A method and apparatus for monitoring the condition of a smelting furnace

Abstract

This invention provides a method and apparatus for monitoring the status of a smelting furnace. The method includes: acquiring smelting furnace status data in real time according to a preset acquisition cycle. The smelting furnace status data includes the ignition signals of each ignition gun, the furnace gas temperature, and the outlet flow temperature. The furnace gas temperature variation is obtained based on the furnace gas temperature of two adjacent acquisition cycles. The outlet flow temperature variation is obtained based on the outlet flow temperature of two adjacent acquisition cycles. The production time of each batch of orders is obtained based on the ignition signals, furnace gas temperature, furnace gas temperature variation, and outlet flow temperature variation. This invention accurately determines the production time of the smelting furnace by acquiring status data from the furnace, thereby providing key data support for subsequent order differentiation.

Description

Technical Field

[0001] This invention relates to the field of data processing technology, and in particular to a method and apparatus for monitoring the condition of a smelting furnace. Background Technology

[0002] Driven by the trend of digital transformation, industrial production is developing towards intelligence and precision. More and more automated production and control equipment, as well as information and communication transmission equipment, are being applied to modern industrial production processes. This places increasingly higher demands on data communication, requiring not only reliable continuity of data communication, but also higher requirements for communication stability, purity, and security.

[0003] As a continuous production line, the smelting furnace rarely stops once it is started, and sometimes it even runs continuously. However, in industrial production, the contents of orders are separate. Traditional continuous production enterprises usually rely on personnel experience to confirm the start and end times of orders to distinguish different order contents. This leads to problems such as poor refined management of enterprise operations, unquantifiable personnel operation errors, and inaccurate order cost prediction. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, the present invention provides a method and apparatus for monitoring the status of a smelting furnace, so as to accurately determine the production time of the smelting furnace and thus provide key data support for subsequent order differentiation.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] In a first aspect, the present invention provides a method for monitoring the condition of a smelting furnace, comprising:

[0007] A method for monitoring the condition of a smelting furnace, comprising:

[0008] The furnace status data is collected in real time according to the preset collection cycle. The furnace status data includes the ignition signal of each ignition gun, the furnace gas temperature, and the flow temperature of the outlet flow channel.

[0009] The furnace gas temperature variation of the smelting furnace is obtained based on the furnace gas temperature of two adjacent collection cycles;

[0010] The temperature change of the outlet flow channel is obtained based on the flow channel temperature of two adjacent acquisition cycles.

[0011] The production time of the smelting furnace for each batch of orders is obtained based on the ignition signal, the furnace gas temperature, the furnace gas temperature change, and the trough temperature change.

[0012] The beneficial effects of this invention are as follows: By real-time monitoring of the ignition signal of the smelting furnace, the furnace gas temperature, and the temperature of the outlet trough, the temperature changes of the two temperatures in the two consecutive acquisition cycles can be used to determine whether the smelting furnace and the outlet trough are in a state of heating or cooling. Finally, the production time of the smelting furnace for each batch of orders can be obtained based on the ignition signal, furnace gas temperature, furnace gas temperature change, and outlet trough temperature change. This eliminates the need for judgment based on human experience, and accurately determines the production time of the smelting furnace through the status data collected by the equipment, thereby providing key data support for subsequent order differentiation.

[0013] Optionally, when this batch of orders is the first batch after the furnace is started, the furnace production time for each batch of orders is determined based on the ignition signal, the furnace gas temperature, the furnace gas temperature change, and the trough temperature change, including:

[0014] When the data in at least two consecutive acquisition cycles continuously meet the following conditions: the first furnace gas temperature in the current acquisition cycle is greater than the first temperature threshold, the second furnace gas temperature in the previous acquisition cycle is greater than or equal to the second temperature threshold, and at least two ignition signals in the current acquisition cycle are start-up, then the first start-up production time of the smelting furnace is taken as the first start-up production time. The first temperature threshold is 280-480℃, and the second temperature threshold is 180-240℃.

[0015] After the first start production time, the temperature change time of the trough is sequentially obtained from the temperature change of the trough. When the time interval between the cooling time of the first trough and the heating time of the adjacent previous trough is within the converter time interval and the ignition signal of the large ignition gun is 0 within the same acquisition cycle as the cooling time of the first trough, the cooling time of the first trough is taken as the first end production time of the smelting furnace.

[0016] The time between the first start production time and the first end production time shall be taken as the furnace production time for the first batch of orders;

[0017] When this batch of orders is a subsequent order following the first batch, the smelting furnace production time for each batch of orders is determined based on the ignition signal, the furnace gas temperature, the furnace gas temperature change, and the trough temperature change, including:

[0018] The start time of the flow channel heating after the previous smelting furnace production time is obtained from the flow channel temperature change. If the ignition signal of the large ignition gun at the same time as the start time is 0, then the furnace gas cooling signal is searched from the previous smelting furnace production time. The first furnace gas heating signal after the furnace gas cooling signal is taken as the second start time of the smelting furnace. The smelting furnace includes a large ignition gun.

[0019] After the second start production time, the temperature change time of the trough is sequentially obtained from the temperature change of the trough. When the time interval between the cooling time of the second trough and the heating time of the adjacent previous trough is within the converter time interval and the ignition signal of the large ignition gun is 0 within the same acquisition cycle as the cooling time of the second trough, the cooling time of the second trough is taken as the second end production time of the smelting furnace.

[0020] The time between the second start production time and the second end production time shall be used as the furnace production time for the subsequent order.

[0021] As described above, by differentiating between different batches of orders and employing different calculation methods, the start time of the first order is more accurately determined by combining the furnace gas temperature in two consecutive acquisition cycles and at least two ignition signals. The start time of subsequent orders is more accurately determined by combining the characteristics of the flow channel heating and the furnace gas temperature first decreasing and then increasing. The end time of the smelting furnace is accurately determined by the flow channel cooling time, the converter time interval, and the ignition signal, thus enabling accurate determination of the smelting furnace's production time.

[0022] Optionally, after collecting the smelting furnace status data in real time according to a preset collection cycle, the method further includes:

[0023] The difference between the furnace gas temperatures in two adjacent acquisition cycles is used to determine whether the first temperature difference threshold is exceeded. If so, the furnace status data obtained in the current acquisition cycle is discarded.

[0024] The difference between the temperatures of the flow channels in two adjacent acquisition cycles is used to determine whether the second temperature difference threshold is exceeded. If so, the furnace status data obtained in the current acquisition cycle is discarded.

[0025] As described above, when the temperature difference before and after exceeds an unreasonable threshold, the furnace status data is discarded to ensure the legality of the data.

[0026] Optionally, obtaining the temperature change of the outlet channel based on the channel temperature of two adjacent acquisition cycles includes:

[0027] If the temperature data of the flow channel in the previous acquisition cycle is less than the third temperature threshold, and the temperature data of the flow channel in the current acquisition cycle is greater than the third temperature threshold, then the flow channel exiting the furnace is heating up. The server time at the current acquisition cycle is recorded as the flow channel heating time. The third temperature threshold is 80-120℃.

[0028] If the temperature data of the flow channel in the previous acquisition cycle is greater than the third temperature threshold, and the temperature data of the flow channel in the current acquisition cycle is less than the third temperature threshold, then the flow channel exiting the furnace is cooling down, and the server time at the current acquisition cycle is recorded as the flow channel cooling time.

[0029] As described above, 80-120℃ is used as a temperature threshold to determine whether aluminum liquid is being transferred in the furnace trough, so as to determine the temperature change time of the trough, which is an important data basis for determining the production time of the smelting furnace.

[0030] Optionally, the condition is defined as follows: when data in at least two consecutive acquisition cycles continuously satisfy the condition, the condition is defined as follows: when data in three consecutive acquisition cycles continuously satisfy the condition, the condition is defined as follows.

[0031] Optionally, after collecting the smelting furnace status data in real time according to a preset collection cycle, the method further includes:

[0032] The furnace status data is standardized according to preset variable names and preset data types to obtain furnace status data as standard variables.

[0033] After setting the furnace status data, which is a standard variable, to NULL, the data is stored in a FIFO queue.

[0034] Optionally, the step of using the first furnace gas heating signal after the furnace gas cooling signal as the second start-up time of the smelting furnace includes:

[0035] The first furnace gas temperature rise signal in the continuous furnace gas temperature rise signals that appear after the furnace gas cooling signal is taken as the second start time of the smelting furnace.

[0036] As described above, continuous furnace gas heating signals can avoid errors caused by occasional single heating signals, thereby ensuring the accuracy of the start-up time of the smelting furnace.

[0037] Optionally, it also includes:

[0038] A heartbeat packet is sent to the smelting furnace according to a preset heartbeat cycle. If no response signal is received from the smelting furnace, an alarm is triggered indicating a communication disconnection. The heartbeat cycle is shorter than the acquisition cycle.

[0039] Optionally, the heartbeat cycle is 1-20 seconds, and the acquisition cycle is 1-10 minutes.

[0040] As described above, the system uses heartbeat packets at the second level to monitor whether data communication is normal in real time, thereby alerting staff to repair the system promptly when communication is interrupted.

[0041] In a second aspect, the present invention provides a furnace condition monitoring device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement a furnace condition monitoring method provided in the first aspect.

[0042] The technical effects of the furnace condition monitoring device provided in the second aspect are described in the relevant description of the furnace condition monitoring method provided in the first aspect. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the main process of a smelting furnace condition monitoring method according to an embodiment of the present invention;

[0044] Figure 2 This is a schematic diagram of the overall process of a smelting furnace condition monitoring method according to an embodiment of the present invention;

[0045] Figure 3 This is a schematic diagram of the structure of a smelting furnace condition monitoring device according to an embodiment of the present invention.

[0046] [Explanation of Labels in the Attached Image]

[0047] 1: A smelting furnace condition monitoring device;

[0048] 2: Processor;

[0049] 3: Memory. Detailed Implementation

[0050] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0051] Example 1

[0052] This embodiment uses a set of furnace status monitoring methods to determine the specific start time and end time of furnace production, providing important data support for subsequent modeling calculations. These methods include: data acquisition, data initialization, data validity, production time calculation, and heartbeat monitoring.

[0053] In this embodiment, the smelting furnace is equipped with four ignition guns, including two large ignition guns and two small ignition guns, which correspond to four ignition signals. The smelting furnace is heated by using the four ignition signals. At the same time, the smelting furnace is connected to the holding furnace through the outlet chute, so that the aluminum liquid obtained in the smelting furnace flows into the holding furnace through the outlet chute, thereby completing the current batch of orders.

[0054] It should be noted that in this embodiment, an order batch is distinguished by one production cycle of the smelting furnace, not by the actual batch of a customer order. A customer order can correspond to multiple production cycles. For one production cycle, the material of the current batch is added to the smelting furnace. After the material is added, heating begins. When the material is heated to the required performance, it flows through the outlet chute into the holding furnace, and this cycle repeats.

[0055] Meanwhile, the temperature value is not a fixed value over a period of time, but rather fluctuates within a certain range. In this embodiment, the heating and cooling referred to means that the temperature difference must be greater than the minimum temperature difference. For example, if the heating temperature in the smelting furnace is maintained at 780-820°C and the minimum temperature difference is 50°C, then a temperature difference of 50°C between two sampling cycles is considered as heating or cooling.

[0056] The following combination Figure 1 and Figure 2 The various steps of the furnace condition monitoring method provided in this embodiment are described below:

[0057] S1, Data Acquisition

[0058] In this embodiment, step S1 specifically includes:

[0059] S11. Collect furnace status data in real time according to the preset collection cycle. The furnace status data includes the ignition signal of each ignition gun, the furnace gas temperature and the outlet flow temperature.

[0060] S12. Standardize the furnace status data according to the preset variable names and preset data types to obtain furnace status data as standard variables.

[0061] Specifically, key data from smelting furnaces and holding furnaces are collected through a dedicated data interface. Variable names are standardized and data types are determined to meet data calculation requirements, forming standard variables, as shown in Table 1.

[0062] Table 1. Data Format

[0063]

[0064] Based on the received data, the variables required for the calculation formula are: Burner_1, Burner_2, Burner_3, Burner_4, RLLFurnTemp, RLLBathTemp, BWLFurnTemp.

[0065] BWLBathTemp、BWLlaunTemP;

[0066] S2, Data Initialization

[0067] In this embodiment, step S2 specifically includes: setting the furnace status data, which is a standard variable, to NULL and then storing it in a FIFO queue for data storage.

[0068] Therefore, the following variables: Burner_1, Burner_2, Burner_3, Burner_4, RLLFurnTemp, and RLLBathTemp are set to NULL and stored in a FIFO queue named value_deposit, waiting for data to be stored.

[0069] Set the following variables: BWL FurnTemp, BWL BathTemp, and BWLlaunTemP to NULL, and store them in a FIFO queue named value_flow, waiting for data to be stored.

[0070] Thus, the furnace status data includes two sets of data: value_deposit and value_flow.

[0071] S3, Data Legality

[0072] In this embodiment, step S3 specifically includes:

[0073] S31. Determine whether the difference between the furnace gas temperature of two adjacent acquisition cycles exceeds the first temperature difference threshold. If so, discard the smelting furnace status data obtained in the current acquisition cycle.

[0074] S32. Obtain the furnace gas temperature variation of the smelting furnace based on the furnace gas temperature of two adjacent collection cycles;

[0075] Before the calculation, the validity of the data is checked. The algorithm formula for checking the validity is as follows:

[0076] value_deposit[cycles-1]!=null&&value_deposit[cycles-2]!=null.

[0077] The specific steps include:

[0078] 1. Check the validity of the data before value_deposit[cycles-2] and the data after value_deposit[cycles-1] to see if there is a deviation between the two sets of data that exceeds the threshold. If the data exceeds the threshold range, it is discarded. For example, if the difference is 400°, it exceeds the temperature that the smelting furnace can heat up during the collection cycle.

[0079] 2. By comparing the data before value_deposit[cycles-2] with the data after value_deposit[cycles-1], it is determined whether the smelting furnace is in a heating or cooling state, providing important parameters for the next step of determining the accurate production time.

[0080] At this point, we obtain the data group fields that meet the calculation conditions.

[0081] S33. Determine whether the temperature difference between the flow channels in two adjacent acquisition cycles exceeds the second temperature difference threshold. If so, discard the furnace status data obtained in the current acquisition cycle.

[0082] S34. Obtain the temperature change of the outlet flow channel based on the flow channel temperature of two adjacent acquisition cycles.

[0083] In this embodiment, step S34 includes:

[0084] If the temperature data of the flow channel in the previous acquisition cycle is less than the third temperature threshold, and the temperature data of the flow channel in the current acquisition cycle is greater than the third temperature threshold, then the flow channel exiting the furnace is heating up. The server time at the time of the current acquisition cycle is recorded as the heating time of the flow channel. The third temperature threshold is 80-120℃.

[0085] If the temperature data of the flow channel in the previous acquisition cycle is greater than the third temperature threshold, and the temperature data of the flow channel in the current acquisition cycle is less than the third temperature threshold, then the flow channel exiting the furnace is cooling down, and the server time at the time of the current acquisition cycle is recorded as the cooling time of the flow channel.

[0086] Before performing any calculations, the validity of the data is checked. The algorithm for checking validity is as follows:

[0087] value_flow[cycles-1]!=null&&value_flow[cycles-2]!=null.

[0088] In this embodiment, the third temperature threshold is 100°C, and the specific steps include:

[0089] 1. Check the validity of the data before value_flow[cycles-2] and the data after value_flow[cycles-1] to see if there is a deviation between the two sets of data that exceeds the threshold. If the data exceeds the threshold range, it is discarded.

[0090] 2. First, determine whether the furnace flow channel is currently heating up or cooling down by analyzing the changes in the two sets of data, value_flow[cycles-2] and value_flow[cycles-1], in the flow channel variable BWLlaunTemP. The details are as follows:

[0091] value_flow[cycles-2].BWLlaunTemP<100.0&&

[0092] value_flow[cycles-1].BWLlaunTemP>= 100.0

[0093] That is, if the temperature of the flow channel is less than 100 degrees Celsius in the previous data acquisition cycle and greater than 100 degrees Celsius in the current data acquisition cycle, it is judged as a temperature rise, and the flow channeling begins.

[0094] At this point, the server time during the current acquisition cycle is recorded as the tank heating time.

[0095] value_flow[cycles-1].BWLlaunTemP<100.0&&

[0096] value_flow[cycles-2].BWLlaunTemP>= 100.0

[0097] If the temperature of the current data acquisition cycle of the flow channel is less than 100 degrees Celsius, while the temperature of the previous data acquisition cycle is greater than 100 degrees Celsius, it is determined to be a cooling process, and the flow channeling ends.

[0098] At this point, the server time during the current acquisition cycle is recorded as the cooling time of the flow tank.

[0099] S4. Production Time Calculation

[0100] In this embodiment, step S4 specifically includes:

[0101] The production time of the smelting furnace for each batch of orders is determined based on the ignition signal, furnace gas temperature, furnace gas temperature change, and trough temperature change.

[0102] Specifically, if this batch of orders is the first order after the furnace is opened, then step S4 includes:

[0103] S41. When the data in at least two consecutive acquisition cycles continuously meet the following conditions: the first furnace gas temperature in the current acquisition cycle is greater than the first temperature threshold, the second furnace gas temperature in the previous acquisition cycle is greater than or equal to the second temperature threshold, and at least two ignition signals in the current acquisition cycle are start-up, then the first start-up production time of the smelting furnace is taken as the first temperature threshold, which is 280-480℃ and the second temperature threshold is 180-240℃.

[0104] In this embodiment, the condition is defined as follows: when data from at least two consecutive acquisition cycles continuously meet the condition; when data from three consecutive acquisition cycles continuously meet the condition. The first temperature threshold is 400℃, and the second temperature threshold is 200℃.

[0105] Specifically, based on the matching of on-site process data and on-site verification, the calculation formula for the furnace start-up event is as follows:

[0106] cycles>=3&&value_deposit[cycles-1].RLLFurnTemp>400.0&&

[0107] value_deposit[cycles-2].RLLFurnTemp<200.0&&

[0108] value_deposit[cycles-1].Burner_1.value+value_deposit[cycles-1].

[0109] Burner_2.value+value_deposit[cycles-1].Burner_3.value+value_deposit[cycles-1].Burner_4.value>= 2

[0110] Here, cycles is the sampling period count. "&&" represents the AND operation.

[0111] Among them, value_deposit[cycles-1].RLLFurnTemp>400 means that the temperature of the furnace gas obtained in the latest smelting furnace must exceed 400 degrees Celsius.

[0112] The value_deposit[cycles-2].RLLFurnTemp<200 means that the furnace gas temperature during the last data acquisition cycle must not be lower than 200 degrees Celsius, to ensure that this calculation is not the first time the furnace has been started.

[0113] Here, cycles>3 means that more than 3 data acquisition cycles are continuously satisfied, with each data cycle being 5 minutes, that is, the duration exceeds 15 minutes. In other embodiments, the acquisition cycle is 1-10 minutes.

[0114] The expression `value_deposit[cycles-1].Burner_1.value + value_deposit[cycles-1].Burner_2.value + value_deposit[cycles1].Burner_3.value + value_deposit[cycles-1].Burner_4.value >= 2` represents the start-up signals for the four ignition signals of the smelting furnace. Since the smelting furnace is not a device that stops production when it is ignited, based on the current production situation, the equipment is always started by one ignition signal, usually the ignition signal from the small ignition gun, to keep the molten aluminum in the furnace from solidifying. The furnace begins heating when two ignition signals are started simultaneously; typically, the second ignition signal is the ignition signal from the large ignition gun.

[0115] The server system time when all the above conditions are met simultaneously is the accurate time when the smelting furnace starts production.

[0116] S42. After the first start production time, the temperature change time of the trough is obtained sequentially from the temperature change of the trough. When the time interval between the cooling time of the first trough and the heating time of the adjacent previous trough is within the converter time interval and the ignition signal of the large ignition gun is 0 within the same acquisition cycle as the cooling time of the first trough, the cooling time of the first trough is taken as the first end production time of the smelting furnace.

[0117] During the smelting furnace production process, slag is sometimes discharged through the outlet channel. This can cause temperature changes in the channel, such as heating up and cooling down upon shutdown. In such cases, the ignition signal within the cycle is collected to differentiate between heating and slag discharge. A signal of 1 from the main ignition gun in the smelting furnace indicates that heating is still in progress, which may be during slag discharge. It's important to note that the smelting furnace needs to maintain a certain temperature range during production; therefore, the main ignition gun is switched on and off. A signal of 0 from the main ignition gun does not necessarily mean that production has stopped.

[0118] Meanwhile, when the smelting furnace needs to be converted, a small amount of liquid will be slowly discharged for quality analysis. This means that the results of the first one or two quality analyses may be unsatisfactory, requiring parameter adjustments for further smelting. Therefore, the time interval between the cooling time of the first flow channel and the heating time of the adjacent flow channel is used to determine the converter time range. Generally, the length of the outlet flow channel is fixed, and the flow rate of molten aluminum in the smelting furnace remains within a large range. Therefore, the converter time is usually much longer than the previous several times. In a specific example, the time for molten aluminum to pass through the flow channel is 30 minutes. Considering the data collection cycle is five minutes, the converter time range can be set at (24, 36). Setting the converter time range can also mitigate slag discharge issues to some extent, while ensuring that the obtained cooling time of the first flow channel is the converter end time, which can be used as the first end time of the smelting furnace's production.

[0119] S43. The time between the first start time of production and the first end time of production shall be taken as the furnace production time for the first batch of orders.

[0120] When this batch of orders is a subsequent order after the first batch, such as the second or third batch, then step S4 includes:

[0121] S44. Obtain the start time of the heat rise of the trough after the previous smelting furnace production time from the temperature change of the trough. If the ignition signal of the large ignition gun at the same time as the start time is 0, then start looking for the furnace gas cooling signal after the previous smelting furnace production time. Take the first furnace gas heating signal after the furnace gas cooling signal as the second start time of the smelting furnace. The smelting furnace includes the large ignition gun.

[0122] In this embodiment, using the first furnace gas heating signal after the furnace gas cooling signal as the second start-up time of the smelting furnace includes:

[0123] The first furnace gas temperature rise signal in the continuous furnace gas temperature rise signals that appear after the furnace gas cooling signal is taken as the second start time of the smelting furnace.

[0124] That is, after the previous smelting furnace production time, the system begins searching for a furnace gas cooling signal. This signal indicates that the next batch of material is being fed into the smelting furnace, causing the furnace gas temperature to drop. At this point, the feeding process takes about an hour. If the temperature rises for two consecutive cycles, it means that the feeding process has ended and the smelting furnace has started heating. Therefore, the first furnace gas temperature rise signal is taken as the start time for this batch of orders.

[0125] S45. After the second start production time, the temperature change time of the trough is obtained sequentially from the temperature change of the trough. When the time interval between the second trough cooling time and the adjacent previous trough heating time is within the converter time interval and the ignition signal of the large ignition gun is 0 within the same acquisition cycle as the second trough cooling time, the second trough cooling time is taken as the second end production time of the smelting furnace.

[0126] The completion time for subsequent orders will be based on the description of the first batch of orders.

[0127] S46. The time between the second start production time and the second end production time shall be used as the furnace production time for subsequent orders.

[0128] S5, Heartbeat

[0129] In this embodiment, step S4 specifically includes:

[0130] The heartbeat packet is sent to the smelting furnace according to the preset heartbeat cycle. If no response signal is received from the smelting furnace, an alarm is triggered indicating that the communication has been disconnected. The heartbeat cycle is shorter than the acquisition cycle.

[0131] In this embodiment, the heartbeat cycle is 5 seconds. To ensure normal data communication, a heartbeat signal (HeartBeat, normally closed point MB0) is added, and data is collected every 5 seconds. If the normally closed MB0 signal is not received, communication is considered lost, and an alarm is triggered. In other embodiments, the heartbeat cycle is 1-20 seconds.

[0132] Therefore, this embodiment monitors the ignition signal of the smelting furnace, the furnace gas temperature, and the temperature of the outlet flow channel in real time. Based on the temperature changes in the two acquisition cycles, it determines whether the smelting furnace and the outlet flow channel are heating up or cooling down. Then, by differentiating different batches of orders and using different calculation methods, the production time of the smelting furnace is accurately determined, thus providing key data support for subsequent order differentiation.

[0133] Example 2

[0134] Please refer to Figure 3 A furnace status monitoring device 1 includes a memory 3, a processor 2, and a computer program stored in the memory 3 and run on the processor 2. When the processor 2 executes the computer program, it implements the steps in the above embodiment 1.

[0135] Since the apparatus / device described in the above embodiments of the present invention is an apparatus / device used to implement the method of the above embodiments of the present invention, those skilled in the art can understand the specific structure and modifications of the apparatus / device based on the method described in the above embodiments of the present invention, and therefore will not be described again here. All apparatus / devices used in the method of the above embodiments of the present invention fall within the scope of protection of the present invention.

[0136] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, apparatus, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0137] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (devices), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, as well as combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions.

[0138] It should be noted that any reference numerals placed between parentheses in the claims should not be construed as limiting the claims. The word "comprising" does not exclude the presence of components or steps not listed in the claims. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. The invention can be implemented by means of hardware comprising several different components and by means of a suitably programmed computer. In claims that enumerate several means, several of these means may be embodied by the same hardware. The use of the terms first, second, third, etc., is merely for convenience of expression and does not indicate any order. These terms can be understood as part of the component names.

[0139] Furthermore, it should be noted that in the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0140] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the claims should be interpreted to include both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0141] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, then this invention should also include these modifications and variations.

Claims

1. A method of monitoring the state of a smelting furnace, characterized by The method comprises the following steps: collecting smelting furnace state data in real time according to a preset collection period, wherein the smelting furnace state data comprises ignition signals of each ignition gun, a furnace gas temperature of the smelting furnace and a flow channel temperature of a flow channel; obtaining a furnace gas temperature variation of the smelting furnace according to the furnace gas temperatures of two adjacent collection periods; obtaining a flow channel temperature variation of the flow channel according to the flow channel temperatures of two adjacent collection periods; obtaining a smelting furnace production time of each batch order according to the ignition signals, the furnace gas temperature, the furnace gas temperature variation and the flow channel temperature variation.

2. A method of monitoring the condition of a smelting furnace as claimed in claim 1, wherein, When the batch order is the first batch order after the current smelting, the smelting furnace production time of each batch order is obtained according to the ignition signals, the furnace gas temperature, the furnace gas temperature variation and the flow channel temperature variation, which comprises the following steps: when the data in at least two continuous collection periods continuously meet the conditions that the first furnace gas temperature of the current collection period is greater than a first temperature threshold, the second furnace gas temperature of the previous collection period is greater than or equal to a second temperature threshold and at least two ignition signals in the current collection period are start, the first start production time of the smelting furnace is obtained, wherein the first temperature threshold is 280-480 DEG C and the second temperature threshold is 180-240 DEG C; after the first start production time, a flow channel temperature variation time is obtained from the flow channel temperature variation in sequence, when the time interval between the first flow channel cooling time and the adjacent previous flow channel heating time is within the converter time interval and the ignition signal of the large ignition gun in the same collection period as the first flow channel cooling time is 0, the first flow channel cooling time is taken as the first end production time of the smelting furnace; the time between the first start production time and the first end production time is taken as the smelting furnace production time of the first batch order; when the batch order is the subsequent order after the first batch order, the smelting furnace production time of each batch order is obtained according to the ignition signals, the furnace gas temperature, the furnace gas temperature variation and the flow channel temperature variation, which comprises the following steps: the start time of the flow channel heating after the previous smelting furnace production time is obtained from the flow channel temperature variation, if the ignition signal of the large ignition gun at the same time as the start time is 0, the furnace gas cooling signal is searched for from the previous smelting furnace production time, the first furnace gas heating signal after the furnace gas cooling signal is taken as the second start production time of the smelting furnace, and the smelting furnace comprises a large ignition gun; after the second start production time, a flow channel temperature variation time is obtained from the flow channel temperature variation in sequence, when the time interval between the second flow channel cooling time and the adjacent previous flow channel heating time is within the converter time interval and the ignition signal of the large ignition gun in the same collection period as the second flow channel cooling time is 0, the second flow channel cooling time is taken as the second end production time of the smelting furnace; the time between the second start production time and the second end production time is taken as the smelting furnace production time of the subsequent order.

3. A method of monitoring the condition of a smelting furnace as claimed in claim 1, wherein after the step of collecting smelting furnace state data in real time according to a preset collection period, the method further comprises the following steps: determining whether a first temperature difference threshold is exceeded according to a difference between the furnace gas temperatures of two adjacent collection periods, and if so, discarding smelting furnace state data obtained in the current collection period; determining whether a second temperature difference threshold is exceeded according to a difference between the launder temperatures of two adjacent collection periods, and if so, discarding smelting furnace state data obtained in the current collection period.

4. A method of monitoring the condition of a smelting furnace as claimed in claim 1, wherein the determination of the temperature change of the tapping launder according to the launder temperatures of two adjacent collection periods comprises: if the data of the launder temperature in the previous collection period is less than a third temperature threshold and the data of the launder temperature in the current collection period is greater than the third temperature threshold, the tapping launder is in a temperature rise, and the server time at the current collection period is recorded as a temperature rise time of the tapping launder, and the third temperature threshold is 80-120℃; if the data of the launder temperature in the previous collection period is greater than the third temperature threshold and the data of the launder temperature in the current collection period is less than the third temperature threshold, the tapping launder is in a temperature drop, and the server time at the current collection period is recorded as a temperature drop time of the tapping launder.

5. A method of monitoring the condition of a smelting furnace as claimed in claim 2, wherein, when the data in at least two consecutive collection periods continuously satisfy the condition.

6. A method of monitoring the condition of a smelting furnace as claimed in any one of claims 1 to 5, wherein, the real-time collection of smelting furnace state data according to the preset collection period further comprises: normalizing the smelting furnace state data according to a preset variable name and a preset data type to obtain smelting furnace state data of standard variables; storing the smelting furnace state data of standard variables into a FIFO queue after setting them as NULL.

7. A method of monitoring the condition of a smelting furnace as claimed in claim 2, wherein the first furnace gas temperature rise signal after the furnace gas temperature drop signal is taken as a second start production time of the smelting furnace. the first furnace gas temperature rise signal in the continuous furnace gas temperature rise signals after the furnace gas temperature drop signal is taken as a second start production time of the smelting furnace.

8. A method of monitoring the condition of a smelting furnace as claimed in any one of claims 1 to 5, wherein, further comprising: sending a heartbeat packet to the smelting furnace according to a preset heartbeat period, and when no reply signal returned by the smelting furnace can be received, an alarm prompt of communication disconnection is given, and the heartbeat period is less than the collection period.

9. A method of monitoring the condition of a smelting furnace as claimed in claim 8, wherein, the heartbeat period is 1-20 seconds, and the collection period is 1-10 minutes.

10. A smelter condition monitoring apparatus comprising a memory, a processor and a computer program stored on the memory and executable on the processor, characterised in that, the processor implements the smelting furnace state monitoring method according to any one of claims 1-9 when executing the computer program.

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