Smelting furnace air compressor operation energy consumption management and control system and method

Abstract

The invention belongs to the technical field of air compressor operation supervision, and particularly relates to a smelting furnace air compressor operation energy consumption management and control system and method.The system comprises an energy consumption collection and analysis module, a filter ash removal analysis module, an air compressor air inlet analysis module, an air compressor exhaust analysis module and a central monitoring end; whether the filter in the air compressor of the smelting furnace needs to be subjected to ash removal is judged through ash removal necessity analysis, the air inlet condition of the air compressor of the smelting furnace is analyzed when an ash removal unnecessary signal is generated, and the exhaust control performance of the air compressor of the smelting furnace is analyzed when an air inlet normal signal is generated. The operation effect of the smelting furnace air compressor is guaranteed, the operation energy consumption of the smelting furnace air compressor is reduced, the energy consumption performance of the smelting furnace air compressor is monitored, analyzed and early warned in time when related influence factors are eliminated, effective control over the operation energy consumption of the smelting furnace air compressor is achieved, and the workload and management difficulty of management personnel are remarkably reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of air compressor operation supervision, and in particular to a smelting furnace air compressor operation energy consumption control system and method. Background Art

[0002] As the core equipment in the heavy industry, the operating efficiency and energy consumption level of the melting furnace directly affect the economic benefits and environmental impact of the enterprise. As one of the auxiliary equipment of the melting furnace, the air compressor is mainly responsible for providing compressed air to meet various needs in the melting process, such as purging, cooling, sandblasting, etc. Its energy consumption in the operation of the melting furnace accounts for a large proportion; At present, the power consumption of the smelting furnace air compressor is mainly detected by electric energy metering equipment to determine whether its operating energy consumption meets the requirements. Before the energy consumption detection and analysis, the influence of factors related to the filter condition, air intake condition and exhaust control performance cannot be excluded, which is not conducive to the management personnel to make reasonable improvement measures in time, and it is difficult to achieve effective monitoring and control of the operating energy consumption of the smelting furnace air compressor, and it is impossible to ensure the operating effect and energy saving effect of the smelting furnace air compressor; In view of the above technical defects, a solution is now proposed. Summary of the invention

[0003] The purpose of the present invention is to provide a smelting furnace air compressor operating energy consumption control system and method, which solves the problem that the prior art is unable to eliminate the influence of relevant factors before the energy consumption detection and analysis of the smelting furnace air compressor, which is not conducive to the management personnel to make reasonable improvement measures in time, and it is difficult to achieve effective monitoring and control of the operating energy consumption of the smelting furnace air compressor, and the energy consumption control is difficult.

[0004] To achieve the above object, the present invention provides the following technical solutions: A smelting furnace air compressor operation energy consumption control system includes a filter ash removal analysis module, an air compressor intake analysis module, an air compressor exhaust analysis module, an energy consumption collection and analysis module and a central monitoring terminal; the filter ash removal analysis module generates an ash removal alarm signal or an ash removal non-essential signal through ash removal necessity analysis, and sends the ash removal alarm signal to the central monitoring terminal, and sends the ash removal non-essential signal to the air compressor intake analysis module; When the air compressor intake analysis module receives the dust removal non-essential signal, it analyzes the intake condition of the air compressor, generates an intake abnormality signal or an intake normal signal through analysis, and sends the intake abnormality signal to the central monitoring end, and sends the intake normal signal to the air compressor exhaust analysis module; When the air compressor exhaust analysis module receives the normal air intake signal, it analyzes the exhaust control performance of the air compressor, generates an exhaust control optimization signal or an exhaust control error signal through analysis, and sends the exhaust control error signal to the central monitoring end; when generating the dust removal non-essential signal, the air intake normal signal and the exhaust control optimization signal, the energy consumption collection and analysis module obtains the operating mode of the smelting furnace air compressor, collects the actual energy consumption data of the corresponding air compressor under the corresponding operating mode per unit time, generates an energy consumption alarm signal when the actual energy consumption data exceeds the corresponding standard energy consumption data threshold, and sends the energy consumption alarm signal to the central monitoring end.

[0005] Furthermore, the specific analysis process of the necessity analysis of dust removal includes: Obtain the time when the filter in the air compressor was deashed last time and mark it as the adjacent deashing time, calculate the time difference between the adjacent deashing time and the current time to obtain the deashing interval, and mark the total time of the air input of the corresponding air compressor within the deashing interval as the total air supply time value; The total time during which the dust content of the air entering the corresponding air compressor within the dust removal interval exceeds the preset dust content threshold is collected and marked as the dirty input time value, and the total gas supply time value and the dirty input time value are numerically compared with the preset total gas supply time threshold and the preset dirty input time threshold respectively. If the total gas supply time value or the dirty input time value exceeds the corresponding preset threshold, a dust removal alarm signal is generated.

[0006] Furthermore, if the total gas delivery time value and the dirty delivery time value do not exceed the corresponding preset threshold value, the average value of the dust content of the air entering the corresponding air compressor during the dust removal interval is marked as the dirty performance value; The filter dust removal analysis value is obtained by numerically calculating the total gas transmission time value, the dirty transmission time value and the dirty performance value, and the filter dust removal analysis value is numerically compared with the preset filter dust removal analysis threshold. If the filter dust removal analysis value exceeds the preset filter dust removal analysis threshold, a dust removal alarm signal is generated; if the filter dust removal analysis value does not exceed the preset filter dust removal analysis threshold, a dust removal unnecessary signal is generated.

[0007] Furthermore, the specific analysis process of the air compressor intake analysis module is as follows: The temperature of the air entering the corresponding air compressor is collected and marked as the intake temperature measurement value, and the moisture content and dust content in the input air are collected and marked as the intake air moisture value and the intake air dust value respectively, and the intake pressure of the input air is marked as the intake air pressure measurement value; the intake coefficient is obtained by numerically calculating the intake air temperature measurement value, the intake air moisture value, the intake air dust value and the intake air pressure measurement value, and the intake coefficient is numerically compared with the preset intake coefficient threshold value. If the intake coefficient exceeds the preset intake coefficient threshold value, the corresponding intake coefficient is marked as the intake coefficient; The number of intake abnormality coefficients per unit time is obtained and the ratio thereof is calculated with the number of intake coefficients to obtain an intake abnormality detection value, and the average of all intake coefficients per unit time is calculated to obtain an intake evaluation value, and the intake abnormality detection value and the intake evaluation value are numerically compared with the preset intake abnormality detection threshold and the preset intake evaluation threshold, respectively. If the intake abnormality detection value or the intake evaluation value exceeds the corresponding preset threshold, an intake abnormality signal is generated; if both the intake abnormality detection value and the intake evaluation value do not exceed the corresponding preset threshold, a normal intake signal is generated.

[0008] Furthermore, the specific analysis process of the air compressor exhaust analysis module is as follows: The exhaust flow rate and exhaust pressure of the air compressor are collected and marked as exhaust flow condition values ​​and exhaust pressure condition values, respectively, and the exhaust flow condition values ​​and exhaust pressure condition values ​​are numerically compared with the preset exhaust flow condition value range and the preset exhaust pressure condition value range, respectively. If the exhaust flow condition value or the exhaust pressure condition value is not within the corresponding preset range, it is determined that the air compressor is in an exhaust deviation state; The total time that the air compressor is in the exhaust deviation state per unit time is obtained and marked as the exhaust deviation time value, and the deviation values ​​of all exhaust flow condition values ​​per unit time compared with the median value of the preset exhaust flow condition value range are averaged to obtain the value marked as the exhaust flow deviation value, and the deviation values ​​of all exhaust pressure condition values ​​per unit time compared with the median value of the preset exhaust pressure condition value range are averaged to obtain the exhaust pressure deviation value; The exhaust control coefficient is obtained by numerically calculating the exhaust deviation time value, the exhaust flow deviation value and the exhaust pressure deviation value, and the exhaust control coefficient is numerically compared with the preset exhaust control coefficient threshold value. If the exhaust control coefficient exceeds the preset exhaust control coefficient threshold value, an exhaust control error signal is generated; if the exhaust control coefficient does not exceed the preset exhaust control coefficient threshold value, an exhaust control optimization signal is generated.

[0009] Furthermore, the energy consumption collection and analysis module is communicatively connected to the air compressor diagnosis module, and the energy consumption collection and analysis module sends the energy consumption alarm signal to the air compressor diagnosis module. When the air compressor diagnosis module receives the energy consumption alarm signal, it performs an air compressor operation diagnosis analysis, and determines through analysis whether to generate a stop alarm signal or a replacement alarm signal, and sends the stop alarm signal or the replacement alarm signal to the central monitoring terminal.

[0010] Furthermore, the specific analysis process of air compressor operation diagnosis analysis is as follows: The production date of the corresponding air compressor is collected, the interval between the current date and the production date is marked as the air compressor production value, and the total operation time of the corresponding air compressor in the historical stage is marked as the air compressor operation value; And trace back from the current date as the end date and set the detection period with the number of days as K1, and mark the frequency of corresponding air compressor failure within the detection period as the air compressor failure value; obtain the air compressor diagnosis value by numerically calculating the air compressor production value, the air compressor operation value and the air compressor failure value, and compare the air compressor diagnosis value with the preset air compressor diagnosis threshold value. If the air compressor diagnosis value exceeds the preset air compressor diagnosis threshold value, a replacement alarm signal is generated.

[0011] Furthermore, if the air compressor diagnostic value does not exceed the preset air compressor diagnostic threshold, the current start time of the air compressor is collected, the time difference between the current time and the current start time is calculated to obtain the current running time, the current running time is compared with the preset current running time threshold, and if the current running time exceeds the preset current running time threshold, a stop alarm signal is generated; if the current running time does not exceed the preset current running time threshold, the time when the previous air compressor stopped running is collected and marked as the stop time, and the time difference between the stop time and the current start time is calculated to obtain the stop time; The outage compliance value is calculated by comparing the outage duration with the running duration of the previous adjacent operation. If the outage compliance value does not exceed the preset outage compliance threshold, the previous adjacent operation is marked as a characteristic operation and traced back until the outage compliance value of a certain operation exceeds the preset outage compliance threshold, thereby obtaining all characteristic operations of the current operation; The running time of all characteristic operations is obtained, the running time of all characteristic operations and the current running time are summed up to obtain the running condition value, and all the stop time involved are summed up to obtain the stop condition value, the running condition value is ratioed with the stop condition value to obtain the stop necessary coefficient, the stop necessary coefficient is numerically compared with the preset stop necessary coefficient threshold, and if the stop necessary coefficient exceeds the preset stop necessary coefficient threshold, a stop alarm signal is generated.

[0012] Furthermore, the present invention also proposes a method for controlling the energy consumption of a smelting furnace air compressor, comprising the following steps: Step 1: Generate a dust removal alarm signal or a dust removal unnecessary signal through dust removal necessity analysis; Step 2: When the dust removal non-essential signal is generated, the air intake condition of the air compressor is analyzed, and an air intake abnormality signal or an air intake normal signal is generated through the analysis; Step 3: Analyze the exhaust control performance of the air compressor when generating the normal intake signal, and generate an exhaust control good signal or an exhaust control bad signal through the analysis; Step 4: When the dust removal non-essential signal, the air intake normal signal and the exhaust control optimization signal are generated, the energy consumption performance of the corresponding air compressor is analyzed to determine whether to generate an energy consumption alarm signal; Step 5: When a dust removal alarm signal, an abnormal air intake signal, an abnormal exhaust control signal or an energy consumption alarm signal is generated, the central monitoring terminal issues an early warning.

[0013] Compared with the prior art, the present invention has the following beneficial effects: 1. In the present invention, whether it is necessary to clean the filter in the smelting furnace air compressor is determined by analyzing the necessity of ash removal, analyzing the air intake condition of the smelting furnace air compressor when a signal indicating that ash cleaning is not necessary is generated, analyzing the exhaust control performance of the smelting furnace air compressor when a signal indicating that air intake is normal is generated, monitoring and analyzing the energy consumption performance of the smelting furnace air compressor when relevant influencing factors are excluded, and timely warning is provided, so as to achieve effective control over the operating energy consumption of the smelting furnace air compressor, significantly reduce the workload and management difficulty of management personnel, and help ensure the operating effect of the smelting furnace air compressor and reduce its operating energy consumption as much as possible; 2. In the present invention, the energy consumption alarm signal is sent to the air compressor diagnosis module through the energy consumption collection and analysis module. When the air compressor diagnosis module receives the energy consumption alarm signal, it performs air compressor operation diagnosis analysis, and stops the smelting furnace air compressor for rest when a stop alarm signal is generated. When a replacement alarm signal is generated, the smelting furnace air compressor is scrapped as needed, which is conducive to the management personnel to make matching treatment measures for the air compressor, ensuring the subsequent safe, stable and energy-saving operation of the smelting furnace air compressor, and having a high level of intelligence. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to facilitate understanding by those skilled in the art, the present invention is further described below in conjunction with the accompanying drawings; Figure 1 This is a system block diagram of Embodiment 1 of the present invention; Figure 2 This is a system block diagram of Embodiment 2 of the present invention; Figure 3 This is a flow chart of the method of Embodiment 3 of the present invention. DETAILED DESCRIPTION

[0015] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions 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. 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.

[0016] Embodiment 1: Figure 1 As shown, a smelting furnace air compressor operation energy consumption control system proposed by the present invention includes a filter ash removal analysis module, an air compressor intake analysis module, an air compressor exhaust analysis module, an energy consumption collection and analysis module and a central monitoring terminal; The filter dust removal analysis module generates a dust removal alarm signal or a dust removal non-essential signal through dust removal necessity analysis, and sends the dust removal alarm signal to the central monitoring terminal. When the central monitoring terminal receives the dust removal alarm signal, it issues a corresponding warning, which can reasonably analyze the necessity of dust removal of the filter in the air compressor and issue a timely warning to remind the management personnel to quickly clean the filter in the air compressor, reduce the resistance of the air intake system in the air compressor, and thus reduce energy consumption; the specific analysis process of dust removal necessity analysis is as follows: Obtain the time when the filter in the smelting furnace air compressor was deashed last time and mark it as the adjacent deashing time, calculate the time difference between the adjacent deashing time and the current time to obtain the deashing interval, and mark the total time of the corresponding air compressor inputting air within the deashing interval as the total gas transmission time value; The total time during which the dust content of the air entering the corresponding air compressor within the dust removal interval exceeds the preset dust content threshold is collected and marked as the dirty input time value, and the total gas transmission time value and the dirty input time value are numerically compared with the preset total gas transmission time threshold and the preset dirty input time threshold respectively. If the total gas transmission time value or the dirty input time value exceeds the corresponding preset threshold, it indicates that the filter in the air compressor needs to be cleaned and the resistance of the air intake system in the air compressor needs to be reduced to reduce energy consumption, and then a dust removal alarm signal is generated.

[0017] If the total gas delivery time value and the dirty delivery time value do not exceed the corresponding preset threshold value, the average value of the dust content of the air entering the corresponding air compressor during the dust removal interval is marked as the dirty performance value; the total gas delivery time value SY, the dirty delivery time value LX and the dirty performance value TN are numerically calculated by the formula QW=eq×SY+up×LX+hy×TN to obtain the filter dust removal analysis value QW; wherein eq, up, hy are preset weight coefficients with values ​​greater than zero, and the larger the value of the filter dust removal analysis value QW is, the more timely it is necessary to clean the filter in the air compressor; The filter dust removal analysis value QW is numerically compared with the preset filter dust removal analysis threshold. If the filter dust removal analysis value QW exceeds the preset filter dust removal analysis threshold, it indicates that the filter in the air compressor needs to be cleaned at present to reduce the resistance of the intake system in the air compressor to reduce energy consumption, and a dust removal alarm signal is generated; if the filter dust removal analysis value QW does not exceed the preset filter dust removal analysis threshold, it indicates that the filter in the air compressor does not need to be cleaned at present, and a dust removal non-essential signal is generated.

[0018] The filter dust removal analysis module sends the dust removal non-essential signal to the air compressor intake analysis module. When the air compressor intake analysis module receives the dust removal non-essential signal, it analyzes the air intake status of the air compressor, generates an air intake abnormality signal or an air intake normal signal through analysis, and sends the air intake abnormality signal to the central monitoring end. When the central monitoring end receives the air intake abnormality signal, it issues a corresponding warning, which can reasonably analyze the performance of the input air and issue a timely warning to remind the management personnel to adjust the input air in time, reduce the processing difficulty of the air compressor and reduce its operating energy consumption; the specific analysis process of the air compressor intake analysis module is as follows: The temperature of the air entering the corresponding air compressor is collected and marked as the inlet temperature measurement value, and the moisture content and dust content in the input air are collected and marked as the inlet moisture value and the inlet dust value respectively, and the inlet pressure of the input air is marked as the inlet pressure measurement value (the higher the inlet pressure, the less energy the air compressor needs to consume); The air intake coefficient RL is obtained by numerically calculating the air intake temperature measured value QS, the air intake moisture value FX, the air intake dust value NY and the air intake pressure measured value YP through the formula RL=re×QS+se×FX+tu×NY+hp / YP; wherein, re, se, tu and hp are preset proportional coefficients with values ​​greater than zero, and the larger the value of the air intake coefficient RL, the worse the performance of the input air, the greater the processing difficulty of the air compressor, and the higher the energy consumption of air compression processing; The air intake coefficient RL is numerically compared with the preset air intake coefficient threshold. If the air intake coefficient RL exceeds the preset air intake coefficient threshold, it indicates that the performance of the input air is poor and the energy consumption of the air compressor for air compression processing is high, and the corresponding air intake coefficient RL is marked as an air intake error coefficient; the number of air intake error coefficients per unit time is obtained and the ratio of the number of air intake coefficients is calculated to obtain an air intake error detection value, and the average of all air intake coefficients per unit time is calculated to obtain an air intake evaluation value; The intake abnormality detection value and the intake evaluation value are numerically compared with the preset intake abnormality detection threshold and the preset intake evaluation threshold respectively. If the intake abnormality detection value or the intake evaluation value exceeds the corresponding preset threshold, indicating that the condition of the input air is poor, an intake abnormality signal is generated; if both the intake abnormality detection value and the intake evaluation value do not exceed the corresponding preset threshold, indicating that the condition of the input air is good, a intake normal signal is generated.

[0019] The air compressor intake analysis module sends the normal intake signal to the air compressor exhaust analysis module. When the air compressor exhaust analysis module receives the normal intake signal, it analyzes the exhaust control performance of the air compressor, generates an exhaust control optimization signal or an exhaust control abnormality signal through analysis, and sends the exhaust control abnormality signal to the central monitoring end. When the central monitoring end receives the exhaust control abnormality signal, it issues a corresponding warning, which can accurately judge the exhaust control performance of the smelting furnace air compressor. When the exhaust control abnormality signal is generated, it reminds the management personnel to investigate the cause and make reasonable improvement measures, so as to ensure the operation effect of the air compressor and further reduce energy consumption. The specific analysis process of the air compressor exhaust analysis module is as follows: The exhaust flow rate and exhaust pressure of the air compressor are collected and marked as exhaust flow condition values ​​and exhaust pressure condition values, respectively. The exhaust flow condition value and exhaust pressure condition value are numerically compared with the preset exhaust flow condition value range and the preset exhaust pressure condition value range, respectively. If the exhaust flow condition value or the exhaust pressure condition value is not within the corresponding preset range, it indicates that the real-time exhaust control of the air compressor is not good, and it is judged that the air compressor is in an exhaust deviation state; The total time that the air compressor is in the exhaust deviation state per unit time is obtained and marked as the exhaust deviation time value, and the deviation values ​​of all exhaust flow condition values ​​per unit time compared with the median value of the preset exhaust flow condition value range are averaged to obtain the value marked as the exhaust flow deviation value, and the deviation values ​​of all exhaust pressure condition values ​​per unit time compared with the median value of the preset exhaust pressure condition value range are averaged to obtain the exhaust pressure deviation value; The exhaust control coefficient XP is obtained by numerically calculating the exhaust time deviation value SF, the exhaust flow deviation value GX and the exhaust pressure deviation value YW through the formula XP=np×SF+rw×GX+tq×YW; wherein np, rw and tq are preset weight coefficients with values ​​greater than zero, and the larger the value of the exhaust control coefficient XP, the worse the exhaust control condition of the smelting furnace air compressor; The exhaust control coefficient XP is numerically compared with the preset exhaust control coefficient threshold. If the exhaust control coefficient XP exceeds the preset exhaust control coefficient threshold, it indicates that the exhaust control condition of the smelting furnace air compressor is poor, which is not conducive to ensuring the operation effect of the air compressor and reducing energy consumption, and an exhaust control error signal is generated; if the exhaust control coefficient XP does not exceed the preset exhaust control coefficient threshold, it indicates that the exhaust control condition of the smelting furnace air compressor is good, which is conducive to ensuring the operation effect of the air compressor and reducing energy consumption, and an exhaust control excellence signal is generated.

[0020] When the dust removal non-essential signal, air intake normal signal and exhaust control optimization signal are generated, it shows that each factor has little effect on the energy consumption of the smelting furnace air compressor. The energy consumption collection and analysis module obtains the operating mode of the smelting furnace air compressor, and collects the actual energy consumption data of the corresponding air compressor under the corresponding operating mode per unit time. When the actual energy consumption data exceeds the corresponding standard energy consumption data threshold, an energy consumption alarm signal is generated, and the energy consumption alarm signal is sent to the central monitoring end. When the central monitoring end receives the energy consumption alarm signal, it issues a corresponding early warning to remind management personnel to investigate and trace the cause and make reasonable improvement measures to reduce the operating energy consumption of the smelting furnace air compressor as much as possible.

[0021] Embodiment 2: Figure 2 As shown, the difference between this embodiment and the first embodiment is that the energy consumption collection and analysis module is communicatively connected to the air compressor diagnosis module, and the energy consumption collection and analysis module sends the energy consumption alarm signal to the air compressor diagnosis module. When the air compressor diagnosis module receives the energy consumption alarm signal, it performs air compressor operation diagnosis analysis, and determines whether to generate a stop alarm signal or a replacement alarm signal through analysis, and sends the stop alarm signal or the replacement alarm signal to the central monitoring end. When the management personnel receive the stop alarm signal, the smelting furnace air compressor stops running and takes a rest. When the replacement alarm signal is received, the air compressor can be scrapped as needed, which is conducive to the management personnel to make matching treatment measures for the air compressor, and ensure the subsequent safe, stable and energy-saving operation of the smelting furnace air compressor. The specific analysis process of the air compressor operation diagnosis analysis is as follows: The production date of the corresponding air compressor is collected, and the interval between the current date and the production date is marked as the air compressor production value, and the total operation time of the corresponding air compressor in the historical stage is marked as the air compressor operation value; and the detection period is traced back from the current date as the end date and the number of days is set to K1. Preferably, K1 is sixty days; the frequency of failure of the corresponding air compressor in the detection period is marked as the air compressor failure value; The air compressor production value QP, the air compressor operation value HF and the air compressor fault value GM are numerically calculated using the formula GZ=a×QP+c×HF+m×GM to obtain the air compressor diagnostic value GZ; wherein, a, c, and m are preset weight coefficients whose values ​​are greater than zero, and the larger the value of the air compressor diagnostic value GZ, the more serious the performance degradation of the air compressor may be; the air compressor diagnostic value GZ is numerically compared with the preset air compressor diagnostic threshold value. If the air compressor diagnostic value GZ exceeds the preset air compressor diagnostic threshold value, it indicates that the performance degradation of the air compressor may be more serious, which may easily lead to an increase in its operating energy consumption, and a replacement alarm signal is generated.

[0022] Furthermore, if the air compressor diagnostic value GZ does not exceed the preset air compressor diagnostic threshold, the current start time of the air compressor is collected, the time difference between the current time and the current start time is calculated to obtain the current running time, and the current running time is numerically compared with the preset current running time threshold. If the current running time exceeds the preset current running time threshold, it indicates that the current running duration of the smelting furnace air compressor is relatively long, which is likely to increase its energy consumption, and a stop alarm signal is generated; If the current running time does not exceed the preset current running time threshold, the time when the air compressor stopped running last time is collected and marked as the stop time, and the time difference between the stop time and the current start time is calculated to obtain the stop time; The outage compliance value is calculated by comparing the outage duration with the running duration of the previous adjacent operation. If the outage compliance value does not exceed the preset outage compliance threshold, it indicates that the rest time between two adjacent operations is too short and the air compressor status cannot be effectively restored. The previous adjacent operation is marked as a characteristic operation and traced back until the outage compliance value of a certain operation exceeds the preset outage compliance threshold, thereby obtaining all characteristic operations of the current operation; The running time of all characteristic operations is obtained, the running time of all characteristic operations and the current running time are summed up to obtain the running condition value, and all the downtime durations involved are summed up to obtain the stop condition value, and the running condition value is ratioed with the stop condition value to obtain the stop necessary coefficient; The necessary stop coefficient is numerically compared with the preset necessary stop coefficient threshold. If the necessary stop coefficient exceeds the preset necessary stop coefficient threshold, it indicates that the smelting furnace air compressor should be rested in time to restore the air compressor to a good operating state, thereby reducing operating energy consumption, and a stop alarm signal is generated.

[0023] Embodiment 3: Figure 3 As shown, the difference between this embodiment and the first and second embodiments is that the present invention provides a method for controlling the energy consumption of a smelting furnace air compressor, comprising the following steps: Step 1: Generate a dust removal alarm signal or a dust removal unnecessary signal through dust removal necessity analysis; Step 2: When the dust removal non-essential signal is generated, the air intake condition of the air compressor is analyzed, and an air intake abnormality signal or an air intake normal signal is generated through the analysis; Step 3: Analyze the exhaust control performance of the air compressor when generating the normal intake signal, and generate an exhaust control good signal or an exhaust control bad signal through the analysis; Step 4: When the dust removal non-essential signal, the air intake normal signal and the exhaust control optimization signal are generated, the energy consumption performance of the corresponding air compressor is analyzed to determine whether to generate an energy consumption alarm signal; Step 5: When a dust removal alarm signal, an abnormal air intake signal, an abnormal exhaust control signal or an energy consumption alarm signal is generated, the central monitoring terminal issues an early warning.

[0024] The working principle of the present invention: when in use, the necessity of ash removal is analyzed to determine whether the filter in the smelting furnace air compressor needs to be cleaned, so as to timely reduce the resistance of the air intake system in the smelting furnace air compressor, and when a non-essential signal for ash cleaning is generated, the air intake condition of the smelting furnace air compressor is analyzed, and the input air is adjusted in time to reduce the processing difficulty of the smelting furnace air compressor and reduce its operating energy consumption, and when a normal air intake signal is generated, the exhaust control performance of the smelting furnace air compressor is analyzed, which is beneficial to ensure the operating effect of the smelting furnace air compressor and reduce its operating energy consumption, and when relevant influencing factors are excluded, the energy consumption performance of the smelting furnace air compressor is monitored and analyzed through the energy consumption collection and analysis module, and timely warning is issued, so as to realize effective control of the operating energy consumption of the smelting furnace air compressor, significantly reduce the workload and management difficulty of management personnel, and have a high level of intelligence.

[0025] The above formulas are all dimensionless and numerical calculations. The formula is a formula obtained by collecting a large amount of data and performing software simulation to obtain the most recent real situation. The preset parameters in the formula are set by technicians in this field according to actual conditions. The preferred embodiments of the present invention disclosed above are only used to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to only specific implementation methods. Obviously, many modifications and changes can be made according to the contents of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that technicians in the relevant technical field can understand and use the present invention well. The present invention is only limited by the claims and their full scope and equivalents.

Claims

1. A smelting furnace air compressor operation energy consumption control system, characterized in that: It includes a filter dust removal analysis module, an air compressor intake analysis module, an air compressor exhaust analysis module, an energy consumption collection and analysis module and a central monitoring terminal; the filter dust removal analysis module generates a dust removal alarm signal or a dust removal non-essential signal through dust removal necessity analysis, and when generating a dust removal non-essential signal, analyzes the air intake condition of the air compressor through the air compressor intake analysis module, and generates an intake abnormality signal or an intake normal signal through analysis; When generating a normal air intake signal, the exhaust control performance of the air compressor is analyzed through the air compressor exhaust analysis module, and an exhaust control optimization signal or an exhaust control abnormality signal is generated through the analysis; when generating a non-essential dust removal signal, a normal air intake signal and an exhaust control optimization signal, the energy consumption collection and analysis module obtains the operating mode of the smelting furnace air compressor, and collects the actual energy consumption data of the corresponding air compressor under the corresponding operating mode per unit time. When the actual energy consumption data exceeds the corresponding standard energy consumption data threshold, an energy consumption alarm signal is generated, and the energy consumption alarm signal is sent to the central monitoring terminal.

2. A smelting furnace air compressor operation energy consumption control system according to claim 1, characterized in that: The specific analysis process of ash removal necessity analysis includes: The total duration of air input by the corresponding air compressor within the dust removal interval is marked as the total air supply time value. The total duration of the dust content of the air entering the corresponding air compressor within the dust removal interval exceeding the preset dust content threshold is collected and marked as the dirty supply time value. If the total air supply time value or the dirty supply time value exceeds the corresponding preset threshold, a dust removal alarm signal is generated.

3. A smelting furnace air compressor operation energy consumption control system according to claim 2, characterized in that: If the total gas transmission time value and the dirty transmission time value do not exceed the corresponding preset threshold values, the filter dust removal analysis value is obtained by numerically calculating the total gas transmission time value, the dirty transmission time value and the dirty performance value. If the filter dust removal analysis value exceeds the preset filter dust removal analysis threshold, a dust removal alarm signal is generated; if the filter dust removal analysis value does not exceed the preset filter dust removal analysis threshold, a dust removal unnecessary signal is generated.

4. The energy consumption control system for operation of a smelting furnace air compressor according to claim 1 is characterized in that: The specific analysis process of the air compressor intake analysis module is as follows: The intake coefficient is obtained by numerically calculating the intake temperature measurement value, the intake water content value, the intake dust value and the intake pressure measurement value. If the intake coefficient exceeds the preset intake coefficient threshold, the corresponding intake coefficient is marked as the intake abnormality coefficient; the number of intake abnormality coefficients per unit time is obtained and the ratio is calculated with the number of intake coefficients to obtain the intake abnormality detection value, and the average of all intake coefficients per unit time is calculated to obtain the intake evaluation value. If the intake abnormality detection value or the intake evaluation value exceeds the corresponding preset threshold, an intake abnormality signal is generated; otherwise, a normal intake signal is generated.

5. The energy consumption control system for operation of a smelting furnace air compressor according to claim 1 is characterized in that: The specific analysis process of the air compressor exhaust analysis module is as follows: The total time that the air compressor is in the exhaust deviation state per unit time is obtained and marked as the exhaust deviation time value, and the exhaust control coefficient is obtained by numerically calculating the exhaust deviation time value, the exhaust flow deviation value and the exhaust pressure deviation value. If the exhaust control coefficient exceeds the preset exhaust control coefficient threshold, an exhaust control error signal is generated; if the exhaust control coefficient does not exceed the preset exhaust control coefficient threshold, an exhaust control excellence signal is generated.

6. The energy consumption control system for operation of a smelting furnace air compressor according to claim 1 is characterized in that: The energy consumption collection and analysis module is communicatively connected to the air compressor diagnosis module. The energy consumption collection and analysis module sends the energy consumption alarm signal to the air compressor diagnosis module. When the air compressor diagnosis module receives the energy consumption alarm signal, it performs an air compressor operation diagnosis analysis, and determines through analysis whether to generate a stop alarm signal or a replacement alarm signal, and sends the stop alarm signal or the replacement alarm signal to the central monitoring terminal.

7. A smelting furnace air compressor operation energy consumption control system according to claim 6, characterized in that: The specific analysis process of air compressor operation diagnosis analysis is as follows: The air compressor diagnosis value is obtained by numerically calculating the air compressor production value, the air compressor operation value and the air compressor fault value. If the air compressor diagnosis value exceeds the preset air compressor diagnosis threshold, a replacement alarm signal is generated.

8. A smelting furnace air compressor operation energy consumption control system according to claim 7, characterized in that: If the air compressor diagnostic value does not exceed the preset air compressor diagnostic threshold, the time difference between the current time and the start time of operation is calculated to obtain the current operation time. If the current operation time exceeds the preset current operation time threshold, a stop alarm signal is generated; if the operating condition value and the stop condition value are ratio-calculated to obtain the necessary stop coefficient, if the necessary stop coefficient exceeds the preset necessary stop coefficient threshold, a stop alarm signal is generated.

9. A method for controlling the energy consumption of a smelting furnace air compressor, characterized in that: The method adopts the smelting furnace air compressor operating energy consumption control system as described in any one of claims 1-8.

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