A shelling cylinder control method and system based on air pressure detection

Abstract

The present invention discloses a shelling cylinder control method and system based on air pressure detection, which belongs to the field of aluminum electrolysis technology, including: obtaining a waveform diagram and a voltage change curve of the shelling cylinder during the whole shelling process; constructing a shelling cylinder digital model based on the waveform diagram and the voltage change curve; collecting the air pressure of the shelling cylinder in real time, generating control instructions according to the air pressure, voltage and the shelling cylinder digital model; and automatically controlling the shelling cylinder based on the control instructions. Compared with the traditional cylinder, the present invention can retract the hammer head in advance through time setting, reduce the soaking and loss of the hammer head, intelligently detect whether the hammer head has penetrated the shell surface and issue an alarm, and intelligently detect the jamming of the hammer head and issue an alarm, thereby improving production efficiency and product quality.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum electrolysis, and more particularly to a method and system for controlling a shelling cylinder based on air pressure detection. Background Art

[0002] In the electrolytic aluminum production process, the shell breaking cylinder plays a vital role. It is mainly used to break the hard shell covering the surface of the electrolytic cell to ensure that materials such as alumina or fluoride salt can be smoothly put into the electrolytic cell to participate in the electrochemical reaction. However, there are a series of problems in the application of traditional shell breaking cylinders, which seriously affect the production efficiency and product quality. The traditional shell breaking cylinder has the following main problems:

[0003] (1) The traditional shelling cylinder cannot accurately control the hammer's striking force and time, causing the hammer to soak in the electrolyte for too long, causing the hammer to stick to the electrolyte and form a gourd-shaped shape, affecting the quantitative input of materials, producing an anode effect, increasing power consumption and reducing production. In addition, the hammer wears quickly, melts quickly, has a short life, pollutes the aluminum liquid, and affects product quality.

[0004] (2) During the shelling process, if the shell surface is too thick, the traditional shelling cylinder cannot penetrate it and cannot give an alarm in time, requiring manual inspection and intervention. If it is not discovered in time, it will affect the electrochemical reaction of alumina, reduce production efficiency, and waste electrolysis energy consumption.

[0005] (3) Once the hammer head of the traditional shell-breaking cylinder gets stuck, it cannot give an alarm in time, causing the hammer head to be immersed in the electrolyte for a long time, reducing the service life of the hammer head, affecting the iron content in the electrolyte, and reducing the grade of the original aluminum.

[0006] Therefore, how to provide a shelling cylinder control method and system based on air pressure detection to improve production efficiency and product quality is a problem that technical personnel in this field urgently need to solve. Summary of the invention

[0007] In view of this, the present invention provides a shelling cylinder control method and system based on air pressure detection, which monitors the air pressure changes of the shelling cylinder in real time, realizes precise control of the action state of the hammer head, and improves production efficiency and product quality.

[0008] In order to achieve the above object, the present invention adopts the following technical solution:

[0009] A shelling cylinder control method based on air pressure detection, comprising:

[0010] Obtain the waveform diagram and voltage change curve of the whole shelling process of the shelling cylinder;

[0011] Constructing a shelling cylinder digital model based on the waveform diagram and the voltage variation curve;

[0012] Collecting the air pressure and voltage of the shelling cylinder in real time, and generating control instructions according to the air pressure, the voltage and the digital model of the shelling cylinder;

[0013] The shelling cylinder is automatically controlled based on the control instruction.

[0014] Preferably, constructing a shelling cylinder digital model based on the waveform diagram and the voltage variation curve includes:

[0015] The waveform and voltage curve are analyzed respectively to obtain the working time, waveform and voltage value of each stage in the shelling process;

[0016] Acquire waveform features of each stage based on the waveform diagrams of each stage;

[0017] A digital model of the shelling cylinder is constructed based on the working time, waveform characteristics and voltage value.

[0018] Preferably, the air pressure and voltage of the shelling cylinder are collected in real time, and a control instruction is generated according to the air pressure, the voltage and the digital model of the shelling cylinder, including:

[0019] A sensor is used to detect the air pressure in and out of the shelling cylinder pipeline, a real-time waveform is generated according to the air pressure, a shelling stage and the working time and stroke of the shelling stage are determined according to the real-time waveform and the shelling cylinder digital model, the shelling stage is timed, and when the timing reaches the working time of the corresponding shelling stage, a control instruction is issued;

[0020] judging whether the shell breaking hammer head has entered the electrolyte according to the voltage value;

[0021] If it is judged that the electrolyte has not entered, it is determined that the shell hammer head has not penetrated;

[0022] If it is determined that the shell hammer has entered the electrolyte, whether the shell breaking hammer head is recovered normally is determined according to the working time, and a control instruction is generated based on the recovery result.

[0023] Preferably, in the smashing stage, according to issuing a control instruction, the steps include:

[0024] Set up several gear adjustment mechanisms, each gear adjustment mechanism has the same time interval, adjust the set gear according to the data returned after each shelling is completed, and obtain the best recovery time.

[0025] Preferably, when it is monitored that the stroke of the shelling stage is less than the stroke of the shelling stage determined in the digital model of the shelling cylinder, the current stroke runs according to the preset working time and generates an additional hitting command until the shell surface is penetrated. If the shell surface is not penetrated within the preset number of times, an alarm is issued.

[0026] Preferably, when it is monitored that the working time of the recovery stage is less than the recovery working time determined in the digital model of the shelling cylinder, the current stroke runs according to the preset working time, and generates a supplementary shelling and recovery instruction until the recovery is successful. If the recovery is not successful within the preset number of times, an alarm is issued.

[0027] A control system for a shelling cylinder based on air pressure detection, the system is used to implement the above-mentioned shelling cylinder control method based on air pressure detection, the system comprises:

[0028] The acquisition module is used to obtain the waveform diagram and voltage change curve of the whole shelling process of the shelling cylinder;

[0029] A digital model building module is used to build a digital model of the shelling cylinder based on the waveform diagram and the voltage variation curve;

[0030] The control module is used to generate control instructions according to the real-time collected air pressure and voltage of the shell-breaking cylinder and the digital model of the shell-breaking cylinder, and to automatically control the shell-breaking cylinder.

[0031] It can be seen from the above technical solutions that, compared with the prior art, the present invention discloses a shell-breaking cylinder control method and system based on air pressure detection, which can retract the hammer head in advance through time setting, reduce the soaking and loss of the hammer head, intelligently detect whether the hammer head has penetrated the shell surface and issue an alarm, and intelligently detect the jamming of the hammer head and issue an alarm, thereby improving production efficiency and product quality. In addition, the redundant fault setting set by the present invention can ensure that the normal shell-breaking operation of the cylinder will not be affected when the control cabinet fails, thereby ensuring the continuity of production. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0033] Figure 1 A schematic diagram of the method provided by the present invention;

[0034] Figure 2 This is a structural diagram of a device for realizing early recovery, intelligent supplementary smashing and supplementary pulling according to the present invention;

[0035] Figure 3 A system framework diagram provided by the present invention;

[0036] Figure 4 This is the waveform diagram of the entire working process of the shelling cylinder. DETAILED DESCRIPTION

[0037] 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.

[0038] The embodiment of the present invention discloses a shelling cylinder control method based on air pressure detection, such as Figure 1 As shown, including:

[0039] Obtain the waveform diagram and voltage change curve of the whole shelling process of the shelling cylinder;

[0040] Construct a digital model of the shelling cylinder based on the waveform diagram and voltage variation curve;

[0041] The air pressure and voltage of the shelling cylinder are collected in real time, and control instructions are generated according to the air pressure, voltage and digital model of the shelling cylinder. In view of the on-site working conditions of the electrolytic aluminum plant and the system's need for fine pressure sampling, a high-precision and high-environment pressure sensor that can meet the on-site conditions is used as the basis for data collection.

[0042] The shelling cylinder is automatically controlled based on the control instructions.

[0043] Specifically, through a large number of tests, the whole process of cylinder shelling was summarized.

[0044] In another embodiment, the on-site air pressure may vary, resulting in different waveform amplitudes collected; the individual conditions of each electrolytic cell cylinder are also different, resulting in different stage operation times for each cylinder. Therefore, the operation time of a specific cylinder can be obtained by running it several times, and the judgment time of air injection, incomplete injection, and injection can be adjusted accordingly based on this time. If the cylinder is replaced, the time of each stage of cylinder operation can be re-learned to solve the problem of product differences, comprehensively improve the system control accuracy, and reduce the system false alarm rate.

[0045] The digital model of the shelling cylinder is constructed based on the waveform diagram and voltage change curve, including:

[0046] The waveform and voltage curve are analyzed separately to obtain the working time, waveform and voltage value of each stage in the shelling process; Figure 4 The waveform diagram of the whole shelling process is shown;

[0047] Acquire waveform features of each stage based on the waveform diagrams of each stage;

[0048] A digital model of the shelling cylinder is constructed based on working time, waveform characteristics and voltage value.

[0049] Furthermore, the air pressure and voltage of the shelling cylinder are collected in real time, and control instructions are generated according to the air pressure, voltage and the digital model of the shelling cylinder, including:

[0050] A sensor is used to detect the air pressure in and out of the shelling cylinder pipeline, and a real-time waveform is generated according to the air pressure. The shelling stage and the working time and stroke of the shelling stage are determined according to the real-time waveform and the digital model of the shelling cylinder. The shelling stage is timed, and when the timing reaches the working time of the corresponding shelling stage, a control instruction is issued;

[0051] Determine whether the shelling hammer head has entered the electrolyte according to the voltage value;

[0052] If it is judged that the electrolyte has not entered, it is determined that the shell hammer head has not penetrated;

[0053] If it is determined that the electrolyte has entered, whether the shelling hammer head is recovered normally is determined based on the working time, and a control instruction is generated based on the recovery result.

[0054] like Figure 2 As shown, in the embodiment of the present invention, automatic early retraction is achieved by disconnecting the normally closed contact. The supplementary smashing and pulling out are achieved by connecting a normally open contact in parallel with the normally open contact of the on-site slot control cabinet. In terms of intelligent control logic, by controlling the solenoid valve coil circuit, the early retraction, supplementary smashing if the hammer cannot be penetrated, and supplementary pulling out if the hammer cannot be retracted are automatically realized without human intervention, thus saving human resources. At the same time, through the redundant circuit design, it can ensure that the original production control system works normally in the event of problems with the own system, without affecting production operations, and avoiding product risks.

[0055] In the smashing stage, because the hammer has inertia, in order to reduce the time the hammer is immersed in the electrolyte, a retraction command will be issued in advance. After the full stroke time of the cylinder has been obtained, the system will issue a retraction command before the hammer reaches the full stroke.

[0056] Furthermore, in the smashing stage, according to the control instructions issued, including:

[0057] Set up several gear adjustment mechanisms, each gear adjustment mechanism has the same time interval, adjust the set gear according to the data returned after each shelling, and obtain the best recovery time. Specifically, 5 gears of manual experience intervention adjustment can be made, and the recovery time can be manually intervened through the buttons on the control cabinet, and the time can be adjusted to solve the length and depth of the hammer head.

[0058] Furthermore, when it is monitored that the stroke of the shelling stage is less than the stroke of the shelling stage determined in the digital model of the shelling cylinder, the current stroke runs according to the preset working time, and generates an additional hitting command until the shell surface is penetrated. If the shell surface is not penetrated within the preset number of times, an alarm is issued. Specifically, in the digital model, the monitoring intelligence detects that the electrolyte crust cannot be penetrated (compared with the full stroke, when the crust cannot be penetrated, because the hammer head stops moving in advance, the stroke will become shorter, and the time of smashing will also become shorter accordingly, which can determine that the crust cannot be penetrated), and the first stroke is still operated according to the set time (3-5 seconds) of the original factory shelling system, without intelligent intervention. Then the system automatically adds 2 additional hits, each for 5 seconds, and the recovery time is not included in the 5 seconds, and the time and number do not need to be set. In the additional stroke, the next additional smashing will start immediately after the first hammer head is recovered. If the shell surface is penetrated by the first additional smashing, the second additional smashing will not be performed. If the shell surface is not penetrated by the first initial smashing and the subsequent (2-5) additional smashing, an alarm will be issued and manual processing will be carried out.

[0059] In the alarm state, as long as the shell surface is penetrated, the alarm will be lifted. (After the alarm, manual processing will be carried out. If it is not handled, after the alarm, wait until the next round of system smashing, if it has not been penetrated, it will continue to alarm).

[0060] Preferably, when it is monitored that the working time of the recovery stage is less than the recovery working time determined in the digital model of the shelling cylinder, the current stroke runs according to the preset working time, and generates a supplementary shelling recovery instruction until the recovery is successful. If the recovery is not successful within the preset number of times, an alarm is issued. Among them, during the shelling recovery process, if the intelligent system detects that the hammer head is stuck (by recovering the waveform, it is judged whether it is stuck. If it is stuck, the recovery time will be shortened, and the hammer head movement time will also be shortened), if it cannot be recovered, the system will prioritize waiting for the shelling system to complete the entire recovery process, and then automatically supplement the shelling recovery process. The first supplementary pulling process is to smash down first, and start to retract as soon as the full stroke is reached, and try to reduce the time of the hammer head soaking in the electrolyte. The recovery process starts to count 1 second after it hits the shell surface. If it is not recovered successfully, (2-5) supplementary pulling is performed. The process is the same as the first time. If the first supplementary pulling is successful, the second shelling supplementary pulling process will not be performed. If (2-5) supplementary pullings are not successful, an alarm is issued.

[0061] In the alarm state, the alarm is cleared after successful recovery.

[0062] A control system for a shelling cylinder based on air pressure detection, the system is used to implement the above-mentioned shelling cylinder control method based on air pressure detection, such as Figure 3 As shown, the system includes:

[0063] The acquisition module is used to obtain the waveform diagram and voltage change curve of the whole shelling process of the shelling cylinder;

[0064] A digital model building module builds a digital model of the shelling cylinder based on the waveform diagram and voltage change curve;

[0065] The control module is used to generate control instructions according to the real-time collected air pressure and voltage of the shell-breaking cylinder and the digital model of the shell-breaking cylinder, and to automatically control the shell-breaking cylinder.

[0066] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0067] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for controlling a shelling cylinder based on air pressure detection, characterized in that: include: Obtain the waveform diagram and voltage change curve of the whole shelling process of the shelling cylinder; Constructing a shelling cylinder digital model based on the waveform diagram and the voltage variation curve; Collecting the air pressure and voltage of the shelling cylinder in real time, and generating control instructions according to the air pressure, the voltage and the digital model of the shelling cylinder; The shelling cylinder is automatically controlled based on the control instruction.

2. The method for controlling a shelling cylinder based on air pressure detection according to claim 1, characterized in that: The digital model of the shelling cylinder is constructed based on the waveform diagram and the voltage curve, including: The waveform and voltage curve are analyzed respectively to obtain the working time, waveform and voltage value of each stage in the shelling process; Acquire waveform features of each stage based on the waveform diagrams of each stage; A digital model of the shelling cylinder is constructed based on the working time, waveform characteristics and voltage value.

3. The method for controlling a shelling cylinder based on air pressure detection according to claim 2, characterized in that: The air pressure and voltage of the shelling cylinder are collected in real time, and a control instruction is generated according to the air pressure, the voltage and the digital model of the shelling cylinder, including: A sensor is used to detect the air pressure in and out of the shelling cylinder pipeline, a real-time waveform is generated according to the air pressure, a shelling stage and the working time and stroke of the shelling stage are determined according to the real-time waveform and the shelling cylinder digital model, the shelling stage is timed, and when the timing reaches the working time of the corresponding shelling stage, a control instruction is issued; judging whether the shell breaking hammer head has entered the electrolyte according to the voltage value; If it is judged that the electrolyte has not entered, it is determined that the shell hammer head has not penetrated; If it is determined that the shell hammer has entered the electrolyte, whether the shell breaking hammer head is recovered normally is determined according to the working time, and a control instruction is generated based on the recovery result.

4. The method for controlling a shelling cylinder based on air pressure detection according to claim 3 is characterized in that: During the smashing phase, control instructions are issued, including: Set up several gear adjustment mechanisms, each gear adjustment mechanism has the same time interval, adjust the set gear according to the data returned after each shelling is completed, and obtain the best recovery time.

5. The method for controlling a shelling cylinder based on air pressure detection according to claim 4, characterized in that: When it is monitored that the stroke of the shelling stage is less than the stroke of the shelling stage determined in the digital model of the shelling cylinder, the current stroke runs according to the preset working time and generates an additional hitting command until the shell surface is penetrated. If the shell surface is not penetrated within the preset number of times, an alarm is issued.

6. The method for controlling a shelling cylinder based on air pressure detection according to claim 4, characterized in that: When it is monitored that the working time of the recovery stage is less than the recovery working time determined in the digital model of the shelling cylinder, the current stroke runs according to the preset working time and generates a supplementary shelling and recovery instruction until the recovery is successful. If the recovery is not successful within the preset number of times, an alarm is issued.

7. A control system for a shelling cylinder based on air pressure detection, characterized in that: The system is used to implement a shelling cylinder control method based on air pressure detection as described in any one of claims 1 to 6, and the system includes: The acquisition module is used to obtain the waveform diagram and voltage change curve of the whole shelling process of the shelling cylinder; A digital model building module is used to build a digital model of the shelling cylinder based on the waveform diagram and the voltage variation curve; The control module is used to generate control instructions according to the real-time collected air pressure and voltage of the shell-breaking cylinder and the digital model of the shell-breaking cylinder, and to automatically control the shell-breaking cylinder.

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