NJ230 MY

一、KY系列一体化安装型工业温控器的温度测量及控制原理
1、温度测量、显示原理
 温度信号为非电量值，工业控制应用中多是利用温度传感器采集测量物质的温度。通过温度传感器将测量的温度信号转换为电信号，再通过放大、滤波后送A/D转换器，实现模拟信号到相应数字信号的转换，然后利用数字信号处理方法计算得出温度值，实现温度的测量，KY系列一体化安装型工业温控器也是采用这一方法，测量过程如图1所示。

  图1中被放大的测量信号仍为模拟电信号，不能被单片机识别，要实现测量温度值的显示和单片机控制处理，还需要进行模数转换操作，温度信号显示过程如图2所示。

2、温度控制原理
被放大的温度测量信号经A/D模数转换后，成为单片机可识别的数字信号，并将其送入主控单元，与主控单元已设置好的给定值比较，经过PID运算得到输出控制值。此输出控制值用来控制KY系列一体化安装型工业温控器的可控硅模块单元导通角大小，进而控制执行元件加热功率，最终达到控制被测系统温度值的功能。温度控制过程如图3所示。

二、井式炉特性
井式炉是周期式作业炉，适用于杆类、长轴类零件的热处理。
井式炉外壳为钢板和型钢制成圆柱形炉体，全数采用密封焊接。加热元件绕成螺旋状装置在炉膛的搁丝砖上。以电为热源的井式炉为井式电阻炉。
井式电阻炉整个炉膛是一个密闭的空间，具有辐射传热的特性，对没有强制对流的井式炉还应当在炉子的上部与下部适当增加一些功率。由于井式炉结构和电热体布置等原因，炉内的实际温度分布是不均匀的。

三、KY系列一体化安装型工业温控器在井式电阻炉中的应用
  由井式炉炉体特性可知，炉膛内的各区的升温特性不同，而热处理工艺所需要的却是在一个工作空间内的温度分布均匀，并能长时间保持稳定。下面介绍如何应用辉达工控KY系列一体化安装型工业温控器进行井式炉控制，以保证井式炉炉温的均匀性。
  热电偶KY系列一体化安装型工业温控器可实现对炉内局部温度的控制和测量，在这样的条件下，为了确保炉内工作空间炉温的均匀性，采用多区温度控制。
  热电偶测温过程中只有被测介质、零件和热电偶之间的热交换过程达到完全的动态平衡，热电偶检测到的温度才能代表零件温度。但由于它们之间传热的复杂性和测温存在滞后等因素，要想达到完全动态平衡是不可能的，为使热电偶测量温度与零件实际温度相近，采用多点温度采集。
  不同炉子的温度均匀性不同，进行多区工艺曲线控制前，需要先测试炉子的温度均匀特性。具体做法是，首先根据炉体大小和井式炉加热空间分布特性，选用3个测温精度相同的热电偶分别测量井式炉上、中、下三个加热工作区的温度采集，分别作为1、2、3加热区的采集温度。
  再将3个热电偶对应接入三台KY系列一体化安装型工业温控器分别控制1、2、3区加热元件工作，根据3个加热区采集到的温度值与设定温度差值，进行PID运算，在炉子升温过程中，根据各个温区的加热情况，不断调整三区PID控制参数和输出大小，以使三个温区的温度基本一致，即保证整个炉膛内工作区的温度均匀。在调节炉膛温度均匀性的过程中，记录数据，得到炉子的加热特性。温度均匀性测试后，根据测试得出的数据，分别设置三个KY系列一体化安装型工业温控器的工艺曲线参数，进而实现对多个温区的控制。

结束语
  KY系列一体化安装型工业温控器在实际井式炉控制上得到很好的应用，项目应用中的井式炉温度均匀性得到了很好的提升和保证。

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(RR23-2) 2 MAPAL RE50-07 LOCK RINGS

(N1-2-8) 3 BP-6 6VDC BATTERY PACKS

(V5-2) 1  GENERAL ELECTRIC CR4CF-10 CONTACTOR

(H13) 1  FMC 225076 PC BOARD

(8563) McDaniel Controls Pressure Gauge AB-00803 0-1500 psi 1/2"NPT

(9264) Allen Bradley 849-N1A Auxiliary Contact Pneumatic Timer

RECOIL THREAD REPAIR KIT 33080

NEW DAYTON ELECTRIC REMOTE BULB THERMOSTAT 0-50 DEGREE 2E552

ALLEN-BRADLEY 700-C11Z CONTACT CARTRIDGE

(K1-4) 1  CARLO GAVAZZI PUA01CB23500V VOLTAGE AND CURRENT RELAY

Springer JM9A310AT Overload Relay

(Q2-4) 1 VICKERS DGMFN-3-Y-A2W-B2W-21 CONTROL VALVE

OCTAGON SYSTEMS CORP ADAPTER CARD PC-485

RELECO RELAY SOCKET 6A S9-M

EFECTOR SOCKETS SENSOR E18027

IFM EFECTOR PROX SENSOR IY5046

(Q14) JOHN CRANE SEAL KIT

MARKEL TW1510 THERMOSTAT- NO BOX

FESTO 121120 VALVE REPAIR KIT

(V4-1) 1  SQUARE D 9050-JCK-16 120VAC 0.1-10MIN ON DELAY TIMING RELAY

JOHNSON CONTROLS P67AA-7 ELECTRIC PRESSURE SWITCH

75-2407-R2-903 Valves

SMC SQ1130-5B-C6 VALVE

SMC NVFS2310-5DZ VALVE

PHILLIPS A40240 RELAY

LOT OF 4 DODGE 117154 BUSHINGS

LOT OF 5 HYSTER 1355319 GASKET SEALS

LOT OF 5 6071372 CARBIDE INSERTS

LOT OF 5 DICO 6031418R CARBIDE INSERTS

(10288) Foxboro Bellows Pressure Element U101CP

(V45-1) 1  BINKS 45-6311 63A SS SPRAY GUN NOZZLE

EI&S 1612LT11S24 RELAY- NO BOX

(Y6-4) 1 NEW HONEYWELL SKINNER VALVE L60 S044 REPAIR KIT

SKINNER LC2LX10 VALVE

(U2-3) 1 BOX OF 2 NEW CUTLER HAMMER D40RPB REED RELAY POLES

ALLEN-BRADLEY 700-PB40 SERIES A RELAY ACCESSORY

63-1008-A-02L-100 Pressure Gauge

POTTER & BRUMFIELD KRP11AG RELAY

SMC KM13-04-06-3 FITTING LOT OF 5

NUMATICS L01SA4592000030 SOLENOID VALVE

BURNDY KPU-34A26A GUTTER TAP

LOT OF 2 LUBE DEVICES G404-2 GAUGES

Lot of 2 Newport Thermocouples 0.32 DIA 36 Length

FALK 1025G 3.125 10B8804 HUB

SMC SY7340-5L0Z SOLENOID VALVE

(X8-7) 1 NIB MILLER ELECTRIC 051-KR011-63 PISTON ROD SEAL KIT 5/8"

IN LINE LUBRICATORS WPP-AR 8/4 LUBRICATOR

(RR17) DESTACO CPI-RCM-30 RETRACTING CUP MOUNT

(RR23-3) KOGANEI 181E1-83-PSL SOLENOID VALVE

HAYS 2600-1011 SHUR-FLO VALVE

FESTO 151210 HEIGHT COMPENSATOR

IRD MECHANALYSIS INC 941B SENSOR- NO BOX

(K2-1) ASCO S42478 SOLENOID VALVE

(8134) Telemecanique Flashing Red Strobe Light XVA-C441

OMRON 61F-11 RELAY UNIT

NEW COLUMBUS ELECTRIC ET5STS HEATING THERMOSTAT

LOT OF 4 OMRON EE-SX670 SENSORS

New ASCO 096875 REPAIR KIT

OTTO CONTROLS P6-380002 LIMIT SWITCH

SULLAIR 241772 STRAINER KIT

Asco Red-Hat 2 8314G6 valve T20935

LOT OF 3 BRUBAKER 5/8-11 HAND TAPS

HTM ELECTRONICS LCM1-1812P-ARU4

Ashcroft Pressure Gauge 35W1005P-02L-XUL-250

GE CR205X100C AUX CONTACT

FUJI TK-E02-1800 OVERLOAD RELAY

PHD INC GRC141-1-0001 PARALLEL HEAVY DUTY PNEUMATIC GRIPPER

PARKER 032500319 B FLOW CONTROL VALVE

SIEMENS 49AB01 AUX CONTACT-NO BOX

ALLEN-BRADLEY 1794-IB16 INPUT MODULE

SMC SS5Y7-20-05-00T MANIFOLD ASSEMBLY

OMEGA OSK2K850/88008E-TT NO HANDLE SENSOR PROBE

SMC KRR07-13 FITTING LOT OF 7

SMC VXD2130-03N-5DL1 VALVE

TURCK BI-2-EG08-AP6X-0.3M-PSG 3 SENSOR

HORIUCHI MACHINERY MCS-30X10 HYDRAULIC CYLINDER

(Rr25-1) Clarostat 58C2-3K Potentiometer

(V4-4) 1  MAC VALVES 811C-PM-591BA-152 SOLENOID VALVE

(Q5-2) 1 NEW ALLEN BRADLEY 700DC-M310 MINIATURE RELAY

(V19-4) 1 NIB ASCO 208-783 SOLENOID VALVE REPAIR KIT

(X1-2) 1 MICRO SWITCH FE-TLS3 PHOTOELECTRIC SENSOR

(T2-1) 1 NEW SMC VXA324402B VALVE MEDIA

Lot of 3 Allen Bradley MIXED Contacts X-241076 1495-G1 800T-XD6

(R2-6) 1  INTEL F-1114V/R2 MODEM

(H8) 1 NEW ALLEN BRADLEY 700-B200A1 RELAY

(M6-1) 1 HOYT 5631 THERMOSTAT

New Numatics Actuator Hall Effect SH6032

(Q4-3) 1  ALLEN BRADLEY 871TM-DH10NP30-A2 PROXIMITY SWITCH

(10381) Watts Regulator R119-02C

(10274) Maxon 2326.938-12.121-026 DC Motor

(L9) 1  CINCINNATI MILACRON 3-531-2807A CIRCUIT BOARD

(8876) Hycon Filter 0160R010Bn/Hc

Banner PT400 Remote Sensor Receiver 2.4m Range

ABB Timer Off Delay TP401A

JOSLYN CLARK 5M-058 CONTACT KIT

(G1-3) CUTLER-HAMMER D87AE TIMER ATTACHMENT

(T3-2) 1  SQUARE D 9013 GMG-2 SER C PRESSURE SWITCH

(O4-4) 1 New Cutler Hammer C25Anb125A Contactor

NORDSON PC BOARD 244501G

(9846) Ashcroft Pressure Gauge 35-1009-SW-02L-30/10MV SS 3 1/2" NPT Bottom

(Y6-5) 1  CARLO GAVAZZI EAACT231M TIMER ON DELAY

(5383) Gordos I/O Module PB-24SM

(I5) 2 SQUARE D MG24427 AND MG26925 SUPPLEMENTARY PROTECTORS

6244C-847 Motor

LOT OF 5 DICO 6031418 CARBIDE INSERTS

POTTER & BRUMFIELD CHB-38-30003 TIME DELAY RELAY

NCC TIK-1-461 SOLID STATE TIMER

(V38-2) 1 NEW SMC NARBF2000-P AIR VALVE REGULATOR

ELECTRONICS CORP OF AMERICA 42DCB-5000 PHOTOELECTRIC POWER BASE

(X9-6) Mac Valve Pme-112Ca Solenoid Valve

(H3-7) 1  ALLEN BRADLEY 4218580001 OVERLOAD RELAY 4 SIZE 0-1 STARTERS 509

SKF 61800 BEARING

(RR7-1) 1  BELLOFRAM TYPE 70 PRESSURE REGULATOR 1-60 PSIG, 350PSIG MAX

(A8) QUICKCABLE 127510-001 4/0 320A FEM EURO DIN KIT

ASCO 8262C79 VALVE

ALLEN-BRADLEY X-36182 RELAY- NO BOX

Faraday Alarm Signal 5970 87db

OMRON E32-CC200 PHOTOELECTRIC SWITCH

(Rr15-2) New Frost Controls Cpl-25 Photoelectric Sensor

Asco Valve 8262G22-120 1/4" 2W

(G1-5) 1 NEW CONTINENTAL INDUSTRIES INC RSDA660251DO SOLID STATE RELAY

BRADY?32651 TB03-502-281 LABELS

Crossbar For 3 Pole Size 2 Contactor Nib

Allen-Bradley 1485P-P1R5-MN5R1 DeviceNet T-Port Tap

NEW PARKER 14L10GASB LUBRICATOR

(Q2-3)10 Nib Smc Kal04-M6 Fittings

SMC NCME150-0700C cyl, air, cushion

(X9-13) 1 NEW REXROTH CYLINDER 0 822 334 501

(X9-14) 1 PRINTRONICS 101200-901 PC BOARD ASSEMBLY HAMMER DRIVER

(4841)G Lot 2 SMC Solenoid Valve VSS8-8-FG-S-3EZ-V1 24VDC

(X5-10) 1 NIB SSAC SLR2410A SOLID STATE RELAY

(V26) 1 NIB FEDERAL-MOGUL 416077 OIL SEAL

(0333) Bimba Cylinder BIM D-52094-A-1

RED LION CONTROLS APOLLO SLAVE DISPLAY APLSP3A ATB10000 1396

(D1) 1  FESTO MEH-5/2-4.0-I-SA 35 035 SOLENOID VALVE

(6870) Toshiba Laptop Keyboard Replacement for 335CDS P000230810

(4940) Keyence CVIO Connector 32 Pin OP-35341 3M

(Q9-5) 1 NIB GOULD DI-1131-000 INPUT MODULE

(H3-2) 1  JET JSM 512 DIE GRINDER

(8599) Nordson Tfe Hose -6, 5/16 I 843036J 3 Foot

(RR23-3) NEW DANTON GLYCERINE FILLED 0-60 PRESSURE GAUGE

(8617) S-P Cylinder Repair Kit A2020CK006 (Figgie)

NUMATROL CONTROL VALVE RA3-2003

(L27-3) ALLEN-BRADLEY 700-CF400 SERIES A AND 100-F CONTACTOR ASSEMBLY

(U1) 1 ALLEN BRADLEY 1771-OFE1 B ANALOG OUTPUT MODULE

Burling Temperature Control 942352 35-600 deg.

(K4) MOELLER PKZM0-1.6 MOTOR PROTECTOR

(V49-1) 1  BALLUFF BOS 18M-PS-1XA-E5-C-S4 TUBULAR PHOTOELECTRIC SENSOR

New Lot of Banner Apertures AP31-020 AP31-040H MORE

Furnas Contactor 42CF35AJAJT 40A 3P 24VDC

(8203) Allen Bradley Fiber Optic Sensor Rightsight 42EF-G1RCA-A2

MAC VALVE 6321D-000-PM-111DA 61AGC-1JAI 1/4" NPT

(M6-2) 1 ALLEN BRADLEY 100-A12ND3 CONTACTOR WITH RG1986-8-6 NETWORK

(I8-4) 19 SIEMENS MOORE 14230-273 BLUE INK CARTRIDGES

(X9-10) 1  CUTLER-HAMMER E57LAL12T111SD PROXIMITY SWITCH

(L20) LOT OF 2 GE FANUC IC600YB804B INPUT MODULES

(N3-1) 10 SMC VVQ1000-10A-1 PLUG IN PLATE

(T3-2) 1 NEW HONEYWELL 923AB3XM-A7T-L PROXIMITY SWITCH

(7458) R-K Electronics Timer CLRB-115A-2-10M-1M

(D11) 1 NEW MOTOROLA KTBTYPL01 BATTERY PACK

(L9) 1 CINCINNATI MILACRON 3-531-2793A CIRCUIT BOARD

(M5) 1 ALLEN BRADLEY 193-BSB30 OVERLOAD RELAY

(Q4-2) 1 New Efector If5684 Inductive Sensor

(Q2-3) INDUSTRIAL DYNAMICS KT-319 COUNTER

(Q1-1) 1 ALLEN BRADLEY 871C-P15R30 PROXIMITY SWITCH

(9089) Drayton Valve Body Trv3 Radiator Valve

(Y6-2) 1  POTTER & BRUMFIELD KBP-11AG-120 POWER RELAY

(R2-4) 1 NEW PETER PAUL O22NEDGV SOLENOID

Dodge 117156 Taper-Lock Bushing 1-3/16

ROBERTSHAW MG21-2033 PRESSURE CONTROL

SMC SQ113ON-5-C4-X46 VALVE

(RR22-4) CUTLER HAMMER C320KA1 AUXILIARY CONTACT

(V48-1) 1 LOT OF 2 NIB PARKER 12-12 MHN-SS MALE HEX NIPPLE PIPE FITTINGS

(Y6-2) 1  ALLEN BRADLEY 100-A09ND3 CONTACTOR W/ 193-BSC 10 OVERLOAD RELAY

PEARSON A096654 CYLINDER