CN116722749A - Intermediate frequency power supply device for high-temperature blade precision smelting furnace and intelligent control method - Google Patents
Intermediate frequency power supply device for high-temperature blade precision smelting furnace and intelligent control method Download PDFInfo
- Publication number
- CN116722749A CN116722749A CN202310696486.6A CN202310696486A CN116722749A CN 116722749 A CN116722749 A CN 116722749A CN 202310696486 A CN202310696486 A CN 202310696486A CN 116722749 A CN116722749 A CN 116722749A
- Authority
- CN
- China
- Prior art keywords
- temperature
- power supply
- module
- control
- intermediate frequency
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000003723 Smelting Methods 0.000 title claims abstract description 26
- 238000010438 heat treatment Methods 0.000 claims abstract description 42
- 238000006243 chemical reaction Methods 0.000 claims abstract description 19
- 238000004891 communication Methods 0.000 claims description 31
- 238000004321 preservation Methods 0.000 claims description 5
- 238000011065 in-situ storage Methods 0.000 claims description 4
- 239000003990 capacitor Substances 0.000 claims description 3
- 238000001914 filtration Methods 0.000 claims description 3
- 238000003754 machining Methods 0.000 abstract 1
- 230000006698 induction Effects 0.000 description 13
- 230000000630 rising effect Effects 0.000 description 11
- 238000001816 cooling Methods 0.000 description 9
- 238000005495 investment casting Methods 0.000 description 7
- 238000005266 casting Methods 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 238000009529 body temperature measurement Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000001360 synchronised effect Effects 0.000 description 2
- 206010063385 Intellectualisation Diseases 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000000306 component Substances 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000004377 microelectronic Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M5/00—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases
- H02M5/40—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc
- H02M5/42—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters
- H02M5/44—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters using discharge tubes or semiconductor devices to convert the intermediate dc into ac
- H02M5/453—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters using discharge tubes or semiconductor devices to convert the intermediate dc into ac using devices of a triode or transistor type requiring continuous application of a control signal
- H02M5/458—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters using discharge tubes or semiconductor devices to convert the intermediate dc into ac using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/0048—Circuits or arrangements for reducing losses
- H02M1/0054—Transistor switching losses
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/66—Arrangements for connecting between networks having differing types of switching systems, e.g. gateways
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L67/00—Network arrangements or protocols for supporting network services or applications
- H04L67/14—Session management
- H04L67/141—Setup of application sessions
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/02—Induction heating
- H05B6/04—Sources of current
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/02—Induction heating
- H05B6/06—Control, e.g. of temperature, of power
- H05B6/067—Control, e.g. of temperature, of power for melting furnaces
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L2012/40208—Bus networks characterized by the use of a particular bus standard
- H04L2012/40221—Profibus
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L2012/40208—Bus networks characterized by the use of a particular bus standard
- H04L2012/40228—Modbus
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Landscapes
- Engineering & Computer Science (AREA)
- Computer Networks & Wireless Communication (AREA)
- Signal Processing (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- General Induction Heating (AREA)
Abstract
The invention discloses an intermediate frequency power supply device and an intelligent control method for a high-temperature blade precision smelting furnace, wherein the intermediate frequency power supply device comprises an input module, a conversion device, an output module and a protection module, and the modules are electrically connected to exchange energy and data; the intermediate frequency power supply device also comprises an intelligent module, wherein the intelligent module comprises a local control module and a remote control module, and further comprises an operation control module, the operation control module enables the output intermediate frequency power supply to have 4 operation control modes, and the 4 operation modes are respectively: constant current control, constant power control, constant temperature control and process program operation. By adopting the invention, the technical problems of low electric energy conversion efficiency and unintelligy are solved, the stability and consistency of the implementation of the high-temperature heating process are ensured, and the quality and the machining precision of the blade are improved.
Description
Technical Field
The invention belongs to a high-temperature generating device and an intelligent control method of a blade precision smelting furnace, and relates to an intermediate-frequency power supply device and an intelligent control method for the high-temperature blade precision smelting furnace. The invention solves the technical problems of low electric energy conversion efficiency and inauguration, ensures the implementation stability and consistency of the high-temperature heating process, and improves the quality and processing precision of the blade.
Background
In heavy duty gas turbine products, the most central and critical technology is investment precision casting production of high temperature blades. The main technical process of blade investment precision casting comprises the following steps: core making, molding, shell making, dewaxing, roasting, vacuum remelting casting and cleaning. In the process, the remelting casting process is the core of the whole blade investment precision casting process, and the stability and consistency of process implementation are directly related to the quality and qualification rate of blade castings. "vacuum remelting casting" refers to a process of melting a master alloy by heating and casting by intermediate frequency induction in a vacuum investment casting furnace. Particularly for investment casting production of blades for higher grade heavy duty gas turbine products of 300MW, 400MW and the like, the investment casting production of the blades is more critical and core components, and the production of investment casting, particularly high temperature, is the key. At present, an intermediate frequency induction heating power supply is generally used for heating and completing the generation and control of high temperature, but the current intermediate frequency power supply has low electric energy conversion efficiency and is not intelligent.
As a core device for induction heating, an intermediate frequency induction heating power supply is gradually mature as power electronics technology, microelectronics technology and modern control technology develop. Since induction heating technology was applied to industrial production, a great deal of research has been conducted on induction heating power supplies, forming a wide variety of modes of operation and power control. At present, the induction heating power supply mainly has the defects of low electric energy conversion efficiency, low power density per unit volume of the device, large EMI and the like. In order to obtain higher power conversion efficiency, the power supply device is required to have higher input and output power factors, and realize soft switching of power electronic devices so as to reduce switching loss. In order to obtain a large power density, it is required to reduce the volume of the power supply device as much as possible. In order to reduce the EMI of the system, the voltage and the current of the power supply system are ensured to be sine waves, the harmonic component is avoided, and the switching noise of electronic and electronic devices is low. Due to limitations of the current power control mode and the main circuit topology, it becomes very difficult to simultaneously realize the above requirements in the induction heating power supply.
In the prior art, CN113122686a discloses a synchronous induction heating device for gears and a using method thereof, comprising a workbench; the horizontal transverse cantilever of workstation is last to install drive controller, drive controller is connected with the friction pulley, and the friction pulley top is provided with high-frequency coil pipeline and intermediate frequency coil pipeline, and high-frequency coil pipeline is connected with high-frequency power, and intermediate frequency coil pipeline is connected with intermediate frequency power, and high-frequency coil pipeline is connected with cooling controller's water inlet, and intermediate frequency coil pipeline is connected with cooling controller's delivery port, and high-frequency coil pipeline and intermediate frequency coil pipeline all are connected with the induction heating stick, place the gear on the disc of workstation, and the induction heating stick is located the tooth's socket of gear. By adjusting the input frequency of the power supply, the gear is subjected to heat treatment by adopting the synchronous electromagnetic induction heating of the medium-frequency coil and the high-frequency coil, and the phenomenon that the hardening tissue is remarkably differentiated due to uneven distribution of a single-frequency induction heating temperature field in the gear tooth profile direction is avoided. But the structure is complex, the processed workpiece is smaller, and the device is not suitable for heating a large blade smelting furnace.
Disclosure of Invention
The invention aims to solve the technical problems of low electric energy conversion efficiency and non-intelligent in the prior art, and provides an intermediate frequency power supply device for a high-temperature blade precision smelting furnace and an intelligent control method. Thereby ensuring the implementation stability and consistency of the high-temperature heating process and improving the quality and processing precision of the blade.
The invention comprises the following steps: an intermediate frequency power supply device for a high-temperature blade precision smelting furnace is characterized in that: the intermediate frequency power supply device comprises an input module, a conversion device, an output module and a protection module, wherein the modules are electrically connected to exchange energy and data.
Further, to accommodate multi-capability staged output, the output module is capable of outputting 250KW, 150KW, and 100KW; the conversion device includes an inverter; the input module is a rectifying diode and an alternating current contactor, the rectifying diode rectifies three-phase input voltage into direct current, the alternating current contactor is connected to an inverter, the inverter is an IGBT full-bridge inverter, and the inverter can generate high-frequency alternating current voltage and output the high-frequency alternating current voltage to the transformer; for safety and high reliability and intelligent control of the output of the heating temperature, the protection module comprises one or both of an incoming air switch and/or an air switch.
Further, the conversion device comprises a 3-phase bridge rectifier, a filter capacitor, a buffer resistor, a buffer contactor, a reactor and an inverter, wherein the inverter is an IGBT full-bridge inverter, and can generate high-frequency alternating voltage and output intermediate-frequency alternating voltage to a transformer;
further, for output smoothness and reliability, the rectifier and the inverter adopt large-capacitance filtering, the alternating-current contactor outputs a series reactor, and the parallel resistor is arranged on the alternating-current contactor.
Furthermore, in order to realize intelligent control, the intermediate frequency power supply device for the high-temperature blade precision smelting furnace is characterized in that: the intelligent module comprises two modules, namely an in-situ control module and a remote control module.
Furthermore, in order to realize intelligent control, the intermediate frequency power supply device for the high-temperature blade precision smelting furnace is characterized in that: the intelligent module also comprises an operation control module, the operation control module enables the output intermediate frequency power supply to have 4 operation control modes, and the 4 operation modes are respectively: constant current control, constant power control, constant temperature control and process program operation.
Further, the 4 operation modes are respectively:
the first mode of operation is constant current control, and constant current control is: the constant output current operation is the most conventional operation mode, and the operation mode of equipment output is controlled by adjusting the output current of the device;
the second mode of operation is constant power control, which is: the constant output power is operated, and the operation mode of equipment output is controlled by adjusting the output power of the device;
the third mode of operation is constant temperature control, which is: the power supply automatically adjusts the output current and the power by adjusting the target temperature to which the workpiece needs to be heated, so that the workpiece can keep a constant operation mode after reaching the target temperature;
the fourth mode of operation is a process program mode of operation.
Further, for the temperature is more controllable, high temperature blade intermediate frequency power supply unit for precision smelting furnace, its characterized in that: the third operation mode constant temperature control further comprises a temperature feedback module, a heating rate setting module and a PID parameter setting module;
wherein, the temperature feedback module: the temperature information (or signal) can be obtained through an external temperature sensor, and the temperature information is converted into a standard signal and then is input into a power supply for control;
wherein, set up the warm rate module: setting a proper heating rate through a parameter of 'temperature change rate', so that the temperature is linear or non-increased;
wherein, the PID parameter setting module: in a constant temperature control mode, the power supply automatically adjusts output power through a built-in PID control program, proper constant temperature PID parameters are set through parameters, heating according to a set heating rate can be achieved, overshoot is avoided after the temperature reaches a target temperature linearly or nonlinearly, then heat preservation is automatically carried out, and the temperature of a workpiece is kept unchanged at the target temperature;
further, the intermediate frequency power supply device for the high-temperature blade precision smelting furnace is characterized in that: the fourth operation mode is a process program operation mode, and the process program operation mode is as follows: n process programs may be set and stored, each process program may add M programmable (panel input) process segments, each process segment may be customized to Z modes of operation. Wherein N, M and Z are positive integers.
Another aspect of the invention is: a communication system of an intermediate frequency power supply, characterized in that: the communication system of the intermediate frequency power supply comprises a master station, a slave station, a communication protocol of the master station and a communication rule of the slave station;
the communication rule is that the intermediate frequency power supply device adopts MODBUS communication protocol, the master station (s 7-400 PLC) adopts PROFIBUS-DP communication protocol, and communication of two networks is established through the gateway PM-60; the upper computer communication protocol is PROFIBUS-DP, which also serves as a slave station of the master station (s 7-400 PLC).
Compared with the prior art, the invention has the following characteristics and beneficial effects:
(1) The technical scheme disclosed by the invention improves the electric energy conversion efficiency, reduces the switching loss, breaks through the limitation of a main circuit topology structure, innovates a new circuit topology structure, and solves the technical problem of simultaneously realizing a plurality of requirements in an induction heating power supply;
(2) The medium-frequency power supply device and the intelligent control method for the high-temperature blade precision smelting furnace ensure the implementation stability and consistency of a high-temperature heating process and improve the quality and processing precision of the blade;
(3) The total power of the intermediate frequency power supply device disclosed by the technical scheme of the invention can be 500KW, and can be further subdivided into 250KW, 150KW and 100KW, and the structure mode of one driving three is adopted, so that the volume of the device can be effectively reduced, and the better power density can be obtained; and the power factor can be more than 0.9 by adopting a DSP all-digital control mode, so that the power factor conversion efficiency is higher.
Drawings
FIG. 1 is a schematic diagram of an intermediate frequency power supply device for a high temperature blade precision smelting furnace according to an embodiment of the present invention;
fig. 2 is a schematic diagram of a communication network structure of an intermediate frequency power supply according to the present invention.
Detailed Description
The following examples are intended to further illustrate the present invention but are not to be construed as limiting its scope, as many insubstantial modifications and adaptations of the invention that are within the scope of the invention as described above would be within the skill of the art.
Examples: see the drawings.
Note that: the system principle of the intermediate frequency power supply is the prior art, so a schematic diagram is not drawn.
The embodiment of the invention provides an intermediate frequency power supply device for a high-temperature blade precision smelting furnace, which comprises an input module, a conversion device, an output module and a protection module, wherein the modules are electrically connected to exchange energy and data.
Further, to accommodate multi-capability staged output, the output module is capable of outputting 250KW, 150KW, and 100KW; wherein the conversion device comprises an inverter; the input module is a rectifying diode and an alternating current contactor, the rectifying diode rectifies the three-phase input voltage into direct current, the alternating current contactor is connected to an inverter, the inverter is an IGBT full-bridge inverter, and the inverter can generate high-frequency alternating current voltage and output the high-frequency alternating current voltage to a transformer.
For safety and high reliability and intelligent control of the output of the heating temperature, the protection module of the intermediate frequency power supply device comprises one or two of an incoming line air switch and/or an air switch; the conversion device comprises a 3-phase bridge rectifier, a filter capacitor, a buffer resistor, a buffer contactor, a reactor and an inverter, wherein the inverter is an IGBT full-bridge inverter, and the inverter can generate high-frequency alternating voltage and output intermediate-frequency alternating voltage to the transformer.
Further, for output smoothness and reliability, the rectifier and the inverter adopt large-capacitance filtering, the alternating-current contactor outputs a series reactor, and the parallel resistor is arranged on the alternating-current contactor.
Furthermore, in order to realize intelligent control, the invention provides an intermediate frequency power supply device for a high-temperature blade precision smelting furnace, which also comprises an intelligent module, wherein the intelligent module comprises two modules, namely a local control module and a remote control module, the local control module realizes a local control function, and the remote control module realizes a remote control function. The local control module can control the power supply through the operation panel without starting a remote control function, and is called local control; the remote control module is used for controlling the power supply through analog input/output, IO input/output or serial communication of a user interface when starting a remote control function, and is called remote control.
Furthermore, in order to realize intelligent control, the invention provides an intelligent module of an intermediate frequency power supply device for a high-temperature blade precision smelting furnace, which further comprises an operation control module, wherein the operation control module enables the output intermediate frequency power supply to have 4 operation control modes, and the 4 operation modes respectively: constant current control, constant power control, constant temperature control and process program operation.
Wherein, the first operation mode is constant current control, and constant current control: the constant output current operation is the most common operation mode, and the operation mode of equipment output is controlled by adjusting the output current of the device. When the constant-current operation mode is selected, after the target current is set, the current on the inductor is kept unchanged all the time regardless of the change of the load, and the output power is changed along with the change of the load.
Wherein, the second mode of operation is constant power control, which: the constant output power is used for running, and the running mode of the equipment output is controlled by adjusting the output power of the device. When the constant power control mode is selected, when the load changes, the magnitude of the output current is automatically adjusted to meet the condition that the output power is unchanged, but because of different load impedance, the actual output power of the device is limited by rated current, when the output current reaches the rated current and the output power fails to reach the target value, the device keeps rated current output, and therefore, too high power setting can not be reached due to the rated current limitation.
Wherein, the third operation mode is constant temperature control, the constant temperature control: the power supply automatically adjusts the output current and the power by adjusting the target temperature to which the workpiece needs to be heated, so that the workpiece can keep a constant operation mode after reaching the target temperature. When the constant temperature control mode is selected, a temperature signal is transmitted to the device through the temperature sensor, the device can automatically adjust the output power to heat the workpiece to the set target temperature, and then the device automatically keeps the temperature.
Further, for the temperature to be more controllable, the third operation mode constant temperature control further comprises a temperature feedback module, a temperature rising rate setting module and a PID parameter setting module.
Wherein, this temperature feedback module: the temperature information (or signal) can be obtained by an external temperature sensor, converted into a standard signal and then input into a power supply for control. When the constant temperature closed-loop control is used, the device needs to collect real-time temperature signals of the workpiece through temperature sensing, then converts the real-time temperature signals into 4-20mA or 1-5V, and is connected with the equipment through a user interface analog input interface. When the system is operated in situ, at most two paths of temperature signals can be collected simultaneously, and a high temperature point is automatically selected for control. During remote control, the temperature can only be acquired through the second channel input by analog quantity, and the first channel input is converted into a set target temperature value. It should be noted that: the temperature measuring point must be in the heated area of the workpiece, and the temperature sensor is preferably arranged at the highest temperature point of the workpiece, and the temperature sensor with longer time delay for measuring the temperature is not preferably selected in the occasion requiring high heating speed, so that the condition of heating overtemperature is avoided due to larger temperature feedback period.
The common temperature sensor is a thermocouple and an infrared thermometer. When the thermocouple is used for measuring temperature, a temperature signal transmitter is required to be installed, and mV signals output by the thermocouple are converted into 1-5V standard signals; when the infrared thermometer is adopted, the output signal of the infrared thermometer needs to be 1-5V or 4-20 mA. The response speed of the infrared thermometer is high, which can reach tens of milliseconds, the temperature of the workpiece can be reflected rapidly and accurately, and the temperature measurement delay is small; the response time of the thermocouple is longer and is generally more than a few seconds, and for the application occasions with faster heating, the temperature acquired by the power supply can be delayed, so that the actual temperature of the workpiece is too high. The response time parameter of the built-in temperature sensor of the power supply is an inertia time constant, and software can calculate the actual temperature of the workpiece through an inertia link transfer function to control the temperature, so that the workpiece can be effectively prevented from being over-heated due to temperature measurement delay. When the constant-temperature closed-loop control is used, if the temperature sensor is not connected, the power supply can generate 'main temperature control wire break' protection and can not heat.
Wherein, set up the heating rate module: by setting the proper heating rate through the parameter 'temperature change rate', the temperature is linear or nongrowing, the temperature rate can be set to be 0-1638.3 ℃/s (seconds), 0-1638.3 ℃/M (minutes) and 0-1638.3 ℃/H (hours), the time unit conversion can be automatically converted by adding the parameter setting value to be more than 1638.3, for example, when the heating rate is currently set to be 1000 ℃/M, the parameter is changed to be more than 1638.3 ℃/M, the temperature is automatically converted to be 0.0 ℃/s, and the temperature is added to be more than 1638.3 ℃/s and converted to be 0.0 ℃/H. It should be noted that: the set heating rate is not too large, and the heating rate is required to be within a temperature rate range which can be met when the maximum power of the power supply is output, otherwise, the power supply can always output the maximum power, and if the PID parameter is improperly set, the workpiece can be overtemperature.
Wherein, PID parameter sets up the module: in the constant temperature control mode, the power supply automatically adjusts output power through a built-in PID control program, and proper constant temperature PID parameters are set through parameters, so that heating according to a set heating rate can be realized, overshoot is avoided after the temperature reaches the target temperature linearly or nonlinearly, then heat preservation is automatically carried out, and the temperature of a workpiece is kept unchanged at the target temperature. To achieve a perfect temperature profile, it is necessary to set suitable PID parameters, different workpieces and processes, and after the suitable PID parameters are set in advance, if the workpiece and process have little variation, no modification is needed. Under proper working conditions, the second-level rapid temperature control can be realized at the fastest speed through PID parameter adjustment, namely, the higher target temperature can be rapidly reached within a few seconds and kept unchanged.
Finally, the fourth mode of operation is a process program mode of operation, the process program mode of operation: by performing multiple segments of the process program on the power supply, the apparatus operates in accordance with the operating mode of the process program automatically. Wherein, a complex multi-section control process and heat treatment process curve can be realized by adopting a process program operation mode.
In the process program operation mode of the fourth operation mode of the intermediate frequency power supply device disclosed by the embodiment of the invention, N process programs can be set and stored, M programmable (panel input) process sections can be added to each process program, and each process section can be customized into Z operation modes. Wherein N, M and Z are positive integers.
Further, N of the above-mentioned N process programs can be set and stored at most for 16 process programs (1= < n= < 16); m values in the M programmable (panel input) process sections are more than or equal to 1 and less than or equal to 32 (1= < N= < 32), and 32 programmable (panel input) process sections can be added into each process program; the modes of operation of the Z species (1= < z= < 32) may be at least one or seven of one, two, three, four, five, six and/or seven.
Further, the M process segments include seven modes of operation: constant current operation, constant temperature rate operation, manual adjustment, constant power operation, cyclic operation and stop operation.
Constant flow operation: the output current target value, the operation time and the current rising rate can be set, the current rising rate can be set to be unchanged after the output current rises from 0 to the target value according to a certain rate, and the output current rises to the target value according to a maximum rate when being set to 0.
And (3) operating at constant temperature: the heat preservation temperature value and the heat preservation time can be set, the initial current can be set through the preset PID integral value after the section, the temperature of the workpiece is prevented from being reduced due to the fact that the output current starts to integrate from 0, and an external temperature sensor is needed to detect the temperature of the workpiece by the section; the PID parameter and the temperature rising rate parameter in the parameter set can be used for constant temperature timing operation.
Constant temperature rate operation: the temperature rising speed and the temperature rising target temperature can be set, and the temperature falling speed and the temperature lowering target value can also be set, for example, the speed is set to be 100 ℃/s, the target temperature is 600 ℃, and the equipment automatically jumps to the next section after rising to 600 ℃ at the speed of rising by 100 ℃ per second; if the speed is set to be-10 ℃/s, the target temperature is 200 ℃, and the equipment automatically jumps to the next stage after being cooled to 200 ℃ at the speed of 10 ℃ per second.
Of particular note is: in the initial stage, the cooling rate set by the intermediate frequency power supply can be no more than natural cooling rate, because the power supply is not provided with a refrigerating function, if the function of the intermediate frequency power supply is really used, the cooling rate is required to be higher than the natural cooling rateExternal connectionThe temperature sensor detects the temperature of the workpiece and uses the timing function of the section.
Meanwhile, in order to further improve the control intellectualization, the intermediate frequency power supply is further provided with a refrigerating module and a timing module, the refrigerating module and the timing module are mutually matched to meet the technical effect of rapid cooling in a certain time, the cooling rate can be higher than the natural cooling rate, and an external temperature sensor detects the temperature of a workpiece and the timing module is used for completing the timing function.
Manual adjustment operation: when the current enters the section, the output current can be adjusted through the potentiometer on the operation panel, the running time can be set, and the current automatically jumps to the next section after the running time arrives.
Constant power operation: the output power target value, the running time and the power rising rate can be set, the output power can be set to be unchanged after rising from 0 to the target value according to a certain rate, and the output power can be set to be unchanged after rising to the target value according to a maximum rate when being set to 0;
and (3) circularly running: the method can be set to return to a certain section before to rerun, and the cycle time can be set after rerun to the present section;
stopping operation: when the operation is completed in the section, the equipment stops outputting, and if other sections exist after the section, the operation is not continued.
In addition, the embodiment of the invention also discloses a communication system and a communication method of the intermediate frequency power supply, wherein the communication method of the intermediate frequency power supply comprises the following communication rules: the communication system comprises a master station and a slave station and a communication protocol of the master station and the slave station.
The communication rule is that the intermediate frequency power supply device adopts MODBUS communication protocol, the master station (s 7-400 PLC) adopts PROFIBUS-DP communication protocol, and the communication of two networks is established through the gateway PM-60; the upper computer communication protocol is PROFIBUS-DP, which also serves as a slave station of the master station (s 7-400 PLC).
The technical contents of the invention and the technical contents not specifically described in the above embodiments are the same as the prior art, and the raw materials are all commercial products.
The present invention is not limited to the above-described embodiments, and the present invention can be implemented with the above-described advantageous effects.
Claims (10)
1. An intermediate frequency power supply device for a high-temperature blade precision smelting furnace is characterized in that: the intermediate frequency power supply device comprises an input module, a conversion device, an output module and a protection module, wherein the modules are electrically connected to exchange energy and data.
2. The intermediate frequency power supply device for a high temperature blade precision smelting furnace according to claim 1, wherein: the output module can output 250KW, 150KW and 100KW; the conversion device includes an inverter; the input module is a rectifying diode and an alternating current contactor, the rectifying diode rectifies three-phase input voltage into direct current, the alternating current contactor is connected to an inverter, the inverter is an IGBT full-bridge inverter, and the inverter can generate high-frequency alternating current voltage and output the high-frequency alternating current voltage to the transformer; the protection module comprises one or two of an incoming line air switch and/or an air switch.
3. An intermediate frequency power supply device for a high temperature blade precision smelting furnace according to claim 1 or 2, characterized in that: the conversion device comprises a 3-phase bridge rectifier, a filter capacitor, a buffer resistor, a buffer contactor, a reactor and an inverter, wherein the inverter is an IGBT full-bridge inverter, and can generate high-frequency alternating voltage and output intermediate-frequency alternating voltage to a transformer; the rectifier and the inverter adopt large-capacitance filtering, the output of the alternating current contactor is connected with the reactor in series, and the alternating current contactor is connected with the resistor in parallel.
4. An intermediate frequency power supply device for a high temperature blade precision smelting furnace according to claim 1 or 2, characterized in that: the intelligent module comprises two modules, namely an in-situ control module and a remote control module.
5. A medium frequency power supply device for a high temperature blade precision smelting furnace according to claim 3, wherein: the intelligent module comprises two modules, namely an in-situ control module and a remote control module.
6. The intermediate frequency power supply device for high temperature blade precision smelting furnace according to claim 4, wherein: the intelligent module also comprises an operation control module, the operation control module enables the output intermediate frequency power supply to have 4 operation control modes, and the 4 operation modes are respectively: constant current control, constant power control, constant temperature control and process program operation.
7. The intermediate frequency power supply device for high temperature blade precision smelting furnace according to claim 6, wherein: the 4 operation modes are respectively:
the first mode of operation is constant current control, and constant current control is: the constant output current operation is the most conventional operation mode, and the operation mode of equipment output is controlled by adjusting the output current of the device;
a second mode of operation constant power control, the constant power control being: the constant output power is operated, and the operation mode of equipment output is controlled by adjusting the output power of the device;
a third mode of operation constant temperature control, the constant temperature control being: the power supply automatically adjusts the output current and the power by adjusting the target temperature to which the workpiece needs to be heated, so that the workpiece can keep a constant operation mode after reaching the target temperature;
the fourth mode of operation is a process program mode of operation.
8. The intermediate frequency power supply device for a high temperature blade precision smelting furnace according to claim 7, wherein: the third operation mode constant temperature control further comprises a temperature feedback module, a heating rate setting module and a PID parameter setting module;
wherein, the temperature feedback module: the temperature information (or signal) can be obtained through an external temperature sensor, and the temperature information is converted into a standard signal and then is input into a power supply for control;
wherein, set up the warm rate module: setting a proper heating rate through a parameter of 'temperature change rate', so that the temperature is linear or non-increased;
wherein, the PID parameter setting module: in the constant temperature control mode, the power supply automatically adjusts output power through a built-in PID control program, and proper constant temperature PID parameters are set through parameters, so that heating according to a set heating rate can be realized, overshoot is avoided after the temperature reaches the target temperature linearly or nonlinearly, then heat preservation is automatically carried out, and the temperature of a workpiece is kept unchanged at the target temperature.
9. The intermediate frequency power supply device for a high temperature blade precision smelting furnace according to claim 8, wherein: the fourth operation mode is a process program operation mode, and the process program operation mode is as follows: n process programs can be set and stored, each process program can be added with M programmable (panel input) process sections, and each process section can be customized into Z running modes; wherein N, M and Z are positive integers.
10. A communication system of an intermediate frequency power supply, characterized in that: the communication system of the intermediate frequency power supply comprises a master station, a slave station, a communication protocol of the master station and a communication rule of the slave station;
the communication rule is that the intermediate frequency power supply device adopts MODBUS communication protocol, the master station adopts PROFIBUS-DP communication protocol, and communication of two networks is established through the gateway PM-60; the upper computer communication protocol is PROFIBUS-DP, which also serves as a slave station of the master station.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310696486.6A CN116722749A (en) | 2023-06-13 | 2023-06-13 | Intermediate frequency power supply device for high-temperature blade precision smelting furnace and intelligent control method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310696486.6A CN116722749A (en) | 2023-06-13 | 2023-06-13 | Intermediate frequency power supply device for high-temperature blade precision smelting furnace and intelligent control method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN116722749A true CN116722749A (en) | 2023-09-08 |
Family
ID=87865647
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310696486.6A Pending CN116722749A (en) | 2023-06-13 | 2023-06-13 | Intermediate frequency power supply device for high-temperature blade precision smelting furnace and intelligent control method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN116722749A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117348499A (en) * | 2023-11-24 | 2024-01-05 | 山东鼎晟电气科技有限公司 | Remote regulation and control system based on series resonance intermediate frequency induction smelting furnace |
-
2023
- 2023-06-13 CN CN202310696486.6A patent/CN116722749A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117348499A (en) * | 2023-11-24 | 2024-01-05 | 山东鼎晟电气科技有限公司 | Remote regulation and control system based on series resonance intermediate frequency induction smelting furnace |
| CN117348499B (en) * | 2023-11-24 | 2024-02-27 | 山东鼎晟电气科技有限公司 | Remote regulation and control system based on series resonance intermediate frequency induction smelting furnace |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN116722749A (en) | Intermediate frequency power supply device for high-temperature blade precision smelting furnace and intelligent control method | |
| CN109519232A (en) | SHRT unit frequency-conversion device auto-adjustment control method synchronous with turbine speed | |
| CN101720146B (en) | Control method of embedding depth of electrode into ore-smelting electric furnace | |
| CN107876563A (en) | A kind of system of the continuous casting and rolling based on Frequency Induction Heating | |
| CN102230748B (en) | Temperature control system of high temperature furnace | |
| CN108390571A (en) | A kind of tundish electromagnetic heating power supply constant-temperature control method | |
| CN202141955U (en) | High temperature furnace temperature control system based on PLC | |
| CN109268079A (en) | The duty control method of steam turbine in Rotation Process drops in SHRT unit frequency-conversion | |
| CN208509304U (en) | Timesharing exports induction heating power | |
| CN208432894U (en) | A kind of toughened glass production line control system | |
| CN108437176A (en) | A kind of high-frequency current heating curing method for reinforced concrete member production | |
| CN103647460A (en) | Implementation method for medium-frequency heating power supply of reduction furnace | |
| CN109871049B (en) | Multi-zone temperature control system of hot forming equipment | |
| CN109287020A (en) | It is a kind of for promoting the microwave source system and method for microwave output stability | |
| CN202989228U (en) | Large-space hearth of vacuum furnace for heat treatment | |
| CN201807810U (en) | Supersonic frequency brazing device | |
| CN209390403U (en) | It is a kind of for promoting the microwave source system of microwave output stability | |
| CN104570912A (en) | Full-automatic smelting control system and control method for polycrystalline silicon | |
| CN204761745U (en) | Servo heating system | |
| CN202968127U (en) | Automatic temperature control operation system for graphite purification | |
| CN113654202A (en) | Control method and device of three-phase direct-current variable frequency air conditioner | |
| CN213073154U (en) | Automatic induction heating of impedance adjustment, melting variable frequency power supply system | |
| CN205945533U (en) | Electrophoresis electrical power unit | |
| CN111918434A (en) | Induction heating and melting system with automatic impedance adjustment function and adjustment method | |
| CN112456770B (en) | Toughened glass controllable steady-flow heating method based on heating furnace |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |