User requirements
Technical requirements for temperature control equipment used in rail bonding production:
- The temperature controller must support 8 channels. Measurement range: 0–300°C. Measurement error: ±0.5°C.
- Real-time acquisition of 8-channel temperature signals, display of temperature curves, recording of temperature trends, and storage of measured temperature data.
- Control for seven bonding ovens (4 kW each) using thyristors or solid-state contactors. Maintain constant-temperature control with temperature accuracy of ±1°C.
- Control for one platen oven (18 kW) using thyristors or solid-state contactors. Maintain constant-temperature control with temperature accuracy of ±1°C.
- Automatic process temperature scheduling with the following steps:
- Heat to 110°C, hold for 50 min, then stop heating and enter standby.
- Manual start: heat to 200°C, hold for 50 min, then stop heating and enter standby.
- Manual start: heat to 210–240°C, hold for 120 min.
- Automatically cool to 180°C, hold for 80 min, then stop.
- The above temperatures and times are user-configurable. Temperature setpoint range: 0–300°C.
- Timing options: choose timing from the initial heating start to the end, or from the moment the process temperature is reached to the end.
System composition
The monitoring system consists of two main parts.
Data acquisition layer
This layer comprises temperature sensors (type K thermocouples) and a temperature data acquisition module (TP1708P). It collects internal oven temperatures and sends them to the TP1000 paperless recorder for unified display of values, curves, bar charts, and historical alarms, and for storage of all data to facilitate analysis.
Control layer
The control layer implements regulation using a PID regulator and solid-state relays. The measured temperature from the probes is compared with the instrument setpoint; heating continues until the setpoint is reached and then stops or maintains temperature according to the configured process and timing.
The TP1000 paperless recorder can communicate with host computer software to provide real-time display of values, curves, and bar charts. After communication, historical data can be queried, exported, or printed for timely on-site data retrieval and analysis.
