High Speed Sampling And Fault Analysis System Of Induction Furnace

Induction furnace is widely used for smelting steel, iron, copper, aluminum and alloys in industry with advantages of high efficiency, energy-saving and smelting metal uniformly. Because of the high energy required by induction furnace, the power of electrical cabinet of induction furnace is very high. The main circuit of electrical cabinet is rectifier and inverse circuit, whose key component is SCR. Although principle of the main circuit is not complex, it has a variety of auxiliary circuit. Therefore it is difficult to find out fault source when main circuit has fault. Furthermore, when there is a fault in main circuit, maintenance person can only speculate the fault source based on the surface phenomena of fault circuit. The efficiency and accuracy of this approach are very low.To solve above problems, this paper presents high speed sampling and fault analysis system of induction furnace. The system consists of two parts:high speed sampling module and fault analysis module.High speed sampling module samples signals of main circuit and monitors the fault of main circuit with a high speed in real-time. When a fault occurs, the data around fault time will be saved immediately. The fault data can be downloaded locally or remotely and the waveform of data can be displayed in PC. By this way we extend the time range of saved fault information from a time point to a time interval. Then we carry out fault analysis according to the fault data.The main steps of fault analysis are pre-processing, dimensionality reduction and classification. Firstly we divide the fault of circuit into several classes. And secondly we pre-process the fault data. Then the dimensionality can be reduced by ISOMAP (Isometric Mapping) algorithm. When we need to classify a sample point, we put the point into each fault class to compute the reconstruction error of them. The class with the minimum reconstruction error is which class the sample point belongs to.We get more fault information with high speed sampling module and get a classification result of fault data with fault analysis module. The high speed sampling module is the basis of whole system while fault analysis module is the expansion of whole system. The fault information obtained by high speed sampling module provides the accordance for artificial fault analysis while we will get accurate analysis result quickly when we combine artificial fault analysis and automatic fault analysis.