Aluminum processing safety risk early warning method and system

Abstract

The invention provides an aluminum processing safety risk early warning method and system, and belongs to the technical field of aluminum processing deep well casting. Meanwhile, the centralized control system controls the liquid level monitoring and alarming system, the cooling water monitoring and alarming system and the water storage monitoring and alarming system to respectively monitor and alarm the liquid level of molten aluminum at the aluminum outlet of the tipping furnace, parameters of the cooling water system and the water level of the water storage system; the centralized control system integrates liquid level monitoring, accumulated water recognition, cooling water parameter monitoring and storage water level multi-dimensional data monitoring and alarming, centralized monitoring and dynamic grading response of aluminum machining deep well casting full-process risks are achieved, and the active prevention and control capacity of key risks such as high-temperature molten aluminum leakage, casting core area accumulated water, cooling water failure and insufficient water storage is improved; the problems that traditional manual supervision is low in efficiency and high in aluminum leakage explosion risk are solved.

Description

Technical Field

[0001] The present application belongs to the field of deep well casting technology for aluminum processing, and specifically relates to a safety risk early warning method and system for aluminum processing. Background Art

[0002] Deep-well aluminum casting is a vertical, semi-continuous casting process used to produce high-quality aluminum alloy ingots. Widely used in aerospace, automotive, and other fields, its core principle is to efficiently shape molten aluminum through vertical traction and rapid cooling. The production process involves smelting, forging, and crystallization, requiring numerous and complex equipment and logistics facilities distributed on the ground, in the air, and underground. The lifting and transportation requirements are significant, and the risks are high. The process also poses significant risks, such as explosions from hot molten aluminum upon contact with water. Consequently, risk early warning systems are crucial for ensuring production safety. Existing risk monitoring and early warning systems still rely on manual oversight, making it difficult to ensure timely alerts. Summary of the Invention

[0003] The present invention aims to solve at least one of the technical problems existing in the prior art or related art.

[0004] To this end, a first aspect of the present invention provides an aluminum processing safety risk early warning method.

[0005] A second aspect of the present invention provides an aluminum processing safety risk early warning system.

[0006] In view of this, according to a first aspect of an embodiment of the present application, a method for early warning of aluminum processing safety risks is proposed, comprising:

[0007] The centralized control system controls the liquid level monitoring alarm system to issue an alarm prompt based on the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace;

[0008] The centralized control system issues alarms based on the water accumulation status in the core casting area;

[0009] The centralized control system controls the cooling water monitoring and alarm system to issue alarm prompts according to the parameters of the cooling water system;

[0010] The centralized control system controls the water storage monitoring alarm system to issue an alarm prompt based on the water level of the water storage system.

[0011] In a feasible implementation, the centralized control system controls the liquid level monitoring alarm system to issue an alarm prompt according to the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace, including the following steps:

[0012] Pre-set aluminum liquid level safety value;

[0013] Connect the liquid level monitoring and alarm system to the quick shut-off valve and emergency discharge valve on the flow channel;

[0014] The liquid level monitoring and alarm system collects the liquid level information of the aluminum liquid;

[0015] When the liquid level of the aluminum liquid is detected to be higher than the safe value, the liquid level monitoring and alarm system will give an alarm.

[0016] The centralized control system controls the quick shut-off valve and emergency discharge valve to perform closing operations.

[0017] In a feasible implementation, the centralized control system issues an alarm based on the water accumulation state in the casting core area, including the following steps:

[0018] Pre-set the safety value of water depth and water flow rate;

[0019] The visual monitoring system collects image information of water accumulation in the core casting area;

[0020] The visual monitoring system performs liquid surface image cropping and frame processing on the water accumulation image to obtain the water accumulation depth value and water accumulation flow rate value;

[0021] When the visual monitoring system detects that the water depth exceeds the water depth safety value, the centralized control system will issue an alarm prompt, or when the visual monitoring system detects that the water flow rate exceeds the flow rate safety value, the centralized control system will issue an alarm prompt.

[0022] In a feasible implementation, the centralized control system controls the cooling water monitoring alarm system to issue an alarm prompt according to the parameters of the cooling water system, including the following steps:

[0023] Pre-set the first-level safety threshold and second-level safety threshold of various parameters in the cooling water system;

[0024] Connect the cooling water monitoring and alarm system to the quick shut-off valve and emergency discharge valve on the launder;

[0025] The cooling water monitoring and alarm system collects information on the cooling water system's inlet temperature, outlet temperature, inlet pressure, and inlet flow rate;

[0026] When the actual parameter value is detected to exceed the corresponding first-level safety threshold, the cooling water monitoring alarm system will issue an alarm prompt;

[0027] When the actual parameter value is detected to exceed the corresponding secondary safety threshold, the centralized control system controls the quick shut-off valve and emergency discharge valve to perform the closing operation, forcing the smelting furnace to shut down.

[0028] In a feasible implementation, the centralized control system controls the water storage monitoring alarm system to issue an alarm prompt according to the water level of the water storage system, including the following steps:

[0029] Pre-set the water level safety value of each water storage device in the water storage system;

[0030] The water storage monitoring and alarm system monitors the water level information of cooling water pools, hot water pools and high-level water towers;

[0031] When it is detected that the actual water level of the water storage equipment is lower than the water level safety value, the water storage monitoring alarm system will issue an alarm.

[0032] In a feasible implementation, the aluminum processing safety risk early warning method further includes:

[0033] Replace the wire winch system with a hydraulic cylinder;

[0034] Pre-set the speed safety value of the telescopic end of the hydraulic cylinder;

[0035] During the casting of molten aluminum, the acquisition system controls the speed monitoring device to monitor the movement speed of the telescopic end;

[0036] When the deviation between the monitored movement speed and the speed safety value exceeds 10%, the centralized control system will issue an alarm.

[0037] In a feasible implementation, the aluminum processing safety risk early warning method further includes:

[0038] The centralized control system controls the positioning monitoring alarm system based on the number of people in the core casting area and issues alarm prompts.

[0039] In a feasible implementation, the centralized control system controls the positioning monitoring alarm system according to the number of people in the casting core area and issues an alarm prompt, the steps including:

[0040] Collect personnel coordinate information, build 2D or 3D dynamic maps, and display and store personnel distribution density and activity trajectories;

[0041] Monitor the number of people in the core casting area according to the production stage and issue an alarm when there is overcrowding;

[0042] Generate inspection routes based on distribution density and activity trajectories, and issue alarms when inspections fail to follow the planned routes;

[0043] Set up virtual electronic fences around the casting core area and the smelting furnace, and dynamically adjust the warning range according to the working status of the tilting furnace;

[0044] When unauthorized persons are detected approaching the electronic fence area, an alarm will be issued;

[0045] Connect with the work permit system to verify the work permit and operation scope of personnel entering high-risk areas, and issue an alarm when personnel without a permit or exceeding their authority enter high-risk areas.

[0046] In a feasible implementation, the aluminum processing safety risk early warning method further includes:

[0047] Daily manual inspection of all alarm systems, quick-shut valves, and emergency discharge valves;

[0048] When the alarm system, quick shut-off valve or emergency discharge valve fails to operate or malfunctions, the centralized control system will be manually controlled to issue an alarm prompt;

[0049] When the number of failures or malfunctions exceeds 3 times per week, production will be stopped;

[0050] Conduct a full-process safety check on the production system and resume production after the check is completed.

[0051] According to a second aspect of an embodiment of the present application, an aluminum processing safety risk early warning system is proposed, which is applied to the aluminum processing safety risk early warning method of any of the above technical solutions, including:

[0052] Liquid level monitoring and alarm system: The liquid level monitoring and alarm system is installed at the aluminum outlet of the tilting furnace. The liquid level monitoring and alarm system is connected to the centralized control system. The centralized control system controls the liquid level monitoring and alarm system to monitor the aluminum liquid level at the aluminum outlet and issue an alarm prompt.

[0053] Cooling water monitoring and alarm system: The cooling water monitoring and alarm system is installed on the cooling water system. The cooling water monitoring and alarm system is connected to the centralized control system. The centralized control system controls the cooling water monitoring and alarm system to monitor the parameters of the cooling water system and issue alarm prompts.

[0054] The water storage monitoring and alarm system is installed on the water storage system. The water storage monitoring and alarm system is connected to the centralized control system. The centralized control system controls the water storage monitoring and alarm system to monitor the parameters of the water storage system and issue alarm prompts.

[0055] Compared with the prior art, the aluminum processing safety risk early warning method and system of the present application have the following beneficial effects:

[0056] The centralized control system issues alarm prompts based on the water accumulation status in the core casting area. At the same time, the centralized control system controls the liquid level monitoring alarm system, cooling water monitoring alarm system and water storage monitoring alarm system to monitor and alarm the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace, the parameters of the cooling water system and the water level of the water storage system respectively. The centralized control system integrates liquid level monitoring, water accumulation identification, cooling water parameter monitoring and water storage level multi-dimensional data monitoring and alarm, realizing centralized risk monitoring and dynamic graded response for the entire process of deep-well casting of aluminum processing, improving the active prevention and control capabilities of key risks such as leakage of high-temperature aluminum liquid, water accumulation in the core casting area, cooling water failure, insufficient water storage, etc., and solving the problems of low efficiency and high risk of aluminum leakage and explosion in traditional manual supervision. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present application. The same reference symbols are used throughout the drawings to represent the same components. In the drawings:

[0058] Figure 1 This is a schematic flowchart of the steps of an aluminum processing safety risk warning method according to an embodiment of the present application. DETAILED DESCRIPTION

[0059] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0060] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. Throughout the description of this application, "plurality" means two or more, unless otherwise specifically defined.

[0061] In this application, unless otherwise specified or limited, the terms "mounted," "connected," "connect," "fixed," etc. should be understood broadly. For example, they can refer to fixed connection, detachable connection, or integral connection; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on specific circumstances.

[0062] The preferred embodiments of the present application are described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present application and are not used to limit the present application.

[0063] like Figure 1 As shown, according to the first aspect of the embodiment of the present application, a method for early warning of aluminum processing safety risks is proposed, comprising:

[0064] Step 100: The centralized control system controls the liquid level monitoring alarm system to issue an alarm prompt according to the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace;

[0065] Step 200: The centralized control system issues an alarm based on the water accumulation status in the core casting area;

[0066] Step 300: The centralized control system controls the cooling water monitoring and alarm system to issue an alarm prompt according to the parameters of the cooling water system;

[0067] Step 400: The centralized control system controls the water storage monitoring alarm system to issue an alarm prompt according to the water level of the water storage system.

[0068] In the aluminum processing safety risk warning method provided by the embodiment of the present application, the centralized control system issues an alarm prompt based on the water accumulation status in the casting core area. At the same time, the centralized control system controls the liquid level monitoring alarm system, the cooling water monitoring alarm system, and the water storage monitoring alarm system to monitor and alarm the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace, the parameters of the cooling water system, and the water level of the water storage system, respectively. The centralized control system integrates liquid level monitoring, water accumulation identification, cooling water parameter monitoring, and multi-dimensional data monitoring and alarm of water storage level, realizing centralized risk monitoring and dynamic graded response for the entire process of deep well casting of aluminum processing, improving the active prevention and control capabilities of key risks such as leakage of high-temperature aluminum liquid, water accumulation in the casting core area, cooling water failure, and insufficient water storage, and solving the problems of low efficiency and high risk of aluminum leakage and explosion in traditional manual supervision.

[0069] In a feasible implementation, the centralized control system controls the liquid level monitoring alarm system to issue an alarm prompt according to the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace, including the following steps:

[0070] Pre-set aluminum liquid level safety value;

[0071] Connect the liquid level monitoring and alarm system to the quick shut-off valve and emergency discharge valve on the flow channel;

[0072] The liquid level monitoring and alarm system collects the liquid level information of the aluminum liquid;

[0073] When the liquid level of the aluminum liquid is detected to be higher than the safe value, the liquid level monitoring and alarm system will give an alarm.

[0074] The centralized control system controls the quick shut-off valve and emergency discharge valve to perform closing operations.

[0075] This technical solution provides specific steps for generating an alarm based on the molten aluminum level at the tilting furnace's tapping port. A pre-set safety level triggers the closure of the quick-shutoff valve and emergency discharge valve when the aluminum level exceeds this level. The centralized control system quickly responds, activating the furnace's safe tilting mode and automatically controlling the flow. This hard-wired interlocking control ensures that the risk of aluminum overflow is promptly blocked, significantly improving efficiency compared to traditional manual intervention and effectively preventing explosions caused by leaking aluminum and contact with water.

[0076] Furthermore, a mechanical locking device is provided at the aluminum outlet of the tilting furnace, so that the centralized control system is interlocked with the casting system, and the liquid level sensor is interlocked with the quick shut-off valve and emergency discharge valve on the flow channel, forming a dual protection mechanism for the liquid level sensor and the mechanical locking device.

[0077] In a feasible implementation, the centralized control system issues an alarm based on the water accumulation state in the casting core area, including the following steps:

[0078] Pre-set the safety value of water depth and water flow rate;

[0079] The visual monitoring system collects image information of water accumulation in the core casting area;

[0080] The visual monitoring system performs liquid surface image cropping and frame processing on the water accumulation image to obtain the water accumulation depth value and water accumulation flow rate value;

[0081] When the visual monitoring system detects that the water depth exceeds the water depth safety value, the centralized control system will issue an alarm prompt, or when the visual monitoring system detects that the water flow rate exceeds the flow rate safety value, the centralized control system will issue an alarm prompt.

[0082] This technical solution provides specific steps for issuing alarm prompts based on the water accumulation status in the core casting area. The safety values of water accumulation depth and water accumulation flow rate are pre-set. Dynamic analysis is performed based on visual frame processing to accurately identify the water accumulation depth and flow rate in the image. When the water accumulation depth exceeds the safety value, the centralized control system will issue an alarm prompt. The edge clipping algorithm is used to eliminate environmental interference, shorten the time for discovering water accumulation risks, improve the accuracy of monitoring, and reduce the probability of aluminum liquid exploding when encountering non-productive water accumulation on the ground in the core casting area.

[0083] In a feasible implementation, the centralized control system controls the cooling water monitoring alarm system to issue an alarm prompt according to the parameters of the cooling water system, including the following steps:

[0084] Pre-set the first-level safety threshold and second-level safety threshold of various parameters in the cooling water system;

[0085] Connect the cooling water monitoring and alarm system to the quick shut-off valve and emergency discharge valve on the launder;

[0086] The cooling water monitoring and alarm system collects information on the cooling water system's inlet temperature, outlet temperature, inlet pressure, and inlet flow rate;

[0087] When the actual parameter value is detected to exceed the corresponding first-level safety threshold, the cooling water monitoring alarm system will issue an alarm prompt;

[0088] When the actual parameter value is detected to exceed the corresponding secondary safety threshold, the centralized control system controls the quick shut-off valve and emergency discharge valve to perform the closing operation, forcing the smelting furnace to shut down.

[0089] In this technical solution, specific steps are given for issuing alarm prompts based on the parameters of the cooling water system, and a parameter classification threshold mechanism for the cooling water system is established in advance, wherein the first-level threshold triggers an alarm and the second-level threshold forces a shutdown. Key indicators such as inlet and outlet water temperature, inlet water pressure, and inlet water flow fluctuations are monitored in real time; by interlocking the control of the quick shut-off valve and the emergency discharge valve, crystallizer rupture accidents caused by cooling water failure are avoided, thereby reducing the probability of aluminum deep well casting production suspension due to cooling water system failure.

[0090] In a feasible implementation, the centralized control system controls the water storage monitoring alarm system to issue an alarm prompt according to the water level of the water storage system, including the following steps:

[0091] Pre-set the water level safety value of each water storage device in the water storage system;

[0092] The water storage monitoring and alarm system monitors the water level information of cooling water pools, hot water pools and high-level water towers;

[0093] When it is detected that the actual water level of the water storage equipment is lower than the water level safety value, the water storage monitoring alarm system will issue an alarm.

[0094] In this technical solution, specific steps are given for issuing alarm prompts based on the parameters of the water storage equipment. The water level safety values of each water storage equipment in the water storage system are pre-set. The water storage monitoring alarm system calibrates the water levels of the cooling water pool, hot water pool and high-level water tower in real time. When the water level is lower than the corresponding water level safety value, the water replenishment alarm is triggered to ensure the continuous and stable operation of the cooling water system and reduce the risk of deep well casting cooling interruption due to insufficient water level.

[0095] In a feasible implementation, the aluminum processing safety risk early warning method further includes:

[0096] Replace the wire winch system with a hydraulic cylinder;

[0097] Pre-set the speed safety value of the telescopic end of the hydraulic cylinder;

[0098] During the casting of molten aluminum, the acquisition system controls the speed monitoring device to monitor the movement speed of the telescopic end;

[0099] When the deviation between the monitored movement speed and the speed safety value exceeds 10%, the centralized control system will issue an alarm.

[0100] In this technical solution, a hydraulic cylinder replaces the wire winch system, and a speed monitoring device is used to monitor the cylinder speed, achieving millisecond-level early warning of abnormal casting speed. Compared with the risk of traditional wire rope breakage, the hydraulic cylinder combined with the speed monitoring device improves the stability and reliability of molten aluminum transportation, prevents sudden shaking of the molten aluminum container due to wire rope jamming, prevents molten aluminum from spilling during transportation, and reduces the probability of secondary accidents caused by transportation equipment failure.

[0101] In a feasible implementation, the aluminum processing safety risk early warning method further includes: the centralized control system controls the positioning monitoring alarm system according to the number of people in the casting core area to issue an alarm prompt.

[0102] In this technical solution, the positioning monitoring alarm system identifies the number of people on site in the foundry workshop, and the centralized control system issues safety risk warnings based on the number of people on site in the foundry workshop, controls the entry of non-production personnel, and reduces the accident rate caused by operational errors.

[0103] In a feasible implementation, the centralized control system controls the positioning monitoring alarm system according to the number of people in the casting core area and issues an alarm prompt, the steps including:

[0104] The centralized control system controls the positioning monitoring alarm system based on the number of people in the casting core area and issues an alarm prompt. The steps include:

[0105] Collect personnel coordinate information, build 2D or 3D dynamic maps, and display and store personnel distribution density and activity trajectories;

[0106] Monitor the number of people in the core casting area according to the production stage and issue an alarm when there is overcrowding;

[0107] Generate inspection routes based on distribution density and activity trajectories, and issue alarms when inspections fail to follow the planned routes;

[0108] Set up virtual electronic fences around the casting core area and the smelting furnace, and dynamically adjust the warning range according to the working status of the tilting furnace;

[0109] When unauthorized persons are detected approaching the electronic fence area, an alarm will be issued;

[0110] Connect with the work permit system to verify the work permit and operation scope of personnel entering high-risk areas, and issue an alarm when personnel without a permit or exceeding their authority enter high-risk areas.

[0111] In this technical solution, the positioning monitoring and alarm system components use 2D or 3D dynamic maps to display the coordinates and activity trajectories of personnel, and then monitor the number of people in the casting core area according to different production stages, issue overcrowding alarms, and strictly control the number of people on site; the positioning monitoring and alarm system is linked to the intelligent inspection system, and the positioning monitoring and alarm system optimizes the inspection route according to the distribution density and activity trajectory of personnel, and issues an alarm when the activity trajectory of personnel is different from the planned inspection route; virtual electronic fences are set up around the casting core area and the smelting furnace to issue out-of-bounds alarms; the positioning monitoring and alarm system is linked to the job ticket system, and issues an alarm when unauthorized or over-authorized personnel enter high-risk areas, strictly controlling the entry of non-production personnel.

[0112] In a feasible implementation, the aluminum processing safety risk early warning method further includes:

[0113] Daily manual inspection of all alarm systems, quick-shut valves, and emergency discharge valves;

[0114] When the alarm system, quick shut-off valve or emergency discharge valve fails to operate or malfunctions, the centralized control system will be manually controlled to issue an alarm prompt;

[0115] When the number of failures or malfunctions exceeds 3 times per week, production will be stopped;

[0116] Conduct a full-process safety check on the production system and resume production after the check is completed.

[0117] In this technical solution, through daily manual inspections of the alarm system, quick shut-off valves and emergency discharge valves, combined with the automated alarm mechanism of the centralized control system, rapid identification and precise positioning of equipment failures are achieved. When the cumulative number of failures exceeds three times in a week, a forced shutdown mechanism is triggered, effectively blocking potential risks and forming a closed-loop safety management system of "prevention-response-blocking-optimization". When the frequency of safety risk warnings increases, centralized safety inspections are carried out to extend the safe production cycle.

[0118] According to the second aspect of the present application, an aluminum processing safety risk warning system is proposed, which is applied to the aluminum processing safety risk warning method such as any one of the above-mentioned technical solutions, including: a liquid level monitoring and alarm system, a cooling water monitoring and alarm system and a water storage monitoring and alarm system. The liquid level monitoring and alarm system is arranged at the aluminum outlet of the tilting furnace, and the liquid level monitoring and alarm system is connected to the centralized control system. The centralized control system controls the liquid level monitoring and alarm system to monitor the aluminum liquid level at the aluminum outlet and to issue an alarm prompt; the cooling water monitoring and alarm system is arranged on the cooling water system, and the cooling water monitoring and alarm system is connected to the centralized control system. The centralized control system controls the cooling water monitoring and alarm system to monitor and issue an alarm prompt for the parameters of the cooling water system; the water storage monitoring and alarm system is arranged on the water storage system, and the water storage monitoring and alarm system is connected to the centralized control system. The centralized control system controls the water storage monitoring and alarm system to monitor and issue an alarm prompt for the parameters of the water storage system.

[0119] Through the aluminum processing safety risk early warning system provided by the embodiment of the present application, the centralized control system controls the liquid level monitoring and alarm system, the cooling water monitoring and alarm system, and the water storage monitoring and alarm system to monitor and alarm the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace, the parameters of the cooling water system, and the water level of the water storage system respectively. The centralized control system integrates liquid level monitoring, water accumulation identification, cooling water parameter monitoring, and multi-dimensional data monitoring and alarm of water storage level, realizing centralized risk monitoring and dynamic graded response of the entire process of deep well casting of aluminum processing, improving the active prevention and control capabilities of key risks such as leakage of high-temperature aluminum liquid, water accumulation in the core area of casting, cooling water failure, insufficient water storage, etc., and solving the problems of low efficiency of traditional manual supervision and high risk of aluminum leakage and explosion.

[0120] Furthermore, the aluminum processing safety risk warning system also includes a visual monitoring system and a positioning monitoring and alarm system. The visual monitoring system and the positioning monitoring and alarm system are arranged in the casting core area. The visual monitoring system is connected to the centralized control system, and the positioning monitoring and alarm system is connected to the centralized control system. The visual monitoring system collects image information of water accumulation in the casting core area, and the centralized control system issues an alarm prompt based on the water accumulation in the image, thereby shortening the time for discovering water accumulation risks, improving the accuracy of monitoring, and reducing the probability of explosion of molten aluminum when encountering non-productive water accumulation on the ground in the casting core area; the centralized control system controls the positioning monitoring and alarm system to perform positioning monitoring and alarm prompts on the number of people in the casting core area, controls the number of personnel, and then controls the entry of non-production personnel, thereby reducing the accident rate caused by operational errors.

[0121] The aluminum processing safety risk warning system provided in the embodiment of the present application is applied to the aluminum processing safety risk warning method such as any of the above-mentioned technical solutions, so the aluminum processing safety risk warning system has all the beneficial effects of the aluminum processing safety risk warning method of the above-mentioned technical solutions.

[0122] It is easy for those skilled in the art to understand that the above embodiments can be freely combined and superimposed without conflict.

[0123] The above are merely preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, and improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application. The above are merely preferred embodiments of the present application. It should be noted that those skilled in the art may make various improvements and variations without departing from the technical principles of the present application, and such improvements and variations shall also be considered within the scope of protection of the present application.

Claims

1. A method for early warning of aluminum processing safety risks, characterized in that: The aluminum processing safety risk early warning method includes: The centralized control system controls the liquid level monitoring alarm system to issue an alarm prompt based on the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace; The centralized control system issues an alarm based on the water accumulation status in the core casting area; The centralized control system controls the cooling water monitoring alarm system to issue an alarm prompt according to the parameters of the cooling water system; The centralized control system controls the water storage monitoring alarm system to issue an alarm prompt according to the water level of the water storage system.

2. The aluminum processing safety risk early warning method according to claim 1, characterized in that: The centralized control system controls the liquid level monitoring alarm system to issue an alarm prompt according to the liquid level of the aluminum liquid at the aluminum outlet of the tilting furnace, including the following steps: Pre-set aluminum liquid level safety value; Connect the liquid level monitoring and alarm system to the quick shut-off valve and emergency discharge valve on the flow trough; The liquid level monitoring and alarm system collects liquid level information of the aluminum liquid; When the liquid level of the aluminum liquid is detected to be higher than the aluminum liquid level safety value, the liquid level monitoring and alarm system will give an alarm prompt; The centralized control system controls the quick shut-off valve and the emergency discharge valve to perform closing operations.

3. The aluminum processing safety risk early warning method according to claim 1, characterized in that: The centralized control system issues an alarm based on the water accumulation state in the casting core area, including the following steps: Pre-set the safety value of water depth and water flow rate; The visual monitoring system collects image information of water accumulation in the casting core area; The visual monitoring system performs liquid surface image cropping and frame processing on the water accumulation image to obtain the water accumulation depth value and water accumulation flow rate value; When the visual monitoring system detects that the water depth value exceeds the water depth safety value, the centralized control system issues an alarm prompt, or when the visual monitoring system detects that the water flow rate value exceeds the flow rate safety value, the centralized control system issues an alarm prompt.

4. The aluminum processing safety risk early warning method according to claim 1, characterized in that: The centralized control system controls the cooling water monitoring alarm system to issue an alarm prompt according to the parameters of the cooling water system, including the following steps: Pre-set the first-level safety threshold and second-level safety threshold of various parameters in the cooling water system; Connect the cooling water monitoring and alarm system to the quick shut-off valve and emergency discharge valve on the flow trough; The cooling water monitoring and alarm system collects information on the inlet water temperature, outlet water temperature, inlet water pressure and inlet water flow of the cooling water system; When the actual parameter value is detected to exceed the corresponding first-level safety threshold, the cooling water monitoring alarm system will issue an alarm prompt; When it is monitored that the actual parameter value exceeds the corresponding secondary safety threshold, the centralized control system controls the quick shut-off valve and the emergency discharge valve to perform closing operations, forcing the smelting furnace to shut down.

5. The aluminum processing safety risk early warning method according to claim 1, characterized in that: The centralized control system controls the water storage monitoring alarm system to issue an alarm prompt according to the water level of the water storage system, including the following steps: Presetting a water level safety value for each water storage device in the water storage system; The water storage monitoring and alarm system monitors the water level information of the cooling water pool, hot water pool and high-level water tower; When it is detected that the actual water level of the water storage equipment is lower than the water level safety value, the water storage monitoring alarm system will issue an alarm prompt.

6. The aluminum processing safety risk early warning method according to claim 1, characterized in that: The aluminum processing safety risk early warning method further includes: Replace the wire winch system with a hydraulic cylinder; Presetting a speed safety value for the telescopic end of the hydraulic cylinder; During the casting of the molten aluminum, the acquisition system controls the speed monitoring device to monitor the movement speed of the telescopic end; When it is monitored that the deviation between the movement speed and the speed safety value exceeds 10%, the centralized control system will issue an alarm.

7. The aluminum processing safety risk early warning method according to claim 1, characterized in that: The aluminum processing safety risk early warning method further includes: The centralized control system controls the positioning monitoring alarm system according to the number of people in the casting core area and issues an alarm prompt.

8. The aluminum processing safety risk early warning method according to claim 7, characterized in that: The centralized control system issues an alarm prompt based on the number of people in the casting core area, and the positioning monitoring alarm system includes the following steps: Collect personnel coordinate information, build 2D or 3D dynamic maps, and display and store personnel distribution density and activity trajectories; Monitor the number of people in the core casting area according to the production stage and issue an alarm when there is overcrowding; Generate an inspection route based on the distribution density and the activity trajectory, and issue an alarm when the inspection fails to follow the planned route; Virtual electronic fences are respectively set up around the casting core area and the smelting furnace, and the warning range is dynamically adjusted according to the working status of the tilting furnace; When an unauthorized person is detected approaching the electronic fence area, an alarm is issued; Connected with the work permit system, it verifies the work permits and operating scope of personnel entering high-risk areas, and issues an alarm when personnel without a permit or exceeding their authority enter the high-risk areas.

9. A method for early warning of aluminum processing safety risks according to any one of claims 1 to 8, characterized in that: The aluminum processing safety risk early warning method further includes: Daily manual inspection of all alarm systems, quick-shut valves, and emergency discharge valves; When the alarm system, the quick shut-off valve or the emergency discharge valve fails to operate or malfunctions, the centralized control system is manually controlled to issue an alarm prompt; When the number of failures or malfunctions exceeds 3 times per week, production will be stopped; Conduct a full-process safety check on the production system and resume production after the check is completed.

10. An aluminum processing safety risk early warning system, characterized in that: The aluminum processing safety risk early warning method as claimed in any one of claims 1 to 9 comprises: A liquid level monitoring and alarm system is provided at the aluminum outlet of the tilting furnace. The liquid level monitoring and alarm system is connected to a centralized control system, and the centralized control system controls the liquid level monitoring and alarm system to monitor the aluminum liquid level at the aluminum outlet and issue an alarm. A cooling water monitoring and alarm system is provided on the cooling water system and is connected to the centralized control system. The centralized control system controls the cooling water monitoring and alarm system to monitor the parameters of the cooling water system and issue alarm prompts. A water storage monitoring and alarm system is provided on the water storage system and is connected to the centralized control system. The centralized control system controls the water storage monitoring and alarm system to monitor and alarm the parameters of the water storage system.

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