Fault Diagnosis Methods for Aluminum Electrolysis Cells

Abstract

The present invention relates to the technical field of electrolytic aluminum production, and provides a method for diagnosing faults of aluminum electrolytic cells. The method collects and analyzes aluminum liquid precipitation rate data of the aluminum electrolytic cell, determines an abnormal electrolytic reaction area, and uses this data to analyze electrolytic current data in the aluminum electrolytic cell, judges whether a current loss event occurs in the aluminum electrolytic cell, analyzes current transmission data between different cathodes in the aluminum electrolytic cell, determines leakage fault information of the aluminum electrolytic cell, and adjusts the cathode working state in the aluminum electrolytic cell. The method also analyzes aluminum liquid dynamic data of the aluminum electrolytic cell, determines an abnormal aluminum liquid fluctuation area, collects cathode current data in the aluminum electrolytic cell, detects current parameters in the aluminum electrolytic cell by region, and provides a parameter basis for judging whether a cathode damage fault occurs in the aluminum electrolytic cell. Based on the cathode damage fault information, the method predicts electrolytic reaction state change information in the aluminum electrolytic cell, and judges whether the aluminum electrolytic cell can continue to perform electrolysis work, thereby improving the accuracy and reliability of fault diagnosis of the aluminum electrolytic cell.

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 primarily uses cryolite-alumina molten salt electrolysis. This involves placing an electrolyte within an electrolytic cell, dissolving alumina into the electrolyte, and applying a direct current to the electrolyte, reducing the alumina to liquid aluminum. An aluminum electrolytic cell primarily consists of two components: an anode and a cathode. During electrolysis, problems such as excessive leakage current or cathode damage are inevitable, impacting the cell's proper operation. Existing techniques typically inspect the cell's cathode and related circuitry to determine the type and severity of any fault. This approach requires specialized personnel to disassemble the cell, preventing simultaneous fault diagnosis and testing while the cell is operating, increasing the cost of troubleshooting. The current between the anode and cathode within the cell is a critical parameter for its operation. Faults in the cell can manifest as abnormalities. Therefore, simultaneous testing and analysis of parameters such as current during operation is crucial for diagnosing and identifying faults. Summary of the Invention

[0003] In view of the defects of the prior art, the present invention provides a method for diagnosing faults in aluminum electrolytic cells. The method collects and analyzes the aluminum liquid precipitation rate data of the aluminum electrolytic cell, determines the abnormal electrolytic reaction area, 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 electrolysis 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; The system uses state data to determine the area with abnormal aluminum liquid fluctuation, collects cathode current data in the aluminum electrolytic cell, and detects the current parameters in the aluminum electrolytic cell by region, providing parameter basis for judging whether the aluminum electrolytic cell has a cathode damage fault. Based on the cathode damage fault information, it also predicts 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 perform electrolysis. The current data and aluminum liquid dynamic data of the aluminum electrolytic cell are analyzed simultaneously, and the fault of the aluminum electrolytic cell is identified from different aspects, thereby improving the accuracy and reliability of the fault diagnosis of the aluminum electrolytic cell.

[0004] The present invention provides a method for diagnosing faults in an aluminum electrolysis cell, comprising the following steps:

[0005] 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 electrolysis reaction abnormal area in the aluminum electrolysis cell; based on the spatial state information of the electrolysis reaction abnormal area, collecting electrolysis current data in the aluminum electrolysis cell;

[0006] Step S2: analyzing the electrolysis current data to determine whether a current loss event occurs in the aluminum electrolysis cell; if a current loss event occurs, obtaining current transmission data between different cathodes in the aluminum electrolysis cell; obtaining leakage fault information of the aluminum electrolysis cell based on change characteristic information of the current transmission data, and adjusting the cathode working state in the aluminum electrolysis cell accordingly;

[0007] Step S3, acquiring the aluminum liquid dynamic data of the aluminum electrolysis cell, analyzing the aluminum liquid dynamic data, and determining the aluminum liquid abnormal fluctuation area in the aluminum electrolysis cell; based on the spatial state information of the aluminum liquid abnormal fluctuation area, collecting the corresponding cathode current data in the aluminum electrolysis cell;

[0008] Step S4: Analyze the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell; based on the cathode damage fault information, predict the electrolysis reaction state change information in the aluminum electrolysis cell to determine whether the aluminum electrolysis cell can continue to perform electrolysis work.

[0009] In one embodiment disclosed in the present application, 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:

[0010] Based on the cathode distribution state in the aluminum electrolysis cell, the reaction areas corresponding to all cathodes in the aluminum electrolysis cell are determined; a dynamic image of the electrolysis reaction inside the aluminum electrolysis cell is collected, and based on the reaction areas corresponding to all cathodes, the dynamic image of the electrolysis reaction is segmented to obtain a plurality of dynamic sub-images of the electrolysis reaction corresponding to all reaction areas; each dynamic sub-image of the electrolysis reaction is identified to obtain aluminum liquid precipitation rate data for each reaction area; wherein the aluminum liquid precipitation rate data includes the weight of aluminum liquid deposited by the electrolysis reaction in each reaction area per unit time;

[0011] 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.

[0012] In one embodiment disclosed in the present application, in step S1, based on the spatial state information of the abnormal electrolysis reaction area, collecting electrolysis current data in the aluminum electrolysis cell includes:

[0013] 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.

[0014] In one embodiment disclosed in the present application, in step S2, analyzing the electrolysis current data to determine whether a current loss event occurs inside the aluminum electrolysis cell includes:

[0015] Performing mean calculation on the electrolysis current data to obtain an average electrolysis current value of the electrolyte reaction space within a preset time interval; comparing the average electrolysis current value with a preset current threshold; if the average electrolysis current value is less than the preset current threshold, determining that a current loss event has occurred inside the aluminum electrolysis cell; otherwise, determining that no current loss event has occurred inside the aluminum electrolysis cell.

[0016] In one embodiment disclosed in the present application, in step S2, when a current loss event occurs, obtaining current transmission data between different cathodes in the aluminum electrolysis cell includes:

[0017] 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.

[0018] In one embodiment disclosed in the present application, 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, and the cathode working state in the aluminum electrolysis cell is adjusted accordingly, including:

[0019] Analyzing the current transmission data to obtain leakage current intensity change data between cathodes corresponding to the reaction region corresponding to the current loss event and other adjacent reaction regions during the current transmission process;

[0020] Based on the leakage current intensity change data, determining whether the corresponding cathode has a leakage current exceeding a preset intensity threshold and a preset duration threshold; if so, determining the corresponding cathode as a leakage fault source of the aluminum electrolysis cell, thereby generating leakage fault information of the aluminum electrolysis cell;

[0021] 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.

[0022] In one embodiment disclosed in the present application, in 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 includes:

[0023] Performing thermal infrared photography on the aluminum electrolysis cell to obtain a thermal infrared dynamic image of the aluminum liquid in the aluminum electrolysis cell, analyzing the thermal infrared dynamic image of the aluminum liquid to obtain aluminum liquid flow velocity data and aluminum liquid level rise velocity data of the aluminum electrolysis cell during the electrolysis process, and using the data as the aluminum liquid dynamic data;

[0024] Analyzing the aluminum liquid flow velocity data and the aluminum liquid level rise velocity data to determine an average amplitude of aluminum liquid fluctuations in a reaction area corresponding to each cathode in the aluminum electrolysis cell;

[0025] The average amplitude of the aluminum liquid fluctuation is compared with a 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.

[0026] In one embodiment disclosed in the present application, in 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:

[0027] Based on the distribution position information of the aluminum liquid fluctuation abnormal area in the aluminum electrolysis cell, cathode injection current data of the aluminum liquid fluctuation abnormal area is obtained as the corresponding cathode current data in the aluminum electrolysis cell.

[0028] In one embodiment disclosed in the present application, in step S4, analyzing the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell includes:

[0029] 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.

[0030] In one embodiment disclosed in the present application, 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 operation includes:

[0031] Based on the position information of the damaged cathode in the aluminum electrolytic cell, data-driven inspection processing is performed on the circuit corresponding 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.

[0032] Compared with the existing technology, the aluminum electrolysis cell fault diagnosis method collects and analyzes the aluminum liquid precipitation rate data of the aluminum electrolysis cell, determines the abnormal area of the electrolysis reaction, 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 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; analyzes the current transmission data between different cathodes in the aluminum electrolysis cell to determine the leakage fault information of the aluminum electrolysis cell, and determines whether a current loss event occurs in the aluminum electrolysis cell; analyzes the current transmission data between different cathodes in the aluminum electrolysis cell to determine the leakage fault information of the aluminum electrolysis cell, and determines whether a current loss event occurs in the aluminum electrolysis cell; analyzes the current transmission data between different cathodes in the aluminum electrolysis cell to determine the leakage fault information of the aluminum electrolysis cell, and determines whether a current loss event occurs in the aluminum electrolysis cell; analyzes the current transmission data between different cathodes in 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; analyzes the current transmission data between different cathodes in the aluminum electrolysis cell to determine whether a current loss event occurs in the aluminum electrolysis cell; determines whether a current loss event occurs in the aluminum electrolysis cell, and determines ... The abnormal area of aluminum liquid fluctuation is determined to collect cathode current data in the aluminum electrolytic cell. 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 perform electrolysis work. The current data and aluminum liquid dynamic data of the aluminum electrolytic cell are analyzed simultaneously, and the fault of the aluminum electrolytic cell is identified from different aspects, thereby improving the accuracy and reliability of fault diagnosis of the aluminum electrolytic cell.

[0033] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the present invention. The purposes 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.

[0034] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. 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 any creative work.

[0036] Figure 1 A schematic flow chart of the aluminum electrolysis cell fault diagnosis method provided by the present invention. DETAILED DESCRIPTION

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0038] See Figure 1 , is a flow chart of a method for diagnosing faults in an aluminum electrolysis cell according to an embodiment of the present invention. The method for diagnosing faults in an aluminum electrolysis cell comprises:

[0039] 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 electrolysis reaction abnormal area in the aluminum electrolysis cell; based on the spatial state information of the electrolysis reaction abnormal area, collecting electrolysis current data in the aluminum electrolysis cell;

[0040] Step S2: Analyze the electrolysis current data to determine whether a current loss event occurs in the aluminum electrolysis cell; if a current loss event occurs, obtain current transmission data between different cathodes in the aluminum electrolysis cell; obtain leakage fault information of the aluminum electrolysis cell based on the change characteristic information of the current transmission data, and adjust the working state of the cathodes in the aluminum electrolysis cell accordingly;

[0041] Step S3, obtaining dynamic data of the aluminum liquid of the aluminum electrolysis cell, analyzing the dynamic data of the aluminum liquid, and determining an abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell; based on the spatial state information of the abnormal aluminum liquid fluctuation area, collecting corresponding cathode current data in the aluminum electrolysis cell;

[0042] Step S4: Analyze the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell; based on the cathode damage fault information, predict the electrolysis reaction state change information in the aluminum electrolysis cell to determine whether the aluminum electrolysis cell can continue to perform electrolysis work.

[0043] The aluminum electrolytic cell fault diagnosis method collects and analyzes aluminum liquid precipitation rate data of the aluminum electrolytic cell to determine the abnormal electrolytic reaction area, thereby collecting electrolytic current data in the aluminum electrolytic cell; analyzes the electrolytic current data to determine whether a current loss event has occurred 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 electrolysis efficiency and safety; analyzes the aluminum liquid dynamic data of the aluminum electrolytic cell to determine the abnormal aluminum liquid fluctuation area, thereby collecting cathode current data in the aluminum electrolytic cell, and detects the current parameters in the aluminum electrolytic cell in different areas to provide a parameter basis for determining whether a cathode damage fault has occurred 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 to determine whether the aluminum electrolytic cell can continue to perform electrolysis work. The current data and aluminum liquid dynamic data of the aluminum electrolytic cell are simultaneously analyzed to identify the aluminum electrolytic cell fault from different aspects, thereby improving the accuracy and reliability of the aluminum electrolytic cell fault diagnosis.

[0044] 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 electrolysis reaction abnormal area in the aluminum electrolysis cell, including:

[0045] Based on the cathode distribution state in the aluminum electrolysis cell, the reaction areas corresponding to all cathodes in the aluminum electrolysis cell are determined; a dynamic image of the electrolysis reaction inside the aluminum electrolysis cell is collected, and based on the reaction areas corresponding to all cathodes, the dynamic image of the electrolysis reaction is segmented to obtain a plurality of dynamic sub-images of the electrolysis reaction corresponding to all reaction areas; each dynamic sub-image of the electrolysis reaction is identified to obtain aluminum liquid precipitation rate data for each reaction area; wherein the aluminum liquid precipitation rate data includes the weight of aluminum liquid deposited by the electrolysis reaction in each reaction area per unit time;

[0046] 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 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.

[0047] In the above technical solution, during the electrolysis process in an aluminum reduction cell, the aluminum oxide dispersed within the electrolyte undergoes an electrolytic reduction reaction to produce liquid aluminum metal (i.e., liquid aluminum). Under the action of gravity, the liquid aluminum gradually settles to the bottom of the cell. The rate of liquid aluminum deposition in different areas of the cell bottom depends on the rate of the electrolytic reduction reaction in that area. Under normal circumstances, the electrolytic reduction reaction rate should be uniform across all areas of the cell. However, if leakage occurs in a certain area of the cell, the electrolytic current in that area will be too low, reducing the electrolytic reduction reaction rate. When leakage occurs in a certain area of the cell, it is directly manifested in the actual electrolysis reaction as a decrease in the liquid aluminum deposition rate. Therefore, by monitoring the changes in the liquid aluminum deposition rate within the cell, it is possible to determine whether leakage has occurred and where it has occurred. To differentiate and identify the aluminum precipitation rates at all cathode locations within an aluminum reduction cell, the reaction regions corresponding to each cathode within the cell are determined based on the cathode distribution within the cell (i.e., the region within the electrolyte where the current injected by each cathode reacts). The cell interior is dynamically photographed to generate a dynamic image of the corresponding electrolytic reaction. This image is then segmented based on the reaction regions corresponding to each cathode, yielding several dynamic sub-images corresponding to each reaction region. Each sub-image is then identified to determine the aluminum precipitation rate for each reaction region and quantify the weight of aluminum precipitation generated per unit time by the electrolytic reaction in each reaction region. The precipitation rate data is then analyzed over time to determine whether the precipitation rate in each reaction region shows a decreasing trend. This allows for accurate identification of abnormal electrolytic reaction regions within the cell, providing a reliable basis for subsequent identification of leakage current losses within the cell.

[0048] Preferably, in step S1, based on the spatial state information of the abnormal electrolysis reaction area, collecting electrolysis current data in the aluminum electrolysis cell includes:

[0049] 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.

[0050] In the above technical solution, the abnormal electrolytic reaction area refers to the area at the bottom of the aluminum electrolytic cell where the precipitation rate of aluminum liquid gradually decreases. In order to accurately obtain the electrolytic current size of the corresponding electrolyte in the aluminum electrolytic cell corresponding to the abnormal electrolytic reaction area, the spatial position information of the abnormal electrolytic reaction area in the aluminum electrolytic cell is used as a reference to map the global electrolyte space in the aluminum electrolytic cell to determine the electrolyte reaction space of the abnormal electrolytic reaction 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 filtering to reduce the interference of the current sensor's own internal noise on the electrolytic current during the electrolytic current detection process, thereby improving the accuracy of subsequent judgment of current loss events inside the aluminum electrolytic cell.

[0051] Preferably, in step S2, analyzing the electrolysis current data to determine whether a current loss event occurs inside the aluminum electrolysis cell includes:

[0052] The electrolysis current data is averaged to obtain an 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.

[0053] In the above technical solution, the electrolysis current data characterizes the state of the electrolytic reduction efficiency of aluminum in the electrolyte in the aluminum electrolysis cell. The larger the electrolysis current, the higher the electrolytic reduction efficiency of aluminum in the electrolyte. The greater the current loss due to leakage current in the aluminum electrolysis cell, the smaller the electrolysis current in the electrolyte, resulting in a correspondingly lower electrolytic reduction efficiency of aluminum in the electrolyte. In order to accurately determine whether a current loss event has occurred inside the aluminum electrolysis cell, 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 then compared with a threshold to determine whether a current loss event has occurred inside the aluminum electrolysis cell, providing accurate data basis for further determining the cathode that caused the current loss.

[0054] Preferably, in step S2, when a current loss event occurs, current transmission data between different cathodes in the aluminum electrolysis cell is obtained, including:

[0055] 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.

[0056] 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 current size transmitted between different cathodes in the aluminum electrolytic cell is accurately determined, providing a data basis for judging whether the aluminum electrolytic cell has a leakage.

[0057] 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:

[0058] Analyzing the current transmission data to obtain leakage current intensity change data between the cathodes corresponding to the reaction region corresponding to the current loss event and other adjacent reaction regions during the current transmission process;

[0059] Based on the leakage current intensity change data, determining whether the corresponding cathode has a leakage current exceeding a preset intensity threshold and a preset duration threshold; if so, determining the corresponding cathode as a leakage fault source of the aluminum electrolysis cell, thereby generating leakage fault information of the aluminum electrolysis cell;

[0060] 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.

[0061] In the above technical solution, the current transmission data is analyzed to obtain 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. Based on the leakage current intensity change data, it is determined whether the corresponding cathode has a leakage current exceeding a preset intensity threshold and a 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 sources in the aluminum electrolytic cell that are allowed to be closed are determined. If the leakage fault source is distributed at the edge of the aluminum electrolytic cell, the leakage fault source is determined as a leakage fault source that is allowed to be closed, and the cathode corresponding to the leakage fault source is switched to the 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.

[0062] Preferably, in 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 includes:

[0063] Performing thermal infrared photography on the aluminum electrolysis cell to obtain a thermal infrared dynamic image of the aluminum liquid in the aluminum electrolysis cell, analyzing the thermal infrared dynamic image of the aluminum liquid to obtain aluminum liquid flow velocity data and aluminum liquid level rise velocity data of the aluminum electrolysis cell during the electrolysis process, and using the data as the aluminum liquid dynamic data;

[0064] Analyze the aluminum liquid flow velocity data and the aluminum liquid level rise velocity data to determine the average amplitude of aluminum liquid fluctuations in the reaction area corresponding to each cathode in the aluminum electrolysis cell;

[0065] The average amplitude of the aluminum liquid fluctuation is compared with a 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 electrolytic cell; otherwise, the corresponding reaction area is not determined as the abnormal aluminum liquid fluctuation area in the aluminum electrolytic cell.

[0066] In the above technical solution, as the electrolysis reaction proceeds within the aluminum reduction cell, the volume of molten aluminum generated within the cell increases accordingly, and the molten aluminum deposited at the bottom of the cell also begins to flow. Thermal infrared imaging of the cell is performed to obtain a dynamic image of the molten aluminum within the cell. This dynamic image is analyzed to obtain data on the flow velocity and level rise of the molten aluminum during the electrolysis process. This is used to determine the average amplitude of the molten aluminum fluctuation in the reaction region corresponding to each cathode within the cell, thereby dynamically characterizing the molten aluminum generated by the reaction within the cell. This average amplitude of the molten aluminum fluctuation is compared with a preset amplitude threshold. If the average amplitude of the molten aluminum fluctuation exceeds the preset amplitude threshold, the corresponding reaction region is determined as an abnormal molten aluminum fluctuation region within the cell; otherwise, the corresponding reaction region is not determined as an abnormal molten aluminum fluctuation region within the cell, thereby spatially locating the abnormal molten aluminum fluctuation within the cell.

[0067] 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:

[0068] 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.

[0069] In the above technical solution, 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. In this way, the current injected into the aluminum electrolytic cell by the cathode suspected to be damaged in the aluminum electrolytic cell can be globally obtained, providing a data basis for the subsequent accurate judgment of whether the cathode is damaged.

[0070] Preferably, in step S4, analyzing the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell includes:

[0071] 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.

[0072] In the above technical solution, the cathode injection current data in the region of abnormal aluminum liquid fluctuation is analyzed to determine the cathode injection current density distribution information in the region of abnormal aluminum liquid fluctuation, that is, the amount of current injected per unit area in the region of abnormal aluminum liquid fluctuation. If the difference between the upper and lower limits of the floating variation of the cathode injection current density value in the region of abnormal aluminum liquid fluctuation exceeds a preset difference threshold, the location of the damaged cathode in the aluminum electrolysis cell is determined and used as cathode damage fault information in the aluminum electrolysis cell.

[0073] 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:

[0074] Based on the position information of the damaged cathode in the aluminum electrolytic cell, data-driven inspection processing is performed on the circuit corresponding 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.

[0075] In the above technical solution, based on the position information of the damaged cathode at the bottom of the aluminum electrolytic cell, a data-driven inspection process is performed on the circuit connected to the damaged cathode. That is, the drive signal restart inspection is performed on the circuit connected to the damaged cathode. If the damaged cathode can inject current normally again after the drive signal restart inspection, the damaged cathode is judged to be in a software fault state; otherwise, the damaged cathode is judged to be in a hardware fault state. Based on the type of software fault state or hardware fault state of the cathode, it is determined whether the aluminum electrolytic cell can continue to perform electrolysis. For example, if the cathode is in a software fault state, it indicates that the aluminum electrolytic cell can continue to perform electrolysis; if the cathode is in a hardware fault state, it indicates that the aluminum electrolytic cell cannot continue to perform electrolysis, thereby improving the accuracy and reliability of aluminum electrolytic cell fault diagnosis.

[0076] As can be seen from the contents of the above embodiments, the aluminum electrolytic cell fault diagnosis method 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 electrolysis efficiency and safety; analyzes the dynamic data of the aluminum liquid in the aluminum electrolytic cell , determine the area where the aluminum liquid fluctuates abnormally, and use this to collect the cathode current data in the aluminum electrolytic cell. The current parameters in the aluminum electrolytic cell are detected in different areas to provide parameter basis for judging whether a cathode damage fault has occurred in the aluminum electrolytic cell; based on the cathode damage fault information, the electrolysis reaction state change information in the aluminum electrolytic cell is predicted to judge whether the aluminum electrolytic cell can continue to perform electrolysis work. The current data and aluminum liquid dynamic data of the aluminum electrolytic cell are analyzed simultaneously, and the faults of the aluminum electrolytic cell are identified from different aspects, thereby improving the accuracy and reliability of the fault diagnosis of the aluminum electrolytic cell.

[0077] Obviously, those skilled in the art may make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if such changes and modifications fall within the scope of the claims and their equivalents, the present invention is intended to include such changes and modifications.

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 electrolysis reaction abnormal 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, 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 abnormal aluminum liquid fluctuation area, the corresponding cathode current data in the aluminum electrolysis cell is collected; wherein, obtaining the aluminum liquid dynamic data of the aluminum electrolysis cell includes: performing thermal infrared photography on the aluminum electrolysis cell to obtain a thermal infrared aluminum liquid dynamic image in the aluminum electrolysis cell, analyzing the thermal infrared aluminum liquid dynamic image to obtain aluminum liquid flow velocity data and aluminum liquid level rise velocity data of the aluminum electrolysis cell during the electrolysis process, and using the data as the aluminum liquid dynamic data; Step S4: Analyze the cathode current data to determine cathode damage fault information in the aluminum electrolysis cell; based on the cathode damage fault information, predict the electrolysis reaction state change information in the aluminum electrolysis cell 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, wherein: In the step S1, based on the structural state of the aluminum electrolysis cell, 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 electrolysis cell, the reaction areas corresponding to all cathodes in the aluminum electrolysis cell are determined; a dynamic image of the electrolysis reaction inside the aluminum electrolysis cell is collected, and based on the reaction areas corresponding to all cathodes, the dynamic image of the electrolysis reaction is segmented to obtain a plurality of dynamic sub-images of the electrolysis reaction corresponding to all reaction areas; each dynamic sub-image of the electrolysis reaction is identified to obtain aluminum liquid precipitation rate data for each reaction area; wherein the aluminum liquid precipitation rate data includes the weight of aluminum liquid deposited by the electrolysis 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, wherein: In the step S1, based on the spatial state information of the abnormal electrolysis reaction area, electrolysis 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, wherein: In step S2, the electrolysis current data is analyzed to determine whether a current loss event occurs inside the aluminum electrolysis cell, including: Performing mean calculation on the electrolysis current data to obtain an average electrolysis current value of the electrolyte reaction space within a preset time interval; comparing the average electrolysis current value with a preset current threshold; if the average electrolysis current value is less than the preset current threshold, determining that a current loss event has occurred inside the aluminum electrolysis cell; otherwise, determining 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 step S2, based on the change characteristic information of the current transmission data, leakage fault information of the aluminum electrolysis cell is obtained, and the cathode working state in the aluminum electrolysis cell is adjusted accordingly, including: Analyzing the current transmission data to obtain leakage current intensity change 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, determining whether the corresponding cathode has a leakage current exceeding a preset intensity threshold and a preset duration threshold; if so, determining the corresponding cathode as a 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 step S3, analyzing the dynamic data of the aluminum liquid to determine the abnormal aluminum liquid fluctuation area in the aluminum electrolysis cell includes: Analyzing the aluminum liquid flow velocity data and the aluminum liquid level rise velocity data to determine an average amplitude of aluminum liquid fluctuations in a reaction area corresponding to each cathode in the aluminum electrolysis cell; The average amplitude of the aluminum liquid fluctuation is compared with a 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, wherein: In step S3, based on the spatial state information of the aluminum liquid fluctuation abnormal area, 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, 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 step S4, the cathode current data is analyzed to determine cathode damage fault information in the aluminum electrolysis cell, including: 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.

10. The aluminum electrolysis cell fault diagnosis method according to claim 9, characterized in that: 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 corresponding 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.

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