**I. Overview:**
Heating furnaces are widely used across various industries, including factories and mines. They play a crucial role in the metallurgical industry for heat treatment, drying, solidification, and maintaining constant temperatures in scientific research equipment. These furnaces can be categorized into several types: natural convection furnaces, electric blast furnaces, high-temperature muffle furnaces, and gas or electric heating roller kilns. The temperature control range of these devices spans from room temperature up to thousands of degrees Celsius.
During the temperature control process, it's essential to record data effectively. This can be achieved using a program temperature regulator or a measuring instrument with communication capabilities, which stores data on a flash memory card. One such innovative solution is the AI-2070S/C split-type paperless recorder, featuring a true-color human-machine interface. This device combines control and recording functions in a compact, user-friendly system. Its practical design, affordability, and ease of use have made it popular in the market. If you're looking for an efficient temperature monitoring and control system, this product is worth considering. For more details, feel free to contact us.
**1. Advantages of the Split Paperless Recorder System:**
The AI-2070S/C split-type paperless recorder is part of a new generation of true-color human-machine interface systems designed for measurement and control. It finds applications in industries such as textile machinery, packaging, pharmaceuticals, rubber, heavy machinery, testing equipment, power, HVAC, environmental protection, petrochemicals, aerospace, coal, water treatment, metallurgy, cables, and rail transportation.
This device supports full-screen display of each channel, allowing real-time monitoring of temperature, pressure, flow, and other parameters. It features a touch screen that can integrate flow charts for small DCS control systems. Each channel updates data every 50 milliseconds, offering superior performance compared to traditional paperless recorders by combining human-machine interface and recording functions.
Hardware includes a high-brightness TFT LCD display and a resistive touch screen, along with a control unit and data storage module. It supports a wide range of signal inputs and outputs, including DC voltage, current, resistance, thermocouples, RTDs, infrared thermometers, frequency, AC voltage, current, and power. Additional functions include dry and wet bulb temperature measurement, square root calculation, flow accumulation, and compensation. It also offers PID control, alarm functions, and switch input/output capabilities.
The system provides rich graphical displays, showing real-time data, curves, bar graphs, and historical trends. It supports program recipes, patrol history checks, alarms, and reports. With 1–32 channels displayed at once, users can view detailed data, curves, and adjust settings manually or automatically. Process maps offer a comprehensive overview, while historical data reports and alarm responses are easily accessible.
**2. Program Control Features:**
The AI-2070S/C allows users to display hyperbolic running diagrams and track program progress. It enables immediate setting of temperature programs, including heating, constant temperature, and cooling. Users can save and replay program recipes, start, stop, or pause operations, and manually adjust output during operation. It also allows real-time modification of segment numbers and control parameters.
**3. Flowchart Functionality:**
Users can create custom process flowcharts. Pre-set digital output (DO) contacts allow motor start/stop control via buttons. DI modules can monitor motor status and display animations. This feature enhances operational visibility and control.
**4. Data Storage and Management:**
The AI-2070S/C supports up to 2GB USB storage. Default sampling intervals are 60 seconds, with storage durations varying based on the number of channels. For example, 4 channels can store about 560 days of data, while 8 channels can store around 346 days. Users can adjust sampling intervals as needed, down to 1 second. Data is stored in FIFO (first-in, first-out) order and can be directly opened on a PC.
**5. Communication and Data Processing:**
Real-time data is exported to a USB drive, with files saved by year/month/day/hour. CSV format reports are generated automatically, and data can be backed up via a card reader.
**II. Communication Function of AI Series Intelligent Temperature Regulators:**
Choosing a reliable communication regulator is key to effective electric furnace control. The AI series intelligent temperature regulators enhance temperature control performance, enabling faster control, shorter production cycles, energy savings, and improved product quality. Their ease of use and efficiency have led to widespread adoption, replacing traditional regulators.
The AI regulator uses an advanced platform concept, converting professional digital adjustment instruments into versatile products. It includes a hardware motherboard with I/O interfaces, display sockets, A/D units, and power supplies. By installing different software, CPUs, and modules, it can support various control requirements, such as thermostats, regulators, and dual-loop controllers.
Its PID adjustment algorithm employs AI-based fuzzy rules, adjusting PID parameters dynamically. When errors are large, it prevents integral saturation; when small, it optimizes control. It learns and adapts to the controlled object, ensuring no overshoot, high precision, and excellent performance.
**III. Functions of AI-2070S/C Split-Type Paperless Recorder:**
The system is structured as an upper and lower machine. The host computer is a true-color human-machine interface AI-2070S/C paperless recorder that integrates AI series instruments for multi-channel digital display. It supports various signals and configurations, including AI PID control.
The interface includes fixed touch buttons for starting full-screen data, accessing menus, and performing actions like viewing instrument screens, light column maps, historical trends, data reports, alarm information, and exporting data. It supports program control with Start, Pause, and Stop functions, as well as manual/automatic switching.
It can connect to multiple models, including external panel-mounted and rail-mounted instruments. The touch screen can be used to display flowcharts for small DCS systems. It simulates switches, buttons, indicators, trend curves, and bar graphs. It supports network communication via RS485, enabling monitoring systems, with 50ms data refresh per channel.
The recorder can display temperature, pressure, and flow on flowcharts, providing colorful visualizations of device status. Users can start motors, move crucibles, open/close furnace doors, and manage combustion. All data is recorded on CF cards or USB drives, with curve reports printed for reference.
**IV. Lower Machine Functionality:**
The temperature regulator performs program PID adjustments based on measured and set values, controlling thyristors to stabilize furnace temperature. It connects via RS485 to the AI intelligent program type PID temperature regulator, displaying hyperbolic operation diagrams on the touch screen.
Users can control the program instrument on the screen, switching between manual and automatic modes, modifying segments, and adjusting parameters. It also recalls recorded temperature curves and prints reports.
**V. Real-Time Data, Historical Curve, and Alarm Information Query:**
The AI bus-type paperless recorder saves data to a U disk, which can be inserted at any time. Standard 2GB U disks store data efficiently. Data can be copied to a PC as CSV Excel files, organized by year/month/day/hour.
On the query screen, users can check historical temperature data, mark vertical axis as temperature and horizontal as time, and search by time advance or shift. The alarm history screen records furnace-related alarms, allowing users to set start and end times, and view historical curves, reports, and alarms.
The [Data Export] function allows users to set sampling times, intervals, or export immediately to a USB drive. Reports can be auto-exported, manually exported, or customized. The file size can be adjusted, and remaining memory space is displayed.
**VI. Performance of the New Generation AI Electric Furnace Control Cabinet:**
The AI electric furnace control cabinet features a modular structure, enhancing convenience in design. It supports program-controlled temperature rise and fall, segmentation power limitation for silicon molybdenum rods, and synchronized multi-zone control.
It uses thyristor trigger modules with "burnable" features, capable of triggering various thyristors and power modules. It supports time proportional zero-crossing, phase shifting, and cycle zero-crossing. The AIJK series three-phase modules are reliable and adaptable to various loads.
**VII. Program Curve Arrangement:**
The AI-808PAX3L5L5S4 program table adjuster allows automated setpoint changes according to time rules. It supports 50-segment programming, adjustable rising/falling slopes, and commands like jump, run, pause, and stop. It has two-way event output and alarm functions to control interlocking equipment.
**VIII. Thyristor Selection:**
Thyristor selection depends on load wiring. Star three-phase four-wire loads use bidirectional thyristors or single-phase anti-parallel circuits. Three-phase three-wire loads use single-phase thyristor + diode circuits. Proper thyristor model selection ensures safe and efficient operation.
**IX. Conclusion:**
The AI series thyristor electric furnace control cabinets offer excellent performance, thanks to their modular design. They reduce costs, simplify installation, and improve reliability. With the development of electrical control technology, the new generation of true-color human-machine interface paperless recorders continues to evolve, enhancing electric furnace control systems. As a result, the control technology of electric furnaces has seen significant improvements.
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Guangdong Planet Cabinetry Co., Ltd. , https://www.cnplanetcabinetry.com