铜阀锻前红冲加热炉设计及其温控策略研究
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摘要
以铜阀锻前红冲加热炉为研究对象,对加热炉的基于节能的创新结构设计、基于功能实现的电气系统设计以及基于炉温的控制策略等进行了深入的研究,主要涉及以下几方面：
设计了一种自动进料式的连续加热炉,该加热炉通过提升机、排料器以及推料器实现自动进料；以双层导轨、电热元件以及保温层构成炉体结构。炉体设计围绕节能主线,包括炉体材料的选择,电热元件的布局以及保温层的设计等等。保温层布局借助ANSYS有限元软件进行分析和优化,通过对炉体温度场和热流场的分析,提出了保温层优化方案,并通过实验验证了其准确性和可靠性。
完成加热炉的电气系统设计,主要包括在硬件上实现自动进料的控制、炉温的实时检测与控制以及完善的人机交互等功能。基于实际工况的复杂性考虑,本加热炉又增加了故障自监测功能,对缺料、断炉丝、超温以及传感器损坏等常见故障进行自动报警,并提示用户排除故障方法。
研究以升温快速和不超调为目标的炉温控制策略。提出了将安排过渡过程和BP-PID结合应用于炉温控制的方案,仿真和实验均表明此方法可以很好地解决炉温升温快速性与不超调之间的矛盾。
研究基于加载考虑的炉温控制策略。在进、卸料过程中,炉温会发生大幅波动,影响温控的稳定性和精确性。为此,本文提出了一种将干扰观测器集成到已有温控策略上的方案,仿真和实验均表明集成干扰观测器后,系统鲁棒性大大提高,对大范围的负载干扰有很强抑制作用。为了增加对比性,本文还安排了目前常用的炉温控制策略——模糊控制策略进行比较试验,结果表明模糊控制器只能适应小范围工况变化,在升温性能和对抗大范围负载干扰性能上都不及本文所提出的集成安排过渡过程和干扰观测器的BP-PID控制器。
Making a copper forging furnace as the research object, the studies have been carried out in depth on innovative structure design based on energy-saving and on electrical system design based on function and on control strategies based on furnace temperature.
An automatic feed continuous furnace was designed, which achieved automatic feeding by the elevator, range equipment and pusher; and constituted the furnace body structure with double tracks, electric components and heat insulator. The design of furnace body was based on energy-saving, including the choice of furnace materials, the layout of electric components and the design of heat insulator layers and so on. The heat insulator layers was analyzed and optimized by ANSYS finite element software, and an optimization scheme was proposed after the analysis of temperature and heat flow field of the furnace body. Finally, the accuracy and the reliability of the optimization scheme were verified by experiment.
The electrical system of furnace was completed, including the function realization of automatic feed control, real-time examination and control of temperature and human-computer interaction on the hardware. Considering the complexity of the actual operating, this study added a function of malfunction self-monitoring, which mean when the common malfunctions such as material lacking, furnace wire broken, overheat and sensor damage occurred, the system would alarm automatically, and would prompt the users how to solve the problems as soon as possible.
The temperature control strategy of which the goal was heating rapidly and non-overshoot was studied. Arrange transition course based BP-PID controller was presented. Simulation and experimental results show that this method could solve the contradiction between heating rapidly and non-overshoot well.
The temperature control strategy which considering loading was studied. In the process of load in or out, furnace temperature would fluctuate badly, which affected the stability and precision of temperature control. Therefore, a disturbance observer based on the existing controller was presented. Simulation and experimental results show that the system has very strong inhibitory action to the large range of payload disturbances and its robust is improved greatly, after the disturbance observer is added. In order to increase the contrast, this study also arranged other strategy-fuzzy control strategy which was commonly used at present for comparison experiments, the results show that the fuzzy controller could only adapt to small range condition changes, in the performance of heating and against large range load disturbance, it is worse than the BP-PID controller which integrates the Arrange transition course and disturbance observer.
设计了一种自动进料式的连续加热炉,该加热炉通过提升机、排料器以及推料器实现自动进料；以双层导轨、电热元件以及保温层构成炉体结构。炉体设计围绕节能主线,包括炉体材料的选择,电热元件的布局以及保温层的设计等等。保温层布局借助ANSYS有限元软件进行分析和优化,通过对炉体温度场和热流场的分析,提出了保温层优化方案,并通过实验验证了其准确性和可靠性。
完成加热炉的电气系统设计,主要包括在硬件上实现自动进料的控制、炉温的实时检测与控制以及完善的人机交互等功能。基于实际工况的复杂性考虑,本加热炉又增加了故障自监测功能,对缺料、断炉丝、超温以及传感器损坏等常见故障进行自动报警,并提示用户排除故障方法。
研究以升温快速和不超调为目标的炉温控制策略。提出了将安排过渡过程和BP-PID结合应用于炉温控制的方案,仿真和实验均表明此方法可以很好地解决炉温升温快速性与不超调之间的矛盾。
研究基于加载考虑的炉温控制策略。在进、卸料过程中,炉温会发生大幅波动,影响温控的稳定性和精确性。为此,本文提出了一种将干扰观测器集成到已有温控策略上的方案,仿真和实验均表明集成干扰观测器后,系统鲁棒性大大提高,对大范围的负载干扰有很强抑制作用。为了增加对比性,本文还安排了目前常用的炉温控制策略——模糊控制策略进行比较试验,结果表明模糊控制器只能适应小范围工况变化,在升温性能和对抗大范围负载干扰性能上都不及本文所提出的集成安排过渡过程和干扰观测器的BP-PID控制器。
Making a copper forging furnace as the research object, the studies have been carried out in depth on innovative structure design based on energy-saving and on electrical system design based on function and on control strategies based on furnace temperature.
An automatic feed continuous furnace was designed, which achieved automatic feeding by the elevator, range equipment and pusher; and constituted the furnace body structure with double tracks, electric components and heat insulator. The design of furnace body was based on energy-saving, including the choice of furnace materials, the layout of electric components and the design of heat insulator layers and so on. The heat insulator layers was analyzed and optimized by ANSYS finite element software, and an optimization scheme was proposed after the analysis of temperature and heat flow field of the furnace body. Finally, the accuracy and the reliability of the optimization scheme were verified by experiment.
The electrical system of furnace was completed, including the function realization of automatic feed control, real-time examination and control of temperature and human-computer interaction on the hardware. Considering the complexity of the actual operating, this study added a function of malfunction self-monitoring, which mean when the common malfunctions such as material lacking, furnace wire broken, overheat and sensor damage occurred, the system would alarm automatically, and would prompt the users how to solve the problems as soon as possible.
The temperature control strategy of which the goal was heating rapidly and non-overshoot was studied. Arrange transition course based BP-PID controller was presented. Simulation and experimental results show that this method could solve the contradiction between heating rapidly and non-overshoot well.
The temperature control strategy which considering loading was studied. In the process of load in or out, furnace temperature would fluctuate badly, which affected the stability and precision of temperature control. Therefore, a disturbance observer based on the existing controller was presented. Simulation and experimental results show that the system has very strong inhibitory action to the large range of payload disturbances and its robust is improved greatly, after the disturbance observer is added. In order to increase the contrast, this study also arranged other strategy-fuzzy control strategy which was commonly used at present for comparison experiments, the results show that the fuzzy controller could only adapt to small range condition changes, in the performance of heating and against large range load disturbance, it is worse than the BP-PID controller which integrates the Arrange transition course and disturbance observer.
引文
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[2]. http://www.tzzjj.gov.cn/3831.html,台州市质量技术监督政务网
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[4]. 施慧巍,铜阀锻前加热系统的设计及其温度控制系统的研究[D].杭州：浙江大学,2006.
[5]. 肖兵,毛宗源.燃烧控制器的理论与应用[M].北京：国防工业出版社,2004.
[6]. 张欣欣,殷晓静.火焰加热炉与加热缺陷[J].工业加热,1995(1)：28-30.
[7]. 徐平姣.锻造加热炉的现状及节能途径探析[J],吉林工程技术师范学院学报(工程技术版),2003,19(9)：8-10.
[8]. Hsun-Heng Tsai, Shiuh-Ming Chang. Improvement of fuel consumption and maintenance of heating furnaces using a modified heating pattern. Journal of University of Science and Technology Beijing, Mineral, Metallurgy, Material. 2007,14(1):27-32.
[9]. A. K. Gupta. Clean Energy Conversion from Waste Fuels Using High Temperature Air Combustion Technology. Asian J. Energy Environ.2004,5(4): 223-266.
[10]. M.BOJIC, M.TOMIC.EFFECT OF REFUSE-GAS FUEL USE ONENERGY CONSUMPTION IN AN INDUSTRIAL PUSHER FURNACE.Energy.1998,23(9)：767-775.
[11]. Hamzeh Jafar Karimi, Mohammad Hassan Saidi. Heat Transfer and Energy Analysis of a Pusher Type Reheating Furnace Using Oxygen Enhanced Air for Combustion. JOURNAL OF IRON AND STEEL RESEARCH, INTERNATIONAL.2010,17(4):12-17.
[12]. W.H. Chen, Y.C. Chung, J.L. Liu. Analysis on energy consumption and performance of reheating furnaces in a hot strip mill. International Communications in Heat and Mass Transfer.2005,32:695-706.
[13]. 昂桂兰.工业加热[M].西安：机械电子工业部西安电炉研究所,1991.
[14]. Unal Camdali, Murat Tunc. Exergy analysis and efficiency in an industrial AC electric ARC furnace. Applied Thermal Engineering.2003, Vol.23:p. 2255-2267.
[15]. 雷聚超.一种新的自适应PID控制算法[J].工业仪表与自动化装置,2002,5：23-25.
[16]. 刘秀红.模糊自整定PID控制在电阻炉温度控制中的应用[J].测量与设备,2007,2：25-28.
[17]. A.G. Abilov, Z. Zeybek, O. Tuzunalp, Z. Telatar. Fuzzy temperature control of industrial refineries furnaces through combined feedforward/feedback multivariable cascade systems[J]. Chemical Engineering and Processing,2002, 41:87-98.
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