provides data support to the upper layer, and the upper layer issues management instructions to the lower layer. The data flow flows from the hardware monitoring layer to the man-machine interaction layer; and the control flow flows from the man-machine interaction layer to the data monitoring layer. And a layered structure is adopted, so that the function between layers can be clearly divided. The loose coupling relationship among the layers facilitates the flexible adjustment of the functional modules. That is to say, in this embodiment, the software module includes a data processing module, a model calculation module, and a human-computer interaction module that are arranged inside the industrial personal computer, and functions such as process monitoring, model calculation, and human-computer interaction are realized.
The data processing module is used for receiving and storing temperature information obtained by monitoring the first temperature detection device, the second temperature detection device and the third temperature detection device, and is also used for carrying out data fusion and consistency judgment on the temperature information obtained by measuring the three temperature detection devices, and the specific method for the data fusion and the consistency judgment comprises the following steps: and calculating the mean value mu and the standard deviation sigma of different source data of the same monitoring point, and regarding the data outside the interval of (mu-3 sigma, mu +3 sigma) as noise data rejection.
In the embodiment, the hardware monitoring layer is provided with a plurality of thermocouples, thermal resistors and thermal infrared imagers inside and outside the thawing warehouse, and a large amount of temperature information is transmitted back in the monitoring process. For some key parts, monitoring ranges may overlap, data fusion needs to be carried out on parameter information, and consistency judgment is carried out on data. According to the 3 sigma law, the data has a 99.73% probability distribution in the interval (mu-3 sigma, mu +3 sigma), and the data outside the interval is regarded as noise data rejection. The accuracy of the acquisition parameters is ensured, and support is provided for calculation of an upper model. Meanwhile, the information of the materials to be put in storage, the real-time temperature, the thawing duration and other operation data are stored in a database. On one hand, basic data are provided for the visual display of the human-computer interaction layer; on the other hand, historical data can be traced back at any time, and the running state of the thawing warehouse can be mastered.
The model calculation module is used for calculating thawing time by using a three-dimensional unsteady heat conduction product algorithm by taking temperature information measured by the first temperature detection device as an initial condition and temperature information measured by the second temperature detection device and the third temperature detection device as a modeling parameter for thawing duration calculation.
The product algorithm of three-dimensional unsteady heat conduction in the model calculation module is described below.
Considering that the length and the width of the bottom plate and the side plate of the coal car are far larger than the thickness of the bottom plate and the side plate, the influence of heat dissipation from the edges of the length and the width of the flat plate to the periphery on the temperature distribution in the flat plate is very small, so that the temperature of each point in the flat plate can be regarded as a function of the thickness, the bottom plate and the side plate are idealized into an infinite flat plate, the material thawing problem is regarded as a three-dimensional unsteady heat conduction problem in the heat transfer science, and the product of the solutions of corresponding three one-dimensional problems can be used for representing the temperature distribution, namely the product algorithm of the.
If x, y, and z are coordinate axis directions corresponding to three dimensions, the mathematical description of the unsteady heat conduction process in the x direction is:
initial condition theta(x,0)＝θ0，
Boundary condition
In the formula, theta0＝(t(x，0)-tf) Denotes the initial excess temperature, θ(δ，τ)＝(t(x，τ)-tf) The excess temperature of the coal car at any position and at any time is represented; t is t(x，0)Denotes the initial temperature, t, at an arbitrary positionfRepresents the mean temperature of the hot air in the thawing chamber, t(x，τ)The temperature at an arbitrary position and at an arbitrary time point is shown, δ is the thawing thickness, τ is the thawing time, α is the thermal diffusivity of coal, and λ is the thermal conductivity of coal.
The formula (1) is solved by a separation variable method, and the special solution is
In the formula C1，C2，C3And β are constants that can be solved using boundary conditions, the final form of the solution being
Where δ is the thickness of the thaw, i.e. the distance of the insulation surface from the exterior surface of the compartment, let βnδ＝μnThen, then
As can be seen from formula (3), (α τ/δ2)＝F0The larger the number of stages converges, when F0At > 0.3, the first term of the series is sufficiently accurate to describe the temperature distribution.
In the formula (I), the compound is shown in the specification,
denotes the dimensionless excess temperature, delta, in the x directionxDenotes the thawing thickness in the x direction, μx1Is that
The solution of (1).
Similarly, the temperature distributions in the two directions y and z are:
the temperature distribution within the thawing chamber can be represented by the product of three dimensional solutions, namely:
therefore, the formula for calculating the thawing time τ is:
wherein x, y and z represent coordinate values of any point in the thawing chamber, α represents material (coal)Thermal diffusivity of, deltax、δy、δzRespectively represent the thawing thickness in the x, y and z directions,
representing a dimensionless excess temperature in the x-direction,
representing a dimensionless excess temperature in the y-direction,
denotes the dimensionless excess temperature in the z direction, μx1Is that
Solution of (u), muy1Is that
Solution of (u), muz1Is that
Lambda denotes the thermal conductivity of the material.
Furthermore, the industrial personal computer is also provided with an abnormal data alarming module which is used for sending out an alarming signal when the noise data is obtained in the data processing module. And the abnormal data alarm module receives the monitoring data and the consistency judgment result uploaded by the data processing layer. And directly adopting the average value of the data returned by the sensor under the condition of consistent monitoring results. If a large amount of noise data appear, remind the workman to inspect whether the deviation is because sensor measuring error or trouble arouse, overhaul in time to the trouble device and change, guarantee the accuracy of gathering the parameter. Based on credible sensor data and a priori safety baseline (for example, the boiler air pressure is lower than 2.45MPa, and the temperature is lower than 80 ℃), whether temperature and air pressure are abnormal or not is judged, an alarm is immediately sent for abnormal conditions, an operator is reminded to intervene in time in a striking mode through a man-machine interaction layer, and safety production is guaranteed.
Specifically, the human-computer interaction module is used for unfreezing visual display of intelligent analysis information and configuration management functions of system parameters; specifically, the human-computer interaction module comprises an operation data visualization module and an operation notification reminding module; the operation data visualization module provides simple and direct thawing library operation information for a front-line operator in a windowing and interfacing mode by means of visualization tools such as animation and charts. The displayed information includes: the basic state of the thawing warehouse (idle/warehouse in/thawing warehouse in/out), the basic information of the carried materials, the statistics of thawing duration, the position of each monitoring point, the temperature change curve and the like. Meanwhile, managers can call and inquire historical operating data at any time and display the historical operating data in a chart statistical mode; basic parameters of the system can be configured, such as reset duration statistics and addition and deletion of material types. And the authority of management, inquiry and configuration is strictly controlled, and the safety of enterprise operation information is ensured.
And the operation notification reminding module is used for pushing loading and unloading operation reminding and abnormal condition warning information to an operator. The notification reminding content is displayed in the message window, and the loading and unloading operation reminding content comprises thawing time statistics and a thawing completion notification; the abnormal alarm comprises an abnormal type, abnormal fault occurrence time and abnormal fault occurrence position. The operation of a front-line worker is guided through simple and clear description.
Specifically, the main thawing warehouse state interface provides comprehensive thawing warehouse operation information for managers, and the information comprises key point temperature in the warehouse, thawing progress reminding, thawing warehouse temperature statistical information (highest temperature, lowest temperature and average temperature), a material information table, accumulated thawing amount statistics and the like. And the temperature information interface displays hearth temperature information, temperature information carousel of each monitoring point, temperature equalization trend of each warehouse and the like. The material information interface mainly displays material state statistical information, material information carousel, statistics of unfreezing amount with different calibers and the like. The notification reminding interface mainly displays a thawing progress reminding (reminding 20 minutes before thawing is finished), a thawing completion reminding, an over-temperature warning and a monitoring equipment fault warning, adopts a forced popup mode, and directly transfers to the current page when notification occurs. The video monitoring interface mainly displays the pictures acquired by the monitoring video and monitors the running state in the thawing warehouse by adopting a multi-path display-selective amplification mode.
Taking a thawing warehouse as a calandria thawing facility with hot wind as an example, the temperature data of the bottom and the side of the carriage is collected by a thermal infrared imager at-10 ℃ (namely the initial temperature t)(x,0)＝t(y,τ)＝t(z,τ)The coal car is a 60-ton open wagon, the length, the width and the height of the coal car are respectively 12.46 meters, 3.6 meters and 1.91 meters, the heat conductivity coefficient lambda of the coal is 0.26W/(m DEG C), and the thermal diffusivity is α is 1.58m2The average temperature of the indoor hot air is collected by a thermal resistor and is unfrozen to be tfAt 78 ℃. The thickness x, y, z, and delta can be measured to be a thawing thickness x, y, z, and delta, since the vehicle can be smoothly unloaded at a depth of 20mm from the inner surface of the vehicle compartment and at 5 ℃x＝δy＝δz＝20mm，t(x,τ)＝t(y,τ)＝t(z,τ)At 5 ℃. Substituting the parameters into the formula (8), and calculating the thawing time of the material to be 5.8 hours. And the unfreezing duration prediction result is displayed on a human-computer interface, and the worker is reminded in time when the unfreezing is finished and 20 minutes before the unfreezing is finished. The application result in the production field shows that the thawing is carried out according to the predicted duration, the unloading requirement is completely met, the freezing is relieved, and no slag water is accumulated.
The existing technical scheme focuses on two aspects of preventing the material from freezing and optimizing the design of a thawing warehouse to improve the heat exchange efficiency, and does not research on the prediction of thawing duration. The method for preventing the material from freezing is restricted by the conditions of upstream material suppliers, and the realization process is difficult to control; the adoption of methods such as the design of an electric infrared thawing chamber optimization thawing warehouse requires a large amount of engineering construction, the cost is high, and the feasibility is not strong; the method has the advantages that the unfreezing duration is predicted completely by means of manual experience, the accuracy is low, and the popularization is poor. The invention upgrades and reforms the existing forced convection unfreezing room, acquires operating parameters by additionally arranging the Internet of things equipment, establishes a three-dimensional unsteady heat conduction model, analyzes the unfreezing condition of materials in a carriage in real time, has low cost and strong operability and transportability, can be widely applied to production environments of coal mines, power plants, steel plants, ports and the like, effectively solves the problems of high warehouse return rate, large fuel consumption, low turnover efficiency of a railway wagon and the like, and improves the overall production efficiency of enterprises.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (7)
1. The utility model provides a material intelligent analysis system that unfreezes based on three-dimensional unsteady state heat transfer model which characterized in that includes:
first temperature detection means: the system is arranged at the door of the unfreezing warehouse and used for monitoring the temperature of a carriage and materials when the carrier loader enters and exits;
the second temperature detection device: the method comprises the steps that a thawing warehouse is arranged and used for measuring key point temperature information of a carriage during thawing;
third temperature detection means: the defrosting warehouse is arranged and used for measuring the temperature of the warehouse and the flue gas temperature in the defrosting room;
an industrial personal computer: the system comprises a first temperature detection device, a second temperature detection device, a third temperature detection device and a control device, wherein the first temperature detection device is used for detecting the temperature of a user, the second temperature detection device is used for detecting the temperature of the user, the third temperature detection device is used for detecting the temperature of the user, and the control device is used for receiving and storing temperature information obtained by monitoring of the first temperature detection device;
a user side display: the method is used for displaying the human-computer interface.
2. The intelligent analysis system for material thawing based on the three-dimensional unsteady heat transfer model according to claim 1, wherein the first temperature detection device comprises a plurality of double-spectrum thermal infrared imagers respectively arranged at the outer door head and two sides of the door of the thawing warehouse;
the second temperature detection device comprises a plurality of temperature measurement type thermal infrared imagers which are respectively arranged on two sides of the rail inside the thawing warehouse and are aligned to the bottom and the side surface of the carriage, and a water cooling protective cover device is arranged on the outer side of each thermal infrared imager and is used for carrying out water circulation cooling on the temperature measurement type thermal infrared imagers;
and the third temperature detection device comprises a thermal resistor and a thermocouple and is used for measuring the temperature of the storage temperature and the flue gas temperature in the thawing chamber.
3. The intelligent analysis system for material thawing based on the three-dimensional unsteady heat transfer model according to claim 1, characterized by further comprising a PLC controller, wherein the PLC controller is connected with the first temperature detection device, the second temperature detection device, the third temperature detection device and the industrial personal computer, and is used for realizing data transmission and control between each temperature detection device and the industrial personal computer.
4. The intelligent analysis system for material thawing based on the three-dimensional unsteady heat transfer model according to claim 1, characterized in that a data processing module and a model calculation module are arranged in the industrial personal computer;
the data processing module is used for receiving and storing temperature information obtained by monitoring the first temperature detection device, the second temperature detection device and the third temperature detection device, and is also used for carrying out data fusion and consistency judgment on the temperature information obtained by measuring the three temperature detection devices, and the specific method for the data fusion and the consistency judgment comprises the following steps: calculating the mean value mu and the standard deviation sigma of different source data of the same monitoring point, and eliminating data outside the interval of (mu-3 sigma, mu +3 sigma) as noise data;
the model calculation module is used for calculating the thawing time by using a product algorithm of three-dimensional unsteady heat conduction by taking the temperature information measured by the first temperature detection device as an initial condition and the temperature information measured by the second temperature detection device as a modeling parameter for calculating the thawing time.
5. The intelligent analysis system for material thawing based on the three-dimensional unsteady heat transfer model according to claim 1, wherein the model calculation module is configured to use the temperature information measured by the first temperature detection device as an initial condition, use the temperature information measured by the second temperature detection device as a modeling parameter for thawing duration calculation, and obtain a calculation formula of the thawing time τ by using a product algorithm of three-dimensional unsteady heat conduction:
wherein x, y and z represent coordinate values of any point in the thawing chamber, α represents thermal diffusivity of the material, and deltax、δy、δzRespectively represent the thawing thickness in the x, y and z directions,
representing a dimensionless excess temperature in the x-direction,
representing a dimensionless excess temperature in the y-direction,
denotes the dimensionless excess temperature in the z direction, μx1Is that
Solution of (u), muy1Is that
Solution of (u), muz1Is that
Lambda denotes the thermal conductivity of the material.
6. The intelligent analysis system for material thawing based on the three-dimensional unsteady heat transfer model according to claim 1, characterized in that the industrial personal computer is further provided with an abnormal data alarm module, and the abnormal data alarm module is used for sending out an alarm signal when noise data are obtained in the data processing module.
7. The intelligent analysis system for material thawing based on the three-dimensional unsteady heat transfer model according to claim 1, characterized in that a human-computer interaction module is further arranged in the industrial personal computer and is used for visual display of thawing intelligent analysis information and configuration management functions of system parameters;
the human-computer interaction module comprises an operation data visualization module and an operation notification reminding module; the operation data visualization module is used for displaying the basic state of the thawing library, the basic information of the carried materials, the thawing duration statistics, the positions of all monitoring points and the temperature change curve in a windowing and interfacing mode, and is also used for providing historical operation data query and chart statistics display; and system basic parameter configuration;
the operation notification reminding module is used for pushing loading and unloading operation reminding and abnormal condition warning information to an operator; the loading and unloading operation reminding content comprises thawing time statistics and thawing completion notification; the abnormal alarm comprises an abnormal type, abnormal fault occurrence time and abnormal fault occurrence position.
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