CN117170300A - An automatic gas distribution and temperature rising sintering control device for soft ferrite - Google Patents
An automatic gas distribution and temperature rising sintering control device for soft ferrite Download PDFInfo
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- 238000009826 distribution Methods 0.000 title claims abstract description 42
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- 229910001035 Soft ferrite Inorganic materials 0.000 title description 8
- 239000007789 gas Substances 0.000 claims abstract description 75
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 49
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Abstract
Description
技术领域Technical field
本发明属于PLC控制技术技术领域,尤其涉及一种软磁铁氧体自动配气升温烧结控制装置。The invention belongs to the technical field of PLC control technology, and in particular relates to an automatic gas distribution and temperature rising sintering control device for soft ferrite.
背景技术Background technique
随着电子信息技术的发展,软磁铁氧体材料越来越倾向于高档次,小批量,多品种,交货周期短,一致性好等,以往的推板式气氛保护烧结窑渐渐不能满足这种高档产品和多变的要求。With the development of electronic information technology, soft ferrite materials tend to be more and more high-grade, small batches, multiple varieties, short delivery cycle, good consistency, etc. The previous push plate type atmosphere protection sintering kiln is gradually unable to meet this requirement. High-end products and changing requirements.
自动化设备在各个行业的生产过程中的应用越来越广泛,其中PLC控制技术已成为工业自动化的核心技术之一,具有很高的可靠性、高效性、灵活性和易维护等优点。自动配气升温控制装置,广泛应用于耐火材料、化工陶瓷、粉末冶金、电源能源、新材料等各个领域。自动配气升温控制装置是智能化工厂生产工艺过程中一道非常重要的工序,烧结控制的精准对整个产品质量的影响举足轻重。Automation equipment is increasingly used in the production processes of various industries. PLC control technology has become one of the core technologies of industrial automation, with the advantages of high reliability, efficiency, flexibility and easy maintenance. Automatic gas distribution and temperature rise control devices are widely used in various fields such as refractory materials, chemical ceramics, powder metallurgy, power energy, and new materials. The automatic gas distribution and temperature control device is a very important process in the production process of intelligent chemical plants. The accuracy of sintering control has a significant impact on the quality of the entire product.
因此,亟需一种自动化程度高、智能化的软磁铁氧体自动配气升温烧结控制装置。Therefore, there is an urgent need for a highly automated and intelligent soft ferrite automatic gas distribution and temperature rising sintering control device.
发明内容Contents of the invention
为解决上述技术问题,本发明提出了一种软磁铁氧体自动配气升温烧结控制装置,旨在解决节能降耗,程序升温,压力平衡,自动配气,采样测氧,记录查询等现有技术存在的问题。In order to solve the above technical problems, the present invention proposes an automatic gas distribution and temperature rising sintering control device for soft ferrite, aiming to solve existing problems such as energy saving and consumption reduction, programmed temperature rise, pressure balance, automatic gas distribution, sampling oxygen measurement, record query, etc. Technical problems.
为实现上述目的,本发明提供了一种软磁铁氧体自动配气升温烧结控制装置,包括:In order to achieve the above object, the present invention provides an automatic gas distribution and temperature rising sintering control device for soft ferrite, which includes:
PLC控制器及与所述PLC控制器电性连接的加热系统、控温系统、冷却系统、配气系统、压力系统、测氧系统和上位机;PLC controller and the heating system, temperature control system, cooling system, gas distribution system, pressure system, oxygen measurement system and host computer electrically connected to the PLC controller;
所述PLC控制器用于采集其余系统反馈的信息,并基于反馈的信息进行控制;The PLC controller is used to collect feedback information from other systems and perform control based on the feedback information;
所述加热系统用于对烧结炉的炉内温度进行加热;The heating system is used to heat the furnace temperature of the sintering furnace;
所述控温系统与所述加热系统电性连接,所述控温系统用于采集实时温度、对炉内温度进行设定,以及控制所述加热系统对炉内温度进行加热;The temperature control system is electrically connected to the heating system, and the temperature control system is used to collect real-time temperature, set the temperature in the furnace, and control the heating system to heat the temperature in the furnace;
所述冷却系统用于在测温元件检测到炉内温度达到冷却水设定开启温度后,将冷却水输送到烧结炉的冷却循环部位进行冷却,当炉内温度降低到℃以下时,冷却水关断。The cooling system is used to transport the cooling water to the cooling cycle part of the sintering furnace for cooling after the temperature measuring element detects that the temperature in the furnace reaches the set opening temperature of the cooling water. When the temperature in the furnace drops below ℃, the cooling water Shut down.
所述配气系统用于对不同气体进行比例配气混合,并将混合后的气体输送到炉内;The gas distribution system is used to proportionally mix different gases and transport the mixed gas to the furnace;
所述压力系统用于实时检测炉内压力,基于实际压力情况开启泄压或停止泄压;The pressure system is used to detect the pressure in the furnace in real time, and start or stop pressure relief based on the actual pressure situation;
所述测氧系统用于测氧系统用于测量炉内氧含量实时值,并将氧含量反馈给PLC控制器;The oxygen measuring system is used to measure the real-time value of oxygen content in the furnace and feed the oxygen content back to the PLC controller;
所述上位机用于人机交互及控制。The host computer is used for human-computer interaction and control.
可选的,所述PLC控制器包括采集模块、通讯模块、处理模块、执行模块;Optionally, the PLC controller includes a collection module, a communication module, a processing module, and an execution module;
所述采集模块用于采集若干种炉内信息,并将采集的炉内信息进行模数转换,获得数字信号,所述炉内信息包括气体流量信息、气压信息,水压信息、水流信息;The collection module is used to collect several types of furnace information, and perform analog-to-digital conversion on the collected furnace information to obtain digital signals. The furnace information includes gas flow information, air pressure information, water pressure information, and water flow information;
所述通讯模块用于通过Modbus RTU和TCP通讯方式读取写入数据到恒流调压模块、温控模块、测氧仪;The communication module is used to read and write data to the constant current voltage regulation module, temperature control module, and oxygen meter through Modbus RTU and TCP communication methods;
所述处理模块用于计算处理所述采集模块获得的数字信号,获得控制指令;The processing module is used to calculate and process the digital signals obtained by the acquisition module and obtain control instructions;
所述执行模块用于接收PLC控制器发出的控制指令,输出开关量或者模拟量信号到电磁阀门,气动阀门和三相调功器。The execution module is used to receive control instructions from the PLC controller and output switching or analog signals to electromagnetic valves, pneumatic valves and three-phase power regulators.
可选的,所述控温系统包括温控模块、测温元件;其中,Optionally, the temperature control system includes a temperature control module and a temperature measurement element; wherein,
所述测温元件用于采集热电动势信号,并将所述热电动势信号反馈给温控模块;The temperature measuring element is used to collect thermal electromotive force signals and feed back the thermal electromotive force signals to the temperature control module;
所述温控模块用于接收所述热电动势信号,获取升温信号,并传输给所述加热系统,还用于基于PLC控制器的控制指令进行控温。The temperature control module is used to receive the thermoelectromotive force signal, obtain the temperature rising signal, and transmit it to the heating system, and is also used to control the temperature based on the control instructions of the PLC controller.
可选的,所述加热系统包括若干个加热元件和恒流调压模块;其中,Optionally, the heating system includes several heating elements and constant current voltage regulation modules; wherein,
若干个所述加热元件通过多根串联,角形连接方式连接到一起;Several of the heating elements are connected together through multiple series and angular connections;
所述恒流调压模块用于接收所述温控模块的升温信号,基于所述升温信号控制若干个所述加热元件进行加热。The constant current voltage regulation module is used to receive a temperature rise signal from the temperature control module, and control several heating elements to perform heating based on the temperature rise signal.
可选的,所述冷却系统包括水压检测模块、水流检测模块、气动阀控模块;其中,Optionally, the cooling system includes a water pressure detection module, a water flow detection module, and a pneumatic valve control module; wherein,
所述水压检测模块用于实时检测来水水压,若来水水压大于等于预设的第一水压临界值,则生成水压过高信号传输给所述PLC控制器;The water pressure detection module is used to detect the incoming water pressure in real time. If the incoming water pressure is greater than or equal to the preset first water pressure threshold, an excessive water pressure signal is generated and transmitted to the PLC controller;
所述水流检测模块用于实时检测水流流量,若水流流量小于等于预设的第一流量临界值,则生成断流信号并传输给所述PLC控制器;The water flow detection module is used to detect the water flow in real time. If the water flow is less than or equal to the preset first flow threshold, a flow cutoff signal is generated and transmitted to the PLC controller;
所述气动阀控模块用于基于所述PLC控制器的控制指令进行冷却循环水的开启或关断。The pneumatic valve control module is used to turn on or off the cooling circulating water based on the control instructions of the PLC controller.
可选的,所述配气系统包括气体流量模块、气压检测模块、配气电磁阀控模块;其中,Optionally, the gas distribution system includes a gas flow module, a gas pressure detection module, and a gas distribution solenoid valve control module; wherein,
所述气体流量模块采用气体质量流量控制器控制通入炉内的N2或O2流量,并将实时流量值及异常信号反馈给所述PLC控制器;The gas flow module uses a gas mass flow controller to control the N2 or O2 flow into the furnace, and feeds real-time flow values and abnormal signals to the PLC controller;
所述气压检测模块用于实时检测来气压力是否为第一预设气压值,若是则正常输送气体,若不是则产生异常报警并反馈给所述PLC控制器;The air pressure detection module is used to detect in real time whether the incoming air pressure is the first preset air pressure value. If so, the gas will be delivered normally; if not, an abnormal alarm will be generated and fed back to the PLC controller;
所述配气电磁阀控模块用于配气流程开启后开启阀门。The gas distribution solenoid valve control module is used to open the valve after the gas distribution process is started.
可选的,所述压力系统包括本地压力检测模块、远传压力检测模块和阀控排气模块;其中,Optionally, the pressure system includes a local pressure detection module, a remote pressure detection module and a valve-controlled exhaust module; wherein,
所述本地压力检测模块用于实时就地检测炉内压力,所述本地压力大于等于第一压力设定值时,泄压阀开启,所述本地压力小于第一压力设定值时,泄压阀关闭;The local pressure detection module is used to detect the pressure in the furnace in real time. When the local pressure is greater than or equal to the first pressure setting value, the pressure relief valve is opened. When the local pressure is less than the first pressure setting value, the pressure relief valve is opened. valve closed;
所述远传压力检测模块用于实时远端检测炉内压力,若所述远端压力大于等于预设的第二压力值,则生成排气信号传输给所述PLC控制器,若所述远端压力小于预设的第二压力值,则生成关闭阀门信号传输给所述PLC控制器;The remote pressure detection module is used to remotely detect the pressure in the furnace in real time. If the remote pressure is greater than or equal to the preset second pressure value, an exhaust signal is generated and transmitted to the PLC controller. If the end pressure is less than the preset second pressure value, a valve closing signal is generated and transmitted to the PLC controller;
所述阀控排气模块用于接收所述PLC控制器的控制指令,根据远传压力检测模块反馈的信号进行泄压或停止泄压。The valve-controlled exhaust module is used to receive control instructions from the PLC controller, and perform pressure relief or stop pressure relief according to the signal fed back by the remote pressure detection module.
可选的,所述测氧系统包括采样泵、测氧仪和测氧电磁阀控模块;其中,Optionally, the oxygen measurement system includes a sampling pump, an oxygen meter and an oxygen measurement solenoid valve control module; wherein,
所述采样泵用于抽取气体;The sampling pump is used to extract gas;
所述测氧仪用于对所述采样泵抽取的气体进行测量,分析氧气含量;The oxygen meter is used to measure the gas extracted by the sampling pump and analyze the oxygen content;
所述测氧电磁阀控模块用于进行采样抽气时,开通或关闭阀门。The oxygen measuring solenoid valve control module is used to open or close the valve when sampling and pumping air.
与现有技术相比,本发明具有如下优点和技术效果:Compared with the existing technology, the present invention has the following advantages and technical effects:
(1)本套系统摆脱传统进气采用玻璃转子流量计加手动阀门的控制方式,采用三套不同量程的质量流量控制器,结合动态配气法氧平衡分压计算方式,在不同的氧含量范围内自动调整N2和O2的配气量,自动控制气体流量,混合气体经多个气孔进入炉内,有效保证炉内各位置的气氛均匀;同时精确的流量控制可以保证炉内氧含量的稳定,减少人为控制流量的波动对炉内气氛的影响。(1) This system gets rid of the traditional air intake control method of using glass rotor flowmeter and manual valve. It adopts three sets of mass flow controllers with different ranges, combined with the dynamic gas distribution method oxygen balance partial pressure calculation method, at different oxygen contents. Automatically adjust the gas distribution volume of N 2 and O 2 within the range, automatically control the gas flow, and the mixed gas enters the furnace through multiple pores, effectively ensuring a uniform atmosphere at each position in the furnace; at the same time, precise flow control can ensure that the oxygen content in the furnace is kept constant. Stable, reducing the impact of artificially controlled flow fluctuations on the atmosphere in the furnace.
(2)本套系统具备优秀的配方管理和数据管理功能,可从人机界面设定多种烧结工艺,随时调取任一烧结工艺下载到PLC控制器,工艺设定完成后可进行工艺校验,检查曲线是否正确,同时可实时记录本次生产的各项参数,如压力,温度,流量,氧含量,时长等,所有数据记录在外部存储设备中,掉电保存,有效保护历史烧结数据安全。(2) This system has excellent formula management and data management functions. It can set multiple sintering processes from the human-machine interface, and any sintering process can be downloaded to the PLC controller at any time. After the process setting is completed, the process can be calibrated. Check whether the curve is correct. At the same time, various parameters of this production, such as pressure, temperature, flow, oxygen content, duration, etc., can be recorded in real time. All data are recorded in external storage devices and saved when powered off, effectively protecting historical sintering data. Safety.
(3)本套系统具备先进的安全控制机制,设有压力平衡保护功能,当炉内压力出现超压报警时,自动打开所有排气阀门并关闭所有进气阀门,保证炉体安全,当炉内压力出现低压报警时,进气阀打开进气到第二设定压力并声光报警,保证炉内正压防止产品氧化;设有超温低温保护功能,当测温元件出现异常导致实时温度显示过低时,系统会限制加热启动并报警提示,当实时温度超高限,系统会切断所有加热输出防止炉体熔融;设有流量保护功能,当实时流量和设定流量长时间不一致时,切断流量输出防止质量控制器烧坏。(3) This system has an advanced safety control mechanism and a pressure balance protection function. When an overpressure alarm occurs in the furnace, it will automatically open all exhaust valves and close all inlet valves to ensure the safety of the furnace. When a low-pressure alarm occurs in the internal pressure, the air inlet valve opens to the second set pressure and an audible and visual alarm is issued to ensure positive pressure in the furnace to prevent product oxidation; it is equipped with an over-temperature and low-temperature protection function. When the temperature measurement element is abnormal, the real-time temperature When the display is too low, the system will limit the heating start and give an alarm. When the real-time temperature exceeds the high limit, the system will cut off all heating output to prevent the furnace from melting; it is equipped with a flow protection function. When the real-time flow rate and the set flow rate are inconsistent for a long time, Cut off the flow output to prevent the quality controller from burning out.
附图说明Description of drawings
构成本申请的一部分的附图用来提供对本申请的进一步理解,本申请的示意性实施例及其说明用于解释本申请,并不构成对本申请的不当限定。在附图中:The drawings that form a part of this application are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an improper limitation of this application. In the attached picture:
图1为本发明实施例的整体框架图;Figure 1 is an overall framework diagram of an embodiment of the present invention;
图2为本发明实施例的控制工艺流程图;Figure 2 is a control process flow chart of the embodiment of the present invention;
图3为本发明实施例的PLC控制器组成示意图。Figure 3 is a schematic diagram of the composition of a PLC controller according to an embodiment of the present invention.
附图标记:1、PLC控制器;2、加热系统;3、控温系统;4、冷却系统;5、配气系统;6、压力系统;7、测氧系统;8、上位机;11、采集模块;12、通讯模块;13、处理模块;14、执行模块;21、加热元件;22、恒流调压模块;31、温控模块;32、测温元件;41、水压检测模块;42、水流检测模块;43、气动阀控模块;51、气体流量模块;52、气压检测模块;53、配气电磁阀控模块;61、本地压力检测模块;62、远传压力检测模块;63、阀控排气模块;71、采样泵;72、测氧仪;73、测氧电磁阀控模块。Reference symbols: 1. PLC controller; 2. Heating system; 3. Temperature control system; 4. Cooling system; 5. Gas distribution system; 6. Pressure system; 7. Oxygen measuring system; 8. Host computer; 11. Acquisition module; 12. Communication module; 13. Processing module; 14. Execution module; 21. Heating element; 22. Constant current voltage regulation module; 31. Temperature control module; 32. Temperature measuring element; 41. Water pressure detection module; 42. Water flow detection module; 43. Pneumatic valve control module; 51. Gas flow module; 52. Air pressure detection module; 53. Gas distribution solenoid valve control module; 61. Local pressure detection module; 62. Remote pressure detection module; 63 , Valve-controlled exhaust module; 71. Sampling pump; 72. Oxygen meter; 73. Oxygen measuring solenoid valve-controlled module.
具体实施方式Detailed ways
需要说明的是,在不冲突的情况下,本申请中的实施例及实施例中的特征可以相互组合。下面将参考附图并结合实施例来详细说明本申请。It should be noted that, as long as there is no conflict, the embodiments and features in the embodiments of this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and embodiments.
在本发明的描述中,需要说明的是,术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系,或者是该发明产品使用时惯常摆放的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。此外,术语“第一”、“第二”、“第三”等仅用于区分描述,而不能理解为指示或暗示相对重要性。In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. The indicated orientation or positional relationship is based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the invention is customarily placed when used. It is only for the convenience of describing the invention and simplifying the description, and is not intended to indicate or imply. The devices or elements referred to must have a specific orientation, be constructed and operate in a specific orientation and therefore are not to be construed as limitations of the invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish descriptions and shall not be understood as indicating or implying relative importance.
此外,术语“水平”、“竖直”、“悬垂”等术语并不表示要求部件绝对水平或悬垂,而是可以稍微倾斜。如“水平”仅仅是指其方向相对“竖直”而言更加水平,并不是表示该结构一定要完全水平,而是可以稍微倾斜。Furthermore, the terms "horizontal," "vertical," "overhanging," etc. do not imply a requirement that the component be absolutely horizontal or overhanging, but may be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical". It does not mean that the structure must be completely horizontal, but can be slightly tilted.
在本发明的描述中,还需要说明的是,除非另有明确的规定和限定,术语“设置”、“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以具体情况理解上述术语在本发明中的具体含义。In the description of the present invention, it should also be noted that, unless otherwise clearly stated and limited, the terms "set", "installation", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, It can also be a detachable connection or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be an internal connection between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood on a case-by-case basis.
在本发明中,除非另有明确的规定和限定,第一特征在第二特征之“上”或之“下”可以包括第一和第二特征直接接触,也可以包括第一和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且,第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方,或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方,或仅仅表示第一特征水平高度小于第二特征。In the present invention, unless otherwise expressly provided and limited, the term "above" or "below" a first feature of a second feature may include direct contact between the first and second features, or may also include the first and second features. Not in direct contact but through additional characteristic contact between them. Furthermore, the terms "above", "above" and "above" a first feature on a second feature include the first feature being directly above and diagonally above the second feature, or simply mean that the first feature is higher in level than the second feature. “Below”, “under” and “under” the first feature is the second feature includes the first feature being directly below and diagonally below the second feature, or simply means that the first feature is less horizontally than the second feature.
实施例一Embodiment 1
如图1-3所示,本实施例中提供一种软磁铁氧体自动配气升温烧结控制装置,适用于PLC控制技术领域,提供了一种软磁铁氧体自动配气升温控制装置,包括PLC控制器1,所述PLC控制器1电性连接有加热系统2、控温系统3、冷却系统4、配气系统5、压力系统6、测氧系统7和上位机8。As shown in Figures 1-3, this embodiment provides an automatic gas distribution and temperature rising sintering control device for soft ferrite, which is suitable for the field of PLC control technology. An automatic gas distribution and temperature rising control device for soft ferrite is provided, including PLC controller 1. The PLC controller 1 is electrically connected to a heating system 2, a temperature control system 3, a cooling system 4, a gas distribution system 5, a pressure system 6, an oxygen measurement system 7 and a host computer 8.
在本实施方式中,用户打开电脑,点击桌面上的上位机软件,软件自动加载当前系统状态,在工艺设定界面设定工艺曲线并下载到PLC控制器1,点击启动后,PLC控制器1控制温控模块31输出电流信号给加热系统2,恒流调压模块22根据电流信号大小自动调整电压输出,控制加热元件21发热升温,当实际温度到达冷却水开启温度后,冷却系统4开启运行,当本段工艺需要气氛控制时,配气系统5开启运行,根据设定目标值自动计算流量配比,配气电磁阀控模块53打开,气体质量流量控制器自动输出设定流量值,标准气体和稀释气体输送到混气箱,混合好后的气体输送到炉体内,压力逐渐升高,当远传压力检测模块62检测到炉内压力过高时,阀控排气模块63自动排气恢复炉内压力到正常范围。测氧系统7实时检测炉内气氛并反馈数据到PLC控制器1,根据反馈数据,PLC控制器1输出控制信号给配气系统5,系统自动计算调控输出流量已达到设定值,升温程序运行到最后一段后,程序运行结束,结束整个流程。In this implementation, the user turns on the computer and clicks on the host computer software on the desktop. The software automatically loads the current system status, sets the process curve in the process setting interface and downloads it to the PLC controller 1. After clicking to start, the PLC controller 1 The temperature control module 31 is controlled to output a current signal to the heating system 2. The constant current voltage regulation module 22 automatically adjusts the voltage output according to the size of the current signal, and controls the heating element 21 to heat up. When the actual temperature reaches the cooling water opening temperature, the cooling system 4 starts running. , when this section of the process requires atmosphere control, the gas distribution system 5 starts to operate, automatically calculates the flow ratio according to the set target value, the gas distribution solenoid valve control module 53 opens, and the gas mass flow controller automatically outputs the set flow value, standard The gas and dilution gas are transported to the gas mixing box, and the mixed gas is transported to the furnace body, and the pressure gradually increases. When the remote pressure detection module 62 detects that the pressure in the furnace is too high, the valve-controlled exhaust module 63 automatically exhausts the gas. Restore the pressure in the furnace to the normal range. The oxygen measuring system 7 detects the atmosphere in the furnace in real time and feeds back the data to the PLC controller 1. According to the feedback data, the PLC controller 1 outputs a control signal to the gas distribution system 5. The system automatically calculates and regulates the output flow rate and has reached the set value, and the temperature rise program is run. After reaching the last paragraph, the program ends and the entire process ends.
进一步的,PLC控制器1包括采集模块11、通讯模块12、处理模块13、执行模块14,所述采集模块11输入端和气体流量模块51,气压检测模块52,水压检测模块41,水流检测模块42等输出端连接,用于模拟信号的采集转换,所述处理模块13电性连接有采集模块11、通讯模块12、执行模块14,用于控制处理所有模块的数据行为,所述通讯模块12用于读取写入数据到温控模块31,测氧仪72,所述执行模块14用于执行处理模块13下发的控制命令。Further, the PLC controller 1 includes a collection module 11, a communication module 12, a processing module 13, and an execution module 14. The input terminal of the collection module 11 is a gas flow module 51, an air pressure detection module 52, a water pressure detection module 41, and a water flow detection module. Module 42 and other output terminals are connected for collection and conversion of analog signals. The processing module 13 is electrically connected to a collection module 11, a communication module 12, and an execution module 14 for controlling and processing the data behavior of all modules. The communication module 12 is used to read and write data to the temperature control module 31 and the oxygen meter 72 , and the execution module 14 is used to execute the control command issued by the processing module 13 .
在本实施方式中,PLC控制器1设置为台达DVPSV2系统,具备程序升温软件系统,配气控制软件系统,报警提示记录软件系统,数据采集软件系统;其中程序升温软件系统:软件界面可设定PID控温参数,32段升温程序,每段可单独设定目标温度,升温时间,可设定6种工艺曲线用户可随时调取一种工艺曲线下载到处理模块13中,工艺曲线可设定密码,非管理员账户无法修改查看。配气控制软件系统:软件界面可设定32段配气程序,每段可单独设定目标氧含量,总流量,开环氧系数,通讯模块12可读取测氧仪72的实时测量值并反馈给PLC控制器1。报警提示记录软件系统:软件界面可实时记录显示当前报警,历史报警,报警次数,报警时间,报警信息走马灯,可通过执行模块14声光提示当前报警状态,可手自动复位当前报警状态。数据采集软件系统:软件界面具有实时氧含量,实时温度,目标氧含量,目标温度,N2流量,O2流量等参数记录功能,可根据处理模块13中设定的触发参数,自动对当前实时数据记录并生成EXCEL表格,用户可随时通过历史数据记录查询本烧结批次的工艺情况。In this implementation, the PLC controller 1 is set as Delta's DVPSV2 system, equipped with a programmed temperature-raising software system, a gas distribution control software system, an alarm prompt recording software system, and a data acquisition software system. Among them, the programmed temperature-raising software system: the software interface can be set Fixed PID temperature control parameters, 32-segment heating program, each segment can set the target temperature and heating time independently, and 6 types of process curves can be set. The user can retrieve a process curve at any time and download it to the processing module 13. The process curve can be set Password must be set, and non-administrator accounts cannot modify or view it. Gas distribution control software system: The software interface can set 32 segments of gas distribution programs. Each segment can independently set the target oxygen content, total flow rate, and open epoxy coefficient. The communication module 12 can read the real-time measurement value of the oxygen meter 72 and Feedback to PLC controller 1. Alarm prompt recording software system: The software interface can record and display current alarms, historical alarms, alarm times, alarm time, and alarm information in real time. The current alarm status can be prompted with sound and light through the execution module 14, and the current alarm status can be automatically reset manually. Data acquisition software system: The software interface has real-time oxygen content, real-time temperature, target oxygen content, target temperature, N2 flow, O2 flow and other parameter recording functions. It can automatically record the current real-time data according to the trigger parameters set in the processing module 13. Data is recorded and an EXCEL table is generated. Users can query the process status of this sintering batch at any time through historical data records.
进一步的,加热系统2包括加热元件21,加热元件21通过多根串联,角形连接方式连接在一起,恒流调压模块22中的三相调功器接受来自温控模块31的信号,自动调整控制加热元件21升温。Further, the heating system 2 includes heating elements 21. The heating elements 21 are connected together through multiple series and angular connections. The three-phase power regulator in the constant current voltage regulation module 22 receives the signal from the temperature control module 31 and automatically adjusts. The heating element 21 is controlled to heat up.
在本实施方式中,加热元件21采用多根串联,角形连接方式连接在一起,在一相负载出现断路的情况下,其他两相仍可正常运行。温控模块31根据测温元件32反馈的实时温度,PID自动计算输出量,并输出信号到恒流调压模块22,三相调功器自动调整电压输出到加热元件21,当检测到电流大于最大电流限制量时,自动减小电流输出量,保证炉内正常升温。In this embodiment, multiple heating elements 21 are connected in series and in an angular connection. When one phase of the load is disconnected, the other two phases can still operate normally. The temperature control module 31 automatically calculates the output amount based on the real-time temperature fed back by the temperature measuring element 32, and outputs the signal to the constant current voltage regulation module 22. The three-phase power regulator automatically adjusts the voltage output to the heating element 21. When it detects that the current is greater than When the maximum current limit is reached, the current output is automatically reduced to ensure normal temperature rise in the furnace.
进一步的,冷却系统4包括水压检测模块41水流检测模块42气动阀控模块43,当炉内温度达到冷却水设定开启温度后,气动阀控模块43开启,冷却循环水进入炉体冷却盘管。Further, the cooling system 4 includes a water pressure detection module 41, a water flow detection module 42, a pneumatic valve control module 43. When the temperature in the furnace reaches the set opening temperature of the cooling water, the pneumatic valve control module 43 opens, and the cooling circulating water enters the furnace cooling plate. Tube.
在本实施方式中,水压检测模块41可以检测到来水压力,如压力过高会通过气动阀控模块43切断来水并产生水压过高异常报警,气动阀控模块43正常开启后,水流检测模块42通过靶式流量控制器判断是否断流,当靶式叶片检测到水流过小时,PLC控制器1检测到断流信号,输出断流异常报警并声光提示操作人员。In this embodiment, the water pressure detection module 41 can detect the incoming water pressure. If the pressure is too high, the incoming water will be cut off through the pneumatic valve control module 43 and an abnormal alarm of excessive water pressure will be generated. After the pneumatic valve control module 43 is normally opened, the water flow will The detection module 42 determines whether the flow is interrupted through the target flow controller. When the target blade detects that water is flowing through, the PLC controller 1 detects the flow interruption signal, outputs an abnormal flow interruption alarm, and prompts the operator with sound and light.
进一步的,配气系统5包括气体流量模块51气压检测模块52配气电磁阀控模块53,PLC控制器1控制两种气体质量流量控制器输出不同的流量,两种流量通过稀释后形成的混合气进入炉内。Further, the gas distribution system 5 includes a gas flow module 51, a pressure detection module 52, a gas distribution solenoid valve control module 53, and the PLC controller 1 controls the two gas mass flow controllers to output different flow rates, and the two flow rates are mixed through dilution. Gas enters the furnace.
在本实施方式中,气压检测模块52可实时检测来气压力是否在0.2Mpa,当压力过高和过低时产生异常报警并反馈给处理模块13,配气流程开启后,配气电磁阀控模块53控制阀门打开,N2和O2质量流量控制器分别输出不同流量到混气箱,混合完成的混合气体经阀门输送到烧结炉内,调整当前气氛到目标值。In this embodiment, the air pressure detection module 52 can detect in real time whether the incoming air pressure is 0.2Mpa. When the pressure is too high or too low, an abnormal alarm is generated and fed back to the processing module 13. After the air distribution process is started, the air distribution solenoid valve controls Module 53 controls the opening of the valve, and the N 2 and O 2 mass flow controllers output different flows to the gas mixing box respectively. The mixed gas is transported to the sintering furnace through the valve, and the current atmosphere is adjusted to the target value.
进一步的,压力系统6包括本地压力检测模块61,远传压力检测模块62阀控排气模块63,PLC控制器1中可设定最大压力,报警压力,根据远传压力检测模块62反馈的电流信号,自动调整进出气已保证炉内压力正常可控。Further, the pressure system 6 includes a local pressure detection module 61, a remote pressure detection module 62 and a valve-controlled exhaust module 63. The maximum pressure and alarm pressure can be set in the PLC controller 1 according to the current fed back by the remote pressure detection module 62. signal, automatically adjusting the air inlet and outlet to ensure that the pressure in the furnace is normal and controllable.
在本实施方式中,本地压力检测模块61为机械式压力表,配合压力阀使用,当检测到超压时,压力阀开启排气,远传压力检测模块62为数字式压力表,将压力转换成电流信号传送到采集模块11,当炉内压力过高时,阀控排气模块63自动打开,压力正常后自动关闭,当检测到炉内压力过高或者过低时,均会产生炉压异常报警。In this embodiment, the local pressure detection module 61 is a mechanical pressure gauge, used in conjunction with a pressure valve. When overpressure is detected, the pressure valve opens to exhaust, and the remote pressure detection module 62 is a digital pressure gauge, which converts the pressure into The current signal is transmitted to the acquisition module 11. When the pressure in the furnace is too high, the valve-controlled exhaust module 63 automatically opens and closes automatically when the pressure is normal. When the pressure in the furnace is detected to be too high or too low, a furnace pressure will be generated. Abnormal alarm.
进一步的,测氧系统7中包括测氧仪72测氧电磁阀控模块73,可通过采样泵71实时测量炉内O2含量,并将数据反馈给PLC控制器1。Further, the oxygen measurement system 7 includes an oxygen meter 72 and an oxygen measurement solenoid valve control module 73, which can measure the O 2 content in the furnace in real time through the sampling pump 71 and feed the data back to the PLC controller 1.
在本实施方式中,测氧仪72为氧化锆分析仪,可自动分档检测21%-0.1ppm范围内的氧含量,测氧电磁阀控模块73上的测氧阀开启后,炉内正压通过采样泵71进入氧化锆分析仪,通讯模块12读取分析仪数值。In this embodiment, the oxygen meter 72 is a zirconia analyzer, which can automatically detect the oxygen content in the range of 21%-0.1ppm in stages. After the oxygen measuring valve on the oxygen measuring solenoid valve control module 73 is opened, the furnace is The pressure enters the zirconia analyzer through the sampling pump 71, and the communication module 12 reads the analyzer value.
以上,仅为本申请较佳的具体实施方式,但本申请的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本申请揭露的技术范围内,可轻易想到的变化或替换,都应涵盖在本申请的保护范围之内。因此,本申请的保护范围应该以权利要求的保护范围为准。The above are only preferred specific implementations of the present application, but the protection scope of the present application is not limited thereto. Any person familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application. All are covered by the protection scope of this application. Therefore, the protection scope of this application should be subject to the protection scope of the claims.
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