A silicon charge leakage monitoring system and method

Abstract

The application discloses a kind of silicon material leakage monitoring system and method in the technical field of granular silicon production, system includes: through the raw material unit, buffer unit connected with conveying pipeline, and with the control module of signal connection of the raw material unit and the buffer unit;The raw material unit includes first raw material tank, first weight sensor for measuring the weight of first raw material tank and with the first upper valve and first lower valve of the first raw material tank;Third spare tank, third weight sensor for measuring the weight of third spare tank and with the third upper valve and third lower valve of the third spare tank;The buffer unit includes second buffer tank, second weight sensor for measuring the weight of second buffer tank and with the second upper valve and second lower valve of the second buffer tank.The application can solve the technical problem that when silicon seed crystal is leaked to downstream system in the valve closed state, cannot find, isolate, repair fault valve in time, thereby affecting normal production.

Description

Technical Field

[0001] This invention belongs to the field of granular silicon production technology, and in particular relates to a silicon material leakage monitoring system and method. Background Technology

[0002] In the granular silicon production process system, silicon seed crystals, as the raw material for producing granular silicon, are transported to the reactor through special pipelines. Valves are used to open and close the silicon seed crystal transport. The transport of solid materials causes a certain amount of wear on the pipelines and valves. When the valves are used to transport silicon seed crystals at a high frequency, the damage to the valves will gradually increase, and the valve's sealing performance will deteriorate. Silicon seed crystals will leak into the downstream system when the valves are closed. When the valves are severely worn, especially the amount of silicon seed crystals leaking into the production system and buffer tanks, the amount will gradually increase. Failure to detect, isolate, and repair faulty valves in time will directly affect normal production. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a silicon material leakage monitoring system and method, which can solve the technical problem that when the silicon seed crystal is transported at high frequency by the material switching valve, the silicon seed crystal will leak into the downstream system when the valve is closed, and the faulty valve cannot be detected, isolated and repaired in time, thus affecting normal production.

[0004] To achieve the above objectives, the present invention is implemented using the following technical solution: In a first aspect, the present invention provides a silicon material leakage monitoring system, comprising: The raw material unit and buffer unit are connected by a conveying pipeline, and a control module is signal-connected to the raw material unit and the buffer unit. The raw material unit includes a first raw material tank, a first weight sensor for measuring the weight of the first raw material tank, and a first upper valve and a first lower valve connected to the first raw material tank; a third spare tank, a third weight sensor for measuring the weight of the third spare tank, and a third upper valve and a third lower valve connected to the third spare tank; The buffer unit includes a second buffer tank, a second weight sensor for measuring the weight of the second buffer tank, and a second upper valve and a second lower valve connected to the second buffer tank. The control module is used to control the opening and closing of the valves in the raw material unit and the buffer unit.

[0005] Furthermore, the first upper valve of the first raw material tank, the third upper valve of the third spare tank, and the second upper valve of the second buffer tank are all normally closed valves, while the first lower valve of the first raw material tank, the third lower valve of the third spare tank, and the second lower valve of the second buffer tank are all normally open valves.

[0006] Furthermore, it also includes a display module that is signal-connected to the control module. The display module is used to display the unit cycle, initial weight value, real-time weight value, interlock value, and duration during the leakage monitoring process.

[0007] Secondly, the present invention provides a method for monitoring silicon material leakage, comprising: Within a unit cycle, G1 is obtained by calculating the difference between the initial weight value and the real-time weight value of the first raw material tank, and G3 is obtained by calculating the difference between the initial weight value and the real-time weight value of the third spare tank. The opening and closing of the valve of the first raw material tank is controlled according to G1, and the opening and closing of the valve of the third spare tank is controlled according to G3. G2 is obtained by calculating the difference between the initial weight and the real-time weight of the second buffer tank within a unit period. The valves of the first raw material tank and the third spare tank are controlled according to |G2|.

[0008] Furthermore, it also includes controlling the opening and closing of the second buffer tank valve according to G2.

[0009] Furthermore, controlling the opening and closing of the first raw material tank valve according to G1 includes: When G1 ≥ the interlock value, the control unit issues a command to close both the first upper valve and the first lower valve of the first raw material tank; When G1 is less than the interlock value and G1 continues to increase during the duration, the control unit issues a command to control both the first upper valve and the first lower valve of the first raw material tank to close. When G1 is less than the interlock value and G1 remains stable for a period of time, the control unit issues a command to close the first upper valve of the first raw material tank and open the first lower valve of the first raw material tank. The above condition only occurs after the faulty valve is isolated and repaired. When the leaking valve is repaired and the leak monitoring system is maintained to operate normally, the first upper valve closes, the first lower valve opens, and the leak monitoring system restarts to continue monitoring. Through leak monitoring, process system disorder caused by excessive feeding can be avoided (which may seriously lead to the shutdown of the equipment).

[0010] Furthermore, controlling the opening and closing of the third backup tank valve according to G3 includes: When G3 ≥ the interlock value, the control unit issues a command to close both the third upper valve and the third lower valve of the third spare tank; When G3 is less than the interlock value and G3 continues to increase during the duration, the control unit issues a command to control both the third upper valve and the third lower valve of the third spare tank to close. When G3 is less than the interlock value and remains stable for a period of time, the control unit issues a command to close the third upper valve of the third backup tank and open the third lower valve of the third backup tank. The above condition only occurs after the faulty valve is isolated and repaired. When the leakage valve is repaired and the leakage monitoring system is maintained to operate normally, the third upper valve closes, the third lower valve opens, and the leakage monitoring system restarts to continue monitoring. Through leakage monitoring, process system disorder caused by excessive feeding can be avoided (which may seriously lead to the shutdown of the unit).

[0011] Furthermore, controlling the opening and closing of the valves of the first raw material tank and the third spare tank according to |G2| includes: When |G2|≥interlock value, the control unit identifies whether the first raw material tank or the third spare tank is leaking through the identification program. When the first raw material tank or the third spare tank is leaking, the control unit issues a command to control the lower valve of the corresponding tank to close. When neither the first raw material tank nor the third spare tank is leaking, the control unit issues a command to control the first upper valve of the first raw material tank and the third upper valve of the third spare tank to close, and the first lower valve of the first raw material tank and the third lower valve of the third spare tank to open. When |G2| is less than the interlock value and |G2| continues to increase during the duration, the control unit identifies whether the first raw material tank or the third spare tank is leaking through the identification program. When the first raw material tank or the third spare tank is leaking, the control unit issues a command to control the lower valve of the corresponding tank to close. When neither the first raw material tank nor the third spare tank is leaking, the control unit issues a command to control the first upper valve of the first raw material tank and the third upper valve of the third spare tank to close, and the first lower valve of the first raw material tank and the third lower valve of the third spare tank to open. When |G2| is less than the interlock value and |G2| remains stable during the duration, the control unit issues a command to close the first upper valve of the first raw material tank and the third upper valve of the third spare tank, and open the first lower valve of the first raw material tank and the third lower valve of the third spare tank.

[0012] Furthermore, controlling the opening and closing of the second buffer tank valve according to G2 includes: When the control unit identifies that there is no leakage in the first raw material tank and the third spare tank through the identification program: when G2≥interlock value, and the control unit issues a command to control the second upper valve and the second lower valve of the second buffer tank to close; When G2 is less than the interlock value and G2 continues to increase during the duration, the control unit issues a command to control both the second upper valve and the second lower valve of the second buffer tank to close. When G2 is less than the interlock value and remains stable for a period of time, the control unit issues a command to close the second upper valve of the second buffer tank and open the second lower valve of the second buffer tank. The above condition only occurs after the faulty valve is isolated and repaired. When the leakage valve is repaired and the leakage monitoring system is maintained to operate normally, the second upper valve closes, the second lower valve opens, and the leakage monitoring system restarts to continue monitoring. Through leakage monitoring, process system disorder caused by excessive feeding can be avoided (which may seriously lead to the shutdown of the equipment).

[0013] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, characterized in that the program, when executed by a processor, implements the steps of any of the methods described above.

[0014] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: The opening and closing of the valve of the first raw material tank is controlled according to the difference G1 between the initial weight value and the real-time weight value of the first raw material tank. The opening and closing of the valve of the third spare tank is controlled according to the difference G3 between the initial weight value and the real-time weight value of the third spare tank. The opening and closing of the valves of the first raw material tank and the third spare tank are controlled according to the difference G2 between the initial weight value and the real-time weight value of the second buffer tank and the set identification program. Through the set dual leakage monitoring mechanism, the timeliness of detecting serious leakage is improved, ensuring normal production. During normal production, the first upper valve of the first raw material tank, the third upper valve of the third spare tank, and the second upper valve of the second buffer tank are all normally closed valves, while the first lower valve of the first raw material tank, the third lower valve of the third spare tank, and the second lower valve of the second buffer tank are all normally open valves. When the monitoring system detects a serious leak, the corresponding valve can be replaced to ensure normal production. Attached Figure Description

[0015] Figure 1 is a flowchart of a silicon material leakage monitoring method provided in Embodiment 2 of the present invention.

[0016] Figure 2 is a schematic diagram of a silicon material leakage monitoring system provided in Embodiment 1 of the present invention.

[0017] Figure 3 is a schematic diagram of the display module of a silicon material leakage monitoring system provided in an embodiment of the present invention. Detailed Implementation

[0018] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments and specific features in the embodiments are detailed descriptions of the technical solution of the present application, rather than limitations thereof. In the absence of conflict, the embodiments and technical features in the embodiments can be combined with each other.

[0019] In this article, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship. Example 1:

[0020] This invention provides a silicon material leakage monitoring system, comprising: The system comprises a raw material unit and a buffer unit connected via a conveying pipeline, and a control module connected to the raw material unit and the buffer unit via a signal connection. The raw material unit includes a first raw material tank, a first weight sensor for measuring the weight of the first raw material tank, and a first upper valve and a first lower valve connected to the first raw material tank; a third spare tank, a third weight sensor for measuring the weight of the third spare tank, and a third upper valve and a third lower valve connected to the third spare tank; the buffer unit includes a second buffer tank, a second weight sensor for measuring the weight of the second buffer tank, and a second upper valve and a second lower valve connected to the second buffer tank. Specifically, the first upper valve of the first raw material tank, the third upper valve of the third spare tank, and the second upper valve of the second buffer tank are all normally closed valves. The first lower valve of the first raw material tank, the third lower valve of the third spare tank, and the second lower valve of the second buffer tank are all normally open valves. Normally closed valves are valves used to close after the material conveying requirements are met during normal production. Normally open valves are valves used to close when the monitoring system detects leakage. After the normally open valve is closed, the damage to the normally closed valve can be checked, and if the damage is severe, it can be replaced.

[0021] Among them, the appendix Figure 2 Tanks A, B, and C can be the first raw material tank, the third spare tank, and the second buffer tank, respectively. Valves 1 and 2 can be the first upper valve and the first lower valve, valves 3 and 4 can be the third upper valve and the third lower valve, and valves 5 and 6 can be the second upper valve and the second lower valve. Additionally, [further details omitted]. Figure 2 WI_01A, WI_01B and WI_01C are weighing instruments for measuring the weight of tanks A, B and C, respectively, and have the same function as the first weight sensor, second weight sensor and third weight sensor of this application.

[0022] The control module is used to control the opening and closing of the valves of the raw material unit and the buffer unit. The control module and control logic disclosed in this application can be implemented using the Honeywell DCS system, which is already available in the art.

[0023] like Figure 3As shown, it may also include a display module that is signal-connected to the control module. The display module is used to display the unit cycle, initial weight value, real-time weight value, interlock value and duration during the leakage monitoring process.

[0024] It may also include a production unit for completing the production of silicon material, the production unit being connected to the buffer unit via a conveying pipeline. Example 2:

[0025] Figure 1 This is a flowchart of the silicon material leakage monitoring method in Embodiment 2 of the present invention. This flowchart only illustrates the logical sequence of the methods described in this embodiment. Provided there are no conflicts, different methods may be used in other possible embodiments of the present invention. Figure 1 Complete the steps shown or described in the order indicated.

[0026] The silicon material leakage monitoring method provided in this embodiment can be executed by a silicon material leakage monitoring system, which has the corresponding functional modules and beneficial effects for executing the method. See [link / reference]. Figure 1 The method of this implementation specifically includes the following steps: Step 1: Within a unit cycle, calculate the difference between the initial weight value and the real-time weight value of the first raw material tank (in this embodiment, the weight difference is calculated by subtracting the real-time weight value from the initial weight value) to obtain G1 (in the embodiment provided in this application, the initial weight value and the real-time weight value are both measured by the corresponding weight sensor and then transmitted to the control unit), and calculate the difference between the initial weight value and the real-time weight value of the third spare tank to obtain G3; Step 2: Control the opening and closing of the valve of the first raw material tank according to G1: When G1 ≥ the interlock value (in the embodiments provided in this application, the interlock value is a standard value set according to actual needs. Based on the relationship between the weight difference and this value, the system determines different working conditions, and the control unit executes control commands according to the working conditions), the control unit issues a command to control the first upper valve and the first lower valve of the first raw material tank to be closed. When G1 is less than the interlock value and G1 continues to increase within the duration (in the embodiments provided in this application, the duration is also a standard value set according to actual needs. When the system identifies the change in weight difference within a certain time range, it determines different working conditions, and the control unit executes control commands according to the working conditions), the control unit issues a command to control the first upper valve and the first lower valve of the first raw material tank to be closed. When G1 is less than the interlock value and G1 remains stable over a period of time, the control unit issues a command to close the first upper valve of the first raw material tank and open the first lower valve of the first raw material tank. The opening and closing of the valve of the third backup tank is controlled by G3: When G3 ≥ the interlock value, the control unit issues a command to close both the third upper valve and the third lower valve of the third spare tank; When G3 is less than the interlock value and G3 continues to increase during the duration, the control unit issues a command to control both the third upper valve and the third lower valve of the third spare tank to close. When G3 is less than the interlock value and G3 remains stable during the duration, the control unit issues a command to close the third upper valve of the third backup tank and open the third lower valve of the third backup tank. Step 3: Within a unit period, calculate the difference between the initial weight value and the real-time weight value of the second buffer tank to obtain G2; Step 4: Since G2 is negative at this time, after adding an absolute value to G2, control the opening and closing of the valves of the first raw material tank and the third spare tank according to |G2|: When |G2|≥ the interlock value, the control unit identifies whether the first raw material tank or the third spare tank is leaking through an identification program (in the embodiments provided in this application, the identification program is written using the Honeywell DCS system, which is already in use in the field, and identifying the source of leakage through the identification program is also a conventional prior art in the field, which will not be described in detail here). When the first raw material tank or the third spare tank is leaking, the control unit issues a command to control the lower valve of the corresponding tank to close. When neither the first raw material tank nor the third spare tank is leaking, the control unit issues a command to control the first upper valve of the first raw material tank and the third upper valve of the third spare tank to close, and the first lower valve of the first raw material tank and the third lower valve of the third spare tank to open. When |G2| is less than the interlock value and |G2| continues to increase during the duration, the control unit identifies whether the first raw material tank or the third spare tank is leaking through the identification program. When the first raw material tank or the third spare tank is leaking, the control unit issues a command to control the lower valve of the corresponding tank to close. When neither the first raw material tank nor the third spare tank is leaking, the control unit issues a command to control the first upper valve of the first raw material tank and the third upper valve of the third spare tank to close, and the first lower valve of the first raw material tank and the third lower valve of the third spare tank to open. When |G2| is less than the interlock value and |G2| remains stable during the duration, the control unit issues a command to close the first upper valve of the first raw material tank and the third upper valve of the third spare tank, and open the first lower valve of the first raw material tank and the third lower valve of the third spare tank. Step 5: Control the opening and closing of the second buffer tank valve according to G2: When the control unit identifies that there is no leakage in the first raw material tank and the third spare tank through the identification program: when G2≥interlock value, and the control unit issues a command to control the second upper valve and the second lower valve of the second buffer tank to close; When G2 is less than the interlock value and G2 continues to increase during the duration, the control unit issues a command to control both the second upper valve and the second lower valve of the second buffer tank to close. When G2 is less than the interlock value and G2 remains stable over a period of time, the control unit issues a command to close the second upper valve of the second buffer tank and open the second lower valve of the second buffer tank.

[0027] In other embodiments of this application, since the control part of the upper valve belongs to the existing mature process control system, the lower valve can be opened and closed by the control unit. The other control methods, steps and logic are the same as in this embodiment, and will not be described again here. Example 3:

[0028] This invention also provides a computer-readable storage medium storing a computer program thereon. When executed by a processor, the program implements the steps of the method described in Embodiment 2, and has the corresponding functional modules and beneficial effects of the method.

[0029] Those skilled in the art will understand that embodiments of this application can be provided as methods, apparatus, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application 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.

[0030] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (devices), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0031] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0032] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0033] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A silicon material leakage monitoring system, characterized in that, include: The raw material unit and buffer unit are connected by a conveying pipeline, and a control module is signal-connected to the raw material unit and the buffer unit. The raw material unit includes a first raw material tank, a first weight sensor for measuring the weight of the first raw material tank, and a first upper valve and a first lower valve connected to the first raw material tank; a third spare tank, a third weight sensor for measuring the weight of the third spare tank, and a third upper valve and a third lower valve connected to the third spare tank; The buffer unit includes a second buffer tank, a second weight sensor for measuring the weight of the second buffer tank, and a second upper valve and a second lower valve connected to the second buffer tank. The control module is used to control the opening and closing of the valves of the raw material unit and the buffer unit; Within a unit cycle, G1 is obtained by calculating the difference between the initial weight value and the real-time weight value of the first raw material tank, and G3 is obtained by calculating the difference between the initial weight value and the real-time weight value of the third spare tank. The opening and closing of the valve of the first raw material tank is controlled according to G1, and the opening and closing of the valve of the third spare tank is controlled according to G3. G2 is obtained by calculating the difference between the initial weight and the real-time weight of the second buffer tank within a unit period. Control the opening and closing of the valves of the first raw material tank and the third spare tank according to |G2|; The control of the opening and closing of the first raw material tank valve according to G1 includes: When G1 ≥ the interlock value, the control module issues a command to close both the first upper valve and the first lower valve of the first raw material tank; When G1 is less than the interlock value and G1 continues to increase during the duration, the control module issues a command to control both the first upper valve and the first lower valve of the first raw material tank to close. When G1 is less than the interlock value and G1 remains stable during the duration, the control module issues a command to control the first upper valve of the first raw material tank to close and the first lower valve of the first raw material tank to open. The opening and closing of the third backup tank valve controlled by G3 includes: When G3 ≥ the interlock value, the control module issues a command to close both the third upper valve and the third lower valve of the third spare tank; When G3 is less than the interlock value and G3 continues to increase during the duration, the control module issues a command to control both the third upper valve and the third lower valve of the third spare tank to close. When G3 is less than the interlock value and G3 remains stable during the duration, the control module issues a command to close the third upper valve of the third backup tank and open the third lower valve of the third backup tank.

2. The silicon material leakage monitoring system according to claim 1, characterized in that, The first upper valve of the first raw material tank, the third upper valve of the third spare tank, and the second upper valve of the second buffer tank are all normally closed valves, while the first lower valve of the first raw material tank, the third lower valve of the third spare tank, and the second lower valve of the second buffer tank are all normally open valves.

3. The silicon material leakage monitoring system according to claim 2, characterized in that, It also includes a display module that is signal-connected to the control module. The display module is used to display the unit cycle, initial weight value, real-time weight value, interlock value and duration during the leakage monitoring process.

4. The silicon material leakage monitoring system according to claim 1, characterized in that, It also includes controlling the opening and closing of the valve of the second buffer tank according to G2.

5. The silicon material leakage monitoring system according to claim 1, characterized in that, The control of the opening and closing of the valves of the first raw material tank and the third spare tank according to |G2| includes: When |G2|≥interlock value, the control module identifies whether the first raw material tank or the third spare tank is leaking through the identification program. When the first raw material tank or the third spare tank is leaking, the control module issues a command to close the lower valve of the corresponding tank. When neither the first raw material tank nor the third spare tank is leaking, the control module issues a command to close the first upper valve of the first raw material tank and the third upper valve of the third spare tank, and open the first lower valve of the first raw material tank and the third lower valve of the third spare tank. When |G2| is less than the interlock value and |G2| continues to increase during the duration, the control module identifies whether the first raw material tank or the third spare tank is leaking through the identification program. When the first raw material tank or the third spare tank is leaking, the control module issues a command to control the lower valve of the corresponding tank to close. When neither the first raw material tank nor the third spare tank is leaking, the control module issues a command to control the first upper valve of the first raw material tank and the third upper valve of the third spare tank to close, and the first lower valve of the first raw material tank and the third lower valve of the third spare tank to open. When |G2| is less than the interlock value and |G2| remains stable during the duration, the control module issues a command to close the first upper valve of the first raw material tank and the third upper valve of the third spare tank, and open the first lower valve of the first raw material tank and the third lower valve of the third spare tank.

6. The silicon material leakage monitoring system according to claim 4, characterized in that, The control of the opening and closing of the second buffer tank valve according to G2 includes: When the control module identifies that there is no leakage in the first raw material tank and the third spare tank through the identification program: when G2≥interlock value, and the control module issues a command to control the second upper valve and the second lower valve of the second buffer tank to close; When G2 is less than the interlock value and G2 continues to increase during the duration, the control module issues a command to control both the second upper valve and the second lower valve of the second buffer tank to close. When G2 is less than the interlock value and G2 remains stable over the duration, the control module issues a command to control the second upper valve of the second buffer tank to close and the second lower valve of the second buffer tank to open.

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