Fault diagnosis method for aluminum electrolysis cell

Abstract

The invention relates to the technical field of electrolytic aluminum production, and provides an aluminum electrolysis cell fault diagnosis method which comprises the steps of collecting and analyzing molten aluminum precipitation rate data of an aluminum electrolysis cell, determining an electrolytic reaction abnormal area, analyzing electrolytic current data in the aluminum electrolysis cell, judging whether a current loss event occurs in the aluminum electrolysis cell or not, and judging whether the current loss event occurs in the aluminum electrolysis cell. Analyzing current transmission data among different cathodes in the aluminum electrolysis cell, and determining electric leakage fault information of the aluminum electrolysis cell, so as to adjust working states of the cathodes in the aluminum electrolysis cell, analyze dynamic data of molten aluminum in the aluminum electrolysis cell, determine an abnormal fluctuation area of the molten aluminum, and collect current data of the cathodes in the aluminum electrolysis cell; current parameters in the aluminum electrolysis cell are detected in different regions, and a parameter basis is provided for judging whether a cathode damage fault occurs in the aluminum electrolysis cell or not; based on the cathode damage fault information, the electrolytic reaction state change information in the aluminum electrolysis cell is predicted, so that whether the aluminum electrolysis cell can continuously perform electrolysis work or not is judged, and the fault diagnosis accuracy and reliability of the aluminum electrolysis cell are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electrolytic aluminum production, and in particular to a method for diagnosing faults in aluminum electrolytic cells. Background Art

[0002] The electrolytic aluminum industry mainly adopts the cryolite-alumina molten salt electrolysis method, that is, an electrolyte is placed inside the electrolytic cell, and alumina is dissolved into the electrolyte, and a direct current is applied to the electrolyte, so that the alumina will be reduced to liquid aluminum metal. The aluminum electrolytic cell mainly includes two parts, the anode and the cathode. During the electrolytic operation of the electrolytic cell, problems such as excessive leakage current or cathode damage will inevitably occur, which will affect the normal operation of the electrolytic cell itself. The existing technology usually checks the hardware parts such as the cathode of the electrolytic cell and its related circuits to determine the fault type and situation of the electrolytic cell. This method requires professionals to disassemble the electrolytic cell to achieve, and it is impossible to perform synchronous fault diagnosis and detection while the electrolytic cell is working, which increases the fault diagnosis cost of the electrolytic cell. The current between the anode and cathode in the electrolytic cell is an important parameter for the operation of the electrolytic cell. When the electrolytic cell fails, it will show corresponding abnormal conditions. Therefore, it is of great significance to synchronously detect and analyze parameters such as current during the operation of the electrolytic cell, so as to diagnose and identify the faults of the electrolytic cell. Summary of the invention

[0003] In view of the defects of the prior art, the present invention provides a fault diagnosis method for an aluminum electrolytic cell, which collects and analyzes the aluminum liquid precipitation rate data of the aluminum electrolytic cell, determines the abnormal area of ​​the electrolytic reaction, and collects the electrolytic current data in the aluminum electrolytic cell; analyzes the electrolytic current data to determine whether a current loss event occurs in the aluminum electrolytic cell, and analyzes the current transmission data between different cathodes in the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, thereby adjusting the cathode working state in the aluminum electrolytic cell to avoid excessive leakage current in the cell affecting the electrolytic efficiency and safety; analyzes the aluminum liquid dynamic state of the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, and adjusts the cathode working state in the aluminum electrolytic cell to avoid excessive leakage current in the cell affecting the electrolytic efficiency and safety; analyzes the aluminum liquid dynamic state of the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, and adjusts the cathode working state in the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, and adjusts the leakage fault information of the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, and adjusts the leakage fault state of the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, and adjusts the leakage fault state of the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, and adjusts the leakage fault data ... The state data of the aluminum liquid is used to determine the area where the aluminum liquid fluctuates abnormally, so as to collect the cathode current data in the aluminum reduction cell, and detect the current parameters in the aluminum reduction cell by area, so as to provide parameter basis for judging whether the cathode damage fault occurs in the aluminum reduction cell; based on the cathode damage fault information, the state change information of the electrolytic reaction in the aluminum reduction cell is predicted, so as to judge whether the aluminum reduction cell can continue to carry out electrolysis work, and the current data and aluminum liquid dynamic data of the aluminum reduction cell are analyzed simultaneously, so as to identify the fault of the aluminum reduction cell from different aspects, and improve the accuracy and reliability of fault diagnosis of the aluminum reduction cell.

[0004] The present invention provides a method for diagnosing faults of an aluminum electrolysis cell, comprising the following steps: Step S1, based on the structural state of the aluminum electrolysis cell, collecting aluminum liquid precipitation rate data of the aluminum electrolysis cell; analyzing the aluminum liquid precipitation rate data to determine the abnormal electrolysis reaction area in the aluminum electrolysis cell; based on the spatial state information of the abnormal electrolysis reaction area, collecting electrolysis current data in the aluminum electrolysis cell; Step S2, analyzing the electrolysis current data to determine whether a current loss event occurs inside the aluminum electrolysis cell; when a current loss event occurs, obtaining current transmission data between different cathodes in the aluminum electrolysis cell; based on the change characteristic information of the current transmission data, obtaining leakage fault information of the aluminum electrolysis cell, thereby adjusting the cathode working state in the aluminum electrolysis cell; Step S3, acquiring the aluminum liquid dynamic data of the aluminum electrolysis cell, analyzing the aluminum liquid dynamic data, and determining the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell; based on the spatial state information of the aluminum liquid fluctuation abnormal area, collecting the corresponding cathode current data in the aluminum electrolysis cell; Step S4, analyzing the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell; based on the cathode damage fault information, predicting the electrolysis reaction state change information in the aluminum electrolysis cell, so as to determine whether the aluminum electrolysis cell can continue to perform electrolysis work.

[0005] In one embodiment disclosed in the present application, in the step S1, based on the structural state of the aluminum electrolysis cell, the aluminum liquid precipitation rate data of the aluminum electrolysis cell is collected; the aluminum liquid precipitation rate data is analyzed to determine the abnormal electrolysis reaction area in the aluminum electrolysis cell, including: Based on the cathode distribution state in the aluminum electrolytic cell, the reaction areas corresponding to all the cathodes in the aluminum electrolytic cell are determined; the dynamic image of the electrolytic reaction inside the aluminum electrolytic cell is collected, and based on the reaction areas corresponding to all the cathodes, the dynamic image of the electrolytic reaction is segmented to obtain a number of dynamic sub-images of the electrolytic reaction corresponding to all the reaction areas one by one; each dynamic sub-image of the electrolytic reaction is identified to obtain the aluminum liquid precipitation rate data of each reaction area; wherein the aluminum liquid precipitation rate data includes the aluminum liquid deposition weight generated by the electrolytic reaction in each reaction area per unit time; A time domain variation analysis is performed on the aluminum liquid precipitation rate data to determine whether the aluminum liquid deposition rate in each reaction area shows a gradually decreasing trend; if so, it is determined that the reaction area belongs to an abnormal electrolytic reaction area in the aluminum electrolytic cell; if not, it is determined that the reaction area belongs to a normal electrolytic reaction area in the aluminum electrolytic cell.

[0006] In one embodiment disclosed in the present application, in the step S1, based on the spatial state information of the abnormal electrolytic reaction area, collecting electrolytic current data in the aluminum electrolysis cell includes: Based on the spatial position information of the abnormal electrolysis reaction area in the aluminum electrolysis cell, the electrolyte reaction space of the abnormal electrolysis reaction area in the aluminum electrolysis cell is determined; based on the boundary of the electrolyte reaction space, the electrolysis current data of the electrolyte reaction space is collected, and the electrolysis current data of all electrolyte reaction spaces are subjected to noise reduction filtering.

[0007] In one embodiment disclosed in the present application, in the step S2, analyzing the electrolysis current data to determine whether a current loss event occurs inside the aluminum electrolysis cell includes: Perform mean calculation on the electrolysis current data to obtain an average electrolysis current value of the electrolyte reaction space within a preset time interval; compare the average electrolysis current value with a preset current threshold value; if the average electrolysis current value is less than the preset current threshold value, it is determined that a current loss event has occurred inside the aluminum electrolysis cell; otherwise, it is determined that no current loss event has occurred inside the aluminum electrolysis cell.

[0008] In one embodiment disclosed in the present application, in step S2, when a current loss event occurs, current transmission data between different cathodes in the aluminum electrolysis cell is obtained, including: When a current loss event occurs, based on the position information of the reaction area corresponding to the current loss event in the aluminum electrolysis cell, the current transmission data between the cathodes corresponding to the reaction area corresponding to the current loss event and other adjacent reaction areas are obtained.

[0009] In one embodiment disclosed in the present application, in the step S2, based on the change characteristic information of the current transmission data, the leakage fault information of the aluminum electrolysis cell is obtained, so as to adjust the cathode working state in the aluminum electrolysis cell, including: Analyzing the current transmission data to obtain leakage current intensity variation data between cathodes corresponding to the reaction region corresponding to the current loss event and other adjacent reaction regions during the current transmission process; Based on the leakage current intensity change data, determine whether the corresponding cathode has a leakage current exceeding a preset intensity threshold and a preset duration threshold; if so, determine the corresponding cathode as the leakage fault source of the aluminum electrolysis cell, thereby generating leakage fault information of the aluminum electrolysis cell; Based on the distribution position information of all leakage fault sources in the aluminum electrolysis cell, the leakage fault sources in the aluminum electrolysis cell that are allowed to be shut down are determined, so that the cathodes corresponding to the leakage fault sources that are allowed to be shut down are switched to a closed state.

[0010] In one embodiment disclosed in the present application, in the step S3, the aluminum liquid dynamic data of the aluminum reduction cell is obtained, the aluminum liquid dynamic data is analyzed, and the aluminum liquid fluctuation abnormal area in the aluminum reduction cell is determined, including: Performing thermal infrared photography on the aluminum reduction cell to obtain a thermal infrared dynamic image of aluminum liquid in the aluminum reduction cell, analyzing the thermal infrared dynamic image of aluminum liquid to obtain aluminum liquid flow velocity data and aluminum liquid level rise velocity data of the aluminum reduction cell during the electrolysis process, and using the data as the aluminum liquid dynamic data; Analyze the aluminum liquid flow velocity data and the aluminum liquid level rise velocity data to determine the average amplitude of aluminum liquid fluctuation in the reaction area corresponding to each cathode in the aluminum electrolysis cell; The average amplitude of the aluminum liquid fluctuation is compared with the preset amplitude threshold. If the average amplitude of the aluminum liquid fluctuation exceeds the preset amplitude threshold, the corresponding reaction area is determined as the abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell; otherwise, the corresponding reaction area is not determined as the abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell.

[0011] In one embodiment disclosed in the present application, in the step S3, based on the spatial state information of the abnormal aluminum liquid fluctuation area, the corresponding cathode current data in the aluminum electrolysis cell is collected, including: Based on the distribution position information of the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell, the cathode injection current data of the aluminum liquid fluctuation abnormal area is obtained as the corresponding cathode current data in the aluminum electrolysis cell.

[0012] In one embodiment disclosed in the present application, in the step S4, analyzing the cathode current data to determine the cathode damage fault information in the aluminum electrolysis cell includes: The cathode injection current data in the aluminum liquid abnormal fluctuation area is analyzed to determine the cathode injection current density distribution information in the aluminum liquid abnormal fluctuation area; based on the cathode injection current density distribution information, the position information of the damaged cathode in the aluminum electrolytic cell is determined, and this is used as the cathode damage fault information in the aluminum electrolytic cell.

[0013] In one embodiment disclosed in the present application, in the step S4, based on the cathode damage fault information, predicting the electrolysis reaction state change information in the aluminum electrolysis cell to determine whether the aluminum electrolysis cell can continue to perform electrolysis work includes: Based on the position information of the damaged cathode in the aluminum electrolytic cell, data-driven inspection processing is performed on the circuit connected to the damaged cathode to determine whether the damaged cathode is in a software fault state or a hardware fault state; and based on the type of software fault state or hardware fault state in which the cathode is in, it is determined whether the aluminum electrolytic cell can continue to perform electrolysis.

[0014] Compared with the prior art, the aluminum electrolysis cell fault diagnosis method collects and analyzes the aluminum liquid precipitation rate data of the aluminum electrolysis cell, determines the abnormal electrolysis reaction area, and collects the electrolysis current data in the aluminum electrolysis cell; analyzes the electrolysis current data to determine whether a current loss event occurs in the aluminum electrolysis cell, and analyzes the current transmission data between different cathodes in the aluminum electrolysis cell to determine the leakage fault information of the aluminum electrolysis cell, so as to adjust the cathode working state in the aluminum electrolysis cell to avoid excessive leakage current in the cell affecting the electrolysis efficiency and safety; analyzes the aluminum liquid dynamic data of the aluminum electrolysis cell to determine whether a current loss event occurs in the aluminum electrolysis cell, and determines whether a current loss event occurs in the aluminum electrolysis cell. The abnormal area of ​​aluminum liquid fluctuation is determined to collect cathode current data in the aluminum electrolytic cell, and the current parameters in the aluminum electrolytic cell are detected in different areas to provide parameter basis for judging whether cathode damage fault occurs in the aluminum electrolytic cell; based on the cathode damage fault information, the electrolytic reaction state change information in the aluminum electrolytic cell is predicted to judge whether the aluminum electrolytic cell can continue to carry out electrolysis work, and the current data and aluminum liquid dynamic data of the aluminum electrolytic cell are analyzed simultaneously, so as to identify the fault of the aluminum electrolytic cell from different aspects and improve the accuracy and reliability of fault diagnosis of the aluminum electrolytic cell.

[0015] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description, claims, and drawings.

[0016] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] 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 some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 A schematic flow chart of the aluminum electrolysis cell fault diagnosis method provided by the present invention. DETAILED DESCRIPTION

[0019] 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.

[0020] See also Figure 1 , is a flow chart of a method for diagnosing a fault in an aluminum electrolysis cell provided by an embodiment of the present invention. The method for diagnosing a fault in an aluminum electrolysis cell comprises: Step S1, based on the structural state of the aluminum electrolysis cell, collecting aluminum liquid precipitation rate data of the aluminum electrolysis cell; analyzing the aluminum liquid precipitation rate data to determine the abnormal electrolytic reaction area in the aluminum electrolysis cell; based on the spatial state information of the abnormal electrolytic reaction area, collecting electrolytic current data in the aluminum electrolysis cell; Step S2, analyzing the electrolysis current data to determine whether a current loss event occurs inside the aluminum electrolytic cell; when a current loss event occurs, obtaining current transmission data between different cathodes in the aluminum electrolytic cell; based on the change characteristic information of the current transmission data, obtaining leakage fault information of the aluminum electrolytic cell, thereby adjusting the cathode working state in the aluminum electrolytic cell; Step S3, obtaining the aluminum liquid dynamic data of the aluminum electrolysis cell, analyzing the aluminum liquid dynamic data, and determining the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell; based on the spatial state information of the aluminum liquid fluctuation abnormal area, collecting the corresponding cathode current data in the aluminum electrolysis cell; Step S4, analyzing the cathode current data to determine the cathode damage fault information in the aluminum electrolytic cell; based on the cathode damage fault information, predicting the electrolytic reaction state change information in the aluminum electrolytic cell, so as to determine whether the aluminum electrolytic cell can continue to perform electrolysis work.

[0021] The aluminum electrolytic cell fault diagnosis method collects and analyzes aluminum liquid precipitation rate data of the aluminum electrolytic cell, determines the abnormal electrolytic reaction area, and collects electrolytic current data in the aluminum electrolytic cell; analyzes the electrolytic current data to determine whether a current loss event occurs in the aluminum electrolytic cell, and analyzes the current transmission data between different cathodes in the aluminum electrolytic cell to determine the leakage fault information of the aluminum electrolytic cell, so as to adjust the cathode working state in the aluminum electrolytic cell to avoid excessive leakage current in the cell affecting the electrolytic efficiency and safety; analyzes the aluminum liquid dynamic data of the aluminum electrolytic cell to determine the aluminum liquid fluctuation abnormal area, so as to collect the cathode current data in the aluminum electrolytic cell, and detects the current parameters in the aluminum electrolytic cell in different areas to provide parameter basis for judging whether a cathode damage fault occurs in the aluminum electrolytic cell; and also predicts the electrolytic reaction state change information in the aluminum electrolytic cell based on the cathode damage fault information, so as to judge whether the aluminum electrolytic cell can continue to perform electrolysis work, and simultaneously analyzes the current data and aluminum liquid dynamic data of the aluminum electrolytic cell, identifies the fault of the aluminum electrolytic cell from different aspects, and improves the accuracy and reliability of the fault diagnosis of the aluminum electrolytic cell.

[0022] Preferably, in step S1, based on the structural state of the aluminum electrolysis cell, collecting aluminum liquid precipitation rate data of the aluminum electrolysis cell; analyzing the aluminum liquid precipitation rate data to determine the abnormal electrolysis reaction area in the aluminum electrolysis cell, including: Based on the cathode distribution state in the aluminum electrolytic cell, the reaction areas corresponding to all cathodes in the aluminum electrolytic cell are determined; the dynamic image of the electrolytic reaction inside the aluminum electrolytic cell is collected, and based on the reaction areas corresponding to all cathodes, the dynamic image of the electrolytic reaction is segmented to obtain a number of dynamic sub-images of the electrolytic reaction corresponding to all reaction areas one by one; each dynamic sub-image of the electrolytic reaction is identified to obtain aluminum liquid precipitation rate data of each reaction area; wherein the aluminum liquid precipitation rate data includes the aluminum liquid deposition weight generated by the electrolytic reaction in each reaction area per unit time; The aluminum liquid precipitation rate data is analyzed in the time domain to determine whether the aluminum liquid deposition rate in each reaction area shows a trend of gradually decreasing; if so, it is determined that the reaction area belongs to the abnormal electrolytic reaction area in the aluminum electrolytic cell; if not, it is determined that the reaction area belongs to the normal electrolytic reaction area in the aluminum electrolytic cell.

[0023] In the above technical scheme, during the electrolysis process of the aluminum electrolytic cell, the aluminum oxide dispersed in the electrolyte will undergo an electrolytic reduction reaction to generate liquid aluminum metal (i.e., aluminum liquid), and the aluminum liquid will gradually deposit at the bottom of the aluminum electrolytic cell under the action of its own gravity, and the deposition rate of the aluminum liquid in different areas of the bottom of the aluminum electrolytic cell depends on the electrolytic reduction reaction rate of the corresponding area inside the aluminum electrolytic cell. Under normal circumstances, the electrolytic reduction reaction rate of all areas inside the aluminum electrolytic cell should be uniform, but when leakage occurs in a certain area inside the aluminum electrolytic cell, the electrolytic current of a certain area inside the aluminum electrolytic cell will be too low, thereby reducing the electrolytic reduction reaction rate. When leakage occurs in a certain area inside the aluminum electrolytic cell, it will be intuitively manifested as a decrease in the precipitation rate of aluminum liquid in the actual aluminum electrolysis reaction of the aluminum electrolytic cell. Therefore, by detecting the change in the precipitation rate of aluminum liquid inside the aluminum electrolytic cell, it can be determined whether leakage occurs inside the aluminum electrolytic cell and the location of the leakage. In order to differentiate and identify the aluminum liquid precipitation rate in the corresponding areas of all cathodes in the aluminum electrolytic cell, the reaction areas corresponding to all cathodes in the aluminum electrolytic cell (i.e., the reaction image area of ​​the current injected into the electrolyte by each cathode in the electrolyte) are determined based on the cathode distribution position state in the aluminum electrolytic cell. The interior of the aluminum electrolytic cell is also dynamically photographed to obtain the corresponding dynamic image of the electrolytic reaction, and the dynamic image of the electrolytic reaction is segmented based on the reaction areas corresponding to all cathodes, to obtain a number of dynamic sub-images of the electrolytic reaction corresponding to all reaction areas, and each dynamic sub-image of the electrolytic reaction is identified to determine the aluminum liquid precipitation rate data of each reaction area, and to quantify the aluminum liquid deposition weight generated by the electrolytic reaction in each reaction area per unit time. In addition, the aluminum liquid precipitation rate data is analyzed in the time domain to determine whether the aluminum liquid precipitation rate in each reaction area shows a trend of gradually decreasing, so as to accurately identify the abnormal electrolytic reaction area in the aluminum electrolytic cell, and provide a reliable basis for the subsequent identification of whether leakage current loss occurs in the aluminum electrolytic cell.

[0024] Preferably, in step S1, based on the spatial state information of the abnormal electrolytic reaction area, collecting electrolytic current data in the aluminum electrolysis cell includes: Based on the spatial position information of the abnormal electrolytic reaction area in the aluminum electrolysis cell, the electrolyte reaction space of the abnormal electrolytic reaction area in the aluminum electrolysis cell is determined; based on the boundary of the electrolyte reaction space, the electrolytic current data of the electrolyte reaction space is collected, and the electrolytic current data of all electrolyte reaction spaces are subjected to noise reduction filtering.

[0025] In the above technical scheme, the abnormal electrolytic reaction area refers to the area where the precipitation rate of aluminum liquid at the bottom of the aluminum electrolytic cell gradually decreases. In order to accurately obtain the electrolytic current size of the electrolytic reaction abnormal area corresponding to the corresponding electrolyte in the aluminum electrolytic cell, the spatial position information of the electrolytic reaction abnormal area in the aluminum electrolytic cell is used as a reference to map the global electrolyte space in the aluminum electrolytic cell accordingly, and determine the electrolyte reaction space of the electrolytic reaction abnormal area in the aluminum electrolytic cell. Based on the boundary of the electrolyte reaction space, the electrolytic current data of the electrolyte reaction space is collected, and the electrolytic current data of all electrolyte reaction spaces are subjected to noise reduction and filtering, so as to reduce the interference of the internal noise of the current sensor itself on the electrolytic current during the electrolytic current detection process, and improve the accuracy of subsequent judgment of the current loss event inside the aluminum electrolytic cell.

[0026] Preferably, in step S2, the electrolysis current data is analyzed to determine whether a current loss event occurs inside the aluminum electrolysis cell, including: The electrolysis current data is averaged to obtain the average electrolysis current value of the electrolyte reaction space within a preset time interval; the average electrolysis current value is compared with a preset current threshold value; if the average electrolysis current value is less than the preset current threshold value, it is determined that a current loss event has occurred inside the aluminum electrolysis cell; otherwise, it is determined that no current loss event has occurred inside the aluminum electrolysis cell.

[0027] In the above technical solution, the electrolytic current data characterizes the state of aluminum electrolytic reduction efficiency in the electrolyte in the aluminum electrolytic cell. The larger the electrolytic current, the higher the aluminum electrolytic reduction efficiency in the electrolyte. The larger the current loss caused by leakage current in the aluminum electrolytic cell, the smaller the electrolytic current in the electrolyte, making the aluminum electrolytic reduction efficiency in the electrolyte correspondingly lower. In order to accurately determine whether a current loss event occurs inside the aluminum electrolytic cell, the electrolytic current data is averaged to obtain the average electrolytic current value of the electrolyte reaction space within a preset time interval, and the average electrolytic current value is compared with a threshold value to determine whether a current loss event occurs inside the aluminum electrolytic cell, providing accurate data basis for further determining the cathode that causes the current loss.

[0028] Preferably, in step S2, when a current loss event occurs, current transmission data between different cathodes in the aluminum electrolysis cell is obtained, including: When a current loss event occurs, based on the position information of the reaction area corresponding to the current loss event in the aluminum electrolysis cell, the current transmission data between the cathodes corresponding to the reaction area corresponding to the current loss event and other adjacent reaction areas are obtained.

[0029] In the above technical solution, when a current loss event occurs, based on the position information of the reaction area corresponding to the current loss event in the aluminum electrolytic cell, the current transmission data between the cathodes corresponding to the reaction area corresponding to the current loss event and other adjacent reaction areas are obtained, and the magnitude of the current transmitted between different cathodes in the aluminum electrolytic cell is accurately determined, providing a data basis for judging whether leakage occurs in the aluminum electrolytic cell.

[0030] Preferably, in step S2, based on the change characteristic information of the current transmission data, the leakage fault information of the aluminum electrolysis cell is obtained, so as to adjust the cathode working state in the aluminum electrolysis cell, including: Analyzing the current transmission data to obtain leakage current intensity variation data between cathodes corresponding to the reaction region corresponding to the current loss event and other adjacent reaction regions during the current transmission process; Based on the leakage current intensity change data, determine whether the corresponding cathode has a leakage current exceeding a preset intensity threshold and a preset duration threshold; if so, determine the corresponding cathode as the leakage fault source of the aluminum electrolysis cell, thereby generating leakage fault information of the aluminum electrolysis cell; Based on the distribution position information of all leakage fault sources in the aluminum electrolysis cell, the leakage fault sources in the aluminum electrolysis cell that are allowed to be shut down are determined, so that the cathode corresponding to the leakage fault source that is allowed to be shut down is switched to a closed state.

[0031] In the above technical solution, the current transmission data is analyzed to obtain the leakage current intensity change data between the cathodes corresponding to the reaction area corresponding to the current loss event and other adjacent reaction areas during the current transmission process, and based on the leakage current intensity change data, it is determined whether the corresponding cathode has a leakage current exceeding the preset intensity threshold and exceeding the preset duration threshold. If the corresponding cathode has a leakage current exceeding the preset intensity threshold within the interval exceeding the preset duration threshold, it indicates that the corresponding cathode has a fault and generates leakage current, and the corresponding cathode is determined as the leakage fault source of the aluminum electrolytic cell. Based on the distribution position information of all leakage fault sources in the aluminum electrolytic cell, the leakage fault source allowed to be closed in the aluminum electrolytic cell is determined. If the leakage fault source is distributed at the edge position of the aluminum electrolytic cell, the leakage fault source is determined as a leakage fault source allowed to be closed, and the cathode corresponding to the leakage fault source is switched to a closed state to prevent the leakage fault source from continuously generating a large leakage current and affecting the electrolytic reduction reaction of the aluminum electrolytic cell.

[0032] Preferably, in step S3, the aluminum liquid dynamic data of the aluminum electrolysis cell is obtained, and the aluminum liquid dynamic data is analyzed to determine the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell, including: The aluminum electrolysis cell is photographed by thermal infrared to obtain a thermal infrared dynamic image of aluminum liquid in the aluminum electrolysis cell, and the thermal infrared dynamic image of aluminum liquid is analyzed to obtain aluminum liquid flow velocity data and aluminum liquid level rise velocity data of the aluminum electrolysis cell during the electrolysis process, which are used as the aluminum liquid dynamic data; Analyze the aluminum liquid flow velocity data and the aluminum liquid level rise velocity data to determine the average amplitude of aluminum liquid fluctuation in the reaction area corresponding to each cathode in the aluminum electrolysis cell; The average amplitude of the aluminum liquid fluctuation is compared with the preset amplitude threshold. If the average amplitude of the aluminum liquid fluctuation exceeds the preset amplitude threshold, the corresponding reaction area is determined as the abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell; otherwise, the corresponding reaction area is not determined as the abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell.

[0033] In the above technical scheme, as the electrolytic reaction proceeds inside the aluminum electrolytic cell, the volume of aluminum liquid generated inside the aluminum electrolytic cell also increases accordingly, and the aluminum liquid deposited at the bottom of the aluminum electrolytic cell also flows. The aluminum electrolytic cell is photographed by thermal infrared to obtain a thermal infrared aluminum liquid dynamic image inside the aluminum electrolytic cell, and the thermal infrared aluminum liquid dynamic image is analyzed to obtain the aluminum liquid flow speed data and the aluminum liquid level rise speed data of the aluminum electrolytic cell during the electrolytic operation process, so as to determine the average amplitude of the aluminum liquid fluctuation in the reaction area corresponding to each cathode in the aluminum electrolytic cell, thereby dynamically characterizing the aluminum liquid generated by the reaction inside the aluminum electrolytic cell. The average amplitude of the aluminum liquid fluctuation is compared with the preset amplitude threshold. If the average amplitude of the aluminum liquid fluctuation exceeds the preset amplitude threshold, the corresponding reaction area is determined as the aluminum liquid fluctuation abnormal area in the aluminum electrolytic cell; otherwise, the corresponding reaction area is not determined as the aluminum liquid fluctuation abnormal area in the aluminum electrolytic cell, so as to locate the abnormal aluminum liquid fluctuation inside the aluminum electrolytic cell at the spatial level.

[0034] Preferably, in step S3, based on the spatial state information of the aluminum liquid fluctuation abnormal area, the corresponding cathode current data in the aluminum electrolysis cell is collected, including: Based on the distribution position information of the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell, the cathode injection current data of the aluminum liquid fluctuation abnormal area is obtained as the corresponding cathode current data in the aluminum electrolysis cell.

[0035] In the above technical scheme, based on the distribution position information of the abnormal aluminum liquid fluctuation area in the aluminum electrolytic cell, the cathode injection current data of the abnormal aluminum liquid fluctuation area is obtained, so that the current injected into the aluminum electrolytic cell of the cathode suspected to be damaged in the aluminum electrolytic cell can be globally acquired, providing data basis for the subsequent accurate judgment of whether the cathode is damaged.

[0036] Preferably, in step S4, analyzing the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell includes: The cathode injection current data in the area of ​​abnormal aluminum liquid fluctuation is analyzed to determine the cathode injection current density distribution information in the area of ​​abnormal aluminum liquid fluctuation; based on the cathode injection current density distribution information, the position information of the damaged cathode in the aluminum electrolytic cell is determined, and this is used as the cathode damage fault information in the aluminum electrolytic cell.

[0037] In the above technical solution, the cathode injection current data of the aluminum liquid fluctuation abnormal area is analyzed to determine the cathode injection current density distribution information of the aluminum liquid fluctuation abnormal area, that is, the amount of current injected per unit area in the aluminum liquid fluctuation abnormal area. If the difference between the floating change upper limit and lower limit of the cathode injection current density value in the aluminum liquid fluctuation abnormal area exceeds the preset difference threshold, the position information of the damaged cathode in the aluminum electrolytic cell is determined as the cathode damage fault information in the aluminum electrolytic cell.

[0038] Preferably, in step S4, based on the cathode damage fault information, predicting the electrolysis reaction state change information in the aluminum electrolysis cell to determine whether the aluminum electrolysis cell can continue to perform electrolysis work includes: Based on the position information of the damaged cathode in the aluminum electrolytic cell, data-driven inspection processing is performed on the circuit connected to the damaged cathode to determine whether the damaged cathode is in a software fault state or a hardware fault state; and based on the type of software fault state or hardware fault state in which the cathode is in, it is determined whether the aluminum electrolytic cell can continue to perform electrolysis work.

[0039] In the above technical solution, based on the position information of the damaged cathode at the bottom of the aluminum electrolytic cell, the circuit corresponding to the damaged cathode is subjected to data drive inspection, that is, the circuit corresponding to the damaged cathode is subjected to drive signal restart inspection. When the damaged cathode can inject current normally again after the drive signal restart inspection, it is judged that the damaged cathode is in a software fault state; otherwise, it is judged that the damaged cathode is in a hardware fault state. And based on the type of the cathode being in the software fault state or the hardware fault state, it is judged whether the aluminum electrolytic cell can continue to perform electrolysis work, for example, when the cathode is in the software fault state, it indicates that the aluminum electrolytic cell can continue to perform electrolysis work; when the cathode is in the hardware fault state, it indicates that the aluminum electrolytic cell cannot continue to perform electrolysis work, thereby improving the fault diagnosis accuracy and reliability of the aluminum electrolytic cell.

[0040] It can be seen from the contents of the above embodiments that the aluminum electrolysis cell fault diagnosis method collects and analyzes the aluminum liquid precipitation rate data of the aluminum electrolysis cell, determines the abnormal electrolysis reaction area, and collects the electrolysis current data in the aluminum electrolysis cell; analyzes the electrolysis current data to determine whether a current loss event occurs in the aluminum electrolysis cell, and analyzes the current transmission data between different cathodes in the aluminum electrolysis cell to determine the leakage fault information of the aluminum electrolysis cell, thereby adjusting the cathode working state in the aluminum electrolysis cell to avoid excessive leakage current in the cell affecting the electrolysis efficiency and safety; analyzes the dynamic data of the aluminum liquid in the aluminum electrolysis cell , determine the area where the aluminum liquid fluctuates abnormally, collect the cathode current data in the aluminum electrolytic cell, and detect the current parameters in the aluminum electrolytic cell by area, so as to provide parameter basis for judging whether the cathode damage fault occurs in the aluminum electrolytic cell; based on the cathode damage fault information, predict the change information of the electrolytic reaction state in the aluminum electrolytic cell, so as to judge whether the aluminum electrolytic cell can continue to carry out electrolysis work, and simultaneously analyze the current data and aluminum liquid dynamic data of the aluminum electrolytic cell, identify the fault of the aluminum electrolytic cell from different aspects, and improve the accuracy and reliability of fault diagnosis of the aluminum electrolytic cell.

[0041] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. A method for diagnosing faults in an aluminum electrolytic cell, characterized in that: It includes the following steps: Step S1, based on the structural state of the aluminum electrolysis cell, collecting aluminum liquid precipitation rate data of the aluminum electrolysis cell; analyzing the aluminum liquid precipitation rate data to determine the abnormal electrolysis reaction area in the aluminum electrolysis cell; Based on the spatial state information of the abnormal electrolytic reaction area, collecting electrolytic current data in the aluminum electrolysis cell; Step S2, analyzing the electrolysis current data to determine whether a current loss event occurs inside the aluminum electrolysis cell; When a current loss event occurs, current transmission data between different cathodes in the aluminum electrolysis cell is obtained; Based on the change characteristic information of the current transmission data, the leakage fault information of the aluminum electrolysis cell is obtained, so as to adjust the cathode working state in the aluminum electrolysis cell; Step S3, acquiring the aluminum liquid dynamic data of the aluminum electrolysis cell, analyzing the aluminum liquid dynamic data, and determining the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell; Based on the spatial state information of the abnormal aluminum liquid fluctuation area, collecting the corresponding cathode current data in the aluminum electrolysis cell; Step S4, analyzing the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell; Based on the cathode damage fault information, the electrolysis reaction state change information in the aluminum electrolysis cell is predicted to determine whether the aluminum electrolysis cell can continue to perform electrolysis work.

2. The aluminum electrolysis cell fault diagnosis method according to claim 1, characterized in that: In the step S1, based on the structural state of the aluminum electrolysis cell, the aluminum liquid precipitation rate data of the aluminum electrolysis cell is collected; Analyzing the aluminum liquid precipitation rate data to determine the abnormal electrolytic reaction area in the aluminum electrolysis cell includes: Based on the cathode distribution state in the aluminum electrolytic cell, the reaction areas corresponding to all the cathodes in the aluminum electrolytic cell are determined; the dynamic image of the electrolytic reaction inside the aluminum electrolytic cell is collected, and based on the reaction areas corresponding to all the cathodes, the dynamic image of the electrolytic reaction is segmented to obtain a number of dynamic sub-images of the electrolytic reaction corresponding to all the reaction areas one by one; each dynamic sub-image of the electrolytic reaction is identified to obtain the aluminum liquid precipitation rate data of each reaction area; wherein the aluminum liquid precipitation rate data includes the aluminum liquid deposition weight generated by the electrolytic reaction in each reaction area per unit time; A time domain variation analysis is performed on the aluminum liquid precipitation rate data to determine whether the aluminum liquid deposition rate in each reaction area shows a gradually decreasing trend; if so, it is determined that the reaction area belongs to an abnormal electrolytic reaction area in the aluminum electrolytic cell; if not, it is determined that the reaction area belongs to a normal electrolytic reaction area in the aluminum electrolytic cell.

3. The aluminum electrolysis cell fault diagnosis method according to claim 2, characterized in that: In the step S1, based on the spatial state information of the abnormal electrolytic reaction area, the electrolytic current data in the aluminum electrolysis cell is collected, including: Based on the spatial position information of the abnormal electrolysis reaction area in the aluminum electrolysis cell, the electrolyte reaction space of the abnormal electrolysis reaction area in the aluminum electrolysis cell is determined; based on the boundary of the electrolyte reaction space, the electrolysis current data of the electrolyte reaction space is collected, and the electrolysis current data of all electrolyte reaction spaces are subjected to noise reduction filtering.

4. The aluminum electrolysis cell fault diagnosis method according to claim 3, characterized in that: In step S2, the electrolysis current data is analyzed to determine whether a current loss event occurs inside the aluminum electrolysis cell, including: Perform mean calculation on the electrolysis current data to obtain an average electrolysis current value of the electrolyte reaction space within a preset time interval; compare the average electrolysis current value with a preset current threshold value; if the average electrolysis current value is less than the preset current threshold value, it is determined that a current loss event has occurred inside the aluminum electrolysis cell; otherwise, it is determined that no current loss event has occurred inside the aluminum electrolysis cell.

5. The aluminum electrolysis cell fault diagnosis method according to claim 4, characterized in that: In step S2, when a current loss event occurs, current transmission data between different cathodes in the aluminum electrolysis cell is obtained, including: When a current loss event occurs, based on the position information of the reaction area corresponding to the current loss event in the aluminum electrolysis cell, the current transmission data between the cathodes corresponding to the reaction area corresponding to the current loss event and other adjacent reaction areas are obtained.

6. The aluminum electrolysis cell fault diagnosis method according to claim 5, characterized in that: In the step S2, based on the change characteristic information of the current transmission data, the leakage fault information of the aluminum electrolysis cell is obtained, so as to adjust the cathode working state in the aluminum electrolysis cell, including: Analyzing the current transmission data to obtain leakage current intensity variation data between cathodes corresponding to the reaction region corresponding to the current loss event and other adjacent reaction regions during the current transmission process; Based on the leakage current intensity change data, determine whether the corresponding cathode has a leakage current exceeding a preset intensity threshold and a preset duration threshold; if so, determine the corresponding cathode as the leakage fault source of the aluminum electrolysis cell, thereby generating leakage fault information of the aluminum electrolysis cell; Based on the distribution position information of all leakage fault sources in the aluminum electrolysis cell, the leakage fault sources in the aluminum electrolysis cell that are allowed to be shut down are determined, so that the cathodes corresponding to the leakage fault sources that are allowed to be shut down are switched to a closed state.

7. The aluminum electrolysis cell fault diagnosis method according to claim 6, characterized in that: In the step S3, the aluminum liquid dynamic data of the aluminum electrolysis cell is obtained, the aluminum liquid dynamic data is analyzed, and the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell is determined, including: Performing thermal infrared photography on the aluminum reduction cell to obtain a thermal infrared dynamic image of aluminum liquid in the aluminum reduction cell, analyzing the thermal infrared dynamic image of aluminum liquid to obtain aluminum liquid flow velocity data and aluminum liquid level rise velocity data of the aluminum reduction cell during the electrolysis process, and using the data as the aluminum liquid dynamic data; Analyze the aluminum liquid flow velocity data and the aluminum liquid level rise velocity data to determine the average amplitude of aluminum liquid fluctuation in the reaction area corresponding to each cathode in the aluminum electrolysis cell; The average amplitude of the aluminum liquid fluctuation is compared with the preset amplitude threshold. If the average amplitude of the aluminum liquid fluctuation exceeds the preset amplitude threshold, the corresponding reaction area is determined as the abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell; otherwise, the corresponding reaction area is not determined as the abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell.

8. The aluminum electrolysis cell fault diagnosis method according to claim 7, characterized in that: In the step S3, based on the spatial state information of the abnormal aluminum liquid fluctuation area, the corresponding cathode current data in the aluminum electrolysis cell is collected, including: Based on the distribution position information of the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell, the cathode injection current data of the aluminum liquid fluctuation abnormal area is obtained as the corresponding cathode current data in the aluminum electrolysis cell.

9. The aluminum electrolysis cell fault diagnosis method according to claim 8, characterized in that: In the step S4, the cathode current data is analyzed to determine the cathode damage fault information in the aluminum electrolysis cell, including: The cathode injection current data in the aluminum liquid abnormal fluctuation area is analyzed to determine the cathode injection current density distribution information in the aluminum liquid abnormal fluctuation area; based on the cathode injection current density distribution information, the position information of the damaged cathode in the aluminum electrolytic cell is determined, and this is used as the cathode damage fault information in the aluminum electrolytic cell.

10. The aluminum electrolysis cell fault diagnosis method according to claim 9, characterized in that: In the step S4, based on the cathode damage fault information, predicting the electrolysis reaction state change information in the aluminum electrolysis cell, so as to determine whether the aluminum electrolysis cell can continue to perform electrolysis work, includes: Based on the position information of the damaged cathode in the aluminum electrolytic cell, data-driven inspection processing is performed on the circuit connected to the damaged cathode to determine whether the damaged cathode is in a software fault state or a hardware fault state; and based on the type of software fault state or hardware fault state in which the cathode is in, it is determined whether the aluminum electrolytic cell can continue to perform electrolysis.

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