Submerged arc furnace smelting process data processing system

Abstract

The invention discloses a submerged arc furnace smelting process data processing system. The system comprises a data interface acquisition unit used for acquiring control data, management data, maintenance data and special equipment management data of a submerged arc furnace smelting system; the data accuracy processing unit is used for acquiring control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system for preprocessing; the data reliability processing unit is used for carrying out reliability processing on the data of the submerged arc furnace smelting system after the data preprocessing; the data storage processing unit is used for carrying out diversity storage on the data of the smelting system of the submerged arc furnace after reliability processing; and the data log processing unit is used for automatically generating logs in a process of acquiring various data of the submerged arc furnace smelting system, a data preprocessing process, a diversity storage process and information, warnings and errors generated in a process of reliably processing the data of the submerged arc furnace smelting system, and storing the logs in a mode of automatic backup according to dates.

Description

Technical Field

[0001] The present invention belongs to the field of intelligent manufacturing and relates to a submerged arc furnace smelting process data processing system. Background Art

[0002] The smelting process of an electric arc furnace is a complex high-temperature physical and chemical reaction process involving dozens of reaction variables. It is a typical nonlinear time-varying system with complex structure and unknown mechanism. The production control of electric arc furnace is difficult to solve with conventional detection and control methods. It mainly relies on manual experience judgment and subjective analysis, and lacks high-quality data resources.

[0003] Several existing mechanistic models and sensor-based expert systems related to submerged arc furnace control exist within the industry, but their field applications have been ineffective. To date, closed-loop intelligent control of submerged arc furnace smelting remains unattainable, and acquiring the full-scenario dataset required for intelligent control remains a key challenge.

[0004] Characteristics of existing technologies: Most on-site data interfaces for submerged arc furnaces only cover the control system, with limited data acquisition variables. These interfaces do not fully consider the process properties of submerged arc furnace equipment, making them inflexible during actual on-site smelting.

[0005] The data processing of the smelting process of the submerged arc furnace only uses thresholds and combinational logic filtering, which cannot fully identify abnormal and invalid data and is difficult to apply to the complex process data processing of the submerged arc furnace;

[0006] The process data of each node of the submerged arc furnace is stored in a single relational database. After running on site for a period of time, the query response speed decreases and the system stability is not high.

[0007] Existing data applications for submerged arc furnaces only collect data from databases, lacking the accumulation and application of manual experience, and cannot fully meet the actual production constraints of submerged arc furnaces;

[0008] Most applications of submerged arc furnace smelting models use offline modeling, which is difficult to upgrade and maintain, and cumbersome to use in practice.

[0009] The data output of the submerged arc furnace software system generally adopts the system WEB interface, which is not easy to operate. The data report format and content are basically fixed, and the customization function is lacking. Summary of the Invention

[0010] The smelting process of an electric arc furnace is a typical nonlinear time-varying system with a complex structure and unclear mechanism. In order to solve the problems that are difficult to solve with conventional detection and control methods in electric furnace production control, the technical solution adopted by the present invention is:

[0011] Data interface acquisition unit: used to obtain control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system;

[0012] Data accuracy processing unit: used for pre-processing the control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system acquired by the data interface acquisition unit;

[0013] Data reliability processing unit: used for performing reliability processing on the submerged arc furnace smelting system data preprocessed by the data accuracy processing unit;

[0014] Data storage and processing unit: used for performing diversified storage on the submerged arc furnace smelting system data after reliability processing by the data reliability processing unit;

[0015] Data log processing unit: used for the process of the data interface acquisition unit acquiring various data of the submerged arc furnace smelting system, the data preprocessing process of the data accuracy processing unit, the diversity storage process of the data storage unit, and the information, warnings and errors generated in the process of the submerged arc furnace smelting system data after reliability processing by the data reliability processing unit, automatically generating logs, and storing them in an automatic backup manner by date.

[0016] Furthermore: the data interface acquisition unit includes:

[0017] Control system interface module: used to connect to the control unit of the furnace automation system. In scenarios with multiple control units, inter-controller communication is preferred, and data is merged into the specific storage area of the controller with the lowest data volume. Heartbeat detection and status identification are enabled for the interface status to realize the acquisition of control data of the submerged arc furnace automation system;

[0018] Management system interface module: used to connect to the core requirements of the information management system at all levels of the submerged arc furnace smelting system. It adopts a unified two-way communication interface, receives management requirements, converts them into concise data dimensions, and adds them to the data collection scope to achieve the acquisition of relevant management data information of the submerged arc furnace;

[0019] Inspection and maintenance management module: used to assign identifiable characteristic values to submerged arc furnace production equipment or instruments that are under inspection, maintenance, replacement, or servicing, to represent the current actual status of the equipment;

[0020] Special equipment management module: used to interactively operate the status values, thresholds, cumulative values or statistical values of main / standby switching electric equipment and group hydraulic equipment under different working conditions.

[0021] Furthermore: the data accuracy processing unit includes:

[0022] Data filtering module: used to filter invalid data and abnormal submerged arc furnace data in the furnace automation system;

[0023] Data replenishment module: used to automatically replenish delayed data with pre-set time characteristics to the submerged arc furnace control system data in advance or in advance, establish consistent data association relationships, and perform automatic replenishment processing;

[0024] Data cleaning module: used to filter out data that meets the numerical standards but is repeated or invalid, or to continue with the previous value;

[0025] Data conversion module: used to process the data range of each dimension of the submerged arc furnace and unify the measurement unit and physical meaning;

[0026] Manual correction module: used to correct human input errors and erroneous data in the data collection system.

[0027] Furthermore: the data filtering module includes:

[0028] Custom filtering module: used to combine multiple conditions according to process parameters and production strategies, and automatically filter potential abnormal and invalid data of submerged arc furnaces based on the combined logic or threshold;

[0029] Low-pass filter function module: used to filter out invalid data and abnormal ore-arc furnace data for delayed data, automatically backfill data, filter out repeated or invalid data that meets the standards, or continue with the previous value processing to extract valid and usable data;

[0030] Low-pass filtering function module: used to remove high-frequency noise, smooth data trends, extract effective and usable key data, and filter out the required essential feature data.

[0031] Furthermore, the data storage processing unit:

[0032] Data cache module: used to set up an in-memory database and cache pre-processed data;

[0033] Data partition module: used to set the partition table, plan the data hierarchy of the submerged arc furnace, and perform partition processing on the pre-processed data;

[0034] Data turnover module: used for real-time scheduling and process transfer of all submerged arc furnace data storage resources, setting timed tasks, cleaning historical data, and controlling data increments;

[0035] Time conversion module: used to control the database reading and writing strategy of processed data and standardize data types.

[0036] Furthermore, the time conversion module includes:

[0037] Database time processing module: used to configure the hourly database reading time interval and the length of time to read database data;

[0038] File time processing module: used to process file time by configuring the time of the first data, the time of the last data, and the time length of each data read at one-hour intervals;

[0039] Time type conversion module: used to convert various data types into time types and translate them into user-readable information.

[0040] Furthermore, the data reliability processing unit includes:

[0041] Furnace condition monitoring module: used to capture the instantaneous value and trend value of the key operating parameters of the submerged arc furnace, and monitor abnormal furnace conditions in real time based on the threshold value of the key operating parameters of the submerged arc furnace according to the equipment technology and production process of the submerged arc furnace;

[0042] Special working condition management module: used to specially mark the workshop-level and factory-level scheduling instructions of the submerged arc furnace, and exclude them from the decision-making analysis system of the submerged arc furnace;

[0043] Smelting process constraint module: used to record and filter out abnormal operating data that does not conform to the submerged arc furnace mechanism model and equipment health;

[0044] Expert experience module: used to manually intervene in calibration data that meets specific expert rules, and to provide feedback and modify data sources for special calibration values obtained through manual inspection and random sampling.

[0045] Furthermore, the level management module includes:

[0046] Level management module: used to record log records according to four levels: debug, information, warning and error;

[0047] Record filtering module: used to filter records based on log level, keyword or time range;

[0048] Rollover strategy module: used to automatically roll over to a new file to continue recording when the log file reaches a certain size;

[0049] Security log module: used to record information related to security events and threats;

[0050] Configuration management module: used to dynamically configure the logging level, format, and output target for recording.

[0051] A method for processing data of a submerged arc furnace smelting process, comprising the following steps:

[0052] Obtain control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system;

[0053] Pre-processing of control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system;

[0054] Reliability processing of pre-processed submerged arc furnace smelting system data;

[0055] Diversified storage of submerged arc furnace smelting system data after reliability processing;

[0056] Logs are automatically generated for the information, warnings, and errors generated in the process of obtaining various data of the submerged arc furnace smelting system, control data, management data, maintenance data, special equipment management data, preprocessing process, diversity storage process, and the process of reproducing data of the submerged arc furnace smelting system after reliability processing. These data are stored in an automatic backup mode based on date.

[0057] The present invention provides a submerged arc furnace smelting process data processing system, which particularly relates to submerged arc furnace smelting equipment. It realizes the comprehensive processing of submerged arc furnace production process data, provides data guidance and decision analysis for users, and includes five functional units: data interface processing, data accuracy processing, data storage processing, data reliability processing, and data log processing. It efficiently utilizes submerged arc furnace data resources, mines the value of submerged arc furnace data, and guides the smooth production of submerged arc furnaces.

[0058] This application proposes a data processing system for the smelting process of submerged arc furnaces. This system breaks through the bottleneck of traditional discrete data in the industry and, from the perspectives of data mining, machine learning, and decision analysis, creates a comprehensive processing system for submerged arc furnace process data, providing a standardized solution that can be implemented. It has the following advantages:

[0059] This system takes high-quality data resources as its core and creates a process data processing system suitable for submerged arc furnaces. It comprehensively integrates submerged arc furnace smelting process variables such as electricity, raw materials, flue gas, and inspection and testing, comprehensively processes the inspection data, extracts data-specific features, creates and upgrades submerged arc furnace data models online, introduces production process theory, promotes model evaluation and optimization, promptly diagnoses fault causes, and delivers production guidance in real time, assisting submerged arc furnace production control personnel in decision-making and analysis, effectively reducing the power consumption of smelting products and improving the intelligence level of submerged arc furnaces. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] 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 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 labor.

[0061] Figure 1It is a topological diagram of the data processing system for the smelting process of the submerged arc furnace. DETAILED DESCRIPTION

[0062] It should be noted that, unless there is any conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0063] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings 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. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0064] A submerged arc furnace smelting process data processing system, comprising:

[0065] Data interface acquisition unit: used to obtain control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system;

[0066] Data accuracy processing unit: used for pre-processing the control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system acquired by the data interface acquisition unit;

[0067] Data reliability processing unit: used for performing reliability processing on the submerged arc furnace smelting system data preprocessed by the data accuracy processing unit;

[0068] Data storage and processing unit: used for performing diversified storage on the submerged arc furnace smelting system data after reliability processing by the data reliability processing unit;

[0069] Data log processing unit: used for the process of the data interface acquisition unit acquiring various data of the submerged arc furnace smelting system, the data preprocessing process of the data accuracy processing unit, the diversity storage process of the data storage unit, and the information, warnings and errors generated in the process of the submerged arc furnace smelting system data after reliability processing by the data reliability processing unit, automatically generating logs, and storing them in an automatic backup manner by date.

[0070] The data interface acquisition unit includes:

[0071] Control system interface module: used to connect to the control unit of the hot furnace automation system. For scenarios with multiple control units, inter-controller communication is preferred, and data is merged into the specific storage area of the controller with the lowest data volume. Heartbeat detection and status identification are enabled for the interface status to realize the acquisition of control data of the electric arc furnace automation system; relying on the high real-time performance characteristics of the control system, it is the first to complete functions such as data synchronization verification, improve the consistency and synchronization of multi-dimensional data, and provide necessary guarantees for the quality of subsequent data collection.

[0072] The control system interface module is used to connect to the submerged arc furnace automation system, and the control system variables are collected continuously in a multi-dimensional, full-process, and non-stop manner, providing a primary data source for subsequent analysis.

[0073] Management system interface module: This module is used to connect to the core requirements of the information management systems at all levels of the submerged arc furnace smelting system. It uses a unified two-way communication interface to receive the output instructions of the management requirement system, convert them into concise data dimensions (as a data attribute dimension, added to the collected data), and add them to the data collection scope to achieve the acquisition of submerged arc furnace-related management data information. It also adds them to the data collection scope and sends submerged arc furnace-related data information to provide data support for the upper management system.

[0074] Inspection and Maintenance Management Module: This module is used to assign identifiable characteristic values to submerged arc furnace production equipment or instruments that are undergoing inspection, maintenance, replacement, or servicing, thereby characterizing the equipment's current actual status. In addition to the direct or real-time physical values of traditional control systems, this module adds a series of easily identifiable characteristic values to characterize the equipment's current actual status. This module fully considers the impact of abnormal equipment values on data dimensions and distribution during the inspection and maintenance process, minimizing any negative impacts on data and models while preserving the normal data collection process.

[0075] Special equipment management module: used to manually check and fill in the gaps in the data interface processing unit. By reserving a manual input interface for front-line operators, the status values, thresholds, cumulative values or statistical values of special equipment (electric equipment used for main / standby switching and group hydraulic equipment) under different working conditions can be modified or optimized as needed to interactively operate, more reasonably reflect the operating status of the electric arc furnace equipment, enrich the data content, and avoid generalizing.

[0076] The data accuracy processing unit includes:

[0077] Data filtering module: used to filter invalid data and abnormal submerged arc furnace data in the furnace automation system;

[0078] The data filtering module includes:

[0079] Custom filtering module: used to combine multiple conditions according to process parameters and production strategies, and automatically filter potential abnormal data and invalid data of the submerged arc furnace according to the combined logic or threshold; the custom filtering module automatically filters out invalid data and abnormal submerged arc furnace data according to custom filtering rules, including but not limited to: furnace wall thermocouples, furnace bottom thermocouples, clean gas flue thermocouples, etc., which are often damaged by local excessive temperature and the temperature transmitter outputs full-scale value; instruments such as furnace pressure measurement are often over-range due to furnace collapse and cannot be automatically reset; the electrode voltage sampling point has poor contact between the mechanical structure of the detection device and the electrode shell, and the measured voltage value is displayed as zero.

[0080] It is used to combine multiple conditions according to process parameters and production strategies, and automatically filter potential abnormal and invalid data of the submerged arc furnace based on the combined logic or threshold, as follows:

[0081] Going beyond conventional numerical threshold filtering, we combine multiple conditions based on process parameters and production strategies to generate combined logical or threshold values. Process parameters include: physical and chemical properties of raw materials, electrode paste specifications, and ingredient ratios. Production strategies include: maximum output, minimum unit electricity consumption, minimum overall energy consumption, and optimal product quality.

[0082] Low-pass filtering function module: used to support the automatic filtering of invalid data and abnormal submerged arc furnace data in the big data of submerged arc furnaces, automatically backfill the delayed filtering of invalid data and abnormal submerged arc furnace data, filter out or continue the previous value processing of data that meets the numerical standards but is repeated multiple times or invalid, and extract valid and usable data; use the threshold filtering function module to screen out the required qualified data.

[0083] Low-pass filtering function module: used to support the removal of high-frequency noise in the big data of the submerged arc furnace, smooth the data trend, extract effective and usable key data, and use the low-pass filtering function module to screen out the required essential feature data.

[0084] The data filtering module supports the use of other filtering functions, can add new filtering functions in the custom filtering function module, and can be referenced by other function modules, process the data range of each dimension of the submerged arc furnace, unify the measurement units and physical meanings, normalize some data items, open a manual modification interface, correct human input errors and other system omissions, enhance fault tolerance, and improve the accuracy of submerged arc furnace data.

[0085] Data replenishment module: used to automatically replenish delayed data with pre-set time characteristics to the submerged arc furnace control system data in advance or in delay, establish a consistent data association relationship, and perform automatic replenishment processing; the delayed data includes but is not limited to: raw material composition data measured before submerged arc furnace smelting production, and there is a time difference of several hours between the raw materials entering the furnace; the output data needs to be measured by manual estimation after the furnace is taken out or by weighing after cooling, and there is a certain time difference between the control system data of the submerged arc furnace smelting process; the inspection and testing data needs to be measured by offline inspection and testing instruments after the furnace is finished and cooled.

[0086] Data cleaning module: used to filter out or continue to process data that meets the numerical standards but is repeated or invalid. This includes but is not limited to: communication conversion sensors usually maintain the same sampling value for multiple consecutive time intervals before communication is poor or completely fails. Although the value range does not constitute the filtering condition of the threshold, it has affected the relevance of the data. The data records at the time of the value jump should be retained, and the rest should be filtered out; the radar level sensor will output a constant value during the fault period, but based on the silo unloading trend curve under the premise of stable active power of the submerged arc furnace, the material level value from the time of failure to the time of recovery can be assigned a calculated value according to the material trend curve, reducing the impact on the number and validity of the submerged arc furnace data samples;

[0087] Data transformation module: used to process the data range of various dimensions of the submerged arc furnace, unify the measurement units and physical meanings, and normalize data items of different dimensions according to data modeling requirements, thereby improving data readability and facilitating data modeling applications;

[0088] Manual correction module: used to open the manual modification interface for submerged arc furnace operators to correct human input errors and erroneous data in the data acquisition system, enhance fault tolerance, and improve the accuracy of submerged arc furnace data.

[0089] The data storage processing unit:

[0090] Data cache module: used to set up an in-memory database and cache pre-processed data; improve the efficiency of receiving and distributing real-time data of the submerged arc furnace, reduce interface pressure, and improve processing capabilities;

[0091] Data partitioning module: used to integrate relational, non-relational, time series and other databases, set up partition tables, plan the data hierarchy of the submerged arc furnace, partition the pre-processed data, and accelerate query responses;

[0092] Data turnover module: used for real-time scheduling and process transfer of all submerged arc furnace data storage resources, setting timed tasks, cleaning historical data, and controlling pre-processing data increments;

[0093] Time conversion module: used to control the database reading and writing strategy of preprocessed data and standardize data types.

[0094] The time conversion module includes:

[0095] Database time processing module: used to configure the hourly database reading time interval, which is the length of time to read the database data; the database reading time interval can be 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30, and the length of time to read the database data each time is pushed forward from the reading time;

[0096] File time processing module: used to process file time by configuring the time of the first data, the time of the last data, and the one-hour time interval. The options are 1, 2, 3, 4, 5, 6, 10, 12, 15, 20, 30, and the time length of the read data;

[0097] Time type conversion module: used to convert various data types into time types (yyyy / mm / dd, yyyy-mm-dd, yy.mm.dd and other time types) to achieve accurate time capture, convert various data types into user-readable information, and facilitate the unification and standardization of time records in related modules of the system.

[0098] Furthermore, the data reliability processing unit includes:

[0099] Furnace condition monitoring module: used to capture the instantaneous values and trend values of the key operating parameters of the submerged arc furnace, monitor abnormal furnace conditions in real time based on the threshold values of the key operating parameters of the submerged arc furnace according to the equipment technology and production process of the submerged arc furnace, and issue early warnings;

[0100] The key operating parameters of the submerged arc furnace include furnace pressure, electrode current, electrode voltage and other key operating parameters;

[0101] Special working condition management module: used to specially mark the workshop-level and factory-level scheduling instructions of the submerged arc furnace (for example, temporary load reduction, temporary shutdown, temporary maintenance, etc., which cause data fluctuations and anomalies, and add a dimension attribute to mark them), and not include them in the decision-making analysis system of the submerged arc furnace;

[0102] Smelting process constraint module: Used to record and filter abnormal operating data that does not conform to the submerged arc furnace mechanism model and equipment health (abnormal data that exceeds the equipment tolerance index limit). On the one hand, it records the abnormal data, and on the other hand, it performs relevant filtering operations to avoid outputting decision-making results that have no practical guiding significance and are detrimental to the submerged arc furnace equipment.

[0103] Expert experience module: used to manually intervene in calibration data that meets specific expert rules, provide feedback and modify data sources for special calibration values from manual inspection and random sampling, and improve the reliability of submerged arc furnace data.

[0104] The specific expert rules are a means of artificially supplementing data reliability. For example, laboratory data is generally sampled once per team, with an interval of 8 to 12 hours between each sampling, which cannot fully represent the real-time raw material indicators entering the furnace. The contradiction between such low sampling and high real-time performance requires the introduction of the experience of submerged arc furnace production experts to manually predict and adjust the parameters of the raw material indicators entering the furnace to make production operations more stable. In this process, although there are no data accuracy issues or human errors, the intervention of expert experience is still required in actual production. The level management module includes:

[0105] Level Management Module: Used to record logs according to four levels: debug, information, warning, and error, and automatically generate system logs. Automatic backup is adopted by date, stored in the database, and the management and configuration interface is open; the four levels correspond to different priorities and output strategies;

[0106] Output strategy: no display, display but no recording, recording and prompting, recording and alarming.

[0107] Record filtering module: used to filter records according to log level, keyword or time range, allowing specific conditions to filter and filter information; filtering according to log level, keyword or time range reduces unnecessary log output and improves log analysis efficiency.

[0108] Rollover strategy module: used to support setting rollover strategies based on time or file size. When a log file reaches a certain size, it will automatically roll over to a new file to continue recording. This ensures the manageability of log files and the efficient use of storage space.

[0109] Security Log Module: Used to record information related to security events and threats, such as failed login attempts and permission changes, to record, monitor, and respond to potential security issues;

[0110] Configuration management module: used to dynamically configure the level, format and output target of logging, record, achieve the flexibility of logging, and set it through configuration files or environment variables.

[0111] A method for processing data of a submerged arc furnace smelting process, comprising the following steps:

[0112] S1: Acquire control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system;

[0113] S2: Pre-processing the control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system;

[0114] S3: Reliability processing of pre-processed submerged arc furnace smelting system data;

[0115] S4: Diversified storage of the submerged arc furnace smelting system data after reliability processing;

[0116] S5: Automatically generate logs for the process of obtaining various data of the submerged arc furnace smelting system, control data, management data, maintenance data, special equipment management data, preprocessing process, diversity storage process, and information, warnings and errors generated in the process of submerged arc furnace smelting system data after reliability processing, and store them in an automatic backup method by date.

[0117] The steps S1 / S2 / S3 / S4 / S5 are performed sequentially.

[0118] The submerged arc furnace smelting process data processed by the submerged arc furnace smelting process data processing system can be used for:

[0119] (1) Improve the control model of the submerged arc furnace;

[0120] The smelting process in a submerged arc furnace is a highly complex, high-temperature physical and chemical reaction process involving multiple physical and chemical changes and dozens of reaction variables. It is a typical nonlinear, time-varying system with a complex structure and unclear mechanisms. Currently, there are no submerged arc furnace control models in the industry that incorporate process variables such as raw materials, flue gas, and compensation, resulting in generally crude control capabilities. However, the present invention can integrate these process variables into the control model calculations. Combined with the improvement of the effective sample data set, it is expected to effectively improve the control level of submerged arc furnaces.

[0121] (2) Improve the accuracy of submerged arc furnace data

[0122] Based on custom filtering rules for submerged arc furnaces, invalid and abnormal data are filtered out, delayed data is automatically backfilled, potential submerged arc furnace anomalies are filtered out or processed as previous values, and abnormal operating data that does not conform to the mechanism model and equipment health is processed based on smelting process constraints. Characteristic values are automatically assigned to submerged arc furnace equipment or instruments undergoing overhaul, maintenance, replacement, or servicing. A manual input interface is reserved for frontline operators to modify and optimize the status values or statistical values of special equipment under different operating conditions to more accurately reflect the operating status of the submerged arc furnace equipment. A manual modification interface is available to promptly correct human input errors and other system errors and omissions.

[0123] (3) Enhance the practicality of submerged arc furnace application

[0124] Fully integrate the submerged arc furnace automation system with information management systems at all levels to implement real-time scheduling and process transfer of all submerged arc furnace data storage resources. Set up scheduled tasks, clean up historical data, and control data increments. Set up partition tables, plan data hierarchies, and accelerate query responses. Specially mark submerged arc furnace workshop-level and factory-level scheduling instructions. Manually intervene in calibration data that meets specific expert rules, provide feedback, and modify data sources. Correct model parameters online and, in combination with production process parameters, promptly update and adjust the submerged arc furnace model. Archive important process data and analysis results to ensure that historical data from the entire process is traceable and analyzable.

[0125] The main effects that can be brought to user units are as follows:

[0126] (1) Global optimization of production process

[0127] Currently, submerged arc furnace production relies primarily on manual experience, resulting in ineffective organization and coordination of various production links within the process, which can only achieve local optimization of individual links. By introducing five data processing units, key influencing factors across all production links (such as inspection and maintenance management, special equipment management, furnace condition monitoring, special operating conditions, and smelting process constraints) are incorporated into the same model evaluation scope. This allows for targeted improvements to product production processes, breaking through bottlenecks at individual process nodes, and ultimately achieving global optimization for the entire production process.

[0128] (2) Reduce product power consumption

[0129] By continuously accumulating operational data with excellent production indicators and extracting efficient production parameter combinations, we guide users to operate according to high-efficiency production methods, ensuring the healthy and stable operation of submerged arc furnace equipment. Taking a typical 2×48MVA submerged arc furnace in regular operation as an example, the expected power consumption of the product can be reduced from the current 3400kWh / t to approximately 3330kWh / t, a reduction of approximately 2%. Currently, the average daily power consumption of a single furnace is 900MWh, with an electricity price of 0.37 yuan / kWh. With an average annual operation of 330 days, the annual power consumption reduction for a single furnace is equivalent to approximately 2.2 million yuan, representing a significant energy saving benefit for the user.

[0130] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A submerged arc furnace smelting process data processing system, characterized by: include: Data interface acquisition unit: used to obtain control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system; Data accuracy processing unit: used for pre-processing the control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system acquired by the data interface acquisition unit; Data reliability processing unit: used for performing reliability processing on the submerged arc furnace smelting system data preprocessed by the data accuracy processing unit; Data storage processing unit: used for performing diversified storage of the submerged arc furnace smelting system data after reliability processing by the data reliability processing unit; Data log processing unit: used for the process of the data interface acquisition unit acquiring various data of the submerged arc furnace smelting system, the data preprocessing process of the data accuracy processing unit, the diversity storage process of the data storage unit, and the information, warnings and errors generated in the process of the submerged arc furnace smelting system data after reliability processing by the data reliability processing unit, automatically generating logs, and storing them in an automatic backup manner by date.

2. The submerged arc furnace smelting process data processing system according to claim 1, characterized in that: The data interface acquisition unit includes: Control system interface module: used to connect to the control unit of the furnace automation system. In scenarios with multiple control units, inter-controller communication is preferred, and data is merged into the specific storage area of the controller with the lowest data volume. Heartbeat detection and status identification are enabled for the interface status to realize the acquisition of control data of the submerged arc furnace automation system; Management system interface module: used to connect to the core requirements of the information management system at all levels of the submerged arc furnace smelting system. It adopts a unified two-way communication interface, receives management requirements, converts them into concise data dimensions, and adds them to the data collection scope to achieve the acquisition of relevant management data information of the submerged arc furnace; Inspection and maintenance management module: used to assign identifiable characteristic values to submerged arc furnace production equipment or instruments that are under inspection, maintenance, replacement, or servicing, to represent the current actual status of the equipment; Special equipment management module: used to interactively operate the status values, thresholds, cumulative values or statistical values of main / standby switching electric equipment and group hydraulic equipment under different working conditions.

3. The submerged arc furnace smelting process data processing system according to claim 1, characterized in that: The data accuracy processing unit includes: Data filtering module: used to filter invalid data and abnormal submerged arc furnace data in the furnace automation system; Data replenishment module: used to automatically replenish delayed data with pre-set time characteristics to the submerged arc furnace control system data in advance or in advance, establish consistent data association relationships, and perform automatic replenishment processing; Data cleaning module: used to filter out data that meets the numerical standards but is repeated or invalid, or to continue with the previous value; Data conversion module: used to process the data range of each dimension of the submerged arc furnace and unify the measurement unit and physical meaning; Manual correction module: used to correct human input errors and erroneous data in the data collection system.

4. The submerged arc furnace smelting process data processing system according to claim 2, characterized in that: The data filtering module includes: Custom filtering module: used to combine multiple conditions according to process parameters and production strategies, and automatically filter potential abnormal and invalid data of submerged arc furnaces based on the combined logic or threshold; Low-pass filter function module: used to filter out invalid data and abnormal ore-arc furnace data for delayed data, automatically backfill data, filter out repeated or invalid data that meets the standards, or continue with the previous value processing to extract valid and usable data; Low-pass filtering function module: used to remove high-frequency noise, smooth data trends, extract effective and usable key data, and filter out the required essential feature data.

5. The submerged arc furnace smelting process data processing system according to claim 1, characterized in that: The data storage processing unit: Data cache module: used to set up an in-memory database and cache pre-processed data; Data partition module: used to set the partition table, plan the data hierarchy of the submerged arc furnace, and perform partition processing on the pre-processed data; Data turnover module: used for real-time scheduling and process transfer of all submerged arc furnace data storage resources, setting timed tasks, cleaning historical data, and controlling data increments; Time conversion module: used to control the database reading and writing strategy of processed data and standardize data types.

6. The submerged arc furnace smelting process data processing system according to claim 1, characterized in that: The time conversion module includes: Database time processing module: used to configure the hourly database reading time interval and the length of time to read database data; File time processing module: used to process file time by configuring the time of the first data, the time of the last data, and the time length of each data read at one-hour intervals; Time type conversion module: used to convert various data types into time types and translate them into user-readable information.

7. The submerged arc furnace smelting process data processing system according to claim 1, characterized in that: The data reliability processing unit includes: Furnace condition monitoring module: used to capture the instantaneous value and trend value of the key operating parameters of the submerged arc furnace, and monitor abnormal furnace conditions in real time based on the threshold value of the key operating parameters of the submerged arc furnace according to the equipment technology and production process of the submerged arc furnace; Special working condition management module: used to specially mark the workshop-level and factory-level scheduling instructions of the submerged arc furnace, and exclude them from the decision-making analysis system of the submerged arc furnace; Smelting process constraint module: used to record and filter out abnormal operating data that does not conform to the submerged arc furnace mechanism model and equipment health; Expert experience module: used to manually intervene in calibration data that meets specific expert rules, and to provide feedback and modify data sources for special calibration values obtained through manual inspection and random sampling.

8. The submerged arc furnace smelting process data processing system according to claim 1, characterized in that: The level management module includes: Level management module: used to record log records according to four levels: debug, information, warning and error; Record filtering module: used to filter records based on log level, keyword or time range; Rollover strategy module: used to automatically roll over to a new file to continue recording when the log file reaches a certain size; Security log module: used to record information related to security events and threats; Configuration management module: used to dynamically configure the logging level, format, and output target for recording.

9. A method for processing data of a submerged arc furnace smelting process, characterized by: The following steps are involved: Obtain control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system; Pre-processing of control data, management data, maintenance data and special equipment management data of the submerged arc furnace smelting system; Reliability processing of pre-processed submerged arc furnace smelting system data; Diversified storage of submerged arc furnace smelting system data after reliability processing; Logs are automatically generated for the information, warnings, and errors generated in the process of obtaining various data of the submerged arc furnace smelting system, control data, management data, maintenance data, special equipment management data, preprocessing process, diversity storage process, and the process of reproducing data of the submerged arc furnace smelting system after reliability processing. These data are stored in an automatic backup mode based on date.

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