I. Overview:
Huangshi City Huanggang Friction Film Company is the largest friction sheet manufacturer in China. The use of bell-type sintering furnace sintered metal friction plates is available in all types of cars and limousines. The bell-type sintering furnace is one of the important equipments of the company. For decades, the company has not stopped improving and improving the bell-shaped furnace, and constantly innovated to adapt it to a wider production field. The company recently adopted Yudian AI computer monitoring system with AI808PAI5X3+JK6L1L1S4 to transform the bell furnace with rapid cooling system, which can not only accurately control the temperature during the heating and heat preservation stage, but also control the temperature during the cooling stage. The processing time of each batch is greatly shortened, which greatly improves the production efficiency.
In the bell-type furnace of the rapid cooling system after using Yudian AI808PAI5X3+JK6L1L1S4, the brakes of the ceramic-type premium car brakes have solved the contradiction between high friction coefficient, large wear and short service life through formula optimization test in the development process. It solves the contradiction between high and stable friction coefficient and no noise, and successfully develops a new generation of high performance ceramic type brake pad products with low coefficient of friction coefficient, long service life and comfortable braking. The optimization of process parameters such as temperature, pressure and time, curing temperature and time determined the optimal process parameters, successfully solved the problem of bubble cracking caused by product pressing and solidification, and provided process guarantee for product performance control. Industrialization experiments have good economic and social benefits and domestic and international market prospects.
Second, the introduction of strong convection hood annealing furnace
Strong convection bright hood annealing furnace is mainly used for brass belt, bronze belt, shaped copper belt, copper belt, all kinds of precision copper tube, coinage material, precision strip, composite strip, soft magnetic and hard magnetic alloy, copper Dozens of materials such as alloy wire, standard material, and stainless steel tape. The bell furnace has a maximum charging diameter of 3.2M, a loading height of up to 4M, and a maximum loading capacity of 80T. The hood furnace consists of a heating hood, two furnace seats, two inner hoods and a valve frame. The heating element is uniformly suspended around the furnace by a resistor tape and fixed with ceramic screws.
Workshop production and instrument precision debugging
In the center of the furnace seat is equipped with a strong convection fan, through the operation of the motor to drive the impeller to achieve strong convection, so that the temperature inside the furnace is even, the motor of the fan is a water-cooled sealed two-speed motor, can be realized High and low speed conversion, after the cooling water is passed, it can ensure that the bearing of the motor will not be damaged by heat. A water-cooled rubber sealing ring sealed with the inner cover is mounted on the furnace seat to achieve a sealing effect.
Third, the choice of thermostat:
The electric control cabinet uses the PID zero-crossing trigger temperature control regulator to adjust the power and temperature in the furnace, and is equipped with an over-temperature alarm function. And according to the needs of the upper computer, the configuration software dynamically displays the system control status.
The choice of advanced instruments: We use advanced AI artificial intelligence regulators in the system. The AI ​​regulator is the core part of the temperature control system. The AI ​​instrument is the first to adopt the platform concept. It converts the very professional digital adjustment instrument into the platform design product. The AI ​​artificial intelligence adjustment algorithm is based on fuzzy rules. A new algorithm for PID adjustment uses fuzzy algorithm to adjust the phenomenon of PID saturation integration when the error is large. When the error is small, the improved PID algorithm is used for adjustment, and the automatic learning and memory can be controlled in the adjustment. Part of the characteristics of the object to optimize the effect.
The self-tuning method is simple and convenient to apply: since the self-tuning is performed by positional adjustment, after 2~3 oscillations, the internal microprocessor of the instrument automatically calculates the period, amplitude and waveform according to the oscillation generated by the position control. M 5, P, t and other control parameters. It has the characteristics of no overshoot, high precision, simple parameter determination, and good control effect on complex objects.
In the process of use, AI regulator combines PID adjustment, self-learning and fuzzy control technology to realize self-tuning/adaptive function and precise adjustment without under-adjustment. The performance is far superior to traditional PID regulator.
Fourth, the system architecture:
The whole control system uses RS485 communication bus technology for computer monitoring. Because RS485 bus technology has good real-time, reliability, anti-interference ability and error detection capability, it is widely used in some harsh conditions. Through the serial port to achieve the entire system operation monitoring, its screen includes: on-site simulation map, temperature and pressure display, equipment ground fault status indication, various parameter settings, real-time temperature graph, set temperature graph and alarm information. System control object.
In the system, due to the excellent performance of the AI ​​series instruments, Yudian has developed an AIFCSV9.0 computer monitoring system based on AI instruments and fieldbus features. The AI ​​instrument is equivalent to each control unit in the fieldbus system. It uses RS485 as the field communication bus. It uses the AIBUS communication protocol developed by Yudian, which can realize 100% instrument function operation on the host computer. Read the measured value and set value in real time. , set parameters, automatic / manual bumpless switching, adjust manual output values, start / run / stop program, and have switching input / output operation capabilities. The open structure is free to add control instruments.
Five, temperature control function
Control system We use Yudian AI-808PAI5X3L1L1S4 temperature control table: AI-808P program type instrument is used for occasions that need to automatically change the given value for control according to a certain time rule. It has powerful programming and operation capabilities to further increase the automation of the control device. It has a 50-segment programming function, which can set the rising/lowering slope of a given value of any size; with programmable/operable commands such as jump, run, pause and stop, the program can be modified during program control operation; Event output function. The alarm output can be used to control the interlocking action of other devices to further improve the automation capability of the device; the operation of the program can be executed by running an external switch to suspend or synchronize the operation or convenient operation; Start function and prepare function to make program execution more efficient and complete.
1, function and concept:
Block: The segment number can be from 1-30, and the current segment (STEP) indicates the segment currently being executed.
Set time: refers to the total time of the block setting operation, the unit is min, the valid value is from 1-9999. Running time: refers to the running time of the current segment. When the running time reaches the set time, the program automatically skips a running period.
Jump: The program block can be programmed to automatically jump to any of the 1-30 segments for loop control. Jumps can also be achieved by modifying the value of STEP.
Run/HoLd: When the program is running, it is timed and the setpoint changes according to the pre-programmed program curve. When the program is in the pause state, the timer is stopped and the set value remains unchanged. The meter can be programmed to pause in the block, or it can be paused/runned at any time. The meter still maintains the adjustment function during the pause state.
Stop (stoP): Executing a stop operation will stop the program. At this time, the run time is cleared to 0, the event output switch is reset, and the control output is stopped. When the running operation is executed in the stop state, the instrument will start the running program from the segment number set by STEP. The function of automatic stop can be programmed in the block and the STEP value of the running segment number can be set at the same time. It is also possible to perform a stop operation at any time (STEP is set to 1 after execution, but the user can modify it).
Event output: Occurs by program orchestration. The 2-way alarm switch can be controlled during program operation to facilitate synchronization or interlocking of various external devices.
Power outage/power-on event: refers to the instrument is connected to the power supply or unexpected power failure during operation, and can provide a variety of processing options for the user to choose. The user can set the meter's parameter (run) to set the running status of the meter after power-on. Preparation (rdy) / measured value start function: When the start running program has a deviation between the temperature of the furnace body and the initial temperature set by the meter, and the difference is greater than the positive (or negative) deviation alarm value (dHAL and dLAL), The meter does not immediately perform a positive (or negative) deviation alarm, but first adjusts the measured value to a value less than the deviation alarm value. At this time, the program also pauses the timing and does not output the deviation alarm signal until the positive and negative deviations meet the requirements. Only start the program again. The Ready/Measured Value Start function is also useful for setting up segments that cannot predict the rise/lower time. To allow or cancel the preparation/measurement value start function, set it in the run parameter. The preparation/measurement value start function ensures the integrity of the entire program curve. The preparation/measurement value start function is used to solve the uncertainty caused by the inconsistency between the measured value and the set value at the start-up operation. Efficiency, completeness and compliance with user requirements.
2, the program settings:
Program curve arrangement; program table adjuster can be used to automatically change the given value for control according to a certain time rule. The program is programmed in the format of [temperature-time-temperature], with 50-segment programming function, which can set the rising and falling slope of the given value of any size; with jump (the target segment is limited to the first 30 segments), running Programmable/operable commands such as pause, stop, etc., can be modified during program control operation; have two-way event output function. The alarm output can be used to control other equipment interlocking actions such as: warning lights, fans, and alarms to further improve the equipment automation capability; with power-off processing mode, measured value start-up function and preparation function, the program execution is more efficient and complete.
The program instrument self-tuning sets the first program to the normal temperature or the highest temperature to start the auto-tuning, and the time stops running.
The thyristor trigger adopts the phase shifting trigger. The AIJK6 series is an intelligent three-phase phase shifting trigger and a cycle zero-crossing trigger using the single-chip technology. It is powerful and reliable, and can adapt to various resistance wires and silicon. The carbon rod and the load are various types of industrial electric furnaces such as silicon molybdenum rods and tungsten wires which are stepped down by transformers, and can also be used for the control of soft start of the motor.
Main performance of AIJK6: 0-20mA (0-5V) / 4-20mA (1-5V) signal compatible input; computerized linearization power correction, when the load is resistive, its output power is proportional to the input signal ; phase loss detection, overcurrent detection and alarm function; AIJK6 also has thyristor breakdown and load open circuit detection function; automatic synchronization function, no phase sequence is required when connecting thyristor trigger line; AIJK3 does not even need polarity With all-optical isolation and "burning not bad" technology, the reliability is very high, causing little interference to the input end; the current feedback or delay time adjustable soft start / soft stop function, adapt to silicon molybdenum rod, tungsten wire, motor and Inductive load; contains switching power supply, can be directly powered by 220VAC power supply, and has 5V and 24V two sets of DC power output. AIJK6 alarms when the main circuit is disconnected or missing phase; the main circuit contactor is disconnected; the varistor pressure sensitive absorption is damaged (does not affect heating).
3, parameter settings:
According to the requirements of the system, we can choose various instrument types such as AI-808PAI5X3L1L1S4+AIJK6, use the main output of AI-808P as the control signal of AIJK6 to control the heating output, and increase the 30+20 time program of AI-808P intelligent regulator. Control function, the first 30 segments can be programmed as automatic jump execution, realize loop control, adopt advanced modular design, and have 5 function module sockets: auxiliary input, main output, alarm, auxiliary output and communication.
The input mode of the meter can be freely set to thermocouple, thermal resistance and linear current (voltage). The specific module functions are as follows;
I5: external switch input, control the start and stop of the instrument program;
X3: Photoelectric isolation high precision linear current output;
S4: Photoelectric isolation RS485 communication interface module with isolated power supply;
L1: relay contact switch output module;
AIJK6 series is an intelligent three-phase phase shift trigger and cycle zero-crossing trigger using single-chip technology. It is powerful and reliable. It can adapt to various resistance wires, silicon carbon rods and transformers. Rods, tungsten wires, etc. can be used in various types of industrial electric furnaces, and can also be used for the control of motor soft start. The main features include:
0-20mA (0-5V) / 4-20mA (1-5V) signal compatible input;
Phase loss detection, overcurrent detection and alarm function; AIJK6 also has thyristor breakdown and load open circuit detection function;
Automatic synchronization function, the phase sequence is not required when connecting the thyristor trigger line; AIJK6 does not even need polarity;
The use of photoelectric isolation and "burning not bad" technology, the reliability is very high, causing little interference to the input;
Soft start/soft stop function with adjustable current feedback or delay time, which can adapt to silicon molybdenum rod, tungsten wire, motor and inductive load;
It includes a switching power supply, which can be directly powered by 220VAC power supply, and has two sets of DC power output of 5V and 24V;
The instrument's adjustment function uses an advanced AI artificial intelligence PID adjustment algorithm. The AI ​​artificial intelligence adjustment algorithm is a new algorithm that uses fuzzy rules for PID adjustment. When the error is large, the fuzzy algorithm is used to adjust to eliminate the PID saturation integral phenomenon. When the error is small, the improved PID algorithm is used to adjust. And can automatically learn and memorize some features of the controlled object in the adjustment to optimize the effect. It has the characteristics of no overshoot, high precision, simple parameter determination, and good control effect on complex objects. The improved PID parameters are represented by U-specific M 5, P, t and other control parameters.
Module X3 three-phase shift item trigger, module L1 switch quantity alarm output, module S4 communication RS485 communication
4, debugging method:
After the parameter is set, it must first be self-tuned. The AI ​​artificial intelligence adjustment algorithm is a new algorithm that uses fuzzy rules for PID adjustment. When the error is large, the fuzzy algorithm is used to adjust to eliminate the PID saturation integral phenomenon. When the error is small, the improved PID algorithm is used to adjust. And can automatically learn and memorize some features of the controlled object in the adjustment to optimize the effect. It has the characteristics of no overshoot, high precision, simple parameter determination, and good control effect on complex objects.
The AI ​​series adjustment instrument also has a parameter self-tuning function. When the AI ​​artificial intelligence adjustment mode is used for the first time, the self-tuning function can be activated to assist in determining the control parameters such as M 5, P, and t. When the auto-tuning is started for the first time, the meter can be switched to the display state. In the state where the PV measurement value SV is given, press and hold the semi-circular arc button for about 2 seconds. At this time, the display under the meter will flash to display “At "The words indicate that the meter has entered the self-tuning state. Self-tuning, the instrument performs position adjustment. After 2~3 oscillations, the internal microprocessor of the instrument automatically calculates M 5, P, t, etc. according to the oscillation generated by the position control, analyzing its period, amplitude and waveform. control parameter. If you want to abandon the auto-tuning in advance during the auto-tuning process, you can press and hold the semi-circular arc button for about 2 seconds to stop the display under the instrument from flashing “Atâ€. Depending on the system, the time required for self-tuning can vary from a few seconds to several hours. After the self-tuning of the instrument is completed successfully, the parameter CtrL will be set to 3 (1 at the factory) or 4, so that the auto-tuning cannot be started from the panel by pressing the button again in the future, and the self-tuning can be avoided again by human error. A meter that has started a self-tuning function. If you want to start auto-tuning in the future, you can start it by setting the parameter CtrL to 2. The specific operation should refer to the instruction manual.
The parameter values ​​obtained by the system under different set values ​​are not exactly the same. Before executing the auto-tuning function, the set value should be set to the most common value or intermediate value (for the AI-708P/808P program type instrument, The set value can be changed to meet the requirement by modifying the current block value. If the system is an electric furnace with good insulation performance, the set value should be set at the maximum value used by the system, and then the operation function of starting the auto-tuning should be performed. The setting of parameters CtI (control cycle) and dF (hysteresis) also have an effect on the self-tuning process. Generally speaking, the smaller the set values ​​of these two parameters, the higher the accuracy of the theoretical self-tuning parameters. However, if the dF value is too small, the meter may cause a misalignment of the position adjustment near the given value due to the input fluctuation, which may instead set a completely wrong parameter. It is recommended that CtI = 0-2 and dF = 2.0. In addition, based on the reason for learning, the first time after the end of auto-tuning, the control effect may not be optimal, and it takes a period of time (usually the same time as auto-tuning) to get the best results.
In the process of use, AI regulator combines PID adjustment, self-learning and fuzzy control technology to realize self-tuning/adaptive function and precise adjustment without under-adjustment. The performance is far superior to traditional PID regulator.
Sixth, grounding alarm function:
When the hood furnace generates a ground fault, the ground fault alarm scroll bar status shows the ground state on the flow chart.
Ground fault alarm instrument selection AI-706MAJ1J1J1L5L5S type; using the potential characteristics of the thermocouple's measuring loop, when the relay is running, the temperature displayed by the instrument is normal temperature. When the relay is disconnected, the thermocouple is disconnected to display 1312 to make the meter alarm. Protects the hood furnace.
Seven, software features
The whole system is divided into three levels: management, operation station and industrial site. It can also be divided into two levels: operation station and industrial site. The management team can provide the factory leaders to view the real-time working conditions of the site, and also perform advanced settings such as usage rights and system configuration; the operation station provides real-time monitoring of the computer by the instrument team and technicians; in the event of a computer system failure, the instrument operator The instrument can be directly operated according to the traditional instrument usage method; the industrial field provides various control signals such as analog input/output and digital input/output to the instrument.
(1) Information display screen
On the flow chart, the range picture of the industrial site can be added according to the requirements of the site. The meter display screen mainly displays the current running status information value of the hood type furnace. For example, the current temperature parameter is on the flow chart, real-time trend graph or instrument screen: click [meter display box] to appear the operation platform: you can see the AI ​​meter definition control The name of the device, the bit number, the instrument model, the address, the upper limit of the range, the lower limit of the measurement limit, and the unit of measurement. At this time, all display parameters and control buttons of the AI ​​instrument are reflected on the platform.
(2) Real-time alarm processing screen
The data collected by the system in real time is judged. When the alarm condition is met, the screen will pop up a flashing eye-catching alarm signal with a screen alarm and an audible alarm function. Real-time detection of the abnormal parameters of the measured aluminum furnace parameters and system power supply. Events that occur during program execution can be logged. Specifically, in the monitoring program, the type of the recorded event, the start and end time, the corresponding action, and the like can be set.
(3) Range setting, program setting screen
A user with certain authority can log in with the password and set the range of the measured parameters, so that the measurement error caused by various unpredictable external factors can be finely corrected to ensure the validity and authenticity of the measured data. Sex. This software is suitable for a variety of industrial field applications. For kiln with temperature control, such as: use AI-808P instrument all parameters can be set, can program, view the orientation of the programming program, save multiple program curves, realize upload, download, modify curve online, parameters . Aluminum furnace parameter setting screen configuration manual parameters of the cover furnace, running time, start and stop time, running voltage, etc. Click [Parameter] name to modify [upper limit absolute value alarm value HAL] Fill in the parameters in the dialog box, click "OK" "The parameters are passed down to the field AI meter temperature regulator,
(4) Report print screen
Select the report name, set the print time period of the query time range, select the query interval, etc., generate the report, print at any time, and also select the data export function to export according to the Excel type report. Various reports can be exported to the outside of the software and saved as Microsoft Excel documents or browsers. Report query: Enter the start and end time period to query the historical data; the sample has 1; 3; 5; 15; 30; 60 minutes to select the report.
(5) Real-time data curve screen
Monitor the trend curve of the parameters of the hood furnace, so that you can understand the operation of the aluminum furnace for a period of time. The industrial field temperature controller collects the measured values ​​and edits the real-time curve. It can display 8 real-time curves at the same time and distinguish them by color. The curve shows two graphs of the optional percentage and the real-time curve. It is also possible to mask other curves and display a single curve. Real-time data presented and stored in the system database for future data query and other use.
(6) Historical trend screen
The function is similar to the real-time data curve, except that it shows the operating parameter values ​​of the device over time. Select the historical curve group, set the query time range, display a single bar or display all curves, click Query. A memo can be written on the history curve and 59 words can be written. Print directly on the historical curve. You can select one or more to print the history curve.
(7) Operation log screen
Record the action record corresponding to the operation of the software running. Such as: login system, exit system, print curve name, modify parameters, etc. Select the time period to query the record running status for a certain period of time.
(8) User management screen
Users with different permissions can be allowed to log in. After logging in, related operations can be performed. At the same time, it can also allow users to log out their own identity, which can achieve flexible and convenient application, and ensure the security of the system.
(9) Inspection report screen
According to the operation of the user, the hood furnace is inspected at any time and the operation status is recorded to generate a report. Can be used to release work plans, message notes, can be added at any time.
After the actual production and use certificate, the advantages of using the AIFCS computer monitoring system are as follows:
1. The computer displays the temperature data, curve and ground fault alarm of the cover furnace in full screen. The management keeps abreast of the temperature of the on-site hood furnace, guarantees the quality of the products, and recalls the quality of the products.
2, AIFCS computer monitoring system in the lower layer by the digital display control instrument independently complete monitoring, control, alarm and other functions, the upper layer by the computer to complete centralized monitoring, operation, remote settings and other functions, you can easily interconnect the system and computer group The automatic test system therefore has a high system reliability. This greatly expands the use and scope of the instrument, and the monitoring point can have a system of tens to hundreds of points, which is undoubtedly a better choice. More convenient and faster self-built acquisition adjustment monitoring system.
Eight, the conclusion:
Because the AI ​​artificial intelligence regulator has excellent measurement and control performance, the hood control has brought unprecedented convenience to the design of the hood furnace control cabinet. For example, its output can be equipped with a thyristor trigger module with "burning not bad" characteristics, which can directly trigger various unidirectional, bidirectional thyristors and power modules with time proportional zero crossing, cycle zero crossing or phase shifting, not only Reduce costs, simplify installation and increase reliability. In recent years, with the development of electrical control technology, the automatic control system of the hood furnace has been rapidly developed, and the control system has been well applied and developed. The control technology of the hood furnace is further improved.
Huangshi Saifu Friction Material Co., Ltd. has applied AI instrument program to control the temperature of the hood furnace to produce carbon-based friction materials, non-asbestos polymer composite brake pads, paper-based friction plates, copper-based friction materials and ceramic brake pads. Among them, the first two products passed the appraisal the previous year and reached the international advanced level. In recent years, the company has developed rapidly. Before the restructuring, the sales revenue was 20 million yuan. Now it has doubled to 80 million yuan. It is expected to break through the 100 million yuan mark this year. Last year, the tax paid was 3.8 million yuan. This year, it is expected to exceed 5 million yuan. The city's private enterprises have large profits and taxes. The company has been recognized as a provincial high-tech enterprise by the Provincial Science and Technology Department and has become the largest and most advanced friction material production base in China.
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