CN113433924A - Remote diagnosis system and method for medium-frequency electric furnace - Google Patents
Remote diagnosis system and method for medium-frequency electric furnace Download PDFInfo
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- CN113433924A CN113433924A CN202110627929.7A CN202110627929A CN113433924A CN 113433924 A CN113433924 A CN 113433924A CN 202110627929 A CN202110627929 A CN 202110627929A CN 113433924 A CN113433924 A CN 113433924A
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- 238000004171 remote diagnosis Methods 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims abstract description 12
- 238000012423 maintenance Methods 0.000 claims abstract description 14
- 230000005540 biological transmission Effects 0.000 claims abstract description 13
- 238000012545 processing Methods 0.000 claims abstract description 8
- 238000004458 analytical method Methods 0.000 claims abstract description 4
- 238000001514 detection method Methods 0.000 claims abstract description 4
- 230000006855 networking Effects 0.000 claims abstract description 3
- 238000004064 recycling Methods 0.000 claims abstract description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 42
- 229910052710 silicon Inorganic materials 0.000 claims description 42
- 239000010703 silicon Substances 0.000 claims description 42
- 239000003990 capacitor Substances 0.000 claims description 21
- 238000003745 diagnosis Methods 0.000 claims description 12
- 238000004891 communication Methods 0.000 claims description 6
- 230000006698 induction Effects 0.000 claims description 6
- 238000002955 isolation Methods 0.000 claims description 6
- 238000006243 chemical reaction Methods 0.000 claims description 4
- 238000002405 diagnostic procedure Methods 0.000 claims description 3
- 239000000523 sample Substances 0.000 claims description 3
- 230000000007 visual effect Effects 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 1
- 238000007405 data analysis Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
Abstract
The application discloses remote diagnosis system of intermediate frequency electric stove, including data acquisition system, intelligence control system, network transmission system and high in the clouds diagnostic system, data acquisition system adopts various sensors as basic component, rationally set up the detection position, through utilizing intelligence control system, gather each data, and upload the intelligence control system with data and carry out data processing, the thing networking or the internet of recycling network transmission system upload data to high in the clouds diagnostic system, utilize software to classify data, and analyze the running condition, the fault point of deriving equipment through the analysis to unusual data, confirm the equipment that needs the maintenance, and arrange professional engineer's processing. Has the following advantages: need not maintenance engineer and look over the fault reason at the scene, diagnose equipment through long-range, can judge the fault reason, propose the solution, realize the maintenance to the electric stove trouble fast, improve the utilization ratio of intermediate frequency electric stove. Various risks in the operation process of the medium-frequency electric furnace are reduced.
Description
Technical Field
The invention belongs to the technical field of electric furnace control, and particularly relates to a fault diagnosis system.
Background
At present, electric furnaces are basically operated on site, few systems can be remotely monitored, and even if the remote monitoring systems exist, the remote monitoring systems are monitored based on control rooms in companies, are rarely used for fault diagnosis processing and are basically used for monitoring whether equipment is operated or not. The condition of the medium-frequency electric melting furnace can not be known in time when company management or a responsible person is not on site, the operation adjustment of the electric melting furnace is very inconvenient, particularly, when the medium-frequency electric furnace breaks down, because the skills of operators are not enough, the failure principle can not be judged in time, and a maintenance engineer needs to check the failure reason on site and then can find a solution. In order to realize the principle of rapidly searching faults, a remote diagnosis system is designed and researched.
Disclosure of Invention
The invention aims to solve the technical problems, and provides a remote diagnosis system and a diagnosis method of an intermediate frequency electric furnace, which can judge the fault reason by remotely diagnosing equipment without checking the fault reason on site by a maintenance engineer, provide a solution, quickly realize the maintenance of the electric furnace fault and improve the utilization rate of the intermediate frequency electric furnace. Various risks in the operation process of the medium-frequency electric furnace are reduced.
In order to solve the technical problems, the invention adopts the following technical scheme:
the utility model provides a remote diagnosis system of intermediate frequency electric stove, including data acquisition system, intelligence control system, network transmission system and high in the clouds diagnostic system, data acquisition system adopts various sensors as basic element, the reasonable detection position that sets up, through utilizing intelligence control system, gather each data, and upload data to intelligence control system and carry out data processing, the thing networking of recycling network transmission system or internet upload data to high in the clouds diagnostic system, utilize software to classify data, and analyze the operation condition, the fault point of deriving equipment through the analysis to unusual data, confirm the equipment that needs the maintenance, and arrange professional engineer to handle.
Further, the intelligent control system comprises a PLC, and the model of the PLC is SMART 200.
Furthermore, the PLC is in communication connection with the VA-1512 serial main control board through a 485 communication interface, a pin l01, a pin l02 and a pin l03 of the VA-1512 serial main control board are connected with a data acquisition system, a pin U11 and a pin U12 of the VA-1512 serial main control board are connected with one end of a transformer T1, a pin P11, a pin P10 and a pin P12 of the VA-1512 serial main control board are connected with an inverter pulse board, and the VA-1512 serial main control board is further connected with a display panel.
Furthermore, the remote diagnosis system of the intermediate frequency electric furnace further comprises a 2500KVA transformer T, the 2500KVA transformer T is connected with one end of a circuit breaker Q1, the other end of the circuit breaker Q1 is connected with one end of a rectification controllable V1, one end and the other end of a rectification controllable V1 are connected with one end of a controlled silicon V2, one end of a filter capacitor C1 and one end of a resonance capacitor C2, the other end of a resonance capacitor C2 is connected with one end of a resonance capacitor C3, one end of a furnace body induction coil R1 and one end of a capacitor C4, the other end of a resonance capacitor C3 is connected with one end of a transformer T1, and the other end of a furnace body induction coil R1 and the other end of the capacitor C4 are connected with the other end of a controlled silicon output row W and the other end of the transformer T1.
Furthermore, the other end of the controllable silicon V2 is connected with one end of a breaker Q2, the other end of the breaker Q2 is connected with one end of a 2500KVA transformer T and one end of an air switch KV1, the other end of the air switch KV1 is connected with one end of an alternating current contactor CJ1 and one end of a control stop button SE1, the other end of the stop button SE1 is connected with one end of an external control terminal row, the other end of the external control terminal row is connected with one end of a normally open contact of the alternating current contactor CJ1 and one end of a control start button SE2, the other end of the normally open contact of the alternating current contactor CJ1 and the other end of the control start button SE2 are connected with one end of a coil of the alternating current contactor CJ1, and the other end of the coil of the alternating current contactor CJ1 is connected with the other end of the air switch KV 1.
Furthermore, the other end of the ac contactor CJ1 is connected with one end of an isolation transformer T2, one end of a transformer BK2 and one end of a power transformer T3 of the measuring instrument, the other end of the power transformer T3 of the measuring instrument is connected with one end of a temperature controller SW1 and a temperature probe, the other end of the temperature controller SW1 and the other end of the transformer BK2 are connected with a double rectification protection board, the other end of the isolation transformer T2 is connected with a switching power supply, and the switching power supply is further connected with a PLC.
The diagnostic method comprises the following steps:
step 2, performing data conversion on the detected 1# silicon controlled output current, 2# silicon controlled output current, 3# silicon controlled output current and 4# silicon controlled output current, and transmitting the data to a PLC control system through an analog input channel;
step 3, comparing and judging data, wherein four groups of silicon controlled rectifier output circuits are equal when the silicon controlled rectifier normally works, and if three output currents are equal and one output current is not or slightly different by more than 10%, judging that the silicon controlled rectifier which is not output is damaged;
and 4, outputting the judgment result through a human-computer interface, an audible and visual alarm, a mobile phone APP push and the like.
By adopting the technical scheme, compared with the prior art, the invention has the following technical effects:
1. and selecting a proper sensor to meet the actual requirement of the optimized system. 2. The data transmission can be completed by utilizing the existing network system without independently setting a network, a GPS and the Internet of things. The running state and data can be viewed in real time. 3. The control algorithm realizes the judgment of the fault, can avoid a maintenance engineer from determining the fault after checking on site, improves the maintenance efficiency of equipment maintenance and improves the utilization rate of the equipment.
Drawings
In order to more clearly illustrate the detailed description of the invention or the technical solutions in the prior art, the drawings that are needed in the detailed description of the invention or the prior art will be briefly described below. Throughout the drawings, like elements or portions are generally identified by like reference numerals. In the drawings, elements or portions are not necessarily drawn to scale.
FIG. 1 is a block diagram of a remote diagnosis system for medium frequency electric furnaces according to an embodiment of the present invention;
FIG. 2 is a flow chart of a diagnostic method in an embodiment of the present invention;
fig. 3 is an electrical schematic diagram of a remote diagnosis system of the medium frequency electric furnace in the embodiment of the invention.
Detailed Description
As shown in fig. 3, the intelligent control system comprises a PLC, the model of the PLC is SMART200, the PLC is in communication connection with a VA-1512 series main control board through a 485 communication interface, pins l01, l02 and l03 of the VA-1512 series main control board are connected with a data acquisition system, pins U11 and U12 of the VA-1512 series main control board are connected with one end of a transformer T1, pins P11, P10 and P12 are connected with an inverter pulse board, and the VA-1512 series main control board is further connected with a display panel.
The remote diagnosis system of the intermediate frequency electric furnace further comprises a 2500KVA transformer T, the 2500KVA transformer T is connected with one end of a circuit breaker Q1, the other end of the circuit breaker Q1 is connected with one end of a rectification controllable V1, one end and the other end of the rectification controllable V1 are connected with one end of a silicon controlled rectifier V2, one end of a filter capacitor C1 and one end of a resonant capacitor C2, the other end of the resonant capacitor C2 is connected with one end of a resonant capacitor C3, one end of a furnace body induction coil R1 and one end of a capacitor C4, the other end of the resonant capacitor C3 is connected with one end of a transformer T1, and the other end of the furnace body induction coil R1 and the other end of the capacitor C4 are connected with a silicon controlled rectifier output row W and the other end of the transformer T1.
The other end of the controllable silicon V2 is connected with one end of a breaker Q2, the other end of the breaker Q2 is connected with one end of a 2500KVA transformer T and one end of an air switch KV1, the other end of the air switch KV1 is connected with one end of an alternating current contactor CJ1 and one end of a control stop button SE1, the other end of the stop button SE1 is connected with one end of an external control terminal row, the other end of the external control terminal row is connected with one end of a normally open contact of the alternating current contactor CJ1 and one end of a control start button SE2, the other end of the normally open contact of the alternating current contactor CJ1 and the other end of the control start button SE2 are connected with one end of a coil of the alternating current contactor CJ1, and the other end of the coil of the alternating current contactor CJ1 is connected with the other end of the air switch KV 1.
The other end of the alternating current contactor CJ1 is connected with one end of an isolation transformer T2, one end of a transformer BK2 and one end of a measuring instrument power transformer T3, the other end of the measuring instrument power transformer T3 is connected with one end of a temperature controller SW1 and a temperature probe, the other end of the temperature controller SW1 and the other end of the transformer BK2 are connected with double rectification protection boards, the other end of the isolation transformer T2 is connected with a switching power supply, and the switching power supply is further connected with a PLC.
1. Selection of sensors in a data acquisition system
Due to the operating characteristics of medium frequency electric furnaces, there is a large electromagnetic interference, and therefore, the field sensors must be selected to be interference-resistant sensors, including but not limited to: the pressure sensor, the temperature sensor, the flow sensor, the current sensor, the voltage sensor and the like, and the selected sensor needs to adopt an isolated output mode or corresponding conversion to send signals to the intelligent control system in consideration of the safety of the control system. Meanwhile, due to the requirement on the accuracy of the data and the requirement on the measurement accuracy of the sensor, the accuracy is required to be 1.0 grade under the general condition, the requirement on a special part reaches 0.1 grade, and the force protection data must be accurate.
2. Arrangement of various sensors in a data acquisition system
The arrangement position of the sensors determines whether the acquired data is accurate, so that the scheme has to meet special requirements on each data acquisition point, a plurality of sensor settings are adopted for particularly important data, and a three-to-two mode is adopted for the data selection scheme.
3. Transmission of sensor data in a data acquisition system
After the sensor collects data, the data are digitally processed and then accurately transmitted to an intelligent control system, signal distortion can occur due to interference of the medium-frequency electric furnace in the transmission process, and in order to solve the problem, the influence of interference signals on transmission signals is eliminated by adopting a shielding and grounding mode after full investigation, and the accuracy of the data is ensured.
4. Processing of data in an intelligent control system
After the data are transmitted to the intelligent control system, a corresponding PID control algorithm is made according to the operating characteristics of the electric furnace, the intelligent control system performs optimized operation according to the algorithm in a normal range, an alarm signal is sent out within a certain value exceeding the normal range, an operator is reminded to pay attention to adjustment, the alarm signal is exceeded to meet the furnace shutdown requirement, the electric furnace is immediately alarmed and stopped to operate, meanwhile, real-time operation data are transmitted to a remote cloud end through the Internet of things or the Internet, personnel with related authorities can check the data in real time through corresponding authorities, and the site personnel are guided to perform corresponding speed regulation at any time so as to achieve the optimal state of the operation of the electric furnace.
5. Data uploading in network transmission system
The data is uploaded to a corresponding cloud terminal in a mode that the existing Internet of things or Internet protocol is adopted, and the data is marked and kept secret according to the address distribution principle.
6. Electric furnace remote diagnosis is carried out to high in clouds diagnostic system
The cloud diagnosis system can be operated by adopting a network computer, an IPAD (internet protocol ad), a mobile phone, a notebook computer and the like, the data are analyzed by corresponding software after being uploaded to the cloud, the operation condition of the electric furnace is determined, the operation mode of the electric furnace is prompted, if the operation mode of the electric furnace is abnormal, a corresponding treatment measure scheme is obtained through a corresponding empirical algorithm, if the equipment fails, a fault point of the electric furnace is judged according to corresponding data analysis, judgment information is sent to a maintenance engineer, the maintenance engineer communicates with a site to timely solve the fault, and the system is mainly required to accurately predict the fault reason for the judgment of the fault through the empirical algorithm.
As shown in fig. 2, a method for diagnosing a remote diagnosis system of an intermediate frequency electric furnace includes the steps of:
step 2, performing data conversion on the detected 1# silicon controlled output current, 2# silicon controlled output current, 3# silicon controlled output current and 4# silicon controlled output current, and transmitting the data to a PLC control system through an analog input channel;
step 3, comparing and judging data, wherein four groups of silicon controlled rectifier output circuits are equal when the silicon controlled rectifier normally works, and if three output currents are equal and one output current is not or slightly different by more than 10%, judging that the silicon controlled rectifier which is not output is damaged;
and 4, outputting the judgment result through a human-computer interface, an audible and visual alarm, a mobile phone APP push and the like.
The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to practitioners skilled in this art. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
Claims (7)
1. A remote diagnosis system of a medium frequency electric furnace is characterized in that: including data acquisition system, intelligence control system, network transmission system and high in the clouds diagnostic system, data acquisition system adopts various sensors as basic element, rationally set up the detection position, through utilizing intelligence control system, gather each item data, and upload the data to intelligence control system and carry out data processing, the thing networking of recycling network transmission system or internet upload the data to high in the clouds diagnostic system, utilize software to classify the data, and carry out the analysis to the running condition, the fault point of deriving equipment through the analysis to unusual data, confirm the equipment that needs the maintenance, and arrange professional engineer to handle.
2. The remote diagnosis system of the medium frequency electric furnace and the diagnosis method thereof according to claim 1, characterized in that: the intelligent control system comprises a PLC, and the model of the PLC is SMART 200.
3. The remote diagnosis system of the medium frequency electric furnace and the diagnosis method thereof according to claim 2, characterized in that: the PLC is in communication connection with the VA-1512 series main control board through a 485 communication interface, a pin l01, a pin l02 and a pin l03 of the VA-1512 series main control board are connected with a data acquisition system, a pin U11 and a pin U12 of the VA-1512 series main control board are connected with one end of a transformer T1, a pin P11, a pin P10 and a pin P12 of the VA-1512 series main control board are connected with an inverter pulse board, and the VA-1512 series main control board is further connected with a display panel.
4. The remote diagnosis system of the medium frequency electric furnace and the diagnosis method thereof according to claim 2, characterized in that: the remote diagnosis system of the intermediate frequency electric furnace further comprises a 2500KVA transformer T, the 2500KVA transformer T is connected with one end of a circuit breaker Q1, the other end of the circuit breaker Q1 is connected with one end of a rectification controllable V1, one end and the other end of the rectification controllable V1 are connected with one end of a silicon controlled rectifier V2, one end of a filter capacitor C1 and one end of a resonant capacitor C2, the other end of the resonant capacitor C2 is connected with one end of a resonant capacitor C3, one end of a furnace body induction coil R1 and one end of a capacitor C4, the other end of the resonant capacitor C3 is connected with one end of a transformer T1, and the other end of the furnace body induction coil R1 and the other end of the capacitor C4 are connected with a silicon controlled rectifier output row W and the other end of the transformer T1.
5. The remote diagnosis system of the medium frequency electric furnace and the diagnosis method thereof according to claim 4, characterized in that: the other end of the controllable silicon V2 is connected with one end of a breaker Q2, the other end of the breaker Q2 is connected with one end of a 2500KVA transformer T and one end of an air switch KV1, the other end of the air switch KV1 is connected with one end of an alternating current contactor CJ1 and one end of a control stop button SE1, the other end of the stop button SE1 is connected with one end of an external control terminal row, the other end of the external control terminal row is connected with one end of a normally open contact of the alternating current contactor CJ1 and one end of a control start button SE2, the other end of the normally open contact of the alternating current contactor CJ1 and the other end of the control start button SE2 are connected with one end of a coil of the alternating current contactor CJ1, and the other end of the coil of the alternating current contactor CJ1 is connected with the other end of the air switch KV 1.
6. The remote diagnosis system of the medium frequency electric furnace and the diagnosis method thereof according to claim 5, characterized in that: the other end of the alternating current contactor CJ1 is connected with one end of an isolation transformer T2, one end of a transformer BK2 and one end of a measuring instrument power transformer T3, the other end of the measuring instrument power transformer T3 is connected with one end of a temperature controller SW1 and a temperature probe, the other end of the temperature controller SW1 and the other end of the transformer BK2 are connected with double rectification protection boards, the other end of the isolation transformer T2 is connected with a switching power supply, and the switching power supply is further connected with a PLC.
7. A diagnosis method of a remote diagnosis system of a medium frequency electric furnace according to any one of claims 1 to 6, characterized in that: the diagnostic method comprises the following steps:
step 1, detecting the output current of the 1# silicon controlled rectifier, the output current of the 2# silicon controlled rectifier, the output current of the 3# silicon controlled rectifier and the output current of the 4# silicon controlled rectifier;
step 2, performing data conversion on the detected 1# silicon controlled output current, 2# silicon controlled output current, 3# silicon controlled output current and 4# silicon controlled output current, and transmitting the data to a PLC control system through an analog input channel;
step 3, comparing and judging data, wherein four groups of silicon controlled rectifier output circuits are equal when the silicon controlled rectifier normally works, and if three output currents are equal and one output current is not or slightly different by more than 10%, judging that the silicon controlled rectifier which is not output is damaged;
and 4, outputting the judgment result through a human-computer interface, an audible and visual alarm, a mobile phone APP push and the like.
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Application publication date: 20210924 |