Comprehensive intelligent control system of submerged arc furnace

Abstract

The invention provides a comprehensive intelligent control system for a submerged arc furnace. The comprehensive intelligent control system comprises an auxiliary distributed control subsystem, a Fur-DCS furnace body distributed control subsystem, an SIS control subsystem and a GDS control subsystem. When the submerged arc furnace is a semi-closed submerged arc furnace, the SIS control subsystem collects the stock bin level, the furnace bottom temperature, the furnace wall temperature and the flue gas temperature, and the SIS control subsystem controls a direct discharge scattered flue safety valve and an electric furnace transformer opening. When the submerged arc furnace is a direct-current submerged arc furnace or a closed submerged arc furnace, the SIS control subsystem collects the furnace pressure, the stock bin level, the H2 content and the O2 content, and the SIS control subsystem controls a crude gas diffusion flue safety valve and an electric furnace transformer opening. And the GDS control subsystem is used for completing leakage concentration detection, indication and alarm of combustible gas and toxic gas on site and starting and stopping of an exhaust fan of a chain workshop. The control subsystem is high in stability and reliability due to multi-aspect configuration redundancy; the overall performance of the smelting submerged arc furnace can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of smelting ore-heat furnaces, and in particular to a comprehensive intelligent control system for ore-heat furnaces. Background Art

[0002] At present, the industrial structure of smelting submerged arc furnaces is constantly being optimized, and some production processes are relatively backward and the production capacity that does not meet the environmental protection and energy consumption standards is constantly withdrawn. Especially in recent years, various industries have paid more and more attention to advanced equipment, and a number of projects such as capacity replacement, environmental relocation, and industrial transfer generally require supporting submerged arc furnace equipment with high single-unit capacity and advanced process equipment.

[0003] Existing electric arc furnaces generally have scattered configuration data and cannot be managed in a unified manner. The furnace body and ancillary equipment lack control models and are mainly operated by manual experience. Each system is independent, and there are obvious data "islands" between systems. It is difficult for each unit of the smelting production line to coordinate and optimize the overall situation. Summary of the invention

[0004] According to the above-mentioned problem that the existing submerged arc furnace control system is not perfectly configured, a comprehensive intelligent control system for a submerged arc furnace is provided to eliminate data islands and improve the overall performance of the smelting submerged arc furnace.

[0005] The technical means adopted by the present invention are as follows:

[0006] A comprehensive intelligent control system for a submerged arc furnace, comprising: an auxiliary distributed control subsystem, a Fur-DCS furnace body distributed control subsystem, a SIS control subsystem and a GDS control subsystem;

[0007] The submerged arc furnace is one of a semi-closed submerged arc furnace, a direct current submerged arc furnace or a closed submerged arc furnace;

[0008] When the submerged arc furnace is a semi-closed submerged arc furnace, the auxiliary distributed control subsystem is a Ded-DCS flue gas dust removal distributed control subsystem, which is used to collect and control the signal of the flue gas dust removal and recovery equipment for the high-temperature flue gas generated by the semi-closed submerged arc furnace;

[0009] When the ore-fired furnace is a DC ore-fired furnace, the auxiliary distributed control subsystem is a Ret-DCS rectifier distributed control subsystem, which is used for collecting and controlling the signal of the rectifier device that rectifies the AC power supply into a DC power supply output;

[0010] When the ore-fired furnace is a closed ore-fired furnace, the auxiliary distributed control subsystem is a Pur-DCS purification distributed control subsystem, which is used to collect and control the signal of the purification recovery equipment for the CO generated by the closed ore-fired furnace;

[0011] The Fur-DCS furnace main distributed control subsystem is used to collect and control the signals of the submerged arc furnace main equipment;

[0012] When the submerged arc furnace is a semi-closed submerged arc furnace, the SIS control subsystem collects the material level of the silo, the furnace bottom temperature, the furnace wall temperature, and the flue gas temperature, and the SIS control subsystem controls the direct discharge flue safety valve and the electric furnace transformer disconnection;

[0013] When the ore-fired furnace is a DC ore-fired furnace or a closed ore-fired furnace, the SIS control subsystem collects furnace pressure, silo material level, H2 content, and O2 content, and the SIS control subsystem controls the waste gas release flue safety valve and the electric furnace transformer disconnection;

[0014] The GDS control subsystem completes on-site flammable gas and toxic gas leakage concentration detection, indication, alarm and interlocking workshop exhaust fan start and stop.

[0015] Furthermore, the Ded-DCS flue gas dust removal distributed control subsystem includes: an engineer and operator station Aux-PC Ded-PC, a terminal bus switch T-Switch1A, a terminal bus switch T-Switch1B, a flue gas dust removal control Ded-DCS-CPU, a first flue gas dust removal control substation SCR, a second flue gas dust removal control substation SCR, and a frequency converter; wherein the flue gas dust removal control Ded-DCS-CPU terminal bus Tnet uses A and B dual network redundancy, which are respectively connected to the terminal bus switch T-Switch1A and the terminal bus switch T-Switch1B, and the engineer and operator station Aux-PC Ded-PC is configured with dual network cards, which are respectively connected to the terminal bus switch T-Switch1A and the terminal bus switch T-Switch1B. itch1B realizes the access of A and B dual networks of Tnet; the flue gas dust removal control Ded-DCS-CPU factory bus P-BUS uses A and B dual network redundancy, and is connected to the first flue gas dust removal control substation SCR and the second flue gas dust removal control substation SCR in serial mode; the control substation SCR consists of the first SCR and the second SCR, among which the SCR mainly completes the collection of field signal temperature and pressure signals of water cooling pipes, dry sedimentation coolers, ash unloading devices, and cage-type dust collector equipment, and completes the display output of field control pneumatic valves and indicator lights; the SCR mainly completes the output of control signals of power equipment in the low-voltage distribution room and the collection of operating signals. A ProfiNet communication module is configured in the second flue gas dust removal control substation SCR to communicate with the frequency converter to adjust the driving speed of the main dust removal fan motor;

[0016] The Ret-DCS rectifier distributed control subsystem includes: an engineer and operator station Aux-PCRet-PC, a terminal bus switch T-Switch1A, a terminal bus switch T-Switch1B, a rectifier control Ret-DCS-CPU, a first rectifier distributed control substation SCR, a second rectifier distributed control substation SCR, and a frequency converter; wherein the rectifier control Ret-DCS-CPU terminal bus Tnet uses A and B dual network redundancy, which are respectively connected to the terminal bus switch T-Switch1A and the terminal bus switch T-Switch1B, and the engineer and operator station Aux-PCRet-PC is equipped with dual network cards, which are respectively connected to the terminal bus switch T-Switc h1A, terminal bus switch T-Switch1B realizes the access of A and B dual networks of Tnet; the rectifier control Ret-DCS-CPU factory bus P-BUS uses A and B dual network redundancy, and is connected to the first rectifier distributed control substation SCR and the second rectifier distributed control substation SCR in serial mode; the first rectifier distributed control substation SCR mainly completes the collection of field signal current and voltage signals of thyristors and copper busbar equipment in the rectifier cabinet; the second rectifier distributed control substation SCR mainly completes the output of control signals of rectifier cooling equipment and the collection of operation signals, and a ProfiNet communication module is configured in the second rectifier distributed control substation SCR to communicate with the frequency converter to adjust the driving speed of the cooling water pump motor;

[0017] The Pur-DCS purification distributed control subsystem includes: an engineer and operator station Aux-PC Pur-PC, a terminal bus switch T-Switch1A, a terminal bus switch T-Switch1B, a purification control Pur-DCS-CPU, a first purification distributed control substation SCR, a second purification distributed control substation SCR, and a frequency converter; wherein the purification control Pur-DCS-CPU terminal bus Tnet uses A and B dual network redundancy, which are respectively connected to the terminal bus switch T-Switch1A and the terminal bus switch T-Switch1B, and the engineer and operator station Aux-PC Pur-PC is equipped with dual network cards, which are respectively connected to the terminal bus switch T-Switch1A and the terminal bus switch T-Switch1B. B realizes the access of A and B dual networks of Tnet; the purification control Pur-DCS-CPU factory bus P-BUS uses A and B dual network redundancy, and is connected to the first purification distributed control substation SCR and the second purification distributed control substation SCR in serial mode; the first purification distributed control substation SCR mainly completes the collection of field signal temperature and pressure signals of water-cooled pipes, sedimentation coolers, enclosed buried scraper conveyors, and bag dust collectors, and completes the display output of field control pneumatic valves and indicator lights; the second purification distributed control substation SCR mainly completes the output of control signals of power equipment in the low-voltage distribution room and the collection of operating signals, and a ProfiNet communication module is configured in the second purification distributed control substation SCR to communicate with the frequency converter to realize the adjustment of the driving speed of the rough air fan and the clean air fan motor.

[0018] Further, the Fur-DCS furnace body distributed control subsystem includes: time synchronization server Tsyn-PC, engineer station ES-PC, operation station OS-PC, edge server Edge-PC, advanced control server APC-PC, standard communication server OPC-PC, terminal bus switch T-Switch2A, terminal bus switch T-Switch2B, electric furnace body control Fur-DCS host CPU, electric furnace body control Fur-DCS standby CPU, third-party controller O-PLC, plant bus switch P-Switch1A, plant bus switch P-Switch1B, control substation SCR, inverter;

[0019] The terminal bus Tnet of the furnace body control Fur-DCS host CPU and Fur-DCS backup CPU uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch2A and terminal bus switch T-Switch2B respectively; the time synchronization server Tsyn-PC, engineer station ES-PC, operation station OS-PC, edge server Edge-PC, advanced control server APC-PC, standard communication server OPC-PC equipment are equipped with dual network cards and connected to the terminal bus switch T-Switch2A and terminal bus switch T-Sw itch2B realizes the access of A and B dual networks of Tnet; the electric furnace body control Fur-DCS host CPU and the electric furnace body control Fur-DCS backup CPU factory bus P-BUS use A and B dual network redundancy, which are connected to the control substation SCR in serial mode to form a double closed loop connection to enhance the stability of the system; the third-party controller O-PLC is connected to the factory bus switches P-Switch1A and P-Switch1B in dual network mode; the control substation SCR is divided into the furnace top batching control substation, circulating water control substation, electric furnace transformer control substation, furnace bottom control substation, low voltage distribution substation The electric room control substation; the circulating water control substation completes the signal collection of temperature, pressure and flow of the water distributor, water collector and cooling branch of the ore-heating furnace. Because the ore-heating furnace body is equipped with more than 100 water temperature detection points, the CANWeb fieldbus network module is selected to poll and detect more than 100 temperatures on site. An 8-channel temperature detection CANWeb substation module is set for every 8 temperature detection points, and a CANWeb master station module with a ModbusTCP interface is set to realize real-time communication with the ModbusTCP communication module configured in the main system control substation. The CANWeb substation module also controls the branch water The pneumatic stop valve that cuts off the flow; the electric furnace transformer control substation completes the collection of electrical parameters of the smelting furnace transformer and non-electrical signals such as oil temperature, oil level, and gas alarm, and completes the gear adjustment control of the transformer on-load voltage regulator; the under-furnace control substation completes the collection of furnace door opening and closing, furnace pressure, flue temperature, and furnace discharge equipment signals and the control of solenoid valves; the low-voltage distribution room control substation completes the signal collection and output control of the belt conveyor, vibrating feeder, furnace bottom fan, airtight fan, and hydraulic power pump power circuit, and a ProfiNet communication module is configured in the low-voltage distribution room control substation to communicate with the second inverter to realize the adjustment of the motor drive speed.

[0020] Furthermore, when the ore-fired furnace is a semi-enclosed ore-fired furnace, the batching control substation on the furnace top completes the collection of kiln top transfer belt conveyor, furnace top buffer bin material level, furnace top silo weighing, furnace door lifting signal and the control of the pneumatic discharge valve solenoid valve;

[0021] When the ore-bearing furnace is a direct current ore-bearing furnace or a closed ore-bearing furnace, the batching control substation on the furnace top completes the collection of the kiln top transfer belt conveyor, the material level of the furnace top buffer bin, the weighing signal of the furnace top silo and the control of the pneumatic discharge valve solenoid valve.

[0022] Furthermore, the SIS control subsystem includes: an engineer and operator station Aux-PCSIS-PC, a terminal bus switch T-Switch3A, a terminal bus switch T-Switch3B, a safety control SIS-CPU, and a control substation SCR; wherein the safety control SIS-CPU terminal bus Tnet uses A and B dual network redundancy, which are respectively connected to the terminal bus switch T-Switch3A and the terminal bus switch T-Switch3B, and the engineer and operator station Aux-PCSIS-PC is configured with dual network cards, which are respectively connected to the terminal bus switch T-Switch3A and the terminal bus switch T-Switch3B. The end bus switch T-Switch3B realizes the access of the A and B dual networks of Tnet; the safety control SIS-CPU factory bus P-BUS uses the A and B dual network redundancy and is connected to the control substation SCR in serial mode; the SIS control subsystem is a safety system independent of the DCS control subsystem used to ensure safe production, and its safety level is higher than that of the DCS automation control subsystem. When an abnormality occurs in the automated production system, the SIS will automatically protect it according to the pre-set safety function specifications; a microwave switch is set for the low material level in the silo, and the microwave switch is used as the SIS system signal. The radar level meter enters the DCS system as a control signal.

[0023] Furthermore, when the submerged arc furnace is a semi-enclosed submerged arc furnace, the furnace bottom temperature, furnace wall temperature, and flue gas temperature are too high, and the interlocked direct discharge flue safety valve is opened; according to the accident logic, the upper switch cabinet of the interlocked electric furnace transformer is tripped;

[0024] When the ore-fired furnace is a DC ore-fired furnace or a closed ore-fired furnace, the high furnace pressure interlocking waste gas discharge flue safety valve opens; the high H2 content and O2 content interlocking electric furnace rectifier transformer upper switch cabinet trips.

[0025] Furthermore, the GDS control subsystem includes an engineer and operator station Aux-PCGDS-PC, a terminal bus switch T-Switch4A, a terminal bus switch T-Switch4B, a gas monitoring GDS-CPU, and a control substation SCR; wherein the gas monitoring GDS-CPU terminal bus Tnet uses A and B dual network redundancy, and is respectively connected to the terminal bus switch T-Switch4A and the terminal bus switch T-Switch4B, and the engineer and operator station Aux-PCGDS-PC is configured with dual network cards, which are respectively connected to the terminal bus switch T-Switch4A and the terminal bus switch T-Switch4B to realize the access of the A and B dual networks of Tnet; the gas monitoring GDS-CPU factory bus P-BUS uses A and B dual network redundancy, and is serially connected to the control substation SCR.

[0026] Furthermore, the auxiliary distributed control subsystem, the Fur-DCS furnace body distributed control subsystem, the SIS control subsystem and the GDS control subsystem are all provided with a terminal bus redundant switch T-Switch;

[0027] The terminal bus redundant switch T-Switch includes terminal bus switches T-Switch1A, T-Switch2A, T-Switch3A, T-Switch4A connected one by one in serial manner and terminal bus switches T-Switch1B, T-Switch2B, T-Switch3B, T-Switch4B connected one by one in serial manner.

[0028] Compared with the prior art, the present invention has the following advantages:

[0029] 1. The comprehensive intelligent control system of the ore-fired furnace provided by the present invention eliminates the "islands" in the control system through redundant network interconnection of the four major systems: the auxiliary distributed control subsystem, the Fur-DCS furnace body distributed control subsystem, the SIS control subsystem and the GDS control subsystem, and realizes network data intercommunication, providing stable and reliable support for the automation and intelligence of the entire production.

[0030] 2. The four major systems, namely the auxiliary distributed control subsystem, Fur-DCS furnace main distributed control subsystem, SIS control subsystem and GDS control subsystem, are equipped with their own independent terminal bus switches and factory bus switch devices, so that each system has its own network processing capability. When a switch fails, it will not affect the normal operation of other systems, providing software and hardware support for the use of a safe fault-tolerant working mechanism.

[0031] 3. Compared with the current situation of scattered data, inability to manage in a unified manner, lack of effective mining of data value, and obvious "islands" of independent system data, it provides a network interconnection foundation for collaborative management, global optimization, and overall planning of data, and provides a data interface for the automatic flow of industry data and knowledge and the optimal allocation of resources.

[0032] 4. Redundant systems provide high reliability and system availability. Redundant configuration of the most important automation components reduces the possibility of production downtime and mitigates the consequences of component errors. The higher the risk and cost of production downtime, the more worthwhile it is to use redundant systems. In a redundantly operated system, the failure of individual automation components must not hinder plant operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0034] Figure 1 Schematic diagram of the system structure of the present invention.

[0035] In the figure: 101, engineer and operator station Aux-PC; 102, time synchronization server Tsyn-PC; 103, engineer station ES-PC; 104, operator station OS-PC; 105, edge server Edge-PC; 106, advanced control server APC-PC; 107, standard communication server OPC-PC; 108, engineer and operator station Aux-PCSIS-PC; 109, engineer and operator station Aux-PCGDS-PC; 111-A, terminal bus switch T-Switch1A; 111-B, terminal bus switch T-Swit ch1B; 112-A, terminal bus switch T-Switch2A; 112-B, terminal bus switch T-Switch2B; 113-A, terminal bus switch T-Switch3A; 113-B, terminal bus switch T-Switch3B; 114-A, terminal bus switch T-Switch4A; 114-B, terminal bus switch T-Switch4B; 201, auxiliary control Aux-DCS-CPU; 202, electric furnace body control Fur-DCS host CPU; 203, electric furnace body control Fur-DCS standby C PU; 204, third-party controller O-PLC; 205, safety control SIS-CPU; 206, gas monitoring GDS-CPU; 300-A, plant bus switch P-Switch1A; 300-B, plant bus switch P-Switch1B; 301-1, first flue gas dust removal control substation SCR; 301-2, second flue gas dust removal control substation SCR; 301-3, first rectifier distributed control substation SCR; 301-4, second rectifier distributed control substation SCR; 301-5, first purification distributed control substation SCR; 301-6, second purification distributed control 302-1, batching control substation on the furnace top; 302-2, circulating water control substation; 302-3, electric furnace transformer control substation; 302-4, furnace control substation; 302-5, low voltage distribution room control substation; 303, third control substation SCR; 304, fourth control substation SCR; 310, ProfiNet communication module; 311, first inverter; 312, ModbusTCP communication module; 313, CANWeb master station module; 314, CANWeb substation module; 315, ProfiNet communication module; 316, second inverter; DETAILED DESCRIPTION

[0036] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0037] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0038] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0039] Unless otherwise specifically stated, the relative arrangement of the parts and steps described in these embodiments, the numerical expressions and numerical values ​​do not limit the scope of the present invention. At the same time, it should be clear that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The technology, methods and equipment known to ordinary technicians in the relevant field may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be regarded as part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0040] In the description of the present invention, it is necessary to understand that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "lateral, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention: the directional words "inside and outside" refer to the inside and outside relative to the contours of each component itself.

[0041] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below their position devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0042] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. If not otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0043] In the present invention, the ore-blast furnace is one of a semi-closed ore-blast furnace, a DC ore-blast furnace or a closed ore-blast furnace. The main structures of the three ore-blast furnaces are similar. The semi-closed ore-blast furnace and the closed ore-blast furnace are powered by AC. The semi-closed ore-blast furnace has a liftable furnace door. During normal production, the CO generated reacts with the O2 in the air through combustion, and the generated CO2 and air enter the flue gas dust removal system together. The closed ore-blast furnace uses a furnace cover to cover the furnace chamber and seal it. During normal production, no air enters, and the generated CO directly enters the purification system. The DC ore-blast furnace includes the above two types of furnaces, which are different from the AC ore-blast furnace power supply scheme. The most important feature is that a rectifier system is used to convert AC into DC to provide power for smelting in the ore-blast furnace.

[0044] Example 1

[0045] The present invention provides a comprehensive intelligent control system for semi-closed submerged arc furnaces. Figure 1 As shown in the figure, the hardware network architecture diagram taking a semi-closed submerged arc furnace as an example mainly includes four major control subsystems: Ded-DCS flue gas dust removal, Fur-DCS furnace body, SIS, and GDS.

[0046] The Ded-DCS flue gas dust removal distributed control subsystem is used to collect and control the signals of the flue gas dust removal and recovery equipment for the high-temperature flue gas generated by the semi-closed ore-fired furnace, including: engineer and operator station Aux-PCDed-PC101, terminal bus switch T-Switch1A111-A, terminal bus switch T-Switch1B111-B, flue gas dust removal control Ded-DCS-CPU201, the first flue gas dust removal control substation SCR301-1, the second flue gas dust removal control substation SCR301-2, and the first inverter 311. The terminal bus Tnet of the flue gas dust removal control Ded-DCS-CPU201 uses A and B dual network redundancy, and is connected to the terminal bus switch T-Switch1A111-A and the terminal bus switch T-Switch1B111-B respectively. The engineer and operation station Aux-PCDed-PC101 is equipped with dual network cards and is connected to the terminal bus switch T-Switch1A111-A and the terminal bus switch T-Switch1B111-B respectively to realize the access of the A and B dual networks of Tnet; the factory bus P-BUS of the flue gas dust removal control Ded-DCS-CPU201 uses A and B dual network redundancy, and is connected to the first flue gas dust removal control substation SCR301-1 and the second flue gas dust removal control substation SCR301-2 in serial mode. The first flue gas dust removal control substation SCR301-1 is mainly used to collect on-site temperature, pressure and other signals of water-cooled pipes, dry sedimentation coolers, ash unloading devices, cage-type dust collectors and other equipment, and to control the display output of pneumatic valves and indicator lights on site; the second flue gas dust removal control substation SCR301-2 is mainly used to output control signals of power equipment in the low-voltage distribution room and collect operating signals. A ProfiNet communication module 310 is configured in this substation to communicate with the first frequency converter 311 to adjust the driving speed of the main dust removal fan motor.

[0047] The Fur-DCS furnace body distributed control subsystem is used to realize the acquisition and control of the signals of the semi-closed ore-fired furnace body equipment, including: time synchronization server Tsyn-PC102, engineer station ES-PC103, operation station OS-PC104, edge server Edge-PC105, advanced control server APC-PC106, standard communication server OPC-PC107, terminal bus switch T-Switch2A112-A, terminal bus switch T-Switch2B112-B, electric furnace body control Fur-DCS host CPU202, electric furnace body control Fur-DCS backup CPU203, third-party controller O-PLC204, plant bus switch P-Switch1A300-A, plant bus switch P-Switch1B300-B, control substation SCR302, and inverter 316. The terminal bus Tnet of the furnace body control Fur-DCS host CPU202 and Fur-DCS backup CPU203 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch2A112-A and terminal bus switch T-Switch2B112-B respectively. The time synchronization server Tsyn-PC102, engineer station ES-PC103, operation station OS-PC104, edge server Edge-PC105, advanced control server APC-PC106, and standard communication server OPC-PC107 are equipped with dual network cards and are connected to the terminal bus switch T-Switch2A112-A and T-Switch2B112-B respectively. 112-A, terminal bus switch T-Switch2B112-B realizes the access of A and B dual networks of Tnet; the electric furnace body control Fur-DCS host CPU202, the electric furnace body control Fur-DCS standby CPU203 factory bus P-BUS uses A and B dual network redundancy, and is connected to the first flue gas dust removal control substation SCR301-1 and the second flue gas dust removal control substation SCR301-2 in serial mode to form a double closed loop connection to enhance the stability of the system, and the third-party controller O-PLC104 is connected to the factory bus switch P-Switch1A300-A and P-Switch1B300-B in dual network mode. The control substation SCR302 is divided into the furnace top batching control substation 302-1, the circulating water control substation 302-2, the electric furnace transformer control substation 302-3, the furnace bottom control substation 302-4, and the low-voltage distribution room control substation 302-5.The batching control substation 302-1 on the furnace top completes the acquisition of signals such as the kiln top transfer belt conveyor, the material level of the furnace top buffer bin, the weighing of the furnace top silo, the lifting of the furnace door, and the control of the pneumatic unloading valve solenoid valve; the circulating water control substation 302-2 completes the temperature, pressure, and flow signal acquisition of the water distributor, water collector, and cooling branch of the ore-heating furnace. Because the ore-heating furnace body is equipped with more than 100 water temperature detections, the CANWeb field bus network module is selected to poll more than 100 temperatures on site. An 8-channel temperature detection CANWeb substation module 314 is set for every 8 temperature detection points, and a CANWeb master station module 313 with a ModbusTCP interface is set to realize real-time communication with the ModbusTCP communication module 312 configured in the main system control substation. Such a configuration can save the main system control substation. The number of AI modules configured in the station and the data communication rate are greatly improved, and the project cost is also greatly reduced. The station also controls the pneumatic stop valve used to cut off the branch water flow; the electric furnace transformer control substation 302-3 completes the collection of electrical parameters of the smelting electric furnace transformer and non-electrical signals such as oil temperature, oil level, and gas alarm, and completes the gear adjustment control of the transformer on-load voltage regulator; the furnace control substation 302-4 completes the collection of signals such as furnace door opening and closing, furnace pressure, flue temperature, and furnace discharge equipment, and the control of solenoid valves; the low-voltage distribution room control substation 302-5 completes the signal collection and output control of power circuits such as belt conveyors, vibrating feeders, furnace bottom fans, airtight fans, and hydraulic power pumps. A ProfiNet communication module 315 is configured in this substation to communicate with the frequency converter VVVF316 to realize the adjustment of the motor drive speed.

[0048] SIS control subsystem, safety instrument system, is generally designed according to the content of HAZOP hazard and operability analysis report. The analysis results generally include silo material level, furnace bottom temperature, furnace wall temperature, flue gas temperature, etc. The system completes the collection of the above signals and the control of direct discharge flue safety valve and electric furnace transformer disconnection, including: engineer and operator station Aux-PCSIS-PC108, terminal bus switch T-Switch3A113-A, terminal bus switch T-Switch3B113-B, safety control SIS-CPU205, control substation SCR303. The terminal bus Tnet of the safety control SIS-CPU205 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch3A113-A and the terminal bus switch T-Switch3B113-B respectively. The engineer and operator station Aux-PCSIS-PC108 is equipped with dual network cards and connected to the terminal bus switch T-Switch3A113-A and the terminal bus switch T-Switch3B113-B respectively to realize the access of the A and B dual networks of Tnet; the factory bus P-BUS of the safety control SIS-CPU205 uses A and B dual network redundancy and is connected to the control substation SCR303 in serial mode. The SIS control subsystem is a safety system independent of the DCS control subsystem used to ensure safe production. The safety level is higher than that of the DCS automation control subsystem. When the automation production system is abnormal, the SIS will automatically protect according to the pre-set safety function specifications to reduce the possibility of accidents. A microwave switch is set for low material level in the silo. The microwave switch serves as the SIS system signal, and the radar level meter enters the DCS system as a control signal. The direct exhaust flue valve adopts SIL certified products. When the furnace bottom temperature, furnace wall temperature and flue gas temperature are too high, the interlocked direct exhaust flue safety valve will open; according to the accident logic, the upper switch cabinet of the interlocked electric furnace transformer will trip.

[0049] GDS control subsystem, combustible gas and toxic gas detection and alarm system, completes on-site combustible gas such as acetylene, methane, etc., toxic gas such as carbon monoxide leakage concentration detection, indication, alarm and interlocking workshop exhaust fan start and stop, including: engineer and operation station Aux-PCGDS-PC109, terminal bus switch T-Switch4A114-A, terminal bus switch T-Switch4B114-B, gas monitoring GDS-CPU206, control substation SCR304. The terminal bus Tnet of the gas monitoring GDS-CPU206 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch4A114-A and the terminal bus switch T-Switch4B114-B respectively. The engineer and operation station Aux-PCGDS-PC109 is equipped with dual network cards and connected to the terminal bus switch T-Switch4A114-A and the terminal bus switch T-Switch4B114-B respectively to realize the access of the A and B dual networks of Tnet; the gas monitoring GDS-CPU206 factory bus P-BUS uses A and B dual network redundancy and is connected to the control substation SCR304 in serial mode.

[0050] The four major control subsystems, namely the auxiliary distributed control subsystem, Fur-DCS furnace body, SIS, and GDS, are all equipped with the terminal bus redundant switch T-Switch of this system, which can independently process the data of this system. Such configuration enhances the stability of the entire system. Data from different system switches are only transmitted when data needs to be exchanged between systems. Terminal bus switches T-Switch1A111-A, T-Switch2A112-A, T-Switch3A113-A, and T-Switch4A114-A are connected one by one in serial mode; terminal bus switches T-Switch1B111-B, T-Switch2B112-B, T-Switch3B113-B, and T-Switch4B114-B are connected one by one in serial mode. The switch is modularly designed and rack-mounted. It also supports 24VDC redundant power supply; supports hot swapping under power; supports self-diagnosis, positioning, and alarm of communication faults; supports automatic configuration of adapter fast fault recovery technology for easy online maintenance.

[0051] The controllers of flue gas dust removal control Ded-DCS-CPU201, electric furnace body control Fur-DCS host CPU202, electric furnace body control Fur-DCS standby CPU203, safety control SIS-CPU205, and gas monitoring GDS-CPU206 have power-off protection function. The batteries equipped ensure that the configuration data and process data in the controller will not be lost for a period of time after the controller loses power. The CPU is the core component of the control station to perform control tasks. According to the configurable control strategy required by the ore-fired furnace process, it can control the field objects in real time, realize various types of loop control tasks such as continuous control, sequential control, and logical control, and can realize data acquisition, calculation output, fault detection and alarm, information transmission and other functions. The collected field information is exchanged with three PCs to complete the basic control of the industrial kiln production process equipment.

[0052] The time synchronization server Tsyn-PC102 is an important device used to ensure the time synchronization of each device in the computer network. All PCs and CPUs in the system must unconditionally keep the clock synchronized with the time synchronization server Tsyn-PC102 to ensure the normal operation of network communication.

[0053] The engineer station PC ES-PC103 and the PC that also serves as the engineer station are used as the maintenance platform for system configuration and programming. The engineer station can be used for project configuration, configuration release, configuration network synchronization, configuration backup and restoration. The engineer station is configured with a hard disk mirror to enhance the security of configuration data.

[0054] The operating station PC OS-PC104 and the PC that also serves as the operator station are the human-machine interfaces for operators to monitor and control the production process, maintain equipment and handle accidents, and centrally operate and monitor the production process. The operator station directly obtains real-time data from the control station and dynamically displays real-time / historical data in the form of flow charts, trend charts, etc. The operator sends operation commands to the control station through the operation terminals such as the mouse and keyboard connected to the operating station.

[0055] The edge server Edge-PC105 is a local server deployed in the control subsystem, which is used for big data analysis feature calculation and extraction, data dimension reduction and denoising calculation, analysis and classification learning, generation and optimization of intelligent early warning models, and storage. The result information data interacts with the CPU and OS-PC on the terminal control network Tnet in real time to achieve the purpose of intelligent computing. Data edge computing is performed in the edge server Edge-PC105, which is an open system composed of hardware and software. It can flexibly execute packaged applications based on high-level languages; intuitive integrated factory functions are used for automated collection, processing and exchange of data, and intelligent use of data is realized on the basis of the factory. Based on open industrial Ethernet communication, it is compatible with a variety of Ethernet communication protocols, supports TCP, UDP, ISO-On-TCP, I-Device, S7-Routing communication protocols, and supports SNMP, Web, FTP, NTP and other IT communication services.

[0056] The advanced control server APC-PC106 is used for the advanced control and optimization of electric furnaces, including electrode lifting control, automatic adjustment control of furnace gear shifting, optimization control for increasing production and reducing consumption, design and implementation of soft instruments, mathematical model construction of electric furnace objects, decoupling of multiple control objects and coordinated control design. Based on the underlying data platform, the comprehensive application of data is realized, including but not limited to real-time data browsing and analysis, historical data browsing and analysis, comprehensive analysis of process data, on-site manual data collection, automatic generation of process reports, etc.

[0057] The standard communication server OPC-PC107 provides standard OPC communication interface and Ethernet interface, and uses OPC protocol to exchange data with other systems or upload data to the owner's superior management system.

[0058] The third-party controller O-PLC204 completes the signal collection and control of the auxiliary system equipment of the semi-closed ore-fired furnace, such as the environmental dust removal system, circulating water, air compression station, furnace front discharge equipment, etc., and uses Ethernet communication to exchange data with the electric furnace body control Fur-DCS host CPU202 and the electric furnace body control Fur-DCS backup CPU203.

[0059] The power supply system provides two power supplies (one UPS and one mains) for DCS, SIS, and GDS, both of which are 220VAC 50Hz AC power supplies. Lay the power cable to the control subsystem power distribution cabinet, and complete the laying and wiring of the power cables from the power distribution cabinet to each system cabinet, operating table, and operating station. The 220VAC and 24VDC power supplies of the control cabinet are arranged separately and configured as dual circuits. The system 24VDC power cabinet uses a switching power supply with short-circuit protection. The system power supply and the field instrument power supply are independent of each other and are not mixed. Controller CPU, I / O template, power supply, communication network, Ethernet switch, cabinet, etc. The system network uses redundant and fault-tolerant Ethernet. The failure of a single device or hardware should not affect the safe and normal operation of the entire system. When a line failure is detected, the control subsystem network will automatically switch to the backup channel to ensure the safe and stable operation of the device. Under no circumstances should the process device be in a "blind operation" state that cannot be monitored by the operator due to a network failure.

[0060] DCS, SIS, and GDS are based on an "open" system architecture. The system itself should have hardware equipment that can achieve integration and information exchange with system equipment and platforms of other brands through industrial standard communications, platforms, and protocols. The protocols include HART, Modbus RTU, Modbus TCP, TCP / IP, Profinet, OPC_DA, and OPC_UA, as well as authorizations for the above protocols. Communication cards should be used to communicate with third-party PLCs or heterogeneous devices on site. The communication protocol should be Modbus RTU or Modbus TCP / IP. For heterogeneous devices using the Modbus RTU communication protocol, the third party shall provide the communication address list, verification type, communication rate, and other information. The supplier is responsible for uploading and debugging heterogeneous device communications.

[0061] DCS, SIS, and GDS have certain scalability, including the processing capacity of the control station, power load, communication load, server load, and operation load of the operation station and engineer station, etc. When the control station is running at full load, the system's power supply, software, communication load, and other various loads do not exceed 60%.

[0062] The control subsystem should be able to communicate with other digital electronic devices to obtain status information, measurement values ​​and alarms, and send control instructions. In principle, the communication between the control subsystem and third-party equipment should be completed at the lower layer; DCS, SIS, and GDS are redundant industrial Ethernets, and the communication system provides reliable high-speed data transmission for control stations, operation stations, engineer stations, etc. The transmission rate should not be less than 100Mb / s. The I / O bus connected by P-BUS is a redundant Ethernet, and the transmission rate should not be less than 100Mb / s.

[0063] The redundant control subsystem has excellent control performance: high availability of production and maintenance to avoid shutdowns; avoid unplanned production interruptions, which may cause damage to products in production; reduce maintenance costs; prevent data loss, maintain data integrity, and reduce long waits for restart after failure; unattended, maintenance plans can be better planned. Fully redundant Ethernet supports multiple network structures such as direct connection, star, and ring networks. It can automatically switch redundant data communication systems. The switching time should not be greater than 1S, and a system diagnostic alarm will be generated. No data is lost during switching. Explain the fault detection method and switching method. The control network should support data exchange for all devices connected to the network. It adopts a standard, open local area network structure, is compatible with various models, and supports TCP / IP protocol.

[0064] The flat network structure design isolates the terminal bus Tnet and the factory control network P-BUS on different network segments, ensuring the stability of system data transmission; the use of fully digital real-time Ethernet technology ensures high data consistency.

[0065] Example 2

[0066] The present invention provides a comprehensive intelligent control system for a DC ore-fired furnace. The actual physical connection is as follows: Figure 1 As shown in the figure, the hardware network architecture diagram taking the DC type ore-fired furnace as an example mainly includes four major control subsystems: Ret-DCS rectifier, Fur-DCS furnace body, SIS, and GDS.

[0067] Ret-DCS rectifier distributed control subsystem is used for signal collection and control of the rectifier device that rectifies AC power into DC power output, including: engineer and operator station Aux-PCRet-PC101, terminal bus switch T-Switch1A111-A, terminal bus switch T-Switch1B111-B, rectifier control Ret-DCS-CPU201, first rectifier distributed control substation SCR301-3, second rectifier distributed control substation SCR301-4, and first inverter 311. The rectifier control Ret-DCS-CPU201 terminal bus Tnet uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch1A111-A and the terminal bus switch T-Switch1B111-B respectively. The engineer and operation station Aux-PCRet-PC101 is equipped with dual network cards and connected to the terminal bus switch T-Switch1A111-A and the terminal bus switch T-Switch1B111-B respectively to realize the access of the A and B dual networks of Tnet; the rectifier control Ret-DCS-CPU201 plant bus P-BUS uses A and B dual network redundancy, and is connected to the first rectifier distributed control substation SCR301-3 and the second rectifier distributed control substation SCR301-4 in serial mode. The first rectifier distributed control substation SCR301-3 is mainly used to collect the field signal current, voltage and other signals of the thyristors, copper busbars and other equipment in the rectifier cabinet; the second rectifier distributed control substation SCR301-4 is mainly used to output the control signals of the rectifier cooling equipment and collect the operation signals. A ProfiNet communication module 310 is configured in this substation to communicate with the first frequency converter 311 to adjust the driving speed of the cooling water pump motor.

[0068] The Fur-DCS furnace body distributed control subsystem is used to realize the acquisition and control of the DC ore-fired furnace body equipment signals, including: time synchronization server Tsyn-PC102, engineer station ES-PC103, operation station OS-PC104, edge server Edge-PC105, advanced control server APC-PC106, standard communication server OPC-PC107, terminal bus switch T-Switch2A112-A, terminal bus switch T-Switch2B112-B, electric furnace body control Fur-DCS host CPU202, electric furnace body control Fur-DCS backup CPU203, third-party controller O-PLC204, plant bus switch P-Switch1A300-A, plant bus switch P-Switch1B300-B, control substation SCR302, and inverter 316. The terminal bus Tnet of the furnace body control Fur-DCS host CPU202 and Fur-DCS backup CPU203 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch2A112-A and terminal bus switch T-Switch2B112-B respectively. The time synchronization server Tsyn-PC102, engineer station ES-PC103, operation station OS-PC104, edge server Edge-PC105, advanced control server APC-PC106, and standard communication server OPC-PC107 are equipped with dual network cards and are connected to the terminal bus switch T-Switch2A112-A and T-Switch2B112-B respectively. 112-A, terminal bus switch T-Switch2B112-B realizes the access of A and B dual networks of Tnet; the electric furnace body control Fur-DCS host CPU202, the electric furnace body control Fur-DCS backup CPU203 factory bus P-BUS uses A and B dual network redundancy, and is connected to the first rectifier distributed control substation SCR301-3 and the second rectifier distributed control substation SCR301-4 in serial mode to form a double closed loop connection to enhance the stability of the system, and the third-party controller O-PLC104 is connected to the factory bus switch P-Switch1A300-A and P-Switch1B300-B in dual network mode. The control substation SCR302 is divided into the furnace top batching control substation 302-1, the circulating water control substation 302-2, the electric furnace rectifier transformer control substation 302-3, the furnace bottom control substation 302-4, and the low-voltage distribution room control substation 302-5.The batching control substation 302-1 on the furnace top completes the acquisition of signals such as the kiln top transfer belt conveyor, the material level of the furnace top buffer bin, the weighing of the furnace top silo, and the control of the pneumatic discharge valve solenoid valve; the circulating water control substation 302-2 completes the temperature, pressure, and flow signal acquisition of the DC ore-heating furnace water distributor, water collector, and cooling branch. Because the ore-heating furnace body is equipped with more than 100 water temperature detections, the CANWeb field bus network module is selected to poll more than 100 temperatures on site. An 8-channel temperature detection CANWeb substation module 314 is set for every 8 temperature detection points, and a CANWeb master station module 313 with a ModbusTCP interface is set to realize real-time communication with the ModbusTCP communication module 312 configured in the main system control substation. Such a configuration can save the main system control substation A The number of I modules configured and the data communication rate are greatly improved, and the project cost is also greatly reduced. The station also controls the pneumatic stop valve used to cut off the branch water flow; the electric furnace rectifier transformer control substation 302-3 completes the collection of electrical parameters of the rectifier transformer and non-electrical signals such as oil temperature, oil level, and gas alarm, and completes the gear adjustment control of the transformer on-load voltage regulator; the furnace control substation 302-4 completes the collection of signals such as furnace door opening and closing, furnace pressure, flue temperature, and furnace discharge equipment, and the control of solenoid valves; the low-voltage distribution room control substation 302-5 completes the signal collection and output control of power circuits such as belt conveyors, vibrating feeders, furnace bottom fans, airtight fans, and hydraulic power pumps. A ProfiNet communication module 315 is configured in this substation to communicate with the frequency converter VVVF316 to achieve the adjustment of the motor drive speed.

[0069] SIS control subsystem, safety instrument system, is generally designed according to the content of HAZOP hazard and operability analysis report. The analysis results generally include furnace pressure, silo level, H2 content, O2 content, etc. The system completes the collection of the above signals and the control of the waste gas venting flue safety valve and the electric furnace transformer disconnection, including: engineer and operator station Aux-PCSIS-PC108, terminal bus switch T-Switch3A113-A, terminal bus switch T-Switch3B113-B, safety control SIS-CPU205, control substation SCR303. The terminal bus Tnet of the safety control SIS-CPU205 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch3A113-A and the terminal bus switch T-Switch3B113-B respectively. The engineer and operator station Aux-PCSIS-PC108 is equipped with dual network cards and connected to the terminal bus switch T-Switch3A113-A and the terminal bus switch T-Switch3B113-B respectively to realize the access of the A and B dual networks of Tnet; the factory bus P-BUS of the safety control SIS-CPU205 uses A and B dual network redundancy and is connected to the control substation SCR303 in serial mode. The SIS control subsystem is a safety system independent of the DCS control subsystem used to ensure safe production. The safety level is higher than that of the DCS automation control subsystem. When the automation production system is abnormal, the SIS will automatically protect according to the pre-set safety function specifications to reduce the possibility of accidents. A microwave switch is set for low material level in the silo. The microwave switch serves as the SIS system signal, and the radar level meter enters the DCS system as a control signal. The waste gas flue valve adopts SIL-certified products. The waste gas discharge flue safety valve will be opened when the furnace pressure is high; the upper switch cabinet of the electric furnace rectifier transformer will be tripped when the H2 content and O2 content are high.

[0070] GDS control subsystem, combustible gas and toxic gas detection and alarm system, completes on-site combustible gas acetylene, methane, etc., toxic gas carbon monoxide leakage concentration detection, indication, alarm and interlocking workshop exhaust fan start and stop, including: engineer and operation station Aux-PCGDS-PC109, terminal bus switch T-Switch4A114-A, terminal bus switch T-Switch4B114-B, gas monitoring GDS-CPU206, control substation SCR304. The terminal bus Tnet of the gas monitoring GDS-CPU206 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch4A114-A and the terminal bus switch T-Switch4B114-B respectively. The engineer and operation station Aux-PCGDS-PC109 is equipped with dual network cards and connected to the terminal bus switch T-Switch4A114-A and the terminal bus switch T-Switch4B114-B respectively to realize the access of the A and B dual networks of Tnet; the gas monitoring GDS-CPU206 factory bus P-BUS uses A and B dual network redundancy and is connected to the control substation SCR304 in serial mode.

[0071] The four major control subsystems, Ret-DCS rectifier, Fur-DCS furnace body, SIS, and GDS, are all equipped with the terminal bus redundant switch T-Switch of this system, which can independently process the data of this system. Such configuration enhances the stability of the entire system. Data from different system switches are only transmitted when data needs to be exchanged between systems. Terminal bus switches T-Switch1A111-A, T-Switch2A112-A, T-Switch3A113-A, and T-Switch4A114-A are connected one by one in serial mode; terminal bus switches T-Switch1B111-B, T-Switch2B112-B, T-Switch3B113-B, and T-Switch4B114-B are connected one by one in serial mode. The switch is modularly designed and rack-mounted. It also supports 24VDC redundant power supply; supports hot swapping under power; supports self-diagnosis, positioning, and alarm of communication faults; supports automatic configuration of adapter fast fault recovery technology for easy online maintenance.

[0072] The controllers of rectifier control Ret-DCS-CPU201, furnace body control Fur-DCS host CPU202, furnace body control Fur-DCS standby CPU203, safety control SIS-CPU205, and gas monitoring GDS-CPU206 have power-off protection function. The batteries are equipped to ensure that the configuration data and process data in the controller will not be lost for a period of time after the controller loses power. The CPU is the core component of the control station to perform control tasks. According to the configurable control strategy required by the ore-fired furnace process, it can control the field objects in real time, realize various types of loop control tasks such as continuous control, sequential control, and logical control, and can realize data acquisition, calculation output, fault detection and alarm, information transmission and other functions. The collected field information is exchanged with three PCs to complete the basic control of the industrial kiln production process equipment.

[0073] The time synchronization server Tsyn-PC102 is an important device used to ensure the time synchronization of each device in the computer network. All PCs and CPUs in the system must unconditionally keep the clock synchronized with the time synchronization server Tsyn-PC102 to ensure the normal operation of network communication.

[0074] The engineer station PC ES-PC103 and the PC that also serves as the engineer station are used as the maintenance platform for system configuration and programming. The engineer station can be used for project configuration, configuration release, configuration network synchronization, configuration backup and restoration. The engineer station is configured with a hard disk mirror to enhance the security of configuration data.

[0075] The operating station PC OS-PC104 and the PC that also serves as the operator station are the human-machine interfaces for operators to monitor and control the production process, maintain equipment and handle accidents, and centrally operate and monitor the production process. The operator station directly obtains real-time data from the control station and dynamically displays real-time / historical data in the form of flow charts, trend charts, etc. The operator sends operation commands to the control station through the operation terminals such as the mouse and keyboard connected to the operating station.

[0076] The edge server Edge-PC105 is a local server deployed in the control subsystem, which is used for big data analysis feature calculation and extraction, data dimension reduction and denoising calculation, analysis and classification learning, generation and optimization of intelligent early warning models, and storage. The result information data interacts with the CPU and OS-PC on the terminal control network Tnet in real time to achieve the purpose of intelligent computing. Data edge computing is performed in the edge server Edge-PC105, which is an open system composed of hardware and software. It can flexibly execute packaged applications based on high-level languages; intuitive integrated factory functions are used for automated collection, processing and exchange of data, and intelligent use of data is realized on the basis of the factory. Based on open industrial Ethernet communication, it is compatible with a variety of Ethernet communication protocols, supports TCP, UDP, ISO-On-TCP, I-Device, S7-Routing communication protocols, and supports SNMP, Web, FTP, NTP and other IT communication services.

[0077] The advanced control server APC-PC106 is used for the advanced control and optimization of DC submerged arc furnaces, including electrode lifting control, automatic adjustment control of furnace gear change, optimization control for increasing production and reducing consumption, design and implementation of soft instruments, mathematical model construction of electric furnace objects, decoupling and coordinated control design of multiple control objects. Based on the underlying data platform, the comprehensive application of data is realized, including but not limited to real-time data browsing and analysis, historical data browsing and analysis, comprehensive analysis of process data, on-site manual data collection, automatic generation of process reports, etc.

[0078] The standard communication server OPC-PC107 provides standard OPC communication interface and Ethernet interface, and uses OPC protocol to exchange data with other systems or upload data to the owner's superior management system.

[0079] The third-party controller O-PLC204 completes the signal collection and control of auxiliary system equipment of the DC electric arc furnace, such as the environmental dust removal system, purification system, circulating water, air compression station, furnace front discharge equipment, etc., and uses Ethernet communication to exchange data with the electric furnace body control Fur-DCS host CPU202 and the electric furnace body control Fur-DCS backup CPU203.

[0080] The power supply system provides two power supplies (one UPS and one mains) for DCS, SIS, and GDS, both of which are 220VAC 50Hz AC power supplies. Lay the power cable to the control subsystem power distribution cabinet, and complete the laying and wiring of the power cables from the power distribution cabinet to each system cabinet, operating table, and operating station. The 220VAC and 24VDC power supplies of the control cabinet are arranged separately and configured as dual circuits. The system 24VDC power cabinet uses a switching power supply with short-circuit protection. The system power supply and the field instrument power supply are independent of each other and are not mixed. Controller CPU, I / O template, power supply, communication network, Ethernet switch, cabinet, etc. The system network uses redundant and fault-tolerant Ethernet. The failure of a single device or hardware should not affect the safe and normal operation of the entire system. When a line failure is detected, the control subsystem network will automatically switch to the backup channel to ensure the safe and stable operation of the device. Under no circumstances should the process device be in a "blind operation" state that cannot be monitored by the operator due to a network failure.

[0081] DCS, SIS, and GDS are based on an "open" system architecture. The system itself should have hardware equipment that can achieve integration and information exchange with system equipment and platforms of other brands through industrial standard communications, platforms, and protocols. The protocols include HART, Modbus RTU, Modbus TCP, TCP / IP, Profinet, OPC_DA, and OPC_UA, as well as authorizations for the above protocols. Communication cards should be used to communicate with third-party PLCs or heterogeneous devices on site. The communication protocol should be Modbus RTU or Modbus TCP / IP. For heterogeneous devices using the Modbus RTU communication protocol, the third party shall provide the communication address list, verification type, communication rate, and other information. The supplier is responsible for uploading and debugging heterogeneous device communications.

[0082] DCS, SIS, and GDS have certain scalability, including the processing capacity of the control station, power load, communication load, server load, and operation load of the operation station and engineer station, etc. When the control station is running at full load, the system's power supply, software, communication load, and other various loads do not exceed 60%.

[0083] The control subsystem should be able to communicate with other digital electronic devices to obtain status information, measurement values ​​and alarms, and send control instructions. In principle, the communication between the control subsystem and third-party equipment should be completed at the lower layer; DCS, SIS, and GDS are redundant industrial Ethernets, and the communication system provides reliable high-speed data transmission for control stations, operation stations, engineer stations, etc. The transmission rate should not be less than 100Mb / s. The I / O bus connected by P-BUS is a redundant Ethernet, and the transmission rate should not be less than 100Mb / s.

[0084] The redundant control subsystem has excellent control performance: high availability of production and maintenance to avoid shutdowns; avoid unplanned production interruptions, which may cause damage to products in production; reduce maintenance costs; prevent data loss, maintain data integrity, and reduce long waits for restart after failure; unattended, maintenance plans can be better planned. Fully redundant Ethernet supports multiple network structures such as direct connection, star, and ring networks. It can automatically switch redundant data communication systems. The switching time should not be greater than 1S, and a system diagnostic alarm will be generated. No data is lost during switching. Explain the fault detection method and switching method. The control network should support data exchange for all devices connected to the network. It adopts a standard, open local area network structure, is compatible with various models, and supports TCP / IP protocol.

[0085] The flat network structure design isolates the terminal bus Tnet and the factory control network P-BUS on different network segments, ensuring the stability of system data transmission; the use of fully digital real-time Ethernet technology ensures high data consistency.

[0086] Example 3

[0087] The present invention provides a comprehensive intelligent control system for a closed submerged arc furnace, the actual physical connection is as follows Figure 1 As shown in the figure, the hardware network architecture diagram of a closed submerged arc furnace is taken as an example, which mainly includes four major control subsystems: Pur-DCS purification, Fur-DCS furnace body, SIS, and GDS.

[0088] Pur-DCS purification distributed control subsystem is used to collect and control the signals of purification and recovery equipment for CO generated by closed ore-fired furnace, including: engineer and operation station Aux-PCPur-PC101, terminal bus switch T-Switch1A111-A, terminal bus switch T-Switch1B111-B, purification control Pur-DCS-CPU201, first purification distributed control substation SCR301-5, second purification distributed control substation SCR301-6, first frequency converter 311. The purification control Pur-DCS-CPU201 terminal bus Tnet uses A and B dual network redundancy, and is connected to the terminal bus switch T-Switch1A111-A and the terminal bus switch T-Switch1B111-B respectively. The engineer and operation station Aux-PCPur-PC101 is equipped with dual network cards and is connected to the terminal bus switch T-Switch1A111-A and the terminal bus switch T-Switch1B111-B respectively to realize the access of Tnet's A and B dual networks; the purification control Pur-DCS-CPU201 plant bus P-BUS uses A and B dual network redundancy, and is connected to the first purification distributed control substation SCR301-5 and the second purification distributed control substation SCR301-6 in serial mode. The first purification distributed control substation SCR301-5 is mainly used to collect the on-site temperature, pressure and other signals of water-cooled pipes, sedimentation coolers, enclosed buried scraper conveyors, bag dust collectors and other equipment, and to display and output on-site control pneumatic valves and indicator lights; the second purification distributed control substation SCR301-6 is mainly used to output the control signals of the power equipment in the low-voltage distribution room and collect the operation signals. A ProfiNet communication module 310 is configured in this substation to communicate with the first frequency converter 311 to adjust the driving speed of the rough air fan and the clean air fan motor.

[0089] The Fur-DCS furnace body distributed control subsystem is used to realize the acquisition and control of the signals of the closed ore-fired furnace body equipment, including: time synchronization server Tsyn-PC102, engineer station ES-PC103, operation station OS-PC104, edge server Edge-PC105, advanced control server APC-PC106, standard communication server OPC-PC107, terminal bus switch T-Switch2A112-A, terminal bus switch T-Switch2B112-B, electric furnace body control Fur-DCS host CPU202, electric furnace body control Fur-DCS backup CPU203, third-party controller O-PLC204, plant bus switch P-Switch1A300-A, plant bus switch P-Switch1B300-B, control substation SCR302, and inverter 316. The terminal bus Tnet of the furnace body control Fur-DCS host CPU202 and Fur-DCS backup CPU203 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch2A112-A and terminal bus switch T-Switch2B112-B respectively. The time synchronization server Tsyn-PC102, engineer station ES-PC103, operation station OS-PC104, edge server Edge-PC105, advanced control server APC-PC106, and standard communication server OPC-PC107 are equipped with dual network cards and are connected to the terminal bus switch T-Switch2A112-A and T-Switch2B112-B respectively. 112-A, terminal bus switch T-Switch2B112-B realizes the access of A and B dual networks of Tnet; the electric furnace body control Fur-DCS host CPU202, the electric furnace body control Fur-DCS backup CPU203 factory bus P-BUS uses A and B dual network redundancy, and is connected to the first purification distributed control substation SCR301-5 and the second purification distributed control substation SCR301-6 in serial mode to form a double closed loop connection to enhance the stability of the system, and the third-party controller O-PLC104 is connected to the factory bus switch P-Switch1A300-A and P-Switch1B300-B in dual network mode. The control substation SCR302 is divided into the furnace top batching control substation 302-1, the circulating water control substation 302-2, the electric furnace transformer control substation 302-3, the furnace bottom control substation 302-4, and the low-voltage distribution room control substation 302-5.The batching control substation 302-1 on the furnace top completes the acquisition of signals such as the kiln top transfer belt conveyor, the material level of the furnace top buffer bin, the weighing of the furnace top silo, and the control of the pneumatic unloading valve solenoid valve; the circulating water control substation 302-2 completes the temperature, pressure, and flow signal acquisition of the water distributor, water collector, and cooling branch of the ore-heating furnace. Because the ore-heating furnace body is equipped with more than 100 water temperature detections, the CANWeb field bus network module is selected to poll more than 100 temperatures on site. An 8-channel temperature detection CANWeb substation module 314 is set for every 8 temperature detection points, and a CANWeb master station module 313 with a ModbusTCP interface is set to realize real-time communication with the ModbusTCP communication module 312 configured in the main system control substation. Such a configuration can save the main system control substation AI The number of modules configured and the data communication rate are greatly improved, and the project cost is also greatly reduced. The station also controls the pneumatic stop valve used to cut off the branch water flow; the electric furnace transformer control substation 302-3 completes the collection of electrical parameters of the smelting electric furnace transformer and non-electrical signals such as oil temperature, oil level, and gas alarm, and completes the gear adjustment control of the transformer on-load voltage regulator; the furnace control substation 302-4 completes the collection of signals such as furnace door opening and closing, furnace pressure, flue temperature, and furnace discharge equipment, and the control of solenoid valves; the low-voltage distribution room control substation 302-5 completes the signal collection and output control of power circuits such as belt conveyors, vibrating feeders, furnace bottom fans, airtight fans, and hydraulic power pumps. A ProfiNet communication module 315 is configured in this substation to communicate with the frequency converter VVVF316 to realize the adjustment of the motor drive speed.

[0090] SIS control subsystem, safety instrument system, is generally designed according to the content of HAZOP hazard and operability analysis report. The analysis results generally include furnace pressure, silo level, H2 content, O2 content, etc. The system completes the collection of the above signals and the control of the waste gas venting flue safety valve and the electric furnace transformer disconnection, including: engineer and operator station Aux-PCSIS-PC108, terminal bus switch T-Switch3A113-A, terminal bus switch T-Switch3B113-B, safety control SIS-CPU205, control substation SCR303. The terminal bus Tnet of the safety control SIS-CPU205 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch3A113-A and the terminal bus switch T-Switch3B113-B respectively. The engineer and operator station Aux-PCSIS-PC108 is equipped with dual network cards and connected to the terminal bus switch T-Switch3A113-A and the terminal bus switch T-Switch3B113-B respectively to realize the access of the A and B dual networks of Tnet; the factory bus P-BUS of the safety control SIS-CPU205 uses A and B dual network redundancy and is connected to the control substation SCR303 in serial mode. The SIS control subsystem is a safety system independent of the DCS control subsystem used to ensure safe production. The safety level is higher than that of the DCS automation control subsystem. When the automation production system is abnormal, the SIS will automatically protect according to the pre-set safety function specifications to reduce the possibility of accidents. A microwave switch is set for low material level in the silo. The microwave switch serves as the SIS system signal, and the radar level meter enters the DCS system as a control signal. The waste gas flue valve adopts SIL-certified products. The waste gas discharge flue safety valve will be opened when the furnace pressure is high; the upper switch cabinet of the electric furnace transformer will be tripped when the H2 content and O2 content are high.

[0091] GDS control subsystem, combustible gas and toxic gas detection and alarm system, completes on-site combustible gas acetylene, methane, etc., toxic gas carbon monoxide leakage concentration detection, indication, alarm and interlocking workshop exhaust fan start and stop, including: engineer and operation station Aux-PCGDS-PC109, terminal bus switch T-Switch4A114-A, terminal bus switch T-Switch4B114-B, gas monitoring GDS-CPU206, control substation SCR304. The terminal bus Tnet of the gas monitoring GDS-CPU206 uses A and B dual network redundancy, which are connected to the terminal bus switch T-Switch4A114-A and the terminal bus switch T-Switch4B114-B respectively. The engineer and operation station Aux-PCGDS-PC109 is equipped with dual network cards and connected to the terminal bus switch T-Switch4A114-A and the terminal bus switch T-Switch4B114-B respectively to realize the access of the A and B dual networks of Tnet; the gas monitoring GDS-CPU206 factory bus P-BUS uses A and B dual network redundancy and is connected to the control substation SCR304 in serial mode.

[0092] The four major control subsystems of Pur-DCS purification, Fur-DCS furnace body, SIS, and GDS are all equipped with the terminal bus redundant switch T-Switch of this system, which can independently process the data of this system. Such configuration enhances the stability of the entire system. Data from different system switches are only transmitted when data needs to be exchanged between systems. Terminal bus switches T-Switch1A111-A, T-Switch2A112-A, T-Switch3A113-A, and T-Switch4A114-A are connected one by one in serial mode; terminal bus switches T-Switch1B111-B, T-Switch2B112-B, T-Switch3B113-B, and T-Switch4B114-B are connected one by one in serial mode. The switch is modularly designed and rack-mounted. It also supports 24VDC redundant power supply; supports hot swapping with power on; supports self-diagnosis, positioning, and alarm of communication faults; supports automatic configuration adapter fast fault recovery technology for easy online maintenance.

[0093] Purification control Pur-DCS-CPU201, furnace body control Fur-DCS host CPU202, furnace body control Fur-DCS standby CPU203, safety control SIS-CPU205, gas monitoring GDS-CPU206 controllers have power-off protection function, and the battery is equipped to ensure that the configuration data and process data in the controller will not be lost for a period of time after the controller loses power. The CPU is the core component of the control station to perform control tasks. According to the configurable control strategy required by the ore-fired furnace process, the field objects are controlled in real time to achieve various types of loop control tasks such as continuous control, sequential control, and logical control, and can also realize data acquisition, calculation output, fault detection and alarm, information transmission and other functions. The collected field information is exchanged with three PCs to complete the basic control of industrial kiln production process equipment.

[0094] The time synchronization server Tsyn-PC102 is an important device used to ensure the time synchronization of each device in the computer network. All PCs and CPUs in the system must unconditionally keep the clock synchronized with the time synchronization server Tsyn-PC102 to ensure the normal operation of network communication.

[0095] The engineer station PC ES-PC103 and the PC that also serves as the engineer station are used as the maintenance platform for system configuration and programming. The engineer station can be used for project configuration, configuration release, configuration network synchronization, configuration backup and restoration. The engineer station is configured with a hard disk mirror to enhance the security of configuration data.

[0096] The operating station PC OS-PC104 and the PC that also serves as the operator station are the human-machine interfaces for operators to monitor and control the production process, maintain equipment and handle accidents, and centrally operate and monitor the production process. The operator station directly obtains real-time data from the control station and dynamically displays real-time / historical data in the form of flow charts, trend charts, etc. The operator sends operation commands to the control station through the operation terminals such as the mouse and keyboard connected to the operating station.

[0097] The edge server Edge-PC105 is a local server deployed in the control subsystem, which is used for big data analysis feature calculation and extraction, data dimension reduction and denoising calculation, analysis and classification learning, generation and optimization of intelligent early warning models, and storage. The result information data interacts with the CPU and OS-PC on the terminal control network Tnet in real time to achieve the purpose of intelligent computing. Data edge computing is performed in the edge server Edge-PC105, which is an open system composed of hardware and software. It can flexibly execute packaged applications based on high-level languages; intuitive integrated factory functions are used for automated collection, processing and exchange of data, and intelligent use of data is realized on the basis of the factory. Based on open industrial Ethernet communication, it is compatible with a variety of Ethernet communication protocols, supports TCP, UDP, ISO-On-TCP, I-Device, S7-Routing communication protocols, and supports SNMP, Web, FTP, NTP and other IT communication services.

[0098] The advanced control server APC-PC106 is used for the advanced control and optimization of electric furnaces, including electrode lifting control, automatic adjustment control of furnace gear shifting, optimization control for increasing production and reducing consumption, design and implementation of soft instruments, mathematical model construction of electric furnace objects, decoupling of multiple control objects and coordinated control design. Based on the underlying data platform, the comprehensive application of data is realized, including but not limited to real-time data browsing and analysis, historical data browsing and analysis, comprehensive analysis of process data, on-site manual data collection, automatic generation of process reports, etc.

[0099] The standard communication server OPC-PC107 provides standard OPC communication interface and Ethernet interface, and uses OPC protocol to exchange data with other systems or upload data to the owner's superior management system.

[0100] The third-party controller O-PLC204 completes the signal collection and control of the auxiliary system equipment of the closed ore-fired furnace such as the environmental dust removal system, circulating water, air compression station, furnace front discharge equipment, etc., and uses Ethernet communication to exchange data with the electric furnace body control Fur-DCS host CPU202 and the electric furnace body control Fur-DCS backup CPU203.

[0101] The power supply system provides two power supplies (one UPS and one mains) for DCS, SIS, and GDS, both of which are 220VAC 50Hz AC power supplies. Lay the power cable to the control subsystem power distribution cabinet, and complete the laying and wiring of the power cables from the power distribution cabinet to each system cabinet, operating table, and operating station. The 220VAC and 24VDC power supplies of the control cabinet are arranged separately and configured as dual circuits. The system 24VDC power cabinet uses a switching power supply with short-circuit protection. The system power supply and the field instrument power supply are independent of each other and are not mixed. Controller CPU, I / O template, power supply, communication network, Ethernet switch, cabinet, etc. The system network uses redundant and fault-tolerant Ethernet. The failure of a single device or hardware should not affect the safe and normal operation of the entire system. When a line failure is detected, the control subsystem network will automatically switch to the backup channel to ensure the safe and stable operation of the device. Under no circumstances should the process device be in a "blind operation" state that cannot be monitored by the operator due to a network failure.

[0102] DCS, SIS, and GDS are based on an "open" system architecture. The system itself should have hardware equipment that can achieve integration and information exchange with system equipment and platforms of other brands through industrial standard communications, platforms, and protocols. The protocols include HART, Modbus RTU, Modbus TCP, TCP / IP, Profinet, OPC_DA, and OPC_UA, as well as authorizations for the above protocols. Communication cards should be used to communicate with third-party PLCs or heterogeneous devices on site. The communication protocol should be Modbus RTU or Modbus TCP / IP. For heterogeneous devices using the Modbus RTU communication protocol, the third party shall provide the communication address list, verification type, communication rate, and other information. The supplier is responsible for uploading and debugging heterogeneous device communications.

[0103] DCS, SIS, and GDS have certain scalability, including the processing capacity of the control station, power load, communication load, server load, and operation load of the operation station and engineer station, etc. When the control station is running at full load, the system's power supply, software, communication load, and other various loads do not exceed 60%.

[0104] The control subsystem should be able to communicate with other digital electronic devices to obtain status information, measurement values ​​and alarms, and send control instructions. In principle, the communication between the control subsystem and third-party equipment should be completed at the lower layer; DCS, SIS, and GDS are redundant industrial Ethernets, and the communication system provides reliable high-speed data transmission for control stations, operation stations, engineer stations, etc. The transmission rate should not be less than 100Mb / s. The I / O bus connected by P-BUS is a redundant Ethernet, and the transmission rate should not be less than 100Mb / s.

[0105] The redundant control subsystem has excellent control performance: high availability of production and maintenance to avoid shutdowns; avoid unplanned production interruptions, which may cause damage to products in production; reduce maintenance costs; prevent data loss, maintain data integrity, and reduce long waits for restart after failure; unattended, maintenance plans can be better planned. Fully redundant Ethernet supports multiple network structures such as direct connection, star, and ring networks. It can automatically switch redundant data communication systems. The switching time should not be greater than 1S, and a system diagnostic alarm will be generated. No data is lost during switching. Explain the fault detection method and switching method. The control network should support data exchange for all devices connected to the network. It adopts a standard, open local area network structure, is compatible with various models, and supports TCP / IP protocol.

[0106] The flat network structure design isolates the terminal bus Tnet and the factory control network P-BUS on different network segments, ensuring the stability of system data transmission; the use of fully digital real-time Ethernet technology ensures high data consistency.

[0107] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A comprehensive intelligent control system for a submerged arc furnace, characterized in that: include: Auxiliary distributed control subsystem, Fur-DCS furnace main distributed control subsystem, SIS control subsystem and GDS control subsystem; The submerged arc furnace is one of a semi-closed submerged arc furnace, a direct current submerged arc furnace or a closed submerged arc furnace; When the submerged arc furnace is a semi-closed submerged arc furnace, the auxiliary distributed control subsystem is a Ded-DCS flue gas dust removal distributed control subsystem, which is used to collect and control the signal of the flue gas dust removal and recovery equipment for the high-temperature flue gas generated by the semi-closed submerged arc furnace; When the ore-fired furnace is a DC ore-fired furnace, the auxiliary distributed control subsystem is a Ret-DCS rectifier distributed control subsystem, which is used for collecting and controlling the signal of the rectifier device that rectifies the AC power supply into a DC power supply output; When the ore-fired furnace is a closed ore-fired furnace, the auxiliary distributed control subsystem is a Pur-DCS purification distributed control subsystem, which is used to collect and control the signal of the purification recovery equipment for the CO generated by the closed ore-fired furnace; The Fur-DCS furnace main distributed control subsystem is used to collect and control the signals of the submerged arc furnace main equipment; When the submerged arc furnace is a semi-closed submerged arc furnace, the SIS control subsystem collects the material level of the silo, the furnace bottom temperature, the furnace wall temperature, and the flue gas temperature, and the SIS control subsystem controls the direct discharge flue safety valve and the electric furnace transformer disconnection; When the ore-fired furnace is a DC ore-fired furnace or a closed ore-fired furnace, the SIS control subsystem collects furnace pressure, silo material level, H2 content, and O2 content, and the SIS control subsystem controls the waste gas release flue safety valve and the electric furnace transformer disconnection; The GDS control subsystem completes on-site flammable gas and toxic gas leakage concentration detection, indication, alarm and interlocking workshop exhaust fan start and stop.

2. The comprehensive intelligent control system for a submerged arc furnace according to claim 1 is characterized in that: The Ded-DCS flue gas dust removal distributed control subsystem comprises: an engineer and operator station Aux-PC (101), a terminal bus switch T-Switch1A (111-A), a terminal bus switch T-Switch1B (111-B), a flue gas dust removal control Ded-DCS-CPU (201), a first flue gas dust removal control substation SCR (301-1), a second flue gas dust removal control substation SCR (301-2), and a first frequency converter (311); wherein the terminal bus Tnet of the flue gas dust removal control Ded-DCS-CPU (201) uses A and B dual network redundancy, and is respectively connected to the terminal bus switch T-Switch1A (111-A) and the terminal bus switch T-Switch1B (111-B); the engineer and operator station Aux-PC (101) is configured with dual network cards, which are respectively connected to the terminal bus switch T-Switch1A (111-A) and the terminal bus switch T- Switch1B (111-B) realizes the access of the dual networks A and B of Tnet; the factory bus P-BUS of the flue gas dust removal control Ded-DCS-CPU (201) uses the dual network A and B redundancy and is connected to the first flue gas dust removal control substation SCR (301-1) and the second flue gas dust removal control substation SCR (301-2) in a serial manner; the first flue gas dust removal control substation SCR (301-1) mainly completes the collection of the on-site signal temperature and pressure signals of the water cooling pipe, dry sedimentation cooler, ash unloading device, and cage dust collector equipment, and completes the display output of the on-site control pneumatic valve and indicator light; the second flue gas dust removal control substation SCR (301-2) mainly completes the output of the control signal of the power equipment in the low-voltage distribution room and the collection of the operation signal, and a ProfiNet communication module (310) is configured in the second flue gas dust removal control substation SCR (301-2) to communicate with the first frequency converter (311) to adjust the driving speed of the main dust removal fan motor; The Ret-DCS rectifier distributed control subsystem comprises: an engineer and operator station Aux-PC (101), a terminal bus switch T-Switch1A (111-A), a terminal bus switch T-Switch1B (111-B), a rectifier control Ret-DCS-CPU (201), a first rectifier distributed control substation SCR (301-3), a second rectifier distributed control substation SCR (301-4), and a first frequency converter (311); wherein the rectifier control Ret-DCS-CPU (201) terminal bus Tnet uses A and B dual network redundancy, and is respectively connected to the terminal bus switch T-Switch1A (111-A) and the terminal bus switch T-Switch1B (111-B); the engineer and operator station Aux-PC (101) is configured with dual network cards, which are respectively connected to the terminal bus switch T-Switch1A (111-A) and the terminal bus switch T-Switch1B (111-B). 11-A), the terminal bus switch T-Switch1B (111-B) realizes the access of the A and B dual networks of Tnet; the rectifier control Ret-DCS-CPU (201) factory bus P-BUS uses the A and B dual network redundancy and is connected to the first rectifier distributed control substation SCR (301-3) and the second rectifier distributed control substation SCR (301-4) in a serial manner; the first rectifier distributed control substation SCR (301-3) mainly completes the collection of the field signal current and voltage signals of the thyristor and copper busbar equipment in the rectifier cabinet; the second rectifier distributed control substation SCR (301-4) mainly completes the output of the control signal of the rectifier cooling equipment and the collection of the operation signal, and a ProfiNet communication module (310) is configured in the second rectifier distributed control substation SCR (301-4) to communicate with the first frequency converter (311) to realize the adjustment of the driving speed of the cooling water pump motor; The Pur-DCS purification distributed control subsystem comprises: an engineer and operator station Aux-PC (101), a terminal bus switch T-Switch1A (111-A), a terminal bus switch T-Switch1B (111-B), a purification control Pur-DCS-CPU (201), a first purification distributed control substation SCR (301-5), a second purification distributed control substation SCR (301-6), and a first frequency converter (311); wherein the terminal bus Tnet of the purification control Pur-DCS-CPU (201) uses A and B dual network redundancy, and is respectively connected to the terminal bus switch T-Switch1A (111-A) and the terminal bus switch T-Switch1B (111-B); the engineer and operator station Aux-PC (101) is configured with dual network cards, and is respectively connected to the terminal bus switch T-Switch1A (111-A) and the terminal bus switch T-Switc h1B (111-B) realizes the access of the dual networks A and B of Tnet; the purification control Pur-DCS-CPU (201) factory bus P-BUS uses the dual network A and B redundancy and is connected to the first purification distributed control substation SCR (301-5) and the second purification distributed control substation SCR (301-6) in a serial manner; the first purification distributed control substation SCR (301-5) mainly completes the collection of on-site signal temperature and pressure signals of water cooling pipes, sedimentation coolers, enclosed buried scraper conveyors, and bag dust collector equipment, and completes the display output of on-site control pneumatic valves and indicator lights; the second purification distributed control substation SCR (301-6) mainly completes the output of control signals of power equipment in the low-voltage distribution room and the collection of operating signals, and a ProfiNet communication module (310) is configured in the second purification distributed control substation SCR (301-6) to communicate with the first frequency converter (311) to achieve the adjustment of the driving speed of the rough air fan and the clean air fan motor.

3. The comprehensive intelligent control system for a submerged arc furnace according to claim 1 is characterized in that: The Fur-DCS furnace body distributed control subsystem comprises: a time synchronization server Tsyn-PC (102), an engineer station ES-PC (103), an operation station OS-PC (104), an edge server Edge-PC (105), an advanced control server APC-PC (106), a standard communication server OPC-PC (107), a terminal bus switch T-Switch2A (112-A), a terminal bus switch T-Switch2B (112-B), a furnace body control Fur-DCS host CPU (202), a furnace body control Fur-DCS standby CPU (203), a third-party controller O-PLC (204), a plant bus switch P-Switch1A (300-A), a plant bus switch P-Switch1B (300-B), a second control substation SCR, and a second frequency converter (316); The terminal bus Tnet of the furnace body control Fur-DCS host CPU (202) and Fur-DCS backup CPU (203) uses A and B dual network redundancy, and is respectively connected to the terminal bus switch T-Switch2A (112-A) and the terminal bus switch T-Switch2B (112-B); the time synchronization server Tsyn-PC (102), the engineer station ES-PC (103), the operation station OS-PC (104), the edge server Edge-PC (105), the advanced control server APC-PC (106), and the standard communication server OPC-PC (107) are equipped with dual network cards The electric furnace body control Fur-DCS host CPU (202) and the electric furnace body control Fur-DCS backup CPU (203) respectively connect to the terminal bus switch T-Switch2A (112-A) and the terminal bus switch T-Switch2B (112-B) to realize the access of the A and B dual networks of Tnet; the electric furnace body control Fur-DCS host CPU (202) and the electric furnace body control Fur-DCS backup CPU (203) use the A and B dual network redundancy of the factory bus P-BUS, which are connected to the second control substation SCR in a serial manner to form a double closed loop connection to enhance the stability of the system; the third-party controller O-PLC (204) is connected to the factory bus switch P-Switch1A (300-A) and P-Swit ch1B (300-B); The second control substation SCR is divided into the furnace top batching control substation (302-1), circulating water control substation (302-2), electric furnace transformer control substation (302-3), furnace control substation (302-4), and low-voltage distribution room control substation (302-5); The circulating water control substation (302-2) completes the signal collection of temperature, pressure, and flow of the water distributor, water collector, and cooling branch of the submerged arc furnace. Because the submerged arc furnace body is equipped with more than 100 water temperature detections, the CANWeb fieldbus network module is selected to poll more than 100 temperatures on site. An 8-channel temperature detection CANWeb substation is set for every 8 temperature detection points. The substation module (314) is provided with a CANWeb master station module (313) with a ModbusTCP interface to realize real-time communication with the ModbusTCP communication module (312) configured in the main system control substation. The CANWeb substation module (314) simultaneously controls the pneumatic stop valve used to cut off the branch water flow; the electric furnace transformer control substation (302-3) completes the collection of electrical parameters of the smelting electric furnace transformer and non-electrical signals of oil temperature, oil level, and gas alarm, and completes the gear adjustment control of the transformer on-load voltage regulating switch; the furnace control substation (302-4) completes the collection of furnace door opening and closing, furnace pressure, flue temperature, furnace discharge equipment signals, and the control of electromagnetic valves;The low-voltage power distribution room control substation (302-5) completes the signal collection and output control of the belt conveyor, vibrating feeder, furnace bottom fan, airtight fan, and hydraulic power pump power circuit. A ProfiNet communication module (315) is configured in the low-voltage power distribution room control substation (302-5) to communicate with the second frequency converter (316) to adjust the motor drive speed.

4. The comprehensive intelligent control system for a submerged arc furnace according to claim 3 is characterized in that: When the ore-bearing furnace is a semi-enclosed ore-bearing furnace, the batching control substation (302-1) on the furnace top completes the collection of kiln top transfer belt conveyor, furnace top buffer bin material level, furnace top silo weighing, furnace door lifting signal and the control of the pneumatic discharge valve solenoid valve; When the ore-bearing furnace is a direct current ore-bearing furnace or a closed ore-bearing furnace, the batching control substation (302-1) on the furnace top completes the collection of the kiln top transfer belt conveyor, the furnace top buffer bin material level, the furnace top silo weighing signal and the control of the pneumatic discharge valve solenoid valve.

5. The comprehensive intelligent control system for a submerged arc furnace according to claim 1 is characterized in that: The SIS control subsystem comprises: an engineer and operator station Aux-PCSIS-PC (108), a terminal bus switch T-Switch3A (113-A), a terminal bus switch T-Switch3B (113-B), a safety control SIS-CPU (205), and a third control substation SCR (303); wherein the terminal bus Tnet of the safety control SIS-CPU (205) uses A and B dual network redundancy, and is respectively connected to the terminal bus switch T-Switch3A (113-A) and the terminal bus switch T-Switch3B (113-B); the engineer and operator station Aux-PCSIS-PC (108) is equipped with dual network cards, which are respectively connected to the terminal bus switch T-Switch3A (113-A) and terminal bus switch T-Switch3B (113-B) realize the access of dual networks A and B of Tnet; the safety control SIS-CPU (205) factory bus P-BUS uses dual network A and B redundancy and is connected to the third control substation SCR (303) in serial mode; the SIS control subsystem is a set of safety systems independent of the DCS control subsystem for ensuring safe production, and its safety level is higher than that of the DCS automation control subsystem. When an abnormality occurs in the automation production system, the SIS will automatically protect according to the pre-set safety function specifications; a microwave switch is set for low material level in the silo, and the microwave switch serves as the SIS system signal. The radar level meter enters the DCS system as a control signal.

6. The comprehensive intelligent control system for a submerged arc furnace according to claim 5, characterized in that: When the submerged arc furnace is a semi-enclosed submerged arc furnace, when the furnace bottom temperature, furnace wall temperature and flue gas temperature are too high, the interlocking direct discharge flue safety valve opens; according to the accident logic, the upper switch cabinet of the interlocking electric furnace transformer trips; When the ore-fired furnace is a DC ore-fired furnace or a closed ore-fired furnace, the high furnace pressure interlocking waste gas discharge flue safety valve opens; the high H2 content and O2 content interlocking electric furnace rectifier transformer upper switch cabinet trips.

7. The comprehensive intelligent control system for a submerged arc furnace according to claim 1 is characterized in that: The GDS control subsystem comprises an engineer and operator station Aux-PCGDS-PC (109), a terminal bus switch T-Switch4A (114-A), a terminal bus switch T-Switch4B (114-B), a gas monitoring GDS-CPU (206), and a fourth control substation SCR (304); wherein the terminal bus Tnet of the gas monitoring GDS-CPU (206) uses A and B dual network redundancy, and is respectively connected to the terminal bus switch T-Switch4A (114-A), The terminal bus switch T-Switch4B (114-B) is connected, and the engineer and operation station Aux-PCGDS-PC (109) is equipped with dual network cards and connected to the terminal bus switch T-Switch4A (114-A) and the terminal bus switch T-Switch4B (114-B) respectively to realize the access of the A and B dual networks of Tnet; the gas monitoring GDS-CPU (206) factory bus P-BUS uses A and B dual network redundancy and is connected to the fourth control substation SCR (304) in serial mode.

8. The comprehensive intelligent control system for a submerged arc furnace according to claim 1 is characterized in that: The auxiliary distributed control subsystem, the Fur-DCS furnace body distributed control subsystem, the SIS control subsystem and the GDS control subsystem are all provided with a terminal bus redundant switch T-Switch; The terminal bus redundant switch T-Switch includes terminal bus switches T-Switch1A (111-A), T-Switch2A (112-A), T-Switch3A (113-A), T-Switch4A (114-A) connected one by one in a serial manner and terminal bus switches T-Switch1B (111-B), T-Switch2B (112-B), T-Switch3B (113-B), T-Switch4B (114-B) connected one by one in a serial manner.

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