The IoT products developed by the company are mainly applied in the petrochemical industry, including the online monitoring system for paraffin forming machines, which has received widespread praise from users. The online monitoring system of paraffin forming machine mainly monitors the parameters of three aspects of equipment.
1、 Monitor the tension of the chain
During the refining process, large refineries in our country produce a byproduct - paraffin wax. The process of forming paraffin wax is a slow process that gradually transforms from a hot liquid to a solid. Its characteristic is that it is formed in a cold chamber below zero degrees Celsius without human supervision; The second issue is that the chain used to transport the wax tray consists of seven layers and is 700 meters long, which can easily lead to unsynchronized chains on both sides, causing the wax tray to get stuck during movement and even causing the chain to stretch and damage the entire frame of the machine. Due to workers not being in the cold room and unable to see the chuck, the phenomenon of work stoppage caused by the chuck often occurs. There are many reasons for the chuck, such as the chain being too loose or too tight, the chain being worn and elongated, uneven tension on both sides of the chain, unequal chain link length, asymmetry, gear wear, etc. The BZ2231A paraffin forming machine monitoring system developed and produced by our company is equipped with 14 tension sensors on the 14 spring pull rods of the paraffin forming machine to monitor the tension values on both sides of each layer in the seven layer chain. As long as the two chains on the same layer have basically equal force values, that is to say, the two chains are basically synchronized, there will be no clamping phenomenon. The sensor monitors the changes in the tension of the chain. When the tension state of the sensor changes, the internal circuit sends out corresponding change signals, which are transmitted to the monitoring system host through cables. Host B consists of 14 channels, a single-chip computer, and a display unit. The sensor output signal is amplified by the channel, and after anti-interference processing, it is output to the single-chip computer unit. The computer samples and analyzes the signal and sends it to host A. For example, if the tension of the chain is moderate, the computer will cycle to detect 14 measuring points on 7 layers and display the measured value. If there is no text attached to the corresponding measuring point on the LCD, it indicates that it is working normally; When the tension of the chain is too loose, the displayed value decreases, and the corresponding measuring point on the LCD displays "low force", indicating that the measuring point should tighten the chain to the normal value; When the tension of the chain is too tight, the displayed value increases, and the corresponding channel on the LCD displays a "warning", indicating that the measuring point should loosen the chain to the normal value; When a chuck accident occurs, the tension of a certain layer of chain gradually increases and quickly exceeds the alarm value, displaying the alarm value and "alarm" of this layer, and stopping the machine according to the conditions allowed by the alarm. We set a 14 point warning value and alarm value based on the actual situation. The system host is located in the workers' operating room, and when a problem occurs, the system will give an early warning or alarm. Workers can easily solve the problem in its infancy.
The key to this system is to use the degree of chain tension to reflect the operating status of the forming machine and chuck faults based on the working status of the forming machine. Practice has proven to be effective, as it can not only monitor the occurrence of chuck faults at any position, but also accurately reflect the optimal operation of the entire machine.
This system has the following characteristics for measuring chain tension:
1. Reasonably configure parameters to ensure that the molding machine operates at its optimal state.
The outstanding feature of this system is to ensure that the forming machine works in the best state without any hidden faults. The working parameters of this system are determined based on the type, age, and on-site conditions of the forming machine. At the same time, the forming machine is balanced and adjusted according to the system data, so that the forming machine works in the best state (such as moderate chain tension, appropriate left and right tension, and equal resultant force). Chuck failures will not occur, ensuring that the forming machine runs well and production proceeds smoothly.
2. Monitor the development trend of chuck faults and provide timely data and forecasts to users.
The molding machine works for a long time, and due to mechanical wear or other reasons, it may cause changes in other parameters. If not adjusted and corrected in a timely manner, it will eventually cause serious problems with the chuck. The original alarm device of the molding machine did not have these functions, so it is impossible to know the development trend from normal operation to chuck, which inevitably leads to chuck accidents. This system provides users with precise and intuitive parameters and warning indicators. Users can adjust the changing parameters of the molding machine in a timely manner, so that the molding machine always works in the best state.
If there is an unexpected malfunction of the chuck or chain, the system will immediately sound an alarm and shut down, displaying the location of the fault and minimizing the loss caused by the malfunction.
The installation of sensors is extremely convenient, without changing any of the original functions and states of the molding machine.
3. Bringing great convenience to the maintenance and debugging work of the molding machine.
The maintenance workload of the molding machine is relatively large, and the debugging is difficult, with a long maintenance cycle. Based on the data displayed in this system, debugging is accurate, fast, and work efficiency is greatly improved.
4. The line fault self checking function designed with special technology ensures high reliability of this system.
This system can respond and handle any damage to the sensors, cables, and connectors of the fourteen measuring points on the seventh floor in real time. It can accurately distinguish whether abnormal signals are caused by its own system failure or the monitored molding machine failure. Like a 'living organism', the intact or damaged 'heart' of the extended 'tentacles' has several functions, making the system highly reliable and not prone to false alarms.
2、 Monitor the speed of the chain
At a certain temperature inside the cold chamber, the speed at which the chain travels determines whether the wax board meets the hardness standard when it exits the cold chamber after forming. If it does not meet the specified hardness, the wax board may become soft and unable to detach from the wax tray. Therefore, a sensor for measuring chain speed was installed at the motor drive.
3、 Monitor the temperature of the cold room
If the temperature in the cold room does not meet the requirements, it will seriously affect the quality of wax plate forming. In the past, thermometers were installed in the cold room, but workers needed to enter the cold room to see them. This system is equipped with 5 temperature sensors at the inlet and wax inlet of four air coolers. Workers can timely see the temperature of the cold room in the operating room and deal with it in a timely manner when the temperature cannot be reached.

The upper computer of the system is an industrial PC equipped with BZ2231A control software, which is connected to the BZ2231A host through a bus and can be remotely set up. The administrator can remotely access the monitoring data of the paraffin forming machine at any time.
The use of this system greatly saves maintenance time and production costs for refining enterprises, improves production efficiency, and can create economic benefits of over one million yuan for the country every year. Our company's product occupies 90% of the national market share and has achieved good social and economic benefits.