Electric heating is a device that converts electrical energy into heat to provide heat to the objects being heated. It is widely used in pipeline insulation and heating for instruments in industries such as chemical engineering, steel, petroleum, construction, and food. It helps keep the heated objects within a reasonable temperature range, preventing the medium in pipelines (equipment) from freezing and cracking due to low temperatures, and ensuring normal operation.
However, in the current application process, there is no effective management of electric heating. The heating needs to be manually activated, and after activation, it remains in a long-term power supply state, resulting in energy waste and increased labor intensity for operators.
This system utilizes intelligent sensing, 4G wireless transmission, and automated management to automatically control each heat tracing device. It sets fixed activation and deactivation durations for each device based on their operating characteristics, achieving energy-saving effects while ensuring the normal operation of the equipment, and does not require manual operation.
The system has the following three functions:
1.Power saving
The system collects environmental temperature of the heated equipment, temperature of the heating tape, surface temperature, material of the pipeline (tank), wall thickness, flowing medium, insulation layer parameters, etc. to build a data model, including source database design, data integration, ETL process, data warehouse model creation, structure design of data lake, BI tool presentation design, as well as machine learning or artificial intelligence technologies. It adopts a combination of four digital modeling methods: relational, object, dimension, and time, and embeds 1000+ mining components. It includes mature machine learning algorithms such as classification, regression, clustering, prediction, and association. It calculates the longest power-off interval value of the heating tape under the current state, provides on-site module operation instructions, completes remote power on/off, and minimizes the actual working time of the heating tape while ensuring the normal operation of the equipment, thereby saving electricity and extending the service life of the heating tape. It can save up to 40-80% of electricity.
2. Fault Prediction and Online Diagnosis
The system, through the establishment of information databases, knowledge bases, and large databases, combined with the equipment operation model, relies on online signal monitoring, feature extraction, state recognition, parameter comparison, and forecast decision-making, to predict potential equipment faults in advance. It conducts intelligent diagnosis and analysis of each component's faults and promptly sends messages to the managers to remind them of maintenance and handling, reducing accidents, lowering heat insulation material losses, and ensuring the normal operation of the equipment.
3. Automated management
Without the need for manual operation, managers can view the usage status of each device in the background system or through the mobile APP, including current, voltage, temperature, power, etc. They can also adjust the preset values themselves to meet the equipment requirements.
1. Temperature sensor
It uses 433MHz wireless (or wired) to continuously monitor the temperature of the heating belt, the surface temperature of the equipment, and the ambient temperature, and transmits the data to the control box, providing data support for safe and intelligent operation of the system;
2. Intelligent control module
The module consists of circuit breakers, contactors, and control modules. The module can collect and transmit data such as current, voltage, power, and metering of the controlled equipment to the background system, and receive commands from the background system to start or stop the circuit breakers and contactors;
3. Wireless transmission
It uses a 4G two-way transmission module to wirelessly transmit various data of the control circuit to the background management system and execute the background instructions to send commands to the front-end module for execution.
