A system and method for detecting internal quality defects of prebaked anodes using a multi-point deformation method

Abstract

The present invention discloses a system and method for detecting the internal quality defects of prebaked anodes by a multi-point deformation method, including a frame, a conveying mechanism, a pressurizing mechanism, and a detection mechanism; the system also includes an industrial computer; the pressurizing mechanism and a laser displacement sensor are both connected to the industrial computer; the carbon block is deformed by the pressurizing mechanism, and the detection mechanism detects the deformation of the carbon block and transmits it to the industrial computer. The system of the present invention realizes pressurization of the carbon block to be detected by the joint action of the top pressurizing mechanism and the bottom pressurizing mechanism, and deforms the carbon block by controlling the pressurizing pressure. The laser displacement sensor detects the multi-point position of the carbon block, and the industrial computer calculates the crack situation inside the carbon block, so as to more accurately and quickly judge the quality of the carbon block. Compared with the manual knocking method, the accuracy and operation efficiency of the system are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of prebaked anode carbon block detection, and in particular to a system and method for detecting internal quality defects of prebaked anodes using a multi-point deformation method. Background Art

[0002] Prebaked anodes are made of calcined petroleum coke as aggregate and coal tar as binder, and are used as anode materials for aluminum electrolytic cells. During the production process, the product is first vibrated and molded into green billets, and then baked to become finished carbon blocks. When finished carbon blocks with internal cracks are used in aluminum electrolytic cells, they are prone to falling off or even "falling off the pole", which seriously affects the normal operation of the aluminum electrolytic cell, affects product quality, and may also cause damage to the equipment. Due to the complexity of the production process and raw materials of baked electrodes, it is currently impossible to completely control the cracks of finished carbon blocks through process methods. Therefore, it is necessary to strengthen the internal quality inspection of carbon blocks to prevent unqualified carbon blocks from entering the market.

[0003] In the prior art, the method for detecting internal cracks in finished carbon blocks is to rely on the manual hammering method, which is to manually knock on the finished carbon blocks and listen to the sound to determine the internal cracks. The mechanism of this method is that when the carbon block has internal cracks, its natural frequency changes, and the cracks cause the free vibration damping to increase after the hammering. Therefore, the sound of the carbon block with cracks after being knocked is different from that of the normal carbon block. At present, this method requires a large number of inspection personnel and takes up a lot of manpower.

[0004] Therefore, based on the above technical problems, technicians in this field urgently need to develop an automatic detection system for the internal quality of carbon blocks to ensure that the system can efficiently and automatically determine whether the internal quality of the carbon blocks is qualified and realize the detection of waste products. Summary of the invention

[0005] The purpose of the present invention is to provide a system and method for detecting internal quality defects of prebaked anodes using a multi-point deformation method, which acts on a carbon block by applying pressure and uses a laser displacement sensor to measure deformation data of multiple points of the carbon block to determine the internal quality of the carbon block.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] A system for detecting internal quality defects of prebaked anodes by a multi-point deformation method of the present invention comprises:

[0008] frame;

[0009] A conveying mechanism partially extending into the frame, the conveying mechanism being used to convey the carbon blocks into the frame;

[0010] a pressurizing mechanism integrated into the frame; and

[0011] A detection mechanism, wherein the detection mechanism is a laser displacement sensor integrated in the frame;

[0012] The system also includes:

[0013] Industrial computer;

[0014] The pressurizing mechanism and the laser displacement sensor are both connected to the industrial computer;

[0015] The carbon block is deformed by the pressurizing mechanism, and the detection mechanism detects the deformation amount of the carbon block and transmits it to the industrial computer.

[0016] Furthermore, the frame includes a support frame located at the bottom, and a top frame body fixedly connected to the upper end of the support frame;

[0017] The detection mechanism is installed on the top frame;

[0018] The conveying mechanism extends horizontally to the lower part of the frame and conveys the carbon blocks to the lower part of the detection mechanism.

[0019] Furthermore, the conveying mechanism comprises:

[0020] A track extending in a horizontal direction; and

[0021] A plurality of round rollers arranged at intervals along the extension direction of the track;

[0022] The carbon block is moved to the interior of the support frame by the round roller.

[0023] Furthermore, the pressurizing mechanism is divided into a top pressurizing mechanism located at the upper part of the frame and a bottom pressurizing mechanism located at the lower part of the frame;

[0024] The top frame has an outer frame in a quadrilateral frame structure, and a crossbeam fixedly connected to the inner part of the outer frame;

[0025] The top pressurizing mechanism includes four top hydraulic cylinders and top supports mounted on the ends of the cylinder rods of the top hydraulic cylinders;

[0026] The top hydraulic cylinder adjusts the distance between the top support and the upper surface of the carbon block by extending and retracting its cylinder rod;

[0027] The four top hydraulic cylinders respectively press the four corners of the carbon block through the top support member;

[0028] The bottom pressure mechanism includes a bottom hydraulic cylinder and a bottom pressure head installed at the end of the cylinder rod of the bottom hydraulic cylinder, and the bottom hydraulic cylinder adjusts the distance between the bottom pressure head and the lower surface of the carbon block through its cylinder rod;

[0029] The bottom hydraulic cylinder presses the lower surface of the carbon block through the bottom pressure head;

[0030] A pressure sensor is installed at the bottom pressure head of the bottom hydraulic cylinder, and the pressure sensor is connected to the industrial computer to transmit pressure data to the industrial computer.

[0031] Further, the detection mechanism includes five laser displacement sensors;

[0032] The laser displacement sensor is installed on the crossbeam, and the five laser displacement sensors respectively detect deformation data of different positions of the carbon block and transmit the data to the industrial computer.

[0033] The present invention discloses a method for detecting internal quality defects of prebaked anodes by using a multi-point deformation method. The method mainly comprises the following steps:

[0034] S101, taking 50 normal carbon block samples through manual screening, and transmitting them to the system through the system's conveying mechanism for testing, to obtain normalized deformation matrices ZC1-ZC50;

[0035] S102, selecting 5 carbon blocks with layer crack defects, 5 carbon blocks with longitudinal crack defects, and 5 carbon blocks with delamination defects, and transmitting them to the system through the system's conveying mechanism for testing, and obtaining normalized deformation matrices QX1-QX15;

[0036] S103, establishing a corresponding relationship:

[0037]

[0038] S104, establishing a neural network: the neural network is a classic BP neural network, including an input layer, a hidden layer and an output layer;

[0039] Among them, the input layer nodes receive the obtained deformation matrix, and each node receives a point deformation;

[0040] The output layer is the recognition result, which is a value between 0 and 1, "0" represents the worst quality with defects, and "1" represents the best quality without defects;

[0041] S105, training the neural network with the corresponding relationship (1) as the target value, and obtaining the corresponding relationship between the displacement of the upper surface of the carbon block and various carbon blocks after the training;

[0042] S106. Pressurize the carbon block through the system's pressurizing mechanism to obtain its deformation matrix, input it into the neural network of step S104, calculate and output a value between 0 and 1, and quantitatively determine the quality of the carbon block based on the value.

[0043] In the above technical solution, the system and method for detecting internal quality defects of prebaked anodes by a multi-point deformation method provided by the present invention have the following beneficial effects:

[0044] The system of the present invention achieves pressurization of the carbon block to be tested through the joint action of the top pressurizing mechanism and the bottom pressurizing mechanism, and deforms the carbon block by controlling the pressurizing pressure. The laser displacement sensor detects multiple points of the carbon block and the industrial computer calculates the crack conditions inside the carbon block, thereby judging the quality of the carbon block more accurately and quickly. Compared with the manual knocking method, the accuracy and operating efficiency of the system are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0046] Figure 1 A schematic diagram of the structure of a system for detecting internal quality defects of prebaked anodes using a multi-point deformation method provided by an embodiment of the present invention;

[0047] Figure 2 A neural network structure diagram of a method for detecting internal quality defects of prebaked anodes using a multi-point deformation method provided in an embodiment of the present invention.

[0048] Description of reference numerals:

[0049] 1. Frame; 2. Top pressurizing mechanism; 3. Bottom pressurizing mechanism; 4. Laser displacement sensor; 5. Industrial computer; 6. Carbon block; 7. Conveying mechanism;

[0050] 101, support frame; 102, outer frame; 103, crossbeam;

[0051] 201, top hydraulic cylinder; 202, top support member;

[0052] 301, bottom hydraulic cylinder; 302, bottom pressure head; 303, pressure sensor;

[0053] 701, track; 702, roller. DETAILED DESCRIPTION

[0054] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0055] See also Figure 1 to Figure 2 As shown;

[0056] A system for detecting internal quality defects of prebaked anodes using a multi-point deformation method according to this embodiment includes:

[0057] Frame 1;

[0058] A conveying mechanism 7 partially extending into the frame 1, the conveying mechanism 7 is used to convey the carbon blocks 6 into the frame 1;

[0059] A pressurizing mechanism integrated into the frame 1; and

[0060] A detection mechanism, which is a laser displacement sensor 4 integrated in the frame 1;

[0061] The system also includes:

[0062] Industrial computer 5;

[0063] The pressurizing mechanism and the laser displacement sensor 4 are both connected to the industrial computer 5;

[0064] The carbon block 6 is deformed by the pressurizing mechanism, and the detection mechanism detects the deformation amount of the carbon block 6 and transmits it to the industrial computer 5 .

[0065] Specifically, the present embodiment discloses a system for detecting the internal quality defects of prebaked anodes by a multi-point deformation method, which mainly includes a frame 1, a conveying mechanism 7 for conveying carbon blocks 6, a pressurizing mechanism for pressurizing the carbon blocks 6 entering the system, and a detection mechanism for realizing multi-point detection of the deformation of the carbon blocks 6. Among them, due to the difference in the internal crack conditions of the carbon blocks 6, the deformation conditions of the carbon blocks 6 will also be different under the pressure of the pressurizing mechanism, therefore, by arranging a plurality of laser displacement sensors 4 on the frame 1 to detect the deformation conditions of multiple points of the carbon blocks 6, controlling the pressure of the pressurizing mechanism, and transmitting the multiple groups of deformation data detected by the laser displacement sensors 4 to the industrial computer 5 for calculation and comparison, finally obtaining the internal crack conditions of the carbon blocks 6 to judge the quality of the carbon blocks 6.

[0066] Preferably, the conveying mechanism 7 of this embodiment is used to convey the carbon blocks 6 into and out of the system. Specifically, the conveying mechanism 7 includes:

[0067] A track 701 extending in a horizontal direction; and

[0068] A plurality of round rollers 702 are arranged at intervals along the extension direction of the track 701;

[0069] The carbon block 6 is moved to the inside of the support frame 101 by the round roller 702 .

[0070] Preferably, the pressurizing mechanism of this embodiment is divided into a top pressurizing mechanism 2 located at the upper part of the frame 1 and a bottom pressurizing mechanism 3 located at the lower part of the frame 1;

[0071] The top frame has an outer frame 102 of a quadrilateral frame structure, and a crossbeam 103 fixedly connected to the inner part of the outer frame 102;

[0072] The top pressurizing mechanism 2 includes four top hydraulic cylinders 201 and a top support member 202 mounted on the end of the cylinder rod of the top hydraulic cylinder 201;

[0073] The top hydraulic cylinder 201 adjusts the distance between the top support 202 and the upper surface of the carbon block 6 by extending and retracting its cylinder rod;

[0074] The four top hydraulic cylinders 201 respectively press the four corners of the carbon block 6 through the top support member 202;

[0075] The bottom pressure mechanism 3 includes a bottom hydraulic cylinder 301 and a bottom pressure head 302 installed at the end of the cylinder rod of the bottom hydraulic cylinder 301. The bottom hydraulic cylinder 301 adjusts the distance between the bottom pressure head 302 and the lower surface of the carbon block 6 through its cylinder rod.

[0076] The bottom hydraulic cylinder 301 presses the lower surface of the carbon block 6 through the bottom pressure head 302;

[0077] A pressure sensor 303 is installed at the bottom pressure head 302 of the bottom hydraulic cylinder 301 , and the pressure sensor 303 is connected to the industrial computer 5 to transmit pressure data to the industrial computer 5 .

[0078] In order to be able to pressurize the carbon block 6 in the system, the present embodiment integrates the above-mentioned top pressurizing mechanism 2 and bottom pressurizing mechanism 3 in the frame 1; wherein, the top pressurizing mechanism 2 is distributed at the four corners of the carbon block 6 according to the structure of the carbon block 6 through four top hydraulic cylinders 201, and drives the top support member 202 to move downward through the cylinder rod to press the four corners of the carbon block 6; and the bottom pressurizing mechanism 3 is a bottom hydraulic cylinder 301, which drives the bottom pressure head 302 to move through the cylinder rod to pressurize the carbon block 6 from the bottom of the carbon block 6, and the pressure value is read by the pressure sensor 303, and the pressurization is stopped when the set pressure value is reached; the cooperation of the two pressurizing mechanisms ensures that the carbon block 6 receives a pressure that meets the requirements during detection.

[0079] The implementation process of data analysis is as follows:

[0080] In order to eliminate the rigid body displacement of the carbon block 6 during the pressurization process, when the pressure sensor 303 reads a small value (the characteristic value is 1000N), the laser displacement sensor 4 array obtains the deformation:

[0081]

[0082] Then continue to pressurize to a set value (this value is much smaller than the breaking pressure of the carbon block 6, so it will not cause damage to the carbon block 6, and the value in this embodiment is 20000N). The laser displacement sensor 4 array obtains the deformation, and the deformation matrix during the pressurization process is:

[0083]

[0084] The deformation matrix is:

[0085]

[0086] The normalized deformation matrix is:

[0087]

[0088] The laser displacement sensors 4 of the detection mechanism of this embodiment are distributed in an array, specifically: the detection mechanism includes five laser displacement sensors 4;

[0089] The laser displacement sensors 4 are installed on the crossbeam 103 , and the five laser displacement sensors 4 respectively detect deformation data of different positions of the carbon block 6 and transmit the data to the industrial computer 5 .

[0090] Taking the example of integrating five laser displacement sensors 4 on the frame 1 , the five laser displacement sensors 4 are arranged in an array, four of which are respectively located near the four corners of the carbon block 6 , and the other is located in the middle of the carbon block 6 .

[0091] The present invention discloses a method for detecting internal quality defects of prebaked anodes by using a multi-point deformation method. The method mainly comprises the following steps:

[0092] S101, taking 50 normal carbon block samples through manual screening, and transmitting them to the system through the system's conveying mechanism 7 for testing, to obtain normalized deformation matrices ZC1-ZC50;

[0093] S102, selecting 5 carbon blocks with layer crack defects, 5 carbon blocks with longitudinal crack defects, and 5 carbon blocks with delamination defects, and transmitting them to the system through the system's conveying mechanism 7 for testing, and obtaining normalized deformation matrices QX1-QX15;

[0094] S103, establishing a corresponding relationship:

[0095]

[0096] S104, see Figure 2 As shown, a neural network is established: the neural network is a classic BP neural network, which includes an input layer, a hidden layer and an output layer;

[0097] Among them, the input layer nodes receive the obtained deformation matrix, and each node receives a point deformation;

[0098] The output layer is the recognition result, which is a value between 0 and 1, "0" represents the worst quality with defects, and "1" represents the best quality without defects;

[0099] S105, training the neural network with the corresponding relationship (1) as the target value, and obtaining the corresponding relationship between the displacement of the upper surface of the carbon block and various carbon blocks after the training;

[0100] S106, pressurize the carbon block 6 through the system's pressurizing mechanism, obtain its deformation matrix, input it into the neural network of step S104, calculate and output a value between 0 and 1, and quantitatively determine the quality of the carbon block 6 based on the value. The higher the value, the better the quality of the carbon block.

[0101] In the above technical solution, the system and method for detecting internal quality defects of prebaked anodes by a multi-point deformation method provided by the present invention have the following beneficial effects:

[0102] The system of the present invention realizes pressurization of the carbon block 6 to be tested by the joint action of the top pressurizing mechanism 2 and the bottom pressurizing mechanism 3, and causes the carbon block 6 to be deformed by controlling the pressurizing pressure. The laser displacement sensor 4 detects multiple points of the carbon block 6 and the industrial computer 5 calculates the crack conditions inside the carbon block 6, thereby judging the quality of the carbon block 6 more accurately and quickly. Compared with the manual knocking method, the accuracy and operating efficiency of the system are improved.

[0103] The above description is only by way of illustration of certain exemplary embodiments of the present invention. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A system for detecting internal quality defects of prebaked anodes by a multi-point deformation method, characterized in that: The system includes: Frame (1); a conveying mechanism (7) partially extending into the frame (1), the conveying mechanism (7) being used to convey the carbon blocks (6) into the frame (1); a pressurizing mechanism integrated into the frame (1); and A detection mechanism, the detection mechanism being a laser displacement sensor (4) integrated in the frame (1); The system also includes: Industrial computer (5); The pressurizing mechanism and the laser displacement sensor (4) are both connected to the industrial computer (5); The carbon block (6) is deformed by the pressurizing mechanism, and the detection mechanism detects the deformation amount of the carbon block (6) and transmits the deformation amount to the industrial control computer (5); The system detection method for detecting the internal quality defects of prebaked anodes based on the multi-point deformation method mainly includes the following steps: S101, taking 50 normal carbon block samples through manual screening, and transmitting them to the system through the system's conveying mechanism (7) for testing, to obtain normalized deformation matrices ZC1-ZC50; S102, selecting 5 carbon blocks with layer crack defects, 5 carbon blocks with longitudinal crack defects, and 5 carbon blocks with delamination defects, and transmitting them to the system through the system's conveying mechanism (7) for testing, and obtaining normalized deformation matrices QX1-QX15; S103, establishing a corresponding relationship: ； S104, establishing a neural network: the neural network is a classic BP neural network, including an input layer, a hidden layer and an output layer; Among them, the input layer nodes receive the obtained deformation matrix, and each node receives a point deformation; The output layer is the recognition result, which is a value between 0 and 1, "0" represents the worst quality with defects, and "1" represents the best quality without defects; S105, training the neural network with the corresponding relationship as the target value, and obtaining the corresponding relationship between the displacement of the upper surface of the carbon block and various carbon blocks after the training; S106, pressurizing the carbon block (6) through the system's pressurizing mechanism, obtaining its deformation matrix, inputting it into the neural network of step S104, calculating and outputting a value between 0 and 1, and quantitatively determining the quality of the carbon block (6) based on the value.

2. A system for detecting internal quality defects of prebaked anodes by a multi-point deformation method according to claim 1, characterized in that: The frame (1) comprises a support frame (101) located at the bottom, and a top frame body fixedly connected to the upper end of the support frame (101); The detection mechanism is installed on the top frame; The conveying mechanism (7) extends horizontally to the bottom of the interior of the frame (1) and conveys the carbon block (6) to the bottom of the detection mechanism.

3. The system for detecting internal quality defects of prebaked anodes by a multi-point deformation method according to claim 2, characterized in that: The conveying mechanism (7) comprises: A track (701) extending in a horizontal direction; and A plurality of round rollers (702) arranged at intervals along the extension direction of the track (701); The carbon block (6) is moved to the interior of the support frame (101) via the round roller (702).

4. The system for detecting internal quality defects of prebaked anodes by a multi-point deformation method according to claim 2, characterized in that: The pressurizing mechanism is divided into a top pressurizing mechanism (2) located at the upper part of the frame (1) and a bottom pressurizing mechanism (3) located at the lower part of the frame (1); The top frame has an outer frame (102) in a quadrilateral frame structure, and a crossbeam (103) fixedly connected to the inside of the outer frame (102); The top pressurizing mechanism (2) comprises four top hydraulic cylinders (201) and a top support member (202) mounted on the end of the cylinder rod of the top hydraulic cylinder (201); The top hydraulic cylinder (201) adjusts the distance between the top support member (202) and the upper surface of the carbon block (6) by extending and retracting its cylinder rod; The four top hydraulic cylinders (201) respectively press the four corners of the carbon block (6) through the top support member (202); The bottom pressure mechanism (3) comprises a bottom hydraulic cylinder (301) and a bottom pressure head (302) mounted on the end of a cylinder rod of the bottom hydraulic cylinder (301); the bottom hydraulic cylinder (301) adjusts the distance between the bottom pressure head (302) and the lower surface of the carbon block (6) through its cylinder rod; The bottom hydraulic cylinder (301) presses the lower surface of the carbon block (6) via the bottom pressure head (302); A pressure sensor (303) is installed at the bottom pressure head (302) of the bottom hydraulic cylinder (301), and the pressure sensor (303) is connected to the industrial computer (5) to transmit pressure data to the industrial computer (5).

5. The system for detecting internal quality defects of prebaked anodes by a multi-point deformation method according to claim 4, characterized in that: The detection mechanism comprises five laser displacement sensors (4); The laser displacement sensor (4) is mounted on the crossbeam (103), and the five laser displacement sensors (4) respectively detect deformation data at different positions of the carbon block (6) and transmit the data to the industrial control computer (5).

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