A control system and method for the operating energy consumption of an air compressor in a smelting furnace

Abstract

The present invention belongs to the technical field of air compressor operation supervision, and specifically relates to a system and method for controlling the operation energy consumption of an air compressor in a melting furnace. Among them, the system includes an energy consumption acquisition and analysis module, a filter ash removal analysis module, an air compressor intake analysis module, an air compressor exhaust analysis module, and a central monitoring terminal; the present invention determines whether it is necessary to clean the filter in the air compressor of the melting furnace through the analysis of the necessity of ash removal. When generating a signal indicating that ash removal is not necessary, the intake condition of the air compressor in the melting furnace is analyzed. When generating a signal indicating normal intake, the exhaust control performance of the air compressor in the melting furnace is analyzed, which is beneficial to ensuring the operation effect of the air compressor in the melting furnace and reducing its operation energy consumption. Moreover, when excluding relevant influencing factors, the energy consumption performance of the air compressor in the melting furnace is monitored and analyzed, and early warnings are given in a timely manner, so as to realize the effective control of the operation energy consumption of the air compressor in the melting furnace, and significantly reduce the workload and management difficulty of management personnel.

Description

Technical Field

[0001] The present invention relates to the technical field of air compressor operation supervision, and specifically to a system and method for controlling the operation energy consumption of an air compressor for a melting furnace. Background Technique

[0002] As a core device in the heavy industry field, the operation efficiency and energy consumption level of a melting furnace directly affect the economic benefits of an enterprise and its environmental impact. As one of the auxiliary devices of the melting furnace, an air compressor is mainly responsible for providing compressed air to meet various requirements during the melting process, such as purging, cooling, sandblasting, etc. Its energy consumption during the operation of the melting furnace accounts for a relatively large proportion;

[0003] Currently, mainly through electrical energy metering equipment, the electricity consumption of the air compressor for the melting furnace is detected and it is judged whether its operation energy consumption meets the requirements. Before the energy consumption detection and analysis, the influence of relevant factors such as the filter condition, intake condition, and exhaust control performance cannot be excluded, which is not conducive to managers making reasonable improvement measures in a timely manner, difficult to effectively monitor and control the operation energy consumption of the air compressor for the melting furnace, and unable to ensure the operation effect and energy-saving effect of the air compressor for the melting furnace;

[0004] In view of the above technical defects, a solution is now proposed. Summary of the Invention

[0005] The purpose of the present invention is to provide a system and method for controlling the operation energy consumption of an air compressor for a melting furnace, which solves the problems in the prior art that it is impossible to exclude the influence of relevant factors before the energy consumption detection and analysis of the air compressor for the melting furnace, is not conducive to managers making reasonable improvement measures in a timely manner, is difficult to effectively monitor and control the operation energy consumption of the air compressor for the melting furnace, and has a large energy consumption control difficulty.

[0006] To achieve the above purpose, the present invention provides the following technical solutions:

[0007] A system for controlling the operation energy consumption of an air compressor for a melting furnace includes a filter dust removal analysis module, an air compressor intake analysis module, an air compressor exhaust analysis module, an energy consumption acquisition and analysis module, and a central monitoring terminal; the filter dust removal analysis module generates a dust removal alarm signal or a non-necessary dust removal signal through dust removal necessity analysis, and sends the dust removal alarm signal to the central monitoring terminal, and sends the non-necessary dust removal signal to the air compressor intake analysis module;

[0008] When the air compressor intake analysis module receives the non-necessary dust removal 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 terminal, and sends the intake normal signal to the air compressor exhaust analysis module;

[0009] When the air compressor exhaust analysis module receives a normal intake air signal, it analyzes the exhaust control performance of the air compressor, generates an exhaust control optimization signal or an exhaust control anomaly signal through the analysis, and sends the exhaust control anomaly signal to the central monitoring terminal; when generating a non-essential ash removal signal, a normal intake air signal, and an exhaust control optimization signal, the energy consumption acquisition and analysis module obtains the operating mode of the smelting furnace air compressor, collects the actual energy consumption data of the corresponding air compressor in the corresponding operating mode per unit time, and 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 terminal.

[0010] Furthermore, the specific analysis process of the necessity of ash removal includes:

[0011] Obtain the time of the previous ash removal for the filter in the air compressor and mark it as the adjacent ash removal time. Calculate the time difference between the adjacent ash removal time and the current time to obtain the ash removal interval duration, and mark the total duration of air input by the corresponding air compressor during the ash removal interval duration as the total air input value;

[0012] Collect the total duration during which the dust content of the air entering the corresponding air compressor during the ash removal interval duration exceeds the preset dust content threshold and mark it as the dirty air input value. Compare the total air input value and the dirty air input value with the preset total air input threshold and the preset dirty air input threshold respectively. If the total air input value or the dirty air input value exceeds the corresponding preset threshold, generate an ash removal alarm signal.

[0013] Furthermore, if both the total air input value and the dirty air input value do not exceed the corresponding preset thresholds, mark the average dust content of the air entering the corresponding air compressor during the ash removal interval duration as the dirty performance value;

[0014] Obtain the filter ash removal analysis value through numerical calculation of the total air input value, the dirty air input value, and the dirty performance value. Compare the filter ash removal analysis value with the preset filter ash removal analysis threshold. If the filter ash removal analysis value exceeds the preset filter ash removal analysis threshold, generate an ash removal alarm signal; if the filter ash removal analysis value does not exceed the preset filter ash removal analysis threshold, generate a non-essential ash removal signal.

[0015] Furthermore, the specific analysis process of the air compressor intake analysis module is as follows:

[0016] Collect the temperature of the air entering the corresponding air compressor and label it as the incoming air temperature measurement value, and collect the moisture content and dust content in the input air and label them as the incoming air moisture value and the incoming air dust value respectively, and label the intake pressure of the input air as the incoming air pressure measurement value; obtain the incoming air coefficient through numerical calculation of the incoming air temperature measurement value, the incoming air moisture value, the incoming air dust value, and the incoming air pressure measurement value, and numerically compare the incoming air coefficient with the preset incoming air coefficient threshold. If the incoming air coefficient exceeds the preset incoming air coefficient threshold, label the corresponding incoming air coefficient as the incoming abnormal coefficient;

[0017] Obtain the quantity of the incoming abnormal coefficient per unit time and calculate the ratio with the quantity of the incoming air coefficient to obtain the incoming abnormal detection value, and calculate the average value of all the incoming air coefficients per unit time to obtain the incoming air evaluation value. Numerically compare the incoming abnormal detection value and the incoming air evaluation value with the preset incoming abnormal detection threshold and the preset incoming air evaluation threshold respectively. If the incoming abnormal detection value or the incoming air evaluation value exceeds the corresponding preset threshold, generate an intake air abnormal signal; if both the incoming abnormal detection value and the incoming air evaluation value do not exceed the corresponding preset threshold, generate an intake air normal signal.

[0018] Furthermore, the specific analysis process of the air compressor exhaust analysis module is as follows:

[0019] Collect the exhaust flow rate and exhaust pressure of the air compressor and label them as the exhaust flow condition value and the exhaust pressure condition value respectively. Numerically compare the exhaust flow condition value and the exhaust pressure condition value 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;

[0020] Obtain the total duration of the air compressor being in the exhaust deviation state per unit time and label it as the exhaust deviation time value, and calculate the average value of the deviation values of all the exhaust flow condition values compared with the median of the preset exhaust flow condition value range per unit time and label it as the exhaust flow deviation value, and calculate the average value of the deviation values of all the exhaust pressure condition values compared with the median of the preset exhaust pressure condition value range per unit time to obtain the exhaust pressure deviation value;

[0021] Obtain the exhaust control coefficient through numerical calculation of the exhaust deviation time value, the exhaust flow deviation value, and the exhaust pressure deviation value. Numerically compare the exhaust control coefficient with the preset exhaust control coefficient threshold. If the exhaust control coefficient exceeds the preset exhaust control coefficient threshold, generate an exhaust control abnormal signal; if the exhaust control coefficient does not exceed the preset exhaust control coefficient threshold, generate an exhaust control excellent signal.

[0022] Further, the energy consumption acquisition and analysis module is communicatively connected to the air compressor diagnosis module. The energy consumption acquisition and analysis module sends an energy consumption alarm signal to the air compressor diagnosis module. When the air compressor diagnosis module receives the energy consumption alarm signal, it conducts an operation diagnosis and analysis of the air compressor, determines whether to generate a stop alarm signal or a replacement alarm signal through the analysis, and sends the stop alarm signal or the replacement alarm signal to the central monitoring terminal.

[0023] Further, the specific analysis process of the air compressor operation diagnosis and analysis is as follows:

[0024] Collect the production date of the corresponding air compressor, mark the time interval between the current date and the production date as the air compressor production value, and mark the total operating duration of the corresponding air compressor in the historical stage as the air compressor operation value;

[0025] And set a detection period with a number of days K1 by tracing back from the current date as the end date. Mark the frequency of failures of the corresponding air compressor within the detection period as the air compressor failure value; Calculate the air compressor diagnosis value through numerical calculation of the air compressor production value, the air compressor operation value, and the air compressor failure value, and conduct a numerical comparison between the air compressor diagnosis value and the preset air compressor diagnosis threshold. If the air compressor diagnosis value exceeds the preset air compressor diagnosis threshold, generate a replacement alarm signal.

[0026] Further, if the air compressor diagnosis value does not exceed the preset air compressor diagnosis threshold, collect the start operation time of the air compressor for this time, calculate the time difference between the current time and the start operation time for this time to obtain the operation duration for this time, and conduct a numerical comparison between the operation duration for this time and the preset operation duration threshold for this time. If the operation duration for this time exceeds the preset operation duration threshold for this time, generate a stop alarm signal; If the operation duration for this time does not exceed the preset operation duration threshold for this time, collect the moment when the adjacent previous air compressor stopped operating and mark it as the stop operation moment, and calculate the time difference between the stop operation moment and the start operation time for this time to obtain the stop operation duration;

[0027] Calculate the ratio of the stop operation duration to the operation duration of the adjacent previous operation to obtain the stop compliance value. If the stop compliance value does not exceed the preset stop compliance threshold, mark the adjacent previous operation as a characteristic operation and trace back until the stop compliance value of a certain operation exceeds the preset stop compliance threshold, and thus obtain all the characteristic operations of this operation;

[0028] Obtain the operation durations of all the characteristic operations, calculate the sum of the operation durations of all the characteristic operations and the operation duration for this time to obtain the operation situation value, and calculate the sum of all the involved stop operation durations to obtain the stop situation value. Calculate the ratio of the operation situation value to the stop situation value to obtain the stop necessity coefficient, and conduct a numerical comparison between the stop necessity coefficient and the preset stop necessity coefficient threshold. If the stop necessity coefficient exceeds the preset stop necessity coefficient threshold, generate a stop alarm signal.

[0029] Furthermore, the present invention also provides a method for controlling the operating energy consumption of an air compressor for a smelting furnace, comprising the following steps:

[0030] Step 1: Generate an ash removal alarm signal or a non-necessary ash removal signal through an analysis of the necessity of ash removal;

[0031] Step 2: Analyze the intake condition of the air compressor when a non-necessary ash removal signal is generated, and generate an abnormal intake signal or a normal intake signal through the analysis;

[0032] Step 3: Analyze the exhaust control performance of the air compressor when a normal intake signal is generated, and generate an excellent exhaust control signal or an abnormal exhaust control signal through the analysis;

[0033] Step 4: When a non-necessary ash removal signal, a normal intake signal, and an excellent exhaust control signal are generated, analyze the energy consumption performance of the corresponding air compressor to determine whether an energy consumption alarm signal is generated;

[0034] Step 5: When an ash removal alarm signal, an abnormal intake signal, an abnormal exhaust control signal, or an energy consumption alarm signal is generated, the central monitoring terminal issues a warning.

[0035] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0036] 1. In the present invention, it is judged whether it is necessary to clean the filter in the air compressor of the smelting furnace through an analysis of the necessity of ash removal. When a non-necessary ash removal signal is generated, the intake condition of the air compressor of the smelting furnace is analyzed. When a normal intake signal is generated, the exhaust control performance of the air compressor of the smelting furnace is analyzed. When relevant influencing factors are excluded, the energy consumption performance of the air compressor of the smelting furnace is monitored and analyzed, and a warning is issued in a timely manner, so as to effectively control the operating energy consumption of the air compressor of the smelting furnace, significantly reduce the workload and management difficulty of management personnel, and is beneficial to ensuring the operating effect of the air compressor of the smelting furnace and reducing its operating energy consumption as much as possible;

[0037] 2. In the present invention, the energy consumption alarm signal is sent to the air compressor diagnosis module through the energy consumption acquisition and analysis module. When the air compressor diagnosis module receives the energy consumption alarm signal, it conducts a diagnosis and analysis of the operation of the air compressor. When a stop alarm signal is generated, the air compressor of the smelting furnace stops running and is repaired. When a replacement alarm signal is generated, the air compressor of the smelting furnace is scrapped as needed, which is beneficial for management personnel to take corresponding treatment measures for the air compressor, ensure the subsequent safe, stable and energy-saving operation of the air compressor of the smelting furnace, and has a high level of intelligence. Description of the Drawings

[0038] For the convenience of those skilled in the art to understand, the present invention will be further described below in conjunction with the drawings;

[0039] Figure 1System block diagram of Embodiment 1 in the present invention;

[0040] Figure 2 System block diagram of Embodiment 2 in the present invention;

[0041] Figure 3 Method flowchart of Embodiment 3 in the present invention. Detailed implementation manners

[0042] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0043] Embodiment 1: As Figure 1 shown, a control system for the operating energy consumption of a melting furnace air compressor 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 acquisition analysis module, and a central monitoring terminal;

[0044] The filter ash removal analysis module generates an ash removal alarm signal or an unnecessary ash removal signal through the analysis of the necessity of ash removal, and sends the ash removal alarm signal to the central monitoring terminal. When the central monitoring terminal receives the ash removal alarm signal, it issues a corresponding early warning, which can reasonably analyze the necessity of cleaning the filter in the air compressor and give an early warning in time 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 the energy consumption. The specific analysis process of the analysis of the necessity of ash removal is as follows:

[0045] Obtain the time of the previous ash removal for the filter in the melting furnace air compressor and mark it as the adjacent ash removal time. Calculate the time difference between the adjacent ash removal time and the current time to obtain the ash removal interval duration, and mark the total duration of air input by the corresponding air compressor during the ash removal interval duration as the total air input value;

[0046] Collect the total duration during which the dust content of the air entering the corresponding air compressor during the ash removal interval duration exceeds the preset dust content threshold and mark it as the dirty air input value. Compare the total air input value and the dirty air input value with the preset total air input threshold and the preset dirty air input threshold respectively. If the total air input value or the dirty air input value exceeds the corresponding preset threshold, it indicates that the filter in the air compressor needs to be cleaned currently to reduce the resistance of the air intake system in the air compressor to reduce the energy consumption, and then an ash removal alarm signal is generated.

[0047] If both the total gas transmission time value and the polluted gas transmission time value do not exceed the corresponding preset thresholds, the average dust content of the air entering the corresponding air compressor during the ash removal interval is marked as the polluted performance value; the total gas transmission time value SY, the polluted gas transmission time value LX, and the polluted performance value TN are numerically calculated through the formula QW = eq×SY + up×LX + hy×TN to obtain the filter ash removal analysis value QW; where eq, up, and hy are preset weight coefficients with values greater than zero, and the larger the value of the filter ash removal analysis value QW, the more urgently it indicates that the filter in the air compressor needs to be cleaned;

[0048] The filter ash removal analysis value QW is numerically compared with the preset filter ash removal analysis threshold. If the filter ash removal analysis value QW exceeds the preset filter ash removal analysis threshold, it indicates that the filter in the air compressor needs to be cleaned currently to reduce the resistance of the air intake system in the air compressor and thus reduce energy consumption, and then an ash removal alarm signal is generated; if the filter ash removal analysis value QW does not exceed the preset filter ash removal analysis threshold, it indicates that the filter in the air compressor does not need to be cleaned currently, and then an ash removal non-necessary signal is generated.

[0049] The filter ash removal analysis module sends the ash removal non-necessary signal to the air compressor intake analysis module. When the air compressor intake analysis module receives the ash removal non-necessary signal, it analyzes the intake condition of the air compressor, generates an intake abnormal signal or an intake normal signal through the analysis, and sends the intake abnormal signal to the central monitoring terminal. When the central monitoring terminal receives the intake abnormal signal, it issues a corresponding early warning, which can reasonably analyze the performance condition of the input air and give an early warning in time to remind the management personnel to adjust the input air in time, reduce the processing difficulty of the air compressor and its operating energy consumption; the specific analysis process of the air compressor intake analysis module is as follows:

[0050] The temperature of the air entering the corresponding air compressor is collected and marked as the incoming air temperature measurement value, and the moisture content and dust content in the input air are collected and marked as the incoming air moisture value and the incoming air dust value respectively, and the intake pressure of the input air is marked as the incoming air pressure measurement value (the higher the intake pressure, the less energy the air compressor needs to consume);

[0051] The incoming air temperature measurement value QS, the incoming air moisture value FX, the incoming air dust value NY, and the incoming air pressure measurement value YP are numerically calculated through the formula RL = re×QS + se×FX + tu×NY + hp / YP to obtain the incoming air coefficient RL; where re, se, tu, and hp are preset proportionality coefficients with values greater than zero, and the larger the value of the incoming air 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 for air compression processing;

[0052] Numerically compare the air intake coefficient RL with a 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 treatment is high. Then, mark the corresponding air intake coefficient RL as an abnormal coefficient; obtain the number of abnormal coefficients per unit time and calculate the ratio with the number of air intake coefficients to obtain an abnormal detection value, and calculate the average value of all air intake coefficients per unit time to obtain an air intake evaluation value;

[0053] Numerically compare the abnormal detection value and the air intake evaluation value with a preset abnormal detection threshold and a preset air intake evaluation threshold respectively. If the abnormal detection value or the air intake evaluation value exceeds the corresponding preset threshold, it indicates that the condition of the input air is poor, and then generate an air intake abnormal signal; if both the abnormal detection value and the air intake evaluation value do not exceed the corresponding preset threshold, it indicates that the condition of the input air is good, and then generate an air intake normal signal.

[0054] The air intake analysis module of the air compressor sends the air intake normal signal to the air compressor exhaust analysis module. When the air compressor exhaust analysis module receives the air intake normal signal, it analyzes the exhaust control performance of the air compressor, generates an exhaust control optimization signal or an exhaust control abnormal signal through the analysis, and sends the exhaust control abnormal signal to the central monitoring terminal. When the central monitoring terminal receives the exhaust control abnormal signal, it issues a corresponding warning, which can accurately judge the exhaust control performance of the melting furnace air compressor. When generating an exhaust control abnormal signal, it reminds the management personnel to conduct a cause investigation and make reasonable improvement measures, ensuring the operation effect of the air compressor while further reducing energy consumption; the specific analysis process of the air compressor exhaust analysis module is as follows:

[0055] Collect the exhaust flow rate and exhaust pressure of the air compressor and mark them as the exhaust flow condition value and the exhaust pressure condition value respectively. Numerically compare the exhaust flow condition value and the exhaust pressure condition value with a preset exhaust flow condition value range and a 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 pipe control of the air compressor is poor, and then judge that the air compressor is in an exhaust deviation state;

[0056] Obtain the total duration of the air compressor in the exhaust deviation state per unit time and mark it as the exhaust deviation time value, and calculate the average value of the deviation values of all exhaust flow condition values per unit time compared with the median of the preset exhaust flow condition value range to obtain the marked exhaust flow deviation value, and calculate the average value of the deviation values of all exhaust pressure condition values per unit time compared with the median of the preset exhaust pressure condition value range to obtain the exhaust pressure deviation value;

[0057] The exhaust control coefficient XP is numerically calculated by the formula XP = np×SF + rw×GX + tq×YW, where SF is the exhaust deviation value, GX is the exhaust flow deviation value, and YW is the exhaust pressure deviation value; np, rw, and tq are preset weight coefficients with values greater than zero. Moreover, the larger the value of the exhaust control coefficient XP, the worse the exhaust control condition of the smelting furnace air compressor;

[0058] The exhaust control coefficient XP is numerically compared with a 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. Then, an exhaust control anomaly 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. Then, an exhaust control excellent signal is generated.

[0059] When the ash removal non-essential signal, the intake normal signal, and the exhaust control excellent signal are generated, it indicates that the influence of each factor on the energy consumption of the smelting furnace air compressor is small. The energy consumption acquisition and analysis module obtains the operation mode of the smelting furnace air compressor, collects the actual energy consumption data of the corresponding air compressor in the corresponding operation 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 sent to the central monitoring terminal. When the central monitoring terminal receives the energy consumption alarm signal, it issues a corresponding warning to remind the management personnel to conduct a cause investigation and make reasonable improvement measures to minimize the operation energy consumption of the smelting furnace air compressor.

[0060] Embodiment 2: As Figure 2 shown, the difference between this embodiment and Embodiment 1 is that the energy consumption acquisition and analysis module is communicatively connected to the air compressor diagnosis module. The energy consumption acquisition 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 conducts an operation diagnosis and analysis of the air compressor, determines whether to generate a stop alarm signal or a replacement alarm signal through the analysis, and sends the stop alarm signal or the replacement alarm signal to the central monitoring terminal. When the management personnel receive the stop alarm signal, they stop the operation of the smelting furnace air compressor and conduct repairs. When they receive the replacement alarm signal, they can scrap the air compressor according to needs, which is conducive to the management personnel taking corresponding matching treatment measures for the air compressor to 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 and analysis is as follows:

[0061] Collect the production date of the corresponding air compressor, mark the time interval between the current date and the production date as the production value of the air compressor, and mark the total operating duration of the corresponding air compressor in the historical stage as the operating value of the air compressor; and trace back from the current date as the end date and set the detection period with the number of days as K1. Preferably, K1 is 60 days; mark the frequency of faults occurring to the corresponding air compressor within the detection period as the fault value of the air compressor.

[0062] Perform numerical calculation on the production value QP of the air compressor, the operating value HF of the air compressor, and the fault value GM of the air compressor through the formula GZ = a×QP + c×HF + m×GM to obtain the diagnosis value GZ of the air compressor; where a, c, and m are preset weight coefficients with values greater than zero, and moreover, the larger the value of the diagnosis value GZ of the air compressor, the more serious the possible performance decline of the air compressor; compare the diagnosis value GZ of the air compressor with the preset air compressor diagnosis threshold. If the diagnosis value GZ of the air compressor exceeds the preset air compressor diagnosis threshold, it indicates that the performance decline of the air compressor may be relatively serious and it is likely to cause an increase in its operating energy consumption, then generate a replacement alarm signal.

[0063] Furthermore, if the diagnosis value GZ of the air compressor does not exceed the preset air compressor diagnosis threshold, collect the start operation moment of the air compressor for this time, calculate the time difference between the current moment and the start operation moment for this time to obtain the operation duration for this time, compare the operation duration for this time with the preset operation duration threshold for this time. If the operation duration for this time exceeds the preset operation duration threshold for this time, it indicates that the operation duration of the melting furnace air compressor for this time is relatively long and it is likely to cause an increase in its energy consumption, then generate a stop alarm signal.

[0064] If the operation duration for this time does not exceed the preset operation duration threshold for this time, collect the moment when the air compressor stopped running for the previous adjacent time and mark it as the outage moment, calculate the time difference between the outage moment and the start operation moment for this time to obtain the outage duration.

[0065] Calculate the ratio of the outage duration to the operation duration of the previous adjacent operation to obtain the outage compliance value. If the outage compliance value does not exceed the preset outage compliance threshold, it indicates that the rest duration between two adjacent operations is too short and the state of the air compressor has not been effectively restored. Then mark the previous adjacent operation as a characteristic operation and trace back until the outage compliance value of a certain operation exceeds the preset outage compliance threshold, and accordingly obtain all the characteristic operations of this operation.

[0066] Obtain the operation durations of all the characteristic operations, calculate the sum of the operation durations of all the characteristic operations and the operation duration for this time to obtain the operation condition value, and calculate the sum of all the involved outage durations to obtain the stop condition value. Calculate the ratio of the operation condition value to the stop condition value to obtain the stop necessity coefficient.

[0067] The necessary stop coefficient is numerically compared with a preset necessary stop coefficient threshold. If the necessary stop coefficient exceeds the preset necessary stop coefficient threshold, it indicates that the air compressor of the melting furnace should be repaired in a timely manner to restore the air compressor to a good operating state, thereby reducing the operating energy consumption, and then a stop alarm signal is generated.

[0068] Embodiment 3: As Figure 3 shown, the difference between this embodiment and Embodiment 1 and Embodiment 2 is that a method for controlling the operating energy consumption of an air compressor for a melting furnace proposed by the present invention includes the following steps:

[0069] Step 1: Generate an ash removal alarm signal or an ash removal non-necessary signal through ash removal necessity analysis;

[0070] Step 2: When generating an ash removal non-necessary signal, analyze the intake condition of the air compressor, and generate an intake abnormal signal or an intake normal signal through the analysis;

[0071] Step 3: When generating an intake normal signal, analyze the exhaust control performance of the air compressor, and generate an exhaust control optimization signal or an exhaust control abnormal signal through the analysis;

[0072] Step 4: When generating an ash removal non-necessary signal, an intake normal signal, and an exhaust control optimization signal, analyze the energy consumption performance of the corresponding air compressor to determine whether an energy consumption alarm signal is generated;

[0073] Step 5: When generating an ash removal alarm signal, an intake abnormal signal, an exhaust control abnormal signal, or an energy consumption alarm signal, the central monitoring terminal issues a warning.

[0074] The working principle of the present invention: During use, it is judged whether it is necessary to clean the filter in the air compressor of the melting furnace through ash removal necessity analysis, so as to timely reduce the resistance of the air intake system in the air compressor of the melting furnace. When generating a non-necessary ash removal signal, analyze the intake condition of the air compressor of the melting furnace to timely adjust the input air, reduce the processing difficulty of the air compressor of the melting furnace and its operating energy consumption. When generating an intake normal signal, analyze the exhaust control performance of the air compressor of the melting furnace, which is beneficial to ensuring the operating effect of the air compressor of the melting furnace and reducing its operating energy consumption. And when excluding relevant influencing factors, monitor and analyze the energy consumption performance of the air compressor of the melting furnace through the energy consumption acquisition and analysis module and give a timely warning, realizing the effective control of the operating energy consumption of the air compressor of the melting furnace, significantly reducing the workload and management difficulty of managers, and having a high level of intelligence.

[0075] The above formulas are all dimensionless and only take their numerical values for calculation. The formulas are obtained by collecting a large amount of data for software simulation to get a formula closest to the actual situation. The preset parameters in the formulas are set by those skilled in the art according to the actual situation. The preferred embodiments of the present invention disclosed above are only used to help explain the present invention. The preferred embodiments do not elaborate on all the details and do not limit the invention to only the specific embodiments. Obviously, many modifications and variations can be made according to the content of this specification. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the present invention, so that those skilled in the relevant technical field can well understand and utilize the present invention. The present invention is only limited by the claims and their full scope and equivalents.

Claims

1. A control system for the operating energy consumption of the air compressor of a smelting furnace, characterized in that, It includes a filter ash removal analysis module, an air compressor intake analysis module, an air compressor exhaust analysis module, an energy consumption acquisition 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-necessary signal through ash removal necessity analysis. When generating an ash removal non-necessary signal, the air compressor intake analysis module analyzes the intake condition of the air compressor, and generates an intake abnormal signal or an intake normal signal through the analysis. When generating an intake normal signal, the air compressor exhaust analysis module analyzes the exhaust control performance of the air compressor, and generates an exhaust control optimization signal or an exhaust control abnormal signal through the analysis. When generating an ash removal non-necessary signal, an intake normal signal, and an exhaust control optimization signal, the energy consumption acquisition and analysis module obtains the operating mode of the melting furnace air compressor, collects the actual energy consumption data of the corresponding air compressor in the corresponding operating mode per unit time, and 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 terminal. The specific analysis process of the air compressor intake analysis module is as follows: The intake coefficient is obtained through numerical calculation of 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 an intake abnormal coefficient; the number of intake abnormal coefficients per unit time is obtained and its ratio with the number of intake coefficients is calculated to obtain an intake abnormal detection value, and the average value of all intake coefficients per unit time is calculated to obtain an intake evaluation value. If the intake abnormal detection value or the intake evaluation value exceeds the corresponding preset threshold, an intake abnormal signal is generated; otherwise, an intake normal signal is generated.

2. The operation energy consumption control system for the air compressor of the smelting furnace according to claim 1, wherein, The specific analysis process of the ash removal necessity analysis includes: The total duration of air input by the corresponding air compressor during the ash removal interval is marked as the total air input duration value. The total duration during which the dust content of the air entering the corresponding air compressor during the ash removal interval exceeds the preset dust content threshold is collected and marked as the dirty air input duration value. If the total air input duration value or the dirty air input duration value exceeds the corresponding preset threshold, an ash removal alarm signal is generated.

3. The operation energy consumption control system of a melting furnace air compressor according to claim 2, characterized in that, If both the total air input duration value and the dirty air input duration value do not exceed the corresponding preset threshold, the filter ash removal analysis value is obtained through numerical calculation of the total air input duration value, the dirty air input duration value, and the dirty performance value. If the filter ash removal analysis value exceeds the preset filter ash removal analysis threshold, an ash removal alarm signal is generated; if the filter ash removal analysis value does not exceed the preset filter ash removal analysis threshold, an ash removal non-necessary signal is generated.

4. The energy consumption control system for the air compressor of a smelting furnace according to claim 1, wherein, The specific analysis process of the air compressor exhaust analysis module is as follows: The total duration of the air compressor in the exhaust deviation state per unit time is obtained and marked as the exhaust deviation duration value. The exhaust control coefficient is obtained through numerical calculation of the exhaust deviation duration 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 abnormal signal is generated; if the exhaust control coefficient does not exceed the preset exhaust control coefficient threshold, an exhaust control optimization signal is generated.

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

6. The operation energy consumption control system of a melting furnace air compressor according to claim 5, characterized in that, The specific analysis process of the air compressor operating diagnosis and analysis is as follows: The air compressor diagnosis value is obtained by performing numerical calculations on the air compressor production value, the air compressor operating 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.

7. The operation energy consumption control system of a smelting furnace air compressor according to claim 6, characterized in that, If the air compressor diagnosis value does not exceed the preset air compressor diagnosis threshold, the time difference between the current moment and the start time of the current operation is calculated to obtain the current operation duration. If the current operation duration exceeds the preset current operation duration threshold, a stop alarm signal is generated; if the ratio of the running condition value to the stop condition value is calculated to obtain the stop necessity coefficient, and if the stop necessity coefficient exceeds the preset stop necessity coefficient threshold, a stop alarm signal is generated.

8. A control method for the operating energy consumption of an air compressor in a smelting furnace, characterized in that, This method uses the melting furnace air compressor operating energy consumption control system described in any one of claims 1-7.

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