TWI731213B - Furnace efficiency quantification system - Google Patents

Abstract

A furnace efficiency quantification system is disclosed and comprises a batch annealing apparatus, a base control unit, and a process computer. The batch annealing apparatus has a furnace configured to heat its inner environment, and is provided with a sensor configured to sense temperature of the inner environment. The base control unit is configured to read data of the temperature and convert the data into digital signals, and transmit the digital signals via internet connection. The process computer is configured to receive the digital signals via the internet connection with the base control unit, and decode the digital signals to the corresponding data of temperature, and then write the data in a database. The process computer generates a furnace operation efficiency statistical table based on manufacturing process data stored in the database and the recorded data of temperature.

Description

External furnace efficiency quantification system

The invention relates to steel box sealing annealing equipment, in particular to an external furnace efficiency quantification system.

Annealing is a commonly used method of steel processing, which mainly includes heating and gradual cooling of steel, which can soften the steel for cutting, remove the internal stress generated by normal temperature processing and forging, and improve its ductility. Annealing furnaces are heat treatment equipment used for steel annealing processing, and the most commonly used one is sealed box annealing furnace.

The outer furnace of the box-sealing annealing furnace is a furnace hood-type heating device. In the box sealing annealing process, the steel coils are sent to the box annealing furnace for annealing treatment, and generally batch heat treatment is performed in the form of stacks of several steel coils. The heating efficiency of the external furnace improves the process yield and productivity. Key factors. Due to the pressure of the production line, the external furnace equipment must cooperate with the operation of the production line, and there should not be too many external furnaces in the maintenance state at the same time. However, unscheduled maintenance of the external furnace will also reduce production capacity due to low efficiency. Therefore, how to arrange the maintenance of the outer furnace most in need of maintenance at the most appropriate time has always been an urgent goal of the production unit.

There are two common methods for external furnace maintenance scheduling:

1. Through the computer system to record the number of times the external furnace is used, the value of the counter is accumulated every time it is produced, and when the value of the counter reaches a threshold, the external furnace is arranged for maintenance.

2. Record the hours of each production of the external furnace through the computer system. When the accumulated total hours reaches a certain threshold, the external furnace will be arranged for maintenance.

However, the common problem with the above two methods is that even the same outer furnace, its durability and performance are not completely the same, and the more frequently used or longer hours of the outer furnace does not completely represent its condition and performance. It is poor. If the outer furnace is maintained only according to such a schedule, it may cause the outer furnace in poor condition to be used on site, and the outer furnace in better condition is sent for repair. This greatly reduces the overall production efficiency.

In addition, when multiple external furnaces reach the maintenance threshold at the same time, the order of maintenance needs to be arranged to avoid reducing on-site production capacity. However, when there is no reliable furnace condition analysis data as a basis for judgment, usually all can only be discharged Maintenance, in order to avoid affecting the product yield, but it is also easy to waste the productivity of the external furnace that can continue to be used.

Therefore, it is necessary to provide an external furnace efficiency quantification system to solve the problems of conventional technology.

The main purpose of the present invention is to provide an external furnace efficiency quantification system, which can greatly improve the lack of existing external furnace maintenance schedules, and effectively reduce maintenance manpower and material costs.

In order to achieve the above objective, the present invention provides an external furnace efficiency quantification system, which includes: a box annealing equipment, including an external furnace, the external furnace is used to raise the temperature of the furnace environment, and is provided with a sensor for sensing A temperature sensor; a furnace base control unit that reads the temperature data of the sensor and converts it into a digital signal, establishes a network connection, and sends the digital signal through the network connection; and A program-controlled computer establishes the network connection with the furnace base control unit to receive the digital signal, deconstruct the digital signal into corresponding temperature data, and record it in a database The program-controlled computer generates an external furnace operation efficiency history based on the built-in process data and the recorded temperature data in the database. .

In an embodiment of the present invention, the built-in process data in the database includes temperature rise models corresponding to different process requirements.

In an embodiment of the present invention, the heating model includes a plurality of heating stages and time thresholds corresponding to the heating stages.

In an embodiment of the present invention, the program-controlled computer compares the recorded temperature data with the temperature increase model of the corresponding process to establish an external furnace operation efficiency history including the number of abnormal temperature increases and the number of abnormal temperature increases.

In an embodiment of the present invention, the program-controlled computer judges whether the temperature rise is abnormal according to whether the temperature rise time consumed by the outer furnace in each temperature rise stage exceeds the time threshold corresponding to the temperature rise stage.

In an embodiment of the present invention, when the heating time of the outer furnace in a heating stage exceeds the time threshold corresponding to the heating stage, the program-controlled computer records an abnormal temperature rise and will exceed the time threshold The excess time is regarded as abnormal hours.

In an embodiment of the present invention, the program-controlled computer further establishes a comparison table of quality and external furnace efficiency limits based on the external furnace operation efficiency histories of multiple external furnaces, wherein different product types correspond to different external furnace abnormal rate limits .

1‧‧‧Box sealing annealing equipment

10‧‧‧Outer furnace

2‧‧‧Furnace base control unit

3‧‧‧Program Control Computer

4‧‧‧Human Machine Interface

S01, S02, S03, S04, S05‧‧‧Step

Figure 1 is a system schematic diagram of a preferred embodiment of the external furnace efficiency quantification system of the present invention.

Figure 2 is a schematic diagram of an external furnace heating model of a preferred embodiment of the external furnace efficiency quantification system of the present invention Figure.

Figure 3 is a schematic diagram of the page displayed on the operating efficiency history of the external furnace generated by the external furnace efficiency quantification system of the present invention.

Figure 4 is a page diagram of a comparison table of products and external furnace efficiency limits generated by the external furnace efficiency quantification system of the present invention.

In order to make the above and other objectives, features, and advantages of the present invention more obvious and understandable, the preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings.

Please refer to Figure 1, which is a system schematic diagram of a preferred embodiment of the furnace efficiency quantification system of the present invention. The external furnace efficiency quantification system of the present invention mainly includes a box annealing equipment 1, a furnace base control unit 2, a program-controlled computer 3, and a man-machine interface 4.

The box sealing annealing equipment 1 includes an outer furnace 10. The outer furnace 10 is used to raise the temperature of the furnace environment, and is provided with a sensor for sensing the temperature.

The furnace base control unit 2 is set on the sealing annealing equipment to read the temperature data of the sensor and convert it into a digital signal, and establish a network connection, and send it through the network connection The digital signal.

The program-controlled computer 3 establishes the network connection with the furnace base control unit 2 to receive the digital signal, and deconstruct the digital signal into corresponding temperature data and record it in a database. The database has built-in process data related to sealing and annealing. The program-controlled computer 3 generates an external furnace operation efficiency history based on the built-in process data and the recorded temperature data in the database to show that the external furnace 10 is in Operational efficiency in a certain period of time in the past. In one embodiment, the built-in process data in the database includes temperature-rising models corresponding to different process requirements, which correspond to different processes The temperature parameter and the time threshold of the heating model of the demand are different.

The man-machine interface 4 is used to display the operating efficiency history of the external furnace generated by the program-controlled computer 3, so that the user can evaluate the operating efficiency of the external furnace, and then decide whether to perform maintenance of the external furnace.

Please refer to Figure 1, the process of outputting the operation efficiency history of the external furnace through the above-mentioned external furnace efficiency quantification system, which can specifically include the following steps S01~S05:

Step S01: Read the sensor data on the device and convert it into a digital signal. In this step, the furnace base control unit 2 reads the temperature rise data of the sensor of the outer furnace 10 on the sealing annealing equipment 1 and converts it into a digital signal.

Step S02: Establish a network connection and send a message. The step specifically involves establishing a network connection through the furnace base control unit 2 and sending the digital signal through the network connection.

Step S03: Establish a network connection and receive messages. This step is specifically to establish a network connection with the furnace base control unit 2 through the program-controlled computer 3, and receive the digital signal through the network connection.

Step S04: Deconstruct the message and write the data back to the database. The step is specifically to deconstruct the digital signal into corresponding temperature data by the program-controlled computer 3 and then record it in a database.

Step S05: Process data analysis and statistics, and generate external furnace operation efficiency history. In this step, the program-controlled computer 3 generates the operation efficiency history of the external furnace based on the built-in process data and the recorded temperature data in the database, and displays it on the man-machine interface 4.

Please further refer to FIG. 2, which is a schematic diagram of an external furnace heating model of a preferred embodiment of the external furnace efficiency quantification system of the present invention. In one embodiment, as shown in Figure 2, the temperature-rising model may include a plurality of temperature-rising stages (such as two stages T1 and T2) and the corresponding temperature-rising stages Time threshold (such as TH_t1 and TH_t2). The program-controlled computer 3 can compare the recorded temperature data with the heating model of the corresponding process to establish an operating efficiency history of the external furnace including the number of abnormal heating times and the number of abnormal heating hours. Specifically, the program-controlled computer 3 can determine whether the heating time spent by the external furnace in each heating stage exceeds the time threshold corresponding to the heating stage (for example, the time threshold TH_t1 corresponding to the first heating stage T1). Determine whether the temperature rise is abnormal. Taking the first heating stage T1 shown in Fig. 2 as an example, the programmable computer 3 can determine whether the temperature rise is abnormal according to whether the time taken for the outer furnace to rise to T1 exceeds the time threshold TH_t1 of the preset heating model. When the heating time of the outer furnace in a heating stage exceeds the time threshold corresponding to the heating stage, the program-controlled computer records an abnormal heating, and the exceeding time exceeding the time threshold is regarded as the abnormal hour. For example, if 0.5 hours are exceeded, 0.5 hours will be counted as abnormal hours.

In one embodiment, as shown in FIG. 3, FIG. 3 is a schematic diagram of a page of an external furnace operation efficiency history generated by the external furnace efficiency quantification system of the present invention. The maintenance frequency of the external furnace of the sealing annealing process is performed in units of months. Therefore, the program-controlled computer 3 can analyze the abnormal heating frequency of the external furnace in units of months based on the built-in process data and the recorded temperature data in the database , And generate a single-month statistics of the operation efficiency history of the external furnace, and display it to the user for reference through the man-machine interface 4.

Through the above reliable statistical data, users can refer to the number of abnormal occurrences and the hours of abnormal heating to judge the necessity of external furnace maintenance. In addition, the abnormal temperature rise is quantified through data, and the maintenance unit can arrange the order of repairs according to the severity, solve the problem of insufficient external furnaces caused by the traditional use of the number of times to determine the maintenance timing, and more accurately target the external furnaces that need adjustment Carry out repairs.

With further reference to Figure 4, Figure 4 is an external furnace efficiency quantification system of the present invention The page diagram of the comparison table between the generated product and the external furnace efficiency limit. In one embodiment, the program-controlled computer 3 can simultaneously monitor the temperature rise of the outer furnace 10 of the multiple sealing annealing equipment 1, so it can further establish the operation efficiency history of the multiple outer furnaces as shown in Figure 4. The page diagram of the comparison table between the quality and the efficiency of the external furnace shown is displayed on the man-machine interface 4 for user reference. Among them, different product types correspond to different external furnace abnormal rate limits. Since different products have different quality requirements, products with higher quality requirements need to be equipped with an external furnace with higher heating efficiency. The comparison table of this quality and external furnace efficiency limit can be used to pair products with suitable external furnaces to increase the high production line. Yield rate of quality products.

In summary, compared with the prior art, the present invention effectively quantifies the operating efficiency of the external furnace through the cooperation of the sensor of the external furnace, the furnace base control unit and the program-controlled computer, and then generates the operating efficiency history of the external furnace to assist users Judge the necessity of external furnace maintenance. A comparison table of quality and external furnace efficiency limits can be established for product combinations with different needs, and the product combination can be judged by the computer, allowing users to automatically exclude inapplicable furnaces when selecting external furnaces, and assist production units to improve process yield . Through the furnace efficiency quantification system of the present invention, the originally unfounded equipment maintenance schedule can be greatly improved, and maintenance manpower and material costs can be reduced.

Although the present invention has been disclosed in preferred embodiments, it is not intended to limit the present invention. Anyone familiar with the art can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the present invention The scope of protection shall be subject to the scope of the attached patent application.

1‧‧‧Box sealing annealing equipment

10‧‧‧Outer furnace

2‧‧‧Furnace base control unit

3‧‧‧Program Control Computer

4‧‧‧Human Machine Interface

S01, S02, S03, S04, S05‧‧‧Step

Claims (2)

An external furnace efficiency quantification system, including: a box annealing equipment, including an external furnace, the external furnace is used to heat up the furnace environment, and is provided with a sensor for sensing the temperature; a furnace base The control unit reads the temperature data of the sensor and converts it into a digital signal, establishes a network connection, and sends the digital signal through the network connection; and a program-controlled computer connected to the furnace base The control unit establishes the network connection to receive the digital signal, and deconstruct the digital signal into corresponding temperature data and record it in a database. The program-controlled computer is based on the built-in process data and the recorded data in the database. The temperature data generated by the external furnace operation efficiency history; wherein the built-in process data in the database includes heating models corresponding to different process requirements, and the heating model includes a plurality of heating stages and the time threshold values corresponding to the heating stages; Comparing the recorded temperature data with the heating model of the corresponding process to establish the operating efficiency history of the external furnace including the number of abnormal heating and the number of abnormal heating hours; the program-controlled computer is based on the cost of the external furnace in each heating stage Whether the heating time exceeds the time threshold corresponding to the heating stage to determine whether the heating is abnormal; and the program-controlled computer further establishes a quality and external furnace efficiency limit comparison table based on the external furnace operation efficiency history of multiple external furnaces, where different The product category corresponds to the limit of abnormal rate of different external furnaces. For example, the external furnace efficiency quantification system described in item 1 of the scope of patent application, wherein when the heating time of the external furnace in a heating stage exceeds the time threshold corresponding to the heating stage, the program-controlled computer records an abnormal temperature rise , And treat the time exceeding the time threshold as abnormal hours.

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