CN117572118A - Method and equipment for predicting service life of resistance furnace - Google Patents
Method and equipment for predicting service life of resistance furnace Download PDFInfo
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Abstract
The invention discloses a method and equipment for predicting service life of a resistance furnace, wherein the method comprises the following steps: when the resistance furnace is heated to a preset target temperature, acquiring temperature jump and voltage jump conditions of the resistance furnace in a first time period; analyzing the temperature jump and the voltage jump condition to determine the state of the resistance furnace; if the resistance furnace is in a steady state, acquiring first state data of the resistance furnace once every second time period, and calculating to obtain an initial resistance according to the acquired multiple groups of first state data; acquiring second state data of the resistance furnace once every third time period, and processing and filtering the acquired multiple groups of second state data to obtain multiple groups of actual resistances; and according to the plurality of groups of actual resistances and the time corresponding to the measured actual resistances, determining the actual resistances in the next period by using least square fitting straight line analysis, and alarming if the actual resistances in the next period exceed a preset value. The problems that the resistance furnace is damaged and the detection process is complex in the prior art are solved.
Description
Technical Field
The invention relates to the technical field of resistance furnaces, in particular to a method and equipment for predicting service life of a resistance furnace.
Background
The resistance furnace converts electric energy into heat energy through a metal electric heating element in the furnace so as to heat a workpiece or a material, after long-term high-temperature heating, the resistance wire is easy to oxidize under long-time high current and high temperature, an outer oxide layer of the electric heating element is caused to fall off, the diameter of the electric heating element is reduced, then the electric heating element is oxidized and falls off again, and the electric heating element is circulated again, so that the oxidation and fusing phenomena of the electric heating element are finally caused, and the problems of furnace shutdown, material loss and the like occur.
In order to solve the above problems, the oxidation condition of the electric heating element is usually detected to predict the service life of the resistance furnace. The accurate prediction method is to intercept an electric heating element from the resistance furnace, analyze and compare the material composition components of the electric heating element, and usually the expected service life is reached when the section oxidation rate of the electric heating element reaches 20 percent, but the method can cause damage to the resistance furnace, has complicated detection process and is not easy to use in production.
Disclosure of Invention
The invention aims to solve the technical problems that: the mode of predicting the service life of the resistance furnace in the prior art can cause damage of the resistance furnace, and the detection process is complex, so that the resistance furnace is not easy to use in production.
In order to solve the technical problems, the invention provides a life prediction method of a resistance furnace, which comprises the following steps:
when the resistance furnace is heated to a preset target temperature, acquiring temperature jump and voltage jump conditions of the resistance furnace in a first time period;
analyzing the temperature jump and the voltage jump condition to determine the state of the resistance furnace; if the resistance furnace is in a steady state, acquiring first state data of the resistance furnace every second time period, and calculating to obtain initial resistance according to the acquired multiple groups of first state data;
acquiring second state data of the resistance furnace every third time period, and processing and filtering the acquired multiple groups of second state data to obtain multiple groups of actual resistances;
and according to a plurality of groups of actual resistances and the time corresponding to the measured actual resistances, determining the actual resistances in the next period by using least square fitting straight line analysis, and alarming if the actual resistances in the next period exceed a preset value.
In some embodiments, analyzing the temperature jump and voltage jump conditions to determine the state of the resistance furnace includes:
analyzing the temperature jump and the voltage jump of the resistance furnace in the first time period;
if the temperature jump of the resistance furnace is not more than 1%, and the voltage jump is not more than 10%, determining that the resistance furnace is in a steady state; otherwise, the resistance furnace is in an unsteady state, and the temperature jump and the voltage jump of the resistance furnace in the first time period are acquired again.
In some embodiments, if the resistance furnace is in a steady state, acquiring the first state data of the resistance furnace every second time period, and calculating the initial resistance according to the plurality of sets of the first state data includes:
if the resistance furnace is in a steady state, acquiring current and voltage of the resistance furnace at a first temperature every second time period, and calculating a first resistance;
and defining the first resistor and the first temperature as first combined data, storing the obtained multiple groups of first combined data, and calculating initial resistors according to the multiple groups of first combined data.
In some embodiments, obtaining the second state data of the resistance furnace every third time period, and processing and filtering the plurality of sets of second state data to obtain a plurality of sets of actual resistances includes:
acquiring the voltage and the current of the resistance furnace at the second temperature once every the third time period, and calculating a second resistance;
defining the second resistor and the second temperature as second combined data to obtain a plurality of groups of second combined data;
and filtering the plurality of groups of second combined data to obtain a plurality of groups of actual resistors and storing the actual resistors.
In some embodiments, filtering the plurality of sets of the second combined data to obtain and store a plurality of sets of actual resistances further comprises:
acquiring the temperature jump and the voltage jump condition of the resistance furnace in a third time period;
if the temperature jump exceeds 1%, determining the voltage jump condition; otherwise, re-acquiring the temperature jump and the voltage jump of the resistance furnace in the first time period;
if the voltage jump is not more than 10%, determining that the resistance furnace is in a steady state; otherwise, the resistance furnace is in an unsteady state, and the temperature jump and the voltage jump conditions of the resistance furnace in the first time period are acquired again;
and filtering the second combined data of the resistance furnace in an unsteady state, and storing the second combined data in a steady state.
In some embodiments, determining the actual resistance in the next period by using least square fitting straight line analysis according to the actual resistances and the time corresponding to the measured actual resistances comprises:
constructing a coordinate system;
drawing coordinate points according to the actual resistance and the time of measuring the corresponding actual resistance, and fitting a plurality of coordinate points into a straight line by using a least square method to obtain a straight line equation; the linear equation is y=mx+b; wherein y is the actual resistance, x is the time when the actual resistance is measured, m is the slope, and b is the intercept;
and determining the actual resistance in the next period according to the linear equation analysis.
In some embodiments, when the electrothermal alloy of the resistance furnace is suspended, the preset value is 1.25 times the initial resistance;
when the electrothermal alloy of the resistance furnace is embedded, the preset value is 1.18 times of the initial resistance.
In some embodiments, the determining the actual resistance in the next period by using least square fitting straight line analysis, and if the actual resistance in the next period exceeds a preset value, the alarming further comprises:
if the actual resistance in the next period determined by analysis exceeds a preset value, acquiring a third resistance in actual use in real time, and if the third resistance is larger than or equal to the preset value, giving an alarm; and if the third resistance is smaller than the preset value, re-acquiring second state data.
In some embodiments, further comprising:
and obtaining the final use resistance of the resistance furnace when damaged, and processing the final use resistance and the initial resistance to obtain a new preset value.
The invention also provides a resistance furnace life prediction device, which predicts the service life of the resistance furnace by adopting the resistance furnace life prediction method, wherein the resistance furnace life prediction device comprises a voltage detection sensor, a current detection sensor, a power controller, a temperature detector, a processing system and a display screen;
the power controller is connected with the resistance furnace to control the resistance furnace to heat;
the voltage detection sensor is connected with a metal electric heating element of the resistance furnace to obtain the voltage of the resistance furnace;
the current detection sensor is connected with a metal electric heating element of the resistance furnace to obtain the current of the resistance furnace;
the temperature detector is connected with the resistance furnace to obtain the temperature of the resistance furnace;
the temperature controller is connected with the power controller and the temperature detector to control the temperature of the resistance furnace;
the processing system is connected with the voltage detection sensor, the current detection sensor, the power controller, the temperature detector and the display screen to process and store corresponding data of the resistance furnace.
Compared with the prior art, the life prediction method of the resistance furnace has the beneficial effects that:
according to the embodiment of the invention, after the resistance furnace is heated to the preset target temperature, the temperature jump and the voltage jump condition of the resistance furnace in a first time period are obtained, the temperature jump and the voltage jump condition are analyzed to determine the state of the resistance furnace, if the resistance furnace is in a steady state, the first state data of the resistance furnace are obtained once every second time period, and the initial resistance is calculated according to a plurality of groups of first state data; then, acquiring second state data of the resistance furnace once every third time period, and processing and filtering a plurality of groups of second state data to obtain a plurality of groups of actual resistances; and finally, according to a plurality of groups of actual resistances and the time corresponding to the measured actual resistances, determining the actual resistances in the next period by utilizing least square fitting straight line analysis, and alarming if the actual resistances in the next period exceed a preset value. Compared with the traditional manual furnace body resistance measurement mode, the resistance furnace life prediction method provided by the invention has the advantages that the consistency is better, and the service life of the furnace body can be obtained without the need of people with professional background knowledge. Compared with the method of cutting out the electric heating furnace wire, the method of observing and measuring the outer layer oxide film, the cross section and the like by using a microscope, the service life prediction can be obtained without damaging the electric heating alloy, the damage of the resistance furnace can be avoided, the detection process is simple, and the electric heating furnace wire is easy to use in production.
Drawings
FIG. 1 is a schematic flow chart of a method for predicting service life of a resistance furnace according to an embodiment of the invention;
FIG. 2 is a schematic diagram of a first sub-flow of a method for predicting lifetime of a resistance furnace according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a second sub-flow of a method for predicting lifetime of a resistance furnace according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a third sub-flow of a method for predicting lifetime of a resistance furnace according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a fourth sub-flowchart of a method for predicting lifetime of a resistance furnace according to an embodiment of the present invention;
fig. 6 is a schematic block diagram of a life prediction apparatus for a resistance furnace according to an embodiment of the present invention.
Detailed Description
The following describes in further detail the embodiments of the present invention with reference to the drawings and examples. The following examples are illustrative of the invention and are not intended to limit the scope of the invention.
As shown in fig. 6, the present invention provides a life prediction apparatus for a resistance furnace, for predicting a life of the resistance furnace, the life prediction apparatus including a voltage detection sensor, a current detection sensor, a power controller, a temperature detector, a processing system, and a display screen; the power controller is connected with the resistance furnace to control the resistance furnace to heat; the voltage detection sensor is connected with a metal electric heating element of the resistance furnace to acquire the voltage of the resistance furnace; the current detection sensor is connected with a metal electric heating element of the resistance furnace to obtain the current of the resistance furnace; the temperature detector is connected with the resistance furnace to obtain the temperature of the resistance furnace; the temperature controller is respectively connected with the power controller and the temperature detector to control the temperature of the resistance furnace; the processing system is connected with the voltage detection sensor, the current detection sensor, the power controller, the temperature detector and the display screen to process and store corresponding data of the resistance furnace. It is understood that a temperature sensor is provided on the resistance furnace for detecting the temperature of the resistance furnace, and the temperature sensor is connected with the temperature detector so that the temperature detector acquires the temperature of the resistance furnace.
It should be noted that, the processing system in this embodiment is a programmable controller PLC or a PC industrial personal computer; the voltage detection sensor may be a hall voltage sensor; the current detection sensor may be a hall current sensor; the power controller may be a thyristor, solid state relay, or a Sichuan coulomb power regulator; the temperature controller can be an astronomical P ID temperature controller. The display screen may be a Weilon touch screen or a display.
Two matching modes exist between the electrothermal alloy and the heat insulation material of the resistance furnace, one is suspension type, namely the electrothermal alloy is not contacted with the heat insulation material or is rarely contacted with the heat insulation material, and the electrothermal alloy is fixedly suspended in the furnace through fixing materials such as ceramic bolts and nuts; one is embedded, i.e. electrothermal alloy is in contact with most of the insulation material and is embedded into ceramic fiber by vacuum technique.
As shown in fig. 1, the present invention provides a resistance furnace life prediction method by which the above-described resistance furnace life prediction apparatus predicts the service life of a resistance furnace. Specifically, the resistance furnace life prediction method comprises the following steps:
s110, when the resistance furnace is heated to a preset target temperature, acquiring temperature jump and voltage jump conditions in a first time period of the resistance furnace;
in the step, after the resistance furnace is heated to a preset target temperature, waiting for a first time period, and acquiring the temperature jump and the voltage jump condition of the resistance furnace in the first time period, wherein the first time period can be 30 seconds, 1 minute, 2 minutes, 3 minutes or the like; preferably, the first period of time is 1 minute.
S120, analyzing the temperature jump and the voltage jump to determine the state of the resistance furnace; if the resistance furnace is in a steady state, acquiring first state data of the resistance furnace once every second time period, and calculating to obtain an initial resistance according to the acquired multiple groups of first state data;
in the step, the state of the resistance furnace is determined by analyzing the temperature jump and the voltage jump of the resistance furnace; it can be understood that the resistance furnace has two states, namely a steady state and an unsteady state, and when the resistance furnace reaches the steady state, the measured resistance data of the resistance furnace is more accurate, and the subsequent prediction result is more accurate.
S130, acquiring second state data of the primary resistance furnace every third time period, and processing and filtering the acquired multiple groups of second state data to obtain multiple groups of actual resistances;
in this step, multiple sets of second combined data need to be filtered to reject the data that does not meet the conditions, so as to ensure the accuracy of the subsequent measurement result.
And S140, according to a plurality of groups of actual resistances and the time corresponding to the measured actual resistances, determining the actual resistance in the next period by using least square fitting straight line analysis, and alarming if the actual resistance in the next period exceeds a preset value.
In the step, the abscissa is the time corresponding to the measured actual resistance, the ordinate is the actual resistance, the least square method is used for fitting out the straight line analysis to determine the actual resistance in the next working period, and if the actual resistance exceeds a preset value, an alarm is given, so that the service life of the resistance furnace is predicted.
Based on the method, compared with the traditional method of manually measuring the resistance of the furnace body, the method for predicting the service life of the resistance furnace provided by the embodiment has better consistency, and the service life of the furnace body can be obtained without the need of people with professional background knowledge. Compared with the method of cutting out the electric heating furnace wire, the method of observing and measuring the outer layer oxide film, the cross section and the like by using a microscope, the service life prediction can be obtained without damaging the electric heating alloy, the damage of the resistance furnace can be avoided, the detection process is simple, and the electric heating furnace wire is easy to use in production.
It should be noted that, before step S110, the fixing manner of the metal electric heating element may be selected on the display screen, and the fixing manner may be "hanging" and "embedded", so as to perform different data analysis according to different fixing manners.
It may be understood that the method further includes, before step S110:
s100, acquiring a preset target temperature, and heating the resistance furnace to the preset target temperature;
in the step, a preset target temperature is set according to actual needs, and then a power controller is adopted to control the resistance furnace to start heating and heat to the preset target temperature so as to carry out subsequent work. It can be appreciated that in this embodiment, an allowable temperature deviation value may also be set to reduce a data error caused by temperature fluctuation, so that the temperature can reach the requirement when the temperature is within the range of the allowable temperature deviation value of the preset target temperature. In addition, the heating preset time can be set, and the resistance furnace is heated to the preset target temperature in the heating preset time so as to meet the requirement of heating to the required temperature in the required time.
In some embodiments, when the electrothermal alloy of the resistance furnace is suspended, the preset value is 1.25 times the initial resistance; when the electrothermal alloy of the resistance furnace is embedded, the preset value is 1.18 times of the initial resistance.
It will be appreciated that when the electrothermal alloy of the resistance furnace is embedded, the electrothermal alloy surrounded by the thermal insulation material is about seventy percent of the total volume, and the temperature of the portion is 50-100 degrees celsius higher than the temperature of the electrothermal alloy exposed to air, and most of the faults occur in the electrothermal alloy surrounded by the thermal insulation material. Therefore, when using the resistance furnace of the embedded electrothermal alloy, the coefficient needs to be changed from 1.25 times to 1.18 times.
As shown in fig. 2, in some embodiments, analyzing the temperature jump and the voltage jump conditions to determine the state of the resistance furnace includes:
s121, respectively analyzing the temperature jump and the voltage jump condition of the resistance furnace in the first time period;
in the step, the temperature jump and the voltage jump of the resistance furnace are analyzed and compared to determine which state the resistance furnace is in at the moment, so as to determine the follow-up working process flow.
S122, if the temperature jump of the resistance furnace is not more than 1% and the voltage jump is not more than 10% in the first time period, the resistance furnace is in a steady state at the moment; otherwise, the resistance furnace is in an unsteady state, and the temperature jump and the voltage jump of the resistance furnace in the first time period are acquired again.
It will be appreciated that when the resistance furnace is in a steady state, the temperature and voltage fluctuations tend to be relatively gentle, i.e. the temperature of the resistance furnace mentioned in this embodiment does not jump more than 1%, and the voltage does not jump more than 10%. While the temperature jump of the resistance furnace in this step does not exceed 1%, it is understood that the fluctuation range of the temperature is only within 1% of their overall value. Similarly, the voltage jitter is not more than 10%, and it is understood that the fluctuation range of the voltage is only within 10% of their overall value. That is, the temperature and voltage changes are relatively small and do not cause significant changes in system performance, at which time the steady state of the system is relatively stable and the voltage and temperature changes are within acceptable ranges. Preferably, the temperature jump of the resistance furnace is not more than 0.5%.
When the resistance furnace is in an unsteady state, the temperature jump and the voltage jump of the resistance furnace in the first time period in step S110 need to be obtained again, and the subsequent steps are entered again until the resistance furnace is in a steady state.
In some embodiments, if the resistance furnace is in a steady state, acquiring the first state data of the resistance furnace every second time period, and calculating the initial resistance according to the plurality of sets of first state data includes:
s123, if the resistance furnace is in a steady state, acquiring the current and the voltage of the resistance furnace at the first temperature every second time period, and calculating a first resistance;
in the step, after the resistance furnace reaches a steady state, the voltage and the current of the resistance furnace are obtained through the voltage detection sensor and the current detection sensor every second time period, and the first resistance is calculated through ohm law. In this embodiment, the second period may be 5 seconds, 10 seconds, 15 seconds, 20 seconds, or the like; preferably, the second period of time is 10 seconds. It will be appreciated that the first state data in this embodiment includes the first temperature and the voltage and current of the resistance furnace at that time.
The first temperature in this embodiment is a temperature at which the first resistance of the resistance furnace is measured.
S124, defining the first resistor and the first temperature as first combination data, obtaining a plurality of groups of first combination data, storing the first combination data, and calculating the initial resistor according to the plurality of groups of first combination data.
In this step, after the first resistance is obtained, the first combination data is defined as the temperature in the resistance furnace at that time (i.e., the first temperature), and is stored. In this embodiment, 10, 20 or 30 sets of first combined data may be measured in one cycle, and the obtained sets of data may be stored and calculated to obtain an initial resistance at the current temperature. It will be understood that one cycle refers to the completion of one step S120.
It should be noted that, the current temperature in this step may be understood as an average temperature value obtained by the plurality of sets of first combination data or a temperature after the last set of first combination data is measured.
In some embodiments, calculating the initial resistance from the plurality of sets of first combined data includes:
and removing the maximum value and the minimum value of the first resistors in the plurality of groups of first combined data, calculating to obtain an average value of the plurality of groups of first resistors, and taking the average value as an initial resistor.
In this embodiment, by removing the maximum value and the minimum value of the plurality of sets of data, deviation caused by abnormal values or errors can be removed, and a set of more stable and reliable data is obtained; the average value is then calculated to better characterize the set of data, reducing errors from individual data points, resulting in more accurate data.
As shown in fig. 3, in some embodiments, obtaining the second state data of the resistance furnace every third time period, and processing and filtering the plurality of sets of second state data to obtain a plurality of sets of actual resistances includes:
s131, acquiring the voltage and the current of the resistance furnace at the second temperature once every third time period, and calculating a second resistance;
in the step, after the initial resistance is obtained, the voltage and the current of the resistance furnace are obtained through the voltage detection sensor and the current detection sensor every third time period, and the second resistance is calculated through ohm law. In the present embodiment, the third period of time may be 5 seconds, 10 seconds, 15 seconds, 20 seconds, or the like; preferably, the third period of time is 10 seconds. It will be appreciated that the first state data in this embodiment includes the first temperature and the voltage and current of the resistance furnace at that time.
In this embodiment, the second temperature is a temperature at which the second resistance of the resistance furnace is measured.
S132, defining a second resistor and a second temperature as second combined data to obtain a plurality of groups of second combined data;
in this step, after the second resistance is obtained, the second combination data is defined as the temperature in the resistance furnace at that time (i.e., the second temperature), and is stored. It is to be understood that the second combination data that can be measured in one cycle in the present embodiment is 100 sets, 150 sets, 300 sets, or the like, and is not particularly limited herein.
S133, filtering the plurality of groups of second combined data to obtain a plurality of groups of actual resistors and storing the actual resistors.
In this step, it is necessary to filter the plurality of sets of second combined data to obtain an actual resistance at the current temperature, and store the plurality of sets of obtained data. Through the filtering operation, the data which do not meet the conditions are removed, and the accuracy of the subsequent measuring and calculating result is ensured.
It will be appreciated that the current temperature in this step is the temperature at which the actual resistance is measured, i.e. the second temperature.
As shown in fig. 4, in some embodiments, filtering the plurality of sets of second combined data to obtain and store the plurality of sets of actual resistances further includes:
s1331, acquiring temperature jump and voltage jump conditions of the resistance furnace in a third time period;
in the step, the number of the obtained second combined data is large, and part of the second combined data which does not meet the requirements needs to be removed so as to improve the accuracy of predicting the straight line fitted in the subsequent step; the step mainly judges the condition of the resistance furnace corresponding to the second combination data to determine whether the second combination data meets the requirement.
S1332, if the temperature jump exceeds 1%, determining a voltage jump condition; otherwise, re-acquiring the temperature jump and the voltage jump of the resistance furnace in the first time period;
firstly, analyzing the temperature jumping situation of the resistance furnace, and when the temperature jumping situation is determined to be in the steady-state range of the resistance furnace by analysis, analyzing the voltage jumping situation; when the analysis determines that the temperature jump condition is not within the steady-state range of the resistance furnace, the process returns to step S110, the temperature jump and the voltage jump condition in the first time period of the resistance furnace are re-acquired, and the actual resistance of the resistance furnace is re-acquired.
S1333, if the voltage jump does not exceed 10%, determining that the resistance furnace is in a steady state; otherwise, the resistance furnace is in an unsteady state, and the temperature jump and the voltage jump conditions of the resistance furnace in the first time period are acquired again;
in the step, when the voltage jumping condition is also in the steady-state range of the resistance furnace, determining that the resistance furnace is in a steady state at the moment; when it is determined that the temperature jump condition is not within the steady-state range of the resistance furnace, the process returns to step S110, the temperature jump and the voltage jump condition in the first period of time of the resistance furnace are re-acquired, and the actual resistance of the resistance furnace is re-acquired.
S1334, filtering the second combined data of the resistance furnace in an unsteady state, and storing the second combined data in the steady state.
It will be appreciated that the resistance value may change with temperature during heating in the resistance furnace. When the resistor is not in a steady state, the resistor value may fluctuate greatly, so that the actual value of the resistor cannot be measured accurately. In the step, the second combined data which is not in a steady state is removed, and the second combined data in the steady state is stored, so that the accuracy of data acquisition is improved.
As shown in fig. 5, in some embodiments, determining the actual resistance in the next period using least squares fit straight line analysis based on the plurality of sets of actual resistances and the times corresponding to the measured actual resistances includes:
s141, constructing a coordinate system;
s142, drawing coordinate points according to the actual resistance and the time of measuring the corresponding actual resistance, and fitting a plurality of coordinate points into a straight line by using a least square method to obtain a straight line equation; the linear equation is y=mx+b; wherein y is the actual resistance, x is the time when the corresponding actual resistance is measured, m is the slope, and b is the intercept;
in this step, after calibrating the initial resistance, an actual resistance is recorded every 10 seconds, and the coordinates of the point on the actual resistance/time coordinate system are (x 1, y 1), (x 2, y 2) (x 3, y 3) (… ). 360 groups of points exist within one hour, a straight line is fitted through a least square method, a straight line equation is y=mx+b, and the slope m and the intercept b can be obtained according to the obtained data.
S143, analyzing and determining the actual resistance in the next period according to the linear equation.
In this step, it is preferable to predict the actual resistance of the two heating cycles, that is, the resistance reached by the next two heating cycles is calculated for y=mx+b by a linear equation given the time x required for the two heating cycles.
In some embodiments, the determining the actual resistance in the next period by using least square fitting straight line analysis, and if the actual resistance in the next period exceeds a preset value, the alarming further comprises:
s144, if the actual resistance in the next period determined by analysis exceeds a preset value, acquiring a third resistance in actual use in real time, and if the third resistance is greater than or equal to the preset value, giving an alarm; and if the third resistance is smaller than the preset value, re-acquiring the second state data.
It can be understood that after determining the actual resistance in the next period according to the least square fitting straight line analysis, if the actual resistance is greater than 1.25 times (or 1.18 times) of the initial resistance, or reaches or exceeds 1.25 times (or 1.18 times) of the initial resistance in 10 hours, the data is updated in real time during the working process of the resistance furnace to determine the resistance condition of the resistance furnace, and when the third resistance of the resistance furnace exceeds a preset value, an alarm is given to notify workers to avoid the occurrence of the condition of damaging materials.
In some embodiments, it is understood that in the function image, the slope represents the rate of change of the function. If the slope is positive, the function image is described as tilting upward to the right as the argument increases; if the slope is negative, the illustrative function image is tilted downward to the right as the argument increases. Thus, the slopes up and down represent the rising and falling trends of the function image, respectively.
In this embodiment, the electric heating element of a part of the materials is oxidized to reduce the resistance, the oxide layer is removed, and the resistance is increased, so that when the resistance is reduced (when the slope is negative) in the steady-state mode, a function of the maximum value of the slope in the past curve is taken as a calculation equation of the expected life. It can be understood that in this embodiment, the oxidation condition of the electric heating element is regarded as the most serious condition, and whether the actual resistance of the resistance furnace exceeds the preset value is calculated, so that the accuracy of predicting the service life of the resistance furnace is improved.
In some embodiments, after step S140, further includes:
and obtaining the final use resistance when the resistance furnace is damaged, and processing the final use resistance and the initial resistance to obtain a new preset value.
This step continues for the first time until the resistance furnace is damaged, the data processing system records the end use resistance of the furnace body so that the end use resistance/initial resistance is calculated and based on this value a new scaling factor is derived which replaces 1.25 times (or 1.18 times) the initial resistance at the next use. Specifically, the control system forms a coordinate system in which the X-axis is all times at steady state heating and the Y-axis is all resistances at steady state heating, thereby generating a graph. When the new resistance furnace is in steady state heating, a resistance is obtained, and the resistance is correspondingly matched with the time in steady state heating in a curve, so that the service life of the resistance furnace can be accurately obtained.
In summary, the embodiment of the invention provides a method and equipment for predicting the service life of a resistance furnace, which enable the service life of the furnace body to be accurate, facilitate workshop staff to select a proper furnace body according to the service life, and avoid professional staff to analyze the furnace body. Furthermore, for the production of valuable materials, the material value is far more expensive than that of a furnace body, and the material loss can be avoided by using the method and the equipment for predicting the service life of the resistance furnace. Compared with the traditional mode of manually measuring the resistance of the furnace body, the service life prediction method of the resistance furnace has better consistency, and the service life of the furnace body can be obtained without the need of people with professional background knowledge. Compared with the method of cutting out the electrothermal wire, the method of observing and measuring the outer oxide film, the cross section and the like by using a microscope can obtain the life prediction without damaging electrothermal alloy. Compared with the past mode of detecting the furnace body resistance by stopping the furnace, the scheme has the advantages of high resistance measurement precision and accurate data, and does not need professional personnel to record and analyze the data. Finally, for furnace body design personnel, the service life of the designed furnace body is different from that of the actual furnace body, when the furnace body is damaged, the design needs to be modified in time, and the equipment can retain enough data, including the service time of the furnace body, the oxidation rate of the furnace body, the resistance curve of the furnace body and the like, so that the subsequent upgrading and maintenance are convenient.
The foregoing is merely a preferred embodiment of the present invention, and it should be noted that modifications and substitutions can be made by those skilled in the art without departing from the technical principles of the present invention, and these modifications and substitutions should also be considered as being within the scope of the present invention.
Claims (10)
1. The life prediction method of the resistance furnace is characterized by comprising the following steps of:
when the resistance furnace is heated to a preset target temperature, acquiring temperature jump and voltage jump conditions of the resistance furnace in a first time period;
analyzing the temperature jump and the voltage jump condition to determine the state of the resistance furnace; if the resistance furnace is in a steady state, acquiring first state data of the resistance furnace every second time period, and calculating to obtain initial resistance according to the acquired multiple groups of first state data;
acquiring second state data of the resistance furnace every third time period, and processing and filtering the acquired multiple groups of second state data to obtain multiple groups of actual resistances;
and according to a plurality of groups of actual resistances and the time corresponding to the measured actual resistances, determining the actual resistances in the next period by using least square fitting straight line analysis, and alarming if the actual resistances in the next period exceed a preset value.
2. The method of claim 1, wherein analyzing the temperature jump and voltage jump conditions to determine the state of the resistance furnace comprises:
analyzing the temperature jump and the voltage jump of the resistance furnace in the first time period;
if the temperature jump of the resistance furnace is not more than 1%, and the voltage jump is not more than 10%, determining that the resistance furnace is in a steady state; otherwise, the resistance furnace is in an unsteady state, and the temperature jump and the voltage jump of the resistance furnace in the first time period are acquired again.
3. The method of claim 1, wherein if the resistance furnace is in a steady state, acquiring the first state data of the resistance furnace every second period of time, and calculating an initial resistance from the plurality of sets of the first state data comprises:
if the resistance furnace is in a steady state, acquiring current and voltage of the resistance furnace at a first temperature every second time period, and calculating a first resistance;
and defining the first resistor and the first temperature as first combined data, storing the obtained multiple groups of first combined data, and calculating initial resistors according to the multiple groups of first combined data.
4. The method of claim 1, wherein obtaining the second state data of the resistance furnace once every third period of time and processing and filtering the plurality of sets of second state data to obtain a plurality of sets of actual resistances comprises:
acquiring the voltage and the current of the resistance furnace at the second temperature once every the third time period, and calculating a second resistance;
defining the second resistor and the second temperature as second combined data to obtain a plurality of groups of second combined data;
and filtering the plurality of groups of second combined data to obtain a plurality of groups of actual resistors and storing the actual resistors.
5. The method of predicting life of a resistance furnace of claim 4, wherein filtering the plurality of sets of second combined data to obtain and store a plurality of sets of actual resistances further comprises:
acquiring the temperature jump and the voltage jump condition of the resistance furnace in a third time period;
if the temperature jump exceeds 1%, determining the voltage jump condition; otherwise, re-acquiring the temperature jump and the voltage jump of the resistance furnace in the first time period;
if the voltage jump is not more than 10%, determining that the resistance furnace is in a steady state; otherwise, the resistance furnace is in an unsteady state, and the temperature jump and the voltage jump conditions of the resistance furnace in the first time period are acquired again;
and filtering the second combined data of the resistance furnace in an unsteady state, and storing the second combined data in a steady state.
6. The resistance furnace life prediction method according to claim 1, wherein determining the actual resistance in the next period by using least square fitting straight line analysis according to a plurality of sets of the actual resistances and the times corresponding to the measured actual resistances comprises:
constructing a coordinate system;
drawing coordinate points according to the actual resistance and the time of measuring the corresponding actual resistance, and fitting a plurality of coordinate points into a straight line by using a least square method to obtain a straight line equation; the linear equation is y=mx+b; wherein y is the actual resistance, x is the time when the actual resistance is measured, m is the slope, and b is the intercept;
and determining the actual resistance in the next period according to the linear equation analysis.
7. The resistance furnace life prediction method according to claim 1, wherein when the electrothermal alloy of the resistance furnace is suspended, the preset value is 1.25 times the initial resistance;
when the electrothermal alloy of the resistance furnace is embedded, the preset value is 1.18 times of the initial resistance.
8. The resistance furnace life prediction method according to claim 1, wherein the actual resistance in the next period is determined by using least square fitting straight line analysis, and if the actual resistance in the next period exceeds a preset value, the alarm further comprises:
if the actual resistance in the next period determined by analysis exceeds a preset value, acquiring a third resistance in actual use in real time, and if the third resistance is larger than or equal to the preset value, giving an alarm; and if the third resistance is smaller than the preset value, re-acquiring second state data.
9. The resistance furnace life prediction method according to claim 1, further comprising the steps of:
and obtaining the final use resistance of the resistance furnace when damaged, and processing the final use resistance and the initial resistance to obtain a new preset value.
10. A resistance furnace life predicting device characterized in that the life of a resistance furnace is predicted by adopting the resistance furnace life predicting method according to any one of claims 1 to 9, wherein the resistance furnace life predicting device comprises a voltage detection sensor, a current detection sensor, a power controller, a temperature detector, a processing system and a display screen;
the power controller is connected with the resistance furnace to control the resistance furnace to heat;
the voltage detection sensor is connected with a metal electric heating element of the resistance furnace to obtain the voltage of the resistance furnace;
the current detection sensor is connected with a metal electric heating element of the resistance furnace to obtain the current of the resistance furnace;
the temperature detector is connected with the resistance furnace to obtain the temperature of the resistance furnace;
the temperature controller is connected with the power controller and the temperature detector to control the temperature of the resistance furnace;
the processing system is connected with the voltage detection sensor, the current detection sensor, the power controller, the temperature detector and the display screen to process and store corresponding data of the resistance furnace.
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| CN202311533114.8A CN117572118A (en) | 2023-11-16 | 2023-11-16 | Method and equipment for predicting service life of resistance furnace |
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| CN202311533114.8A CN117572118A (en) | 2023-11-16 | 2023-11-16 | Method and equipment for predicting service life of resistance furnace |
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