Method for crust breaking and blanking control, fault detection alarm and intervention of electrolytic cell

Abstract

The invention discloses an electrolytic bath crust breaking and blanking control, fault detection alarm and intervention method, which comprises an electrolytic bath control machine, the electrolytic bath control machine is connected with a plurality of electrolytic baths, and an intelligent control system is connected in series between the electrolytic bath control machine and the electrolytic baths. And the intelligent control system comprises a shell surface pressing and penetrating control module, a shell surface pressing and non-penetrating control module in an abnormal state, a blanking system control module, a fault detection module, an execution intervention module and a process data acquisition and storage module. And invalid blanking and energy waste are remarkably reduced, meanwhile, the risks of covering material accumulation and hearth sediment are reduced, and the electrolytic reaction stability is improved. Manual inspection and abnormal working condition operation risks are reduced, potential safety hazards in high-temperature, strong-corrosion and strong-magnetic-field environments are reduced, the maintenance time is shortened through fault early warning, and the equipment reliability is improved.

Description

Technical Field

[0001] The present invention relates to a method for controlling crust breaking and material feeding, fault detection, alarm and intervention of an electrolytic cell, belonging to the field of automatic control and intelligent fault diagnosis in aluminum electrolysis production of the metallurgical industry. Background Art

[0002] During the electrolysis process, an alumina crust layer will form on the surface of the electrolyte. Crust breaking uses mechanical hammering or pneumatic devices to break the crust, providing channels for material feeding and gas emission. A certain amount of alumina (Al2O3) is added into the electrolytic cell to maintain the continuous progress of the aluminum electrolysis reaction. Material feeding is carried out immediately after crust breaking to ensure that the alumina evenly covers the surface of the electrolyte.

[0003] However, in the production process of traditional aluminum electrolytic cells, the control of crust breaking and material feeding relies on manual experience and extensive management, with the following pain points: 1. Inefficient process control: Insufficient precision of material feeding leads to excessive consumption of alumina / fluoride, and ineffective material feeding easily forms a pile of covering materials or furnace bottom sediment, destroying the stability of the electrolysis reaction; 2. Lagging fault response: Relying on manual inspection and experience judgment, abnormal working conditions (such as failed crust pressing, pipeline leakage) are difficult to detect in time, with low maintenance efficiency and affecting continuous production; 3. High energy consumption and cost: Redundant pipeline design (such as the original 27 air ducts) and compressed air leakage result in energy waste and rising maintenance costs; 4. Prominent safety hazards: Frequent manual operation intervention (such as trough inspection, blockage treatment), and personnel are exposed to high temperature, strong corrosion and electromagnetic interference environments, with significant safety risks; 5. Bottleneck in technology upgrading: The traditional cell control system lacks data accumulation and intelligent decision-making capabilities, and it is difficult to meet the complex working condition optimization requirements of high-current (500KA level) electrolytic cells.

[0004] Therefore, a method for controlling crust breaking and material feeding, fault detection, alarm and intervention of an electrolytic cell is needed, which can reduce the unit consumption of alumina / fluoride / compressed air, improve the effective breakdown rate of the crust surface, significantly reduce ineffective material feeding and energy waste, while reducing the risk of covering material accumulation and furnace bottom sediment, and enhancing the stability of the electrolysis reaction. Reduce the risk of manual inspection and abnormal working condition operations, reduce safety hazards in high-temperature, strong corrosion and strong magnetic field environments, shorten the maintenance time through early fault warning, and improve the reliability of equipment. Summary of the Invention

[0005] In view of the above, the object of the present invention is to provide a method for controlling the crust breaking and feeding of an electrolytic cell, fault detection, alarm and intervention, which can reduce the unit consumption of alumina / aluminum fluoride / compressed air, improve the effective breakdown rate of the cell surface, significantly reduce ineffective feeding and energy waste, while reducing the risk of covering material accumulation and hearth sedimentation, and enhancing the stability of the electrolytic reaction. It reduces the risk of manual inspection and abnormal working conditions, reduces potential safety hazards in high-temperature, strong corrosion and strong magnetic field environments, shortens the maintenance time through early fault warning, and improves the reliability of equipment, thus overcoming the deficiencies of the prior art.

[0006] The object of the present invention is achieved by the following technical solutions: The present invention discloses a method for controlling the crust breaking and feeding of an electrolytic cell, fault detection, alarm and intervention, which includes an electrolytic cell controller. The electrolytic cell controller is connected to a plurality of electrolytic cells. An intelligent control system is connected in series between the electrolytic cell controller and the electrolytic cells. The intelligent control system includes a crust penetration control module, a non-penetrating crust control module under abnormal conditions, a feeding system control module, a fault detection module, an execution intervention module and a process data acquisition and storage module: The fault detection module includes the detection of an open circuit fault in the solenoid valve coil circuit of the crust breaking cylinder, the detection of a stuck solenoid valve fault in the crust breaking cylinder, the detection of a stuck striker that cannot retract in the crust breaking cylinder, the detection of an open circuit fault in the solenoid valve coil circuit of the feeding cylinder, the detection of a stuck solenoid valve fault in the feeding cylinder, and the detection of a stuck feeding cylinder that cannot retract. The process data acquisition and storage module includes automatically collecting process technical data through the intelligent control system, including the command data for crust breaking and feeding sent by the electrolytic cell controller, as well as the actual effective execution commands detected by the intelligent control system or the data of active intervention execution by the intelligent control system.

[0007] As described above, a crust breaking cylinder and a feeding cylinder are provided in the electrolytic cell. Position detection and alarm devices are provided on both the crust breaking cylinder and the feeding cylinder. The position detection and alarm device consists of a position detection device and an alarm device. The position detection device includes a normally closed upper limit travel switch, a lower limit travel switch, a cylinder piston retraction in-place travel switch with normally closed contacts on the crust breaking cylinder, and detectors for the opening and closing of the cylinder connection control line and the power-off and power-on of the solenoid valve of the crust breaking cylinder. On the feeding cylinder, there are a feeding upper limit switch with normally closed contacts, a feeding connection control line opening and closing switch, a feeding cylinder bellows valve switch, and detectors for the power-off and power-on of the solenoid valve of the feeding cylinder. The position detection device is connected to the signal lights on the control interface, and the control interface is connected to the alarm device.

[0008] For the above, the respective signal lights of the closed state of the upper limit travel switch of the shell-breaking cylinder, the open state of the lower limit travel switch, the open state of the cylinder connection control line, the state where the cylinder piston contracts to the upper position, the power-off state of the shell-breaking cylinder solenoid valve, the closed state of the upper limit travel switch of the material-feeding cylinder for material feeding, the open state of the material-feeding connection control line, the closed state of the bell valve of the material-feeding cylinder, and the power-off state of the material-feeding cylinder solenoid valve are set to light color A; the respective signal lights of the open state of the upper limit travel switch of the shell-breaking cylinder, the closed state of the lower limit travel switch, the closed state of the cylinder connection control line, the state where the cylinder piston moves downward, the power-on state of the shell-breaking cylinder solenoid valve, the open state of the upper limit travel switch of the material-feeding cylinder for material feeding, the closed state of the material-feeding connection control line, the open state of the bell valve of the material-feeding cylinder, and the power-on state of the material-feeding cylinder solenoid valve are set to light color B; the signal lights of the abnormal states of each component of the above-mentioned shell-breaking cylinder and material-feeding cylinder are set to light color C.

[0009] For the above, the control process of the piercing the shell surface control module includes the following steps: Step 1: The electrolytic cell controller issues a shell-breaking command. The shell-breaking solenoid valve is powered on and the signal light changes from light color A to B. The reversing valve of the shell-breaking cylinder reverses, and the shell-breaking cylinder starts to execute the shell-pressing command. The signal light of the upper limit travel switch of the shell-breaking cylinder changes from light color A to B, indicating that the upper limit travel switch of the cylinder is open; Step 2: When the shell-breaking cylinder pierces through the shell surface and moves down to the bottom, the lower limit travel switch of the shell-breaking cylinder closes and the signal light changes from light color A to B, indicating that the shell-breaking cylinder has pierced through the shell surface; Step 3: At this time, the solenoid valve is powered off, the solenoid valve resets, compressed air enters the lower cavity of the shell-breaking cylinder, the shell-breaking cylinder retracts, the lower limit travel switch is open and the signal light changes from light color B to A; Step 4: When the shell-breaking cylinder retracts in place, the upper limit travel switch of the shell-breaking cylinder closes and the signal light changes from light color B to A, indicating that the shell-breaking cylinder has retracted in place and one round of shell-pressing work is completed.

[0010] For the above, the control process of the piercing-through-the-shell surface control module in the abnormal state includes the following steps: Step 1: When the electrolytic cell controller issues a shell-pressing command, the shell-breaking cylinder solenoid valve is powered on and the signal light changes from light color A to B. The reversing valve of the shell-breaking cylinder reverses, and the shell-breaking cylinder starts to execute the shell-pressing command. The signal light of the upper limit travel switch changes from light color A to B, indicating that the upper limit travel switch of the cylinder is open; Step 2: When the cylinder fails to pierce through the shell surface and the shell-pressing duration exceeds 5 seconds and the lower limit travel switch of the shell-pressing cylinder remains normally open, the intelligent control system will automatically determine that the hammer head has not pierced through the shell surface. At this time, the intelligent control system will automatically intervene and the electrolytic cell controller will issue a material-feeding command for the corresponding material-feeding point, and no material will be fed at the material-feeding point; Step 3: Meanwhile, the intelligent control system converts the working state of the shell pressing cylinder to the crust breaking state. At this time, the intelligent control system automatically issues two commands for shell pressing and crust breaking. The shell pressing and crust breaking solenoid valves of the cylinder are energized simultaneously. The shell pressing is converted to crust breaking, and the kinetic energy of crust breaking increases. The number of strikes can be set manually. Step 4: When the crust surface is broken through within the set number of crust breaking times, the intelligent control system does not alarm. After breaking through, the corresponding feeding point feeds materials, and then automatically resumes the control state of the cell controller. Step 5: When the crust breaking cylinder fails to break through the crust surface after exceeding the set number of crust breaking times, the intelligent control system will give a braking alarm, and the audible and visual alarms will be activated at the large surface end and the fume duct end of the electrolytic cell. After manual intervention and reset, the control is restored.

[0011] The control process of the above-mentioned feeding system control module includes the following steps: Step 1: When the crust breaking cylinder breaks through the crust surface, the cell controller of the electrolytic cell issues a feeding command. The solenoid valve of the feeding cylinder is energized, and the signal light changes from color A to color B. The reversing valve of the feeding cylinder reverses, and the feeding cylinder starts to execute the feeding command. The bell valve of the feeder opens, and the signal light changes from color A to color B, and feeding is maintained for 3 seconds. Step 2: After the feeding time is up, the solenoid valve loses power and resets. The feeding cylinder retracts to the in-place position. The upper limit travel switch of the feeding cylinder closes at the end of feeding, and the signal light changes from color B to color A.

[0012] The open circuit fault detection of the solenoid valve coil circuit of the above-mentioned crust breaking cylinder includes: The cell controller of the electrolytic cell issues a shell pressing command. The intelligent control system detects that there is no current in the solenoid valve coil circuit of the crust breaking cylinder. The upper limit travel switch of the crust breaking cylinder is in the closed state. The coil circuit of the crust breaking cylinder reports an open circuit fault, and an audible and visual alarm is issued. The signal light of the control interface connecting the control line changes from color A to color C. The intelligent control system intervenes to make the feeding cylinder not act and prevents feeding. After the fault is repaired and reset, the signal light of the control line connection changes from color C to color B.

[0013] The stuck fault detection of the solenoid valve of the above-mentioned crust breaking cylinder includes: The cell controller of the electrolytic cell issues a shell pressing command. The intelligent control system detects that the solenoid valve coil circuit of the crust breaking cylinder has overcurrent. The upper limit travel switch of the crust breaking cylinder is in the closed state. The solenoid valve of the crust breaking cylinder reports a stuck fault, and an audible and visual alarm is issued. The signal light of the solenoid valve of the crust breaking cylinder on the control interface changes from color B to color C. The intelligent control system intervenes to make the feeding cylinder not act and prevents feeding. After the fault is repaired and reset, the signal light of the solenoid valve of the crust breaking cylinder changes from color C to color B.

[0014] The fault detection that the striking head of the above-mentioned crust breaking cylinder is stuck and cannot be retracted includes: The cell controller of the electrolytic cell issues a crust pressing command. The crust breaking cylinder presses through the crust surface and moves down to the in-place position. When the striking head of the crust breaking cylinder moves upward, it encounters a blockage. The upper limit travel switch and the lower limit travel switch of the crust breaking cylinder are in the off state. The signal lights of the upper limit travel switch and the lower limit travel switch of the crust breaking cylinder are of light color B. The signal light color of the piston rod of the crust breaking cylinder changes from B to C, and an audible and visual alarm is issued. The intelligent control system intervenes to make the feeding cylinder inoperative and prevent feeding. After the maintenance of the fault is processed and reset, the signal light color of the piston rod of the crust breaking cylinder changes from C to A, and the upper limit travel switch of the crust breaking cylinder changes from B to A.

[0015] As described above, the open circuit fault detection of the solenoid valve coil circuit of the feeding cylinder, the stuck fault detection of the solenoid valve of the feeding cylinder, and the stuck and unrecoverable fault detection of the feeding cylinder include: Open circuit fault detection of the solenoid valve coil circuit of the feeding cylinder: The cell controller of the electrolytic cell issues a crust pressing command. The intelligent control system detects that there is no current in the solenoid valve coil circuit of the feeding cylinder. The upper limit travel switch of the feeding cylinder is in the closed state. The connection control line of the feeding cylinder reports an open circuit fault, and an audible and visual alarm is issued. The signal light color of the connection control line of the feeding cylinder on the control interface changes from A to C, and the feeding cylinder is inoperative. After the maintenance of the fault is processed and reset, the signal light color of the connection control line of the feeding cylinder changes from C to B; Stuck fault detection of the solenoid valve of the feeding cylinder: The cell controller of the electrolytic cell issues a crust pressing command. The intelligent control system detects overcurrent in the solenoid valve coil circuit of the feeding cylinder. The upper limit travel switch of the feeding cylinder is in the closed state. The solenoid valve of the feeding cylinder reports a stuck fault, and an audible and visual alarm is issued. The signal light color of the solenoid valve of the feeding cylinder on the control interface changes from B to C, and the feeding cylinder is inoperative. After the maintenance of the fault is processed and reset, the signal light color of the solenoid valve changes from C to B; Stuck and unrecoverable fault detection of the feeding cylinder: The cell controller of the electrolytic cell issues a crust pressing command. The feeding cylinder is in place for feeding. When the feeding cylinder moves upward, it encounters a blockage. The upper limit travel switch of the feeding cylinder is in the off state, and the signal light color is B. The signal light color of the bell valve of the feeding cylinder remains B continuously, and an audible and visual alarm is issued. After the maintenance of the fault is processed and reset, the signal light color of the upper limit travel switch of the feeding cylinder changes from B to A, and the signal light color of the bell of the feeding cylinder changes from B to A.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. Efficiency and cost optimization of the present invention: The single consumption of alumina / aluminum fluoride / compressed air per ton of aluminum decreases, the effective crust breakdown rate is increased, the ineffective feeding and energy waste are significantly reduced, and at the same time, the risk of covering material accumulation and furnace bottom slag is reduced, and the stability of the electrolytic reaction is improved.

[0017] 2. Safety and maintenance improvement: Reduce the risks of manual inspection and abnormal working conditions, lower the safety hazards in high-temperature, strong corrosion, and strong magnetic field environments, shorten the maintenance time through early fault warnings (such as open circuit and jamming alarms), and improve the equipment reliability.

[0018] 3. Intelligence and sustainability: Provide a data foundation for the large-scale electrolytic cell simulation model, promote the dynamic optimization of process parameters and intelligent upgrade, support the transformation of electrolytic aluminum production towards zero ineffective material feeding and essential safety, and contribute to the green and low-carbon development of the industry.

[0019] 4. Compatibility and expandability: The system can be connected in series to the original control system, adapt to complex working conditions with high current (500KA level), high corrosion, and strong electromagnetic interference, and has industrial-level anti-interference capabilities.

[0020] Other advantages, objectives, and features of the present invention will be described to some extent in the subsequent specification, and to some extent, will be obvious to those skilled in the art based on the study of the following text, or can be taught from the practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the following specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the drawings, where: Figure 1 is a schematic diagram of the intelligent control system of the electrolytic cell of the present invention.

[0022] Figure 2 is a schematic diagram of the shell-breaking cylinder of the present invention.

[0023] Figure 3 is a schematic diagram of the alumina / aluminum fluoride feeding shell cylinder of the present invention.

[0024] Figure 4 is the execution process of the normal shell-pressing instruction of the present invention.

[0025] Figure 5 is the flowchart of converting shell-pressing to shell-breaking and breaking through the shell surface within 5 times of the present invention.

[0026] Figure 6 is the flowchart of converting shell-pressing to shell-breaking and not breaking through the shell surface within 5 times of the present invention.

[0027] Figure 7 is a schematic diagram of the working process of the feeding cylinder of the present invention.

[0028] Figure 8 is a schematic diagram of the open circuit fault of the solenoid valve coil circuit of the shell-breaking cylinder of the present invention.

[0029] Figure 9Schematic diagram of the jam fault of the shell-breaking cylinder solenoid valve of the present invention.

[0030] Figure 10 Schematic diagram of the jam and non-retractable fault of the shell-breaking cylinder (striking head) of the present invention.

[0031] Figure 11 Schematic diagram of the open-circuit fault of the solenoid valve coil circuit of the blanking cylinder of the present invention.

[0032] Figure 12 Schematic diagram of the jam fault of the solenoid valve of the blanking cylinder of the present invention.

[0033] Figure 13 Schematic diagram of the jam and non-retractable fault of the blanking cylinder of the present invention. Detailed implementation manners

[0034] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the preferred embodiments are only for illustrating the present invention rather than limiting the protection scope of the present invention.

[0035] As Figures 1-13 shown, a method for controlling the shell-breaking and blanking, fault detection, alarm and intervention of an electrolytic cell disclosed by the present invention includes an electrolytic cell control machine, which is connected to a plurality of electrolytic cells. An intelligent control system is connected in series between the electrolytic cell control machine and the electrolytic cell. As Figure 1 shown, with such a structure, the intelligent control system is connected in series to the original electrolytic cell control system to achieve seamless compatibility with the original system. The intelligent control system includes a piercing shell surface control module, a non-piercing shell surface control module under abnormal conditions, a blanking system control module, a fault detection module, an execution intervention module and a process data acquisition and storage module: The fault detection module includes the open-circuit fault detection of the solenoid valve coil circuit of the shell-breaking cylinder, the jam fault detection of the solenoid valve of the shell-breaking cylinder, the jam and non-retractable fault detection of the striking head of the shell-breaking cylinder, the open-circuit fault detection of the solenoid valve coil circuit of the blanking cylinder, the jam fault detection of the solenoid valve of the blanking cylinder and the jam and non-retractable fault detection of the blanking cylinder. In this way, a closed-loop control network can be constructed through the shell-breaking cylinder, the blanking cylinder of alumina / fluoride salts, the upper and lower limit travel switches, and the detection devices, such as normally closed / normally open limit switches, solenoid valves and control circuits, to feedback the equipment status in real time.

[0036] The process data acquisition and storage module includes automatically collecting process technical data through the intelligent control system, including the instruction data of shell-breaking and blanking sent by the electrolytic cell control machine and the actual effective execution instructions detected by the intelligent control system or the data of the active intervention execution by the intelligent control system. Data recording: automatically collecting the execution status of shell-breaking / blanking instructions, fault events, intervention records and process parameters, such as the shell pressing time and the number of strikes.

[0037] Simulation support: Upload data to the intelligent control database of the electrolytic cell to provide a basis for establishing a simulation model and dynamically optimizing process parameters.

[0038] In the electrolytic cell, there are shell-breaking cylinders and feeding cylinders. Position detection and alarm devices are installed on both the shell-breaking cylinders and the feeding cylinders. The position detection and alarm devices consist of a position detection device and an alarm device. The position detection device includes an upper limit travel switch with a normally closed contact installed on the shell-breaking cylinder, a lower limit travel switch, a cylinder piston retraction-in-place travel switch, and detectors for the opening and closing of the cylinder connection control line and the power-off and power-on of the shell-breaking cylinder solenoid valve. On the feeding cylinder, there are a feeding upper limit switch with a normally closed contact, a feeding connection control line opening and closing switch, a feeding cylinder bellows valve switch, and detectors for the power-off and power-on of the feeding cylinder solenoid valve. The position detection device is connected to the signal lights on the control interface, and the control interface is connected to the alarm device.

[0039] As Figure 2 、 Figure 3 shown, set the respective signal lights of the closed state of the upper limit travel switch of the shell-breaking cylinder, the open state of the lower limit travel switch, the open state of the cylinder connection control line, the cylinder piston retracted to the upper position, the power-off state of the shell-breaking cylinder solenoid valve, the closed state of the feeding upper limit travel switch of the feeding cylinder, the open state of the feeding connection control line, the closed state of the feeding cylinder bellows valve, and the power-off state of the feeding cylinder solenoid valve to light color A; set the respective signal lights of the open state of the upper limit travel switch of the shell-breaking cylinder, the closed state of the lower limit travel switch, the closed state of the cylinder connection control line, the downward movement state of the cylinder piston, the power-on state of the shell-breaking cylinder solenoid valve, the open state of the feeding upper limit travel switch of the feeding cylinder, the closed state of the feeding connection control line, the open state of the feeding cylinder bellows valve, and the power-on state of the feeding cylinder solenoid valve to light color B; set the signal lights of the abnormal states of the above-mentioned components of the shell-breaking cylinder and the feeding cylinder to light color C, where A, B, and C are one of white, red, blue, green, and yellow.

[0040] As Figure 4 shown, the control process of the breakout crust control module includes the following steps: Step 1: The cell controller of the electrolytic cell issues a shell-breaking command. The shell-breaking solenoid valve is powered on and the signal light changes from light color A to B. The shell-breaking cylinder reversing valve changes direction, and the shell-breaking cylinder starts to execute the crust-breaking command. The signal light of the upper limit travel switch of the shell-breaking cylinder changes from light color A to B, indicating that the upper limit travel switch of the cylinder is open; Step 2: When the shell-breaking cylinder breaks through the crust and moves down to the bottom, the lower limit travel switch of the shell-breaking cylinder closes and the signal light changes from light color A to B, indicating that the shell-breaking cylinder has broken through the crust; Step 3: At this time, the solenoid valve is powered off, the solenoid valve resets, compressed air enters the lower cavity of the shell-breaking cylinder, the shell-breaking cylinder retracts, the lower limit travel switch is open and the signal light changes from light color B to A; Step 4: After the shell-breaking cylinder retracts to its in-place position, the upper limit travel switch of the shell-breaking cylinder closes and the signal light changes from color B to A, indicating that the shell-breaking cylinder has retracted to its in-place position and one round of shell pressing work is completed.

[0041] As Figure 5 , Figure 6 shown, the control process of the non-penetrating shell surface control module in abnormal state includes the following steps: Step 1: When the electrolytic cell controller issues a shell pressing command, the solenoid valve of the shell-breaking cylinder is energized and the signal light changes from color A to B. The reversing valve of the shell-breaking cylinder reverses, and the shell-breaking cylinder starts to execute the shell pressing command. The signal light of the upper limit travel switch changes from color A to B, indicating that the upper limit travel switch of the cylinder is disconnected; Step 2: When the cylinder cannot penetrate the shell surface and the shell pressing duration exceeds 5 seconds, and the lower limit travel switch of the shell pressing cylinder is still in the normally open state, the intelligent control system will automatically determine that the hammer head has not penetrated the shell surface. At this time, the intelligent control system will automatically intervene and issue a feeding instruction for the corresponding feeding point by the electrolytic cell controller, and no feeding will occur at the feeding point; Step 3: At the same time, the intelligent control system converts the shell pressing working state of the shell pressing cylinder into a shell breaking state. At this time, the intelligent control system automatically issues two commands of shell pressing and shell breaking. The solenoid valves of the shell pressing and shell breaking of the cylinder are energized at the same time. The shell pressing is converted into shell breaking, and the shell breaking kinetic energy increases. The number of strikes can be set manually; Step 4: When the shell surface is penetrated within the set number of shell breaking times, the intelligent control system does not alarm. After penetration, the corresponding feeding point feeds, and then automatically resumes the control state of the cell controller; Step 5: When the shell-breaking cylinder still fails to penetrate the shell surface after exceeding the set number of shell-breaking times, the intelligent control system will give a braking alarm, and the audible and visual alarms will be given at the large end and the flue end of the electrolytic cell surface. After manual intervention and reset, the control is restored. This can perform abnormal shell pressing intervention: shell pressing timeout determination: if the shell pressing time exceeds 5 seconds or the lower limit is not closed, it is determined as a failure, and it is automatically switched to the "shell breaking mode" to increase the kinetic energy and the number of strikes.

[0042] Alarm for multiple shell breaking failures: When the shell is not penetrated after 5 shell breakings, trigger the audible and visual alarm and stop feeding, and force manual intervention.

[0043] As Figure 7 shown, the control process of the feeding system control module includes the following steps: Step 1: When the shell-breaking cylinder penetrates the shell surface, the electrolytic cell controller issues a feeding instruction. The solenoid valve of the feeding cylinder is energized and the signal light changes from color A to B. The reversing valve of the feeding cylinder reverses, and the feeding cylinder starts to execute the feeding command. The bell valve of the feeder opens and the signal light changes from color A to B, and feeding is maintained for 3 seconds; Step 2: After the feeding time is up, the solenoid valve loses power and resets. The feeding cylinder retracts to its in-place position. The feeding ends. The upper limit travel switch of the feeding cylinder closes, and the signal light changes from color B to A.

[0044] As Figure 8 shown, the open - circuit fault detection of the solenoid valve coil circuit of the shell - breaking cylinder includes: The cell controller of the electrolytic cell issues a shell - pressing command. The intelligent control system detects that there is no current in the return circuit of the solenoid valve coil of the shell - breaking cylinder. The upper - limit travel switch of the shell - breaking cylinder is closed. The coil circuit of the shell - breaking cylinder reports an open - circuit fault, emits an audible and visual alarm. The signal lamp of the control interface connecting the control - line circuit changes from lamp color A to C. The intelligent control system intervenes to make the feeding cylinder not operate, preventing feeding. After the maintenance of the fault is processed and reset, the signal lamp of the control - line circuit changes from lamp color C to B. Coil open - circuit detection: Detecting no current in the loop through a current sensor → Determining it as an open - circuit fault → Triggering an alarm and locking the feeding.

[0045] As Figure 9 shown, the stuck - valve fault detection of the solenoid valve of the shell - breaking cylinder includes: The cell controller of the electrolytic cell issues a shell - pressing command. The intelligent control system detects over - current in the return circuit of the solenoid valve coil of the shell - breaking cylinder. The upper - limit travel switch of the shell - breaking cylinder is closed. The solenoid valve of the shell - breaking cylinder reports a stuck - valve fault, emits an audible and visual alarm. The signal lamp of the solenoid valve of the shell - breaking cylinder on the control interface changes from lamp color B to C. The intelligent control system intervenes to make the feeding cylinder not operate, preventing feeding. After the maintenance of the fault is processed and reset, the signal lamp of the solenoid valve of the shell - breaking cylinder changes from lamp color C to B.

[0046] As Figure 10 shown, the fault detection that the striking head of the shell - breaking cylinder is stuck and cannot be retracted includes: The cell controller of the electrolytic cell issues a shell - pressing command. The shell - breaking cylinder presses through the shell surface and moves down to the place. When the shell - breaking cylinder moves upward, the striking head encounters a block. The upper - limit travel switch and the lower - limit travel switch of the shell - breaking cylinder are disconnected. The signal lamps of the upper - limit travel switch and the lower - limit travel switch of the shell - breaking cylinder are lamp color B. The lamp color of the piston - rod signal lamp of the shell - breaking cylinder changes from B to C, emits an audible and visual alarm. The intelligent control system intervenes to make the feeding cylinder not operate, preventing feeding. After the maintenance of the fault is processed and reset, the lamp color of the piston - rod signal lamp of the shell - breaking cylinder changes from C to A, and the upper - limit travel switch of the shell - breaking cylinder changes from B to A. The shell - breaking cylinder is stuck: The upper - limit travel switch and the lower - limit travel switch are continuously disconnected → The piston - rod signal changes to the warning color of the abnormal state → Triggering an alarm and preventing feeding.

[0047] The open - circuit fault detection of the solenoid valve coil circuit of the feeding cylinder, the stuck - valve fault detection of the solenoid valve of the feeding cylinder, and the fault detection that the feeding cylinder is stuck and cannot be retracted include: As Figure 11As shown in the figure, for the open - circuit fault detection of the solenoid valve coil circuit of the blanking cylinder, when the electrolytic cell controller issues a shell - pressing command, the intelligent control system detects that there is no current in the return circuit of the solenoid valve coil of the blanking cylinder. The upper - limit travel switch of the blanking cylinder is closed, and the connecting control line of the blanking cylinder reports an open - circuit fault, sending out an audible and visual alarm. The light color of the signal lamp on the control interface for the connecting control line of the blanking cylinder changes from A to C, and the blanking cylinder does not operate. After the fault is repaired and reset, the light color of the signal lamp on the connecting control line of the blanking cylinder changes from C to B; For the blanking cylinder jamming: If the bell - jar valve fails to close in time → the signal of the upper - limit travel switch is abnormal → alarm and lock the action.

[0048] As Figure 12 shown, for the jamming fault detection of the solenoid valve of the blanking cylinder, when the electrolytic cell controller issues a shell - pressing command, the intelligent control system detects over - current in the return circuit of the solenoid valve coil of the blanking cylinder. The upper - limit travel switch of the blanking cylinder is closed, and the solenoid valve of the blanking cylinder reports a jamming fault, sending out an audible and visual alarm. The light color of the signal lamp of the solenoid valve of the blanking cylinder on the control interface changes from B to C, and the blanking cylinder does not operate. After the fault is repaired and reset, the light color of the signal lamp of the solenoid valve changes from C to B; As Figure 13 shown, for the detection of the fault that the blanking cylinder cannot be retracted due to jamming, when the electrolytic cell controller issues a shell - pressing command, the blanking cylinder is in place for blanking. When the blanking cylinder moves upward, it encounters jamming. The upper - limit travel switch of the blanking cylinder is open, and the light color of the signal lamp is B. The light color of the signal lamp of the bell - jar valve of the blanking cylinder remains B all the time, sending out an audible and visual alarm. After the fault is repaired and reset, the light color of the signal lamp of the upper - limit travel switch of the blanking cylinder changes from B to A, and the light color of the signal lamp of the bell - jar of the blanking cylinder changes from B to A.

[0049] At the same time, anti - interference and reliability design: Hardware protection: Use high - temperature - resistant, corrosion - resistant materials and shielding technology to adapt to the strong electromagnetic interference and highly corrosive environment of the electrolytic cell.

[0050] Redundant control: In case of faults (such as open - circuit, jamming), automatically cut off the power supply of abnormal equipment to prevent cascading failures.

[0051] Human - machine interaction optimization: The control panel visually displays the equipment status through color signals to improve operation efficiency. Optimization of compressed air in the energy - saving and safety mechanism: By precisely controlling the number of times of shell - breaking and kinetic energy, reduce the consumption of ineffective compressed air.

[0052] Safety interlock: When a fault alarm occurs, forcefully stop blanking to avoid waste of alumina or damage to equipment caused by abnormal operations.

[0053] The above are only the preferred embodiments of the present invention, and do not impose any form of confidentiality restrictions on the present invention. Any simple modifications, equivalent changes, and decorations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A method for controlling the crust breaking and material feeding, fault detection, alarm and intervention of an electrolytic cell, which includes an electrolytic cell controller, and the electrolytic cell controller is connected to a plurality of electrolytic cells, and is characterized in that: An intelligent control system is connected in series between the electrolytic cell controller and the electrolytic cell. The intelligent control system includes a shell penetration control module, a non-shell penetration control module under abnormal conditions, a feeding system control module, a fault detection module, an execution intervention module, and a process data acquisition and storage module: The fault detection module includes open circuit fault detection of the solenoid valve coil circuit of the shell breaking cylinder, jamming fault detection of the solenoid valve of the shell breaking cylinder, jamming and non-retractable fault detection of the striking head of the shell breaking cylinder, open circuit fault detection of the solenoid valve coil circuit of the feeding cylinder, jamming fault detection of the solenoid valve of the feeding cylinder, and jamming and non-retractable fault detection of the feeding cylinder; The process data acquisition and storage module includes automatically collecting process technical data through the intelligent control system, including the command data of shell breaking and feeding issued by the electrolytic cell controller, as well as the actual effective execution commands detected by the intelligent control system or the data of active intervention execution by the intelligent control system.

2. The method for controlling the cell crust breaking and material feeding, fault detection, alarm and intervention according to claim 1, wherein, A shell breaking cylinder and a feeding cylinder are arranged in the electrolytic cell. Position detection and alarm devices are arranged on both the shell breaking cylinder and the feeding cylinder. The position detection and alarm device consists of a position detection device and an alarm device. The position detection device includes an upper limit travel switch with a normally closed contact arranged on the shell breaking cylinder, a lower limit travel switch, a cylinder piston retraction in-place travel switch, and a detector for the opening and closing of the cylinder connection control line and the power-off and power-on of the solenoid valve of the shell breaking cylinder. On the feeding cylinder, there are a feeding upper limit switch with a normally closed contact, a feeding connection control line opening and closing switch, a feeding cylinder bellows valve switch, and a detector for the power-off and power-on of the solenoid valve of the feeding cylinder. The position detection device is connected to the signal lamp on the control interface, and the control interface is connected to the alarm device.

3. The method for controlling the cell crust breaking and feeding, fault detection, alarming and intervention according to claim 1, wherein The signal lamps of the closed state of the upper limit travel switch of the shell breaking cylinder, the open state of the lower limit travel switch, the open state of the cylinder connection control line, the cylinder piston retracted to the upper position, the power-off state of the solenoid valve of the shell breaking cylinder, the closed state of the feeding upper limit travel switch of the feeding cylinder, the open state of the feeding connection control line, the closed state of the feeding cylinder bellows valve, and the power-off state of the solenoid valve of the feeding cylinder are set to lamp color A; the signal lamps of the open state of the upper limit travel switch of the shell breaking cylinder, the closed state of the lower limit travel switch, the closed state of the cylinder connection control line, the downward movement state of the cylinder piston, the power-on state of the solenoid valve of the shell breaking cylinder, the open state of the feeding upper limit travel switch of the feeding cylinder, the closed state of the feeding connection control line, the open state of the feeding cylinder bellows valve, and the power-on state of the solenoid valve of the feeding cylinder are set to lamp color B; the signal lamps of the abnormal states of the components of the above-mentioned shell breaking cylinder and feeding cylinder are set to lamp color C.

4. The method for controlling the cell crust breaking and feeding, fault detection, alarm and intervention according to claim 1, characterized in that, The control process of the shell penetration control module includes the following steps: Step 1: The electrolytic cell controller issues a shell breaking command. The shell breaking solenoid valve is powered on and the signal lamp changes from lamp color A to B. The reversing valve of the shell breaking cylinder reverses, and the shell breaking cylinder starts to execute the shell pressing command. The signal lamp of the upper limit travel switch of the shell breaking cylinder changes from lamp color A to B, indicating that the upper limit travel switch of the cylinder is open; Step 2: After the breakout cylinder presses through the crust surface and moves downward to the bottom, the lower limit travel switch of the breakout cylinder closes and the signal light changes from color A to color B, indicating that the breakout cylinder has pressed through the crust surface; Step 3: At this time, the solenoid valve loses power and resets. Compressed air enters the lower cavity of the breakout cylinder, the breakout cylinder retracts, the lower limit travel switch disconnects, and the signal light changes from color B to color A; Step 4: After the breakout cylinder retracts to the in-place position, the upper limit travel switch of the breakout cylinder closes and the signal light changes from color B to color A, indicating that the breakout cylinder has retracted to the in-place position and one round of crust pressing work is completed.

5. The method for controlling the cell crust breaking and feeding, fault detection, alarm and intervention according to claim 1, characterized in that, The control process of the control module for not being able to press through the crust surface in the abnormal state includes the following steps: Step 1: When the cell controller of the electrolytic cell issues a crust pressing command, the solenoid valve of the breakout cylinder is energized and the signal light changes from color A to color B. The reversing valve of the breakout cylinder changes direction, and the breakout cylinder starts to execute the crust pressing command. The signal light of the upper limit travel switch of the breakout cylinder changes from color A to color B, indicating that the upper limit travel switch of the cylinder is disconnected; Step 2: When the cylinder cannot press through the crust surface and the crust pressing duration exceeds 5 seconds, and the lower limit travel switch of the crust pressing cylinder is still in the normally open state, the intelligent control system will automatically determine that the hammer head has not pressed through the crust surface. At this time, the intelligent control system will automatically intervene and issue a feeding instruction for the corresponding feeding point by the cell controller of the electrolytic cell, and no feeding will occur at the feeding point; Step 3: At the same time, the intelligent control system converts the crust pressing working state of the crust pressing cylinder into the breakout state. At this time, the intelligent control system automatically issues two commands of crust pressing and breakout. The solenoid valves of the cylinder for crust pressing and breakout are energized at the same time. The crust pressing is converted into breakout, and the breakout kinetic energy increases. The number of strikes can be set manually; Step 4: When the crust is broken through within the set number of breakout strikes, the intelligent control system does not alarm. After the breakthrough, the corresponding feeding point feeds materials, and then automatically resumes the control state of the cell controller; Step 5: When the breakout cylinder still fails to break through the crust surface after exceeding the set number of breakout strikes, the intelligent control system will give a braking alarm, and the sound and light alarm will be given at the large surface end and the flue end of the electrolytic cell. After manual intervention and reset, the control is restored.

6. The method for controlling the cell crust breaking and feeding, fault detection, alarming and intervention according to claim 1, characterized in that, The control process of the control module of the feeding system includes the following steps: Step 1: When the breakout cylinder breaks through the crust surface, the cell controller of the electrolytic cell issues a feeding instruction. The solenoid valve of the feeding cylinder is energized and the signal light changes from color A to color B. The reversing valve of the feeding cylinder changes direction, and the feeding cylinder starts to execute the feeding command. The bell valve of the feeder opens and the signal light changes from color A to color B, and feeding is maintained for 3 seconds; Step 2: After the feeding time arrives, the solenoid valve loses power and resets. The feeding cylinder retracts to the in-place position. After the feeding ends, the upper limit travel switch of the feeding cylinder closes, and the signal light changes from color B to color A.

7. The method for controlling the cell crust breaking and material feeding, fault detection, alarm and intervention according to claim 1, wherein The open circuit fault detection of the solenoid valve coil circuit of the breakout cylinder includes: The cell controller of the electrolytic cell issues a crust pressing command. The intelligent control system detects that there is no current in the solenoid valve coil circuit of the breakout cylinder. The upper limit travel switch of the breakout cylinder is in the closed state. The coil circuit of the breakout cylinder reports an open circuit fault, and a sound and light alarm is issued. The signal light of the control interface connecting the control line circuit changes from color A to color C. The intelligent control system intervenes and the feeding cylinder does not act to prevent feeding. After the overhaul and fault handling are reset, the signal light of the connecting control line circuit changes from color C to color B.

8. The method for controlling cell crust breaking and material feeding, fault detection, alarm and intervention according to claim 1, characterized in that, The stuck fault detection of the solenoid valve of the breakout cylinder includes: The cell controller issues a crust pressing command. The intelligent control system detects overcurrent in the solenoid valve coil circuit of the shell breaking cylinder. The upper limit travel switch of the shell breaking cylinder is closed. The solenoid valve of the shell breaking cylinder reports a jamming fault, and gives an audible and visual alarm. The signal lamp of the solenoid valve of the shell breaking cylinder on the control interface changes from lamp color B to C. The intelligent control system intervenes to make the feeding cylinder not operate, preventing feeding. After the maintenance of the fault is processed and reset, the signal lamp of the solenoid valve of the shell breaking cylinder changes from lamp color C to B.

9. The method for controlling the cell crust breaking and material feeding, fault detection, alarm and intervention according to claim 1, characterized in that, The fault detection of the striking head of the shell breaking cylinder being jammed and unable to retract includes: The cell controller issues a crust pressing command. The shell breaking cylinder presses through the crust surface and moves down to the position. When the shell breaking cylinder moves up, the striking head encounters a jam. The upper limit travel switch and the lower limit travel switch of the shell breaking cylinder are open. The signal lamps of the upper limit travel switch and the lower limit travel switch of the shell breaking cylinder are of lamp color B. The lamp color of the piston rod signal lamp of the shell breaking cylinder changes from B to C, and gives an audible and visual alarm. The intelligent control system intervenes to make the feeding cylinder not operate, preventing feeding. After the maintenance of the fault is processed and reset, the lamp color of the piston rod signal lamp of the shell breaking cylinder changes from C to A, and the upper limit travel switch of the shell breaking cylinder changes from B to A.

10. The method for controlling the cell crust breaking and feeding, fault detection, alarm and intervention according to claim 1, wherein, The open circuit fault detection of the solenoid valve coil circuit of the feeding cylinder, the jamming fault detection of the solenoid valve of the feeding cylinder, and the fault detection of the feeding cylinder being jammed and unable to retract include: Open circuit fault detection of the solenoid valve coil circuit of the feeding cylinder. The cell controller issues a crust pressing command. The intelligent control system detects no current in the solenoid valve coil circuit of the feeding cylinder. The upper limit travel switch of the feeding cylinder is closed. The connection control line of the feeding cylinder reports an open circuit fault, and gives an audible and visual alarm. The lamp color of the signal lamp of the connection control line of the feeding cylinder on the control interface changes from A to C, and the feeding cylinder does not operate. After the maintenance of the fault is processed and reset, the lamp color of the signal lamp of the connection control line of the feeding cylinder changes from C to B; Jamming fault detection of the solenoid valve of the feeding cylinder. The cell controller issues a crust pressing command. The intelligent control system detects overcurrent in the solenoid valve coil circuit of the feeding cylinder. The upper limit travel switch of the feeding cylinder is closed. The solenoid valve of the feeding cylinder reports a jamming fault, and gives an audible and visual alarm. The lamp color of the signal lamp of the solenoid valve of the feeding cylinder on the control interface changes from B to C, and the feeding cylinder does not operate. After the maintenance of the fault is processed and reset, the lamp color of the signal lamp of the solenoid valve changes from C to B; Fault detection of the feeding cylinder being jammed and unable to retract. The cell controller issues a crust pressing command. The feeding cylinder feeds to the position. When the feeding cylinder moves up, it encounters a jam. The upper limit travel switch of the feeding cylinder is open and the lamp color of the signal lamp is B. The lamp color of the signal lamp of the bellows valve of the feeding cylinder remains B all the time, and gives an audible and visual alarm. After the maintenance of the fault is processed and reset, the lamp color of the signal lamp of the upper limit travel switch of the feeding cylinder changes from B to A, and the lamp color of the bellows signal lamp of the feeding cylinder changes from B to A.

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