Electrolytic tank core stacking consistency detection device and offline and online detection method thereof

Abstract

The invention provides an electrolytic cell core stacking consistency detection device and an offline and online detection method thereof.The electrolytic cell comprises an upper end plate, a lower end plate and a plurality of cell cores, a standard detection block is arranged on one side of the lower end plate, and the detection device comprises a linear guide rail, a linear motor, an HMI touch screen, a lifting plate, a PLC and two laser ranging modules; the linear guide rail is installed at the end, adjacent to the standard detection block, of the electrolytic cell, the HMI touch screen is fixed to the outer end of the linear guide rail, the lifting plate is located at the inner end of the linear guide rail and driven by the linear motor to ascend and descend along the linear guide rail, and the laser ranging module is fixed to the lifting plate and is perpendicular to one end of the electrolytic cell. The laser ranging module corresponds to the slot core to be detected and the standard detection block in position, and the linear motor, the laser ranging module and the HMI touch screen are all in communication connection with the PLC; according to the method, the detection automation level can be improved, real-time visual display of results is realized, and the problems of low detection efficiency and slow data processing are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of electrolytic cell assembly detection, and in particular to a device for detecting the stacking consistency of electrolytic cell cores and an offline and online detection method thereof. Background Art

[0002] Existing electrolytic cells mainly use three-coordinate contact detection to detect the consistency of cell core stacking. This method is complex to operate, has a large workload, and has low detection efficiency. In addition, the point selection relies heavily on the experience of the measurement personnel. The measurement results need to be analyzed and plotted to obtain intuitive data and charts. The three-coordinate contact detection method can only be used for offline detection after the press-fitting is completed. If the cell core assembly is offset, it cannot be corrected in real time, which may cause sealing failure. Summary of the Invention

[0003] In response to the problems existing in the prior art, the present invention provides an electrolytic cell core stack consistency detection device and offline and online detection methods thereof, which improve the level of detection automation, realize real-time visual display of results, solve the hysteresis problem of offline detection, and solve the problems of low detection efficiency and slow data processing. In order to solve the above technical problems, the technical solution adopted by the present invention is: A device for detecting the stack consistency of electrolytic cell cores, wherein the electrolytic cell comprises an upper end plate, a lower end plate and a plurality of cell cores, and is characterized in that a standard detection block is provided on one side of the lower end plate, and the detection device comprises a linear guide rail, a linear motor, an HMI touch screen, a lifting plate, a PLC controller and two laser ranging modules, wherein the linear guide rail is installed at one end of the electrolytic cell adjacent to the standard detection block, the HMI touch screen is fixed to the outer end of the linear guide rail, the lifting plate is located at the inner end of the linear guide rail, the lifting plate is driven by the linear motor to rise and fall along the linear guide rail, the laser ranging module is fixed to the upper surface of the lifting plate, the laser ranging module is arranged perpendicular to one end of the electrolytic cell, the laser ranging module corresponds to the positions of the cell core to be measured and the standard detection block respectively, and the linear motor, laser ranging module and HMI touch screen are all communicatively connected to the PLC controller.

[0004] Furthermore, the two laser ranging modules are symmetrically arranged on the upper surface of the lifting plate.

[0005] Furthermore, the lifting plate is L-shaped, the vertical part of the lifting plate is lifted and lowered along a linear guide rail, and the laser ranging module is fixed on the horizontal part of the lifting plate.

[0006] The off-line detection method using the electrolytic cell core stack consistency detection device comprises the following steps: Step 1) Install the detection device at the location of the electrolytic cell to be measured, fix the standard detection block to the edge of one side of the lower end plate, and position the two laser ranging modules corresponding to the measurement location of the electrolytic cell and the location of the standard detection block respectively; Step 2) The detection device is powered on, and the PLC controller performs automatic calibration. The laser ranging module scans and obtains the reference point cloud data. The PLC controller extends this data and uses it as the virtual reference line Z0. Step 3) The linear motor drives the laser ranging module to move along the Z axis for dynamic scanning detection, and the PLC controller collects the actual distance value Z of N discrete points on the surface of the slot core to be measured. n ; Step 4) PLC controller uses the formula ΔZ n =Z n -Z0 calculates the relative deviation of each discrete point and uses the shielding optimization algorithm to generate the stacking consistency parameters; Step 5) The PLC controller processes the slot core stack consistency data and converts it into a line graph, generates an inspection report containing the maximum deviation value and consistency parameters, and displays it on the HMI touch screen.

[0007] The online detection method using the electrolytic cell core stack consistency detection device comprises the following steps: Step 1) Install the detection device at the location of the electrolytic cell to be measured, fix the standard detection block to the edge of one side of the lower end plate, and position the two laser ranging modules corresponding to the measurement location of the electrolytic cell and the location of the standard detection block respectively; Step 2) The detection device is powered on, and the PLC controller performs automatic calibration. The laser ranging module scans and obtains the reference point cloud data. The PLC controller extends this data and uses it as the virtual reference line Z0. Step 3) During assembly, the PLC controller performs online testing, using a linear motor to drive the laser ranging module along the Z axis to collect the actual distance value Zn on the surface of the single-section slot core. When a significant difference in distance is detected, for example, >5mm, the single-section slot core inspection is considered complete. Step 4) The PLC controller uses the formula ΔZ n =Z n -Z0 calculates the relative deviation of each point and uses the shielding optimization algorithm to generate the stacking consistency during the single-section assembly process; Step 5) The PLC controller performs online detection based on given judgment criteria, and gives a judgment result, such as NG, and provides adjustment prompts, such as using fully automatic assembly equipment and outputting adjustment signals, which are displayed on the HMI touch screen.

[0008] Compared with the prior art, the present invention has the following technical effects: The present invention adopts non-contact dual-sensor synchronous ranging technology, and drives two laser ranging modules to move vertically through a linear motor. The laser ranging modules measure the distance between the slot core and the standard detection block, and can obtain the slot core stacking consistency data through data differential combing. This solves the problems of complex operation and high workload in the process of electrolytic cell slot core stacking consistency detection, improves the level of detection automation, and reduces manual dependence.

[0009] The present invention establishes a baseline by measuring the standard block, which can effectively eliminate equipment installation errors and errors generated during the movement of the linear motor module; The present invention constructs a "detection-judgment-adjustment" workflow to achieve real-time monitoring and deviation correction reminders, and solve the hysteresis problem of offline detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 It is the overall structural diagram of the present invention; Figure 2 It is another overall structural diagram of the present invention.

[0011] The parts in the accompanying drawings are marked as follows: 1 electrolytic cell, 101 cell core, 102 upper end plate, 103 lower end plate; 2 detection device, 201 linear guide rail, 202 HMI touch screen, 203 lifting plate; 204 laser ranging module, 205 PLC controller; 3 standard detection blocks. DETAILED DESCRIPTION

[0012] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0013] This embodiment provides a device for detecting the consistency of electrolytic cell core stacking. Figure 1 As shown, the electrolytic cell 1 includes an upper end plate 102, a lower end plate 103 and several slot cores 101. The upper and lower ends of the slot core 101 vertically penetrate and are fixed in the mounting holes of the upper end plate 102 and the lower end plate 103. A standard detection block 3 is provided on the right side of the lower end plate 103.

[0014] The detection device 2 includes a linear guide rail 201 , a linear motor, an HMI touch screen 202 , a lifting plate 203 , a PLC controller 205 and two laser ranging modules 204 . The linear motor is communicatively connected to the PLC controller 205 .

[0015] like Figure 2 As shown, the linear guide rail 201 is installed at the front end of the electrolytic cell 1, and the HMI touch screen 202 is fixed at the rear end of the linear guide rail 201. The HMI touch screen 202 is communicatively connected to the PLC controller 205. The HMI touch screen 202 displays the measurement data of the laser ranging module 204, and the parameters of the PLC controller 205 can be adjusted through the HMI touch screen 202, as well as the start and stop of the linear motor can be controlled.

[0016] The lifting plate 203 is located at the rear end of the linear guide rail 201 and is L-shaped. The vertical portion of the lifting plate 203 rises and falls along the linear guide rail 201 . The two laser ranging modules 204 are symmetrically arranged on the horizontal portion of the lifting plate 203 .

[0017] The laser distance measuring module 204 is arranged perpendicular to the front end surface of the electrolytic cell 1 , and is in communication with the PLC controller 205 . The laser distance measuring module 204 corresponds to the positions of the cell core 101 to be measured and the standard detection block 3 , respectively.

[0018] During inspection, the standard inspection block 3 is placed on the lower end plate 103, and the upper surface of the lower end plate 103 is converted into a plane parallel to the slot core 101. Since the slot core 101 of the electrolytic cell 1 has different heights, the point cloud data of the standard inspection block 3 is first collected, and then this data is processed into a virtual reference line in the PLC controller 205 device, thereby measuring the slot core consistency data within the travel range of the linear guide rail 201.

[0019] The off-line detection method using the electrolytic cell core stack consistency detection device includes the following steps: Step 1) Install the detection device 2 at the position of the electrolytic cell 1 to be measured, fix the standard detection block 3 to the right edge of the lower end plate 103, and position the two laser ranging modules 204 corresponding to the measurement position of the electrolytic cell 1 and the position of the standard detection block 3 respectively; Step 2) The detection device 2 is powered on, and the PLC controller 205 performs automatic calibration. The laser ranging module 204 scans and obtains reference point cloud data. The PLC controller 205 extends this data and uses it as the virtual reference line Z0. Step 3) The linear motor drives the laser distance measurement module 204 to move along the Z axis for dynamic scanning detection, and the PLC controller 205 collects the actual distance value Z of N discrete points on the surface of the slot core 101 to be measured. n ; Step 4) PLC controller 205 calculates the value of ΔZ according to the formula n =Z n -Z0 calculates the relative deviation of each discrete point and uses the shielding optimization algorithm to generate the stacking consistency parameters; The shielding optimization algorithm establishes a material feature database by pre-entering the near-infrared absorption spectrum curves, scattering characteristics and mirror reflection threshold parameters of the sealing gasket, membrane electrode, collector plate and electrode frame. In the measurement results, only the material data related to stacking consistency is selected for further processing, and the remaining data is shielded.

[0020] Step 5) The PLC controller 205 processes the slot core stacking consistency data and converts it into a broken line graph, and generates a test report including a maximum deviation value and consistency parameters. The broken line graph and the test report are displayed on the HMI touch screen 202 .

[0021] An online detection method using an electrolytic cell core stack consistency detection device comprises the following steps: Step 1) Install the detection device 2 at the position of the electrolytic cell 1 to be measured, fix the standard detection block 3 to the right edge of the lower end plate 103, and position the two laser ranging modules 204 corresponding to the measurement position of the electrolytic cell 1 and the position of the standard detection block 3 respectively; Step 2) The detection device 2 is powered on, and the PLC controller 205 performs automatic calibration. The laser ranging module 204 scans and obtains reference point cloud data. The PLC controller 205 extends this data and uses it as the virtual reference line Z0. Step 3) During the assembly process, the PLC controller 205 performs online detection and drives the laser distance measurement module 204 to move along the Z axis through the linear motor to collect the actual distance value Z on the surface of the single slot core 101. n When a significant difference in distance is detected, for example, >5 mm, the detection of the single-section slot core 101 is determined to be completed; Step 4) The PLC controller 205 uses the formula ΔZ n =Z n -Z0 calculates the relative deviation of each point and uses the shielding optimization algorithm to generate the stacking consistency during the assembly process of the single-section slot core 101; Step 5) The PLC controller 205 gives a judgment result, such as NG, based on a given judgment basis, and provides an adjustment prompt, such as using fully automatic assembly equipment and outputting an adjustment signal. The judgment result and adjustment prompt are both displayed on the HMI touch screen 202.

[0022] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structures made using the contents of the present invention's description and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A device for detecting the stack consistency of electrolytic cell cores, wherein the electrolytic cell (1) comprises an upper end plate (102), a lower end plate (103) and a plurality of cell cores (101), characterized in that: A standard detection block (3) is provided on one side of the lower end plate (103). The detection device (2) comprises a linear guide rail (201), a linear motor, an HMI touch screen (202), a lifting plate (203), a PLC controller (205) and two laser distance measurement modules (204). The linear guide rail (201) is installed at one end of the electrolytic cell (1) adjacent to the standard detection block (3). The HMI touch screen (202) is fixed to the outer end of the linear guide rail (201). The lifting plate (203) is located at the outer end of the linear guide rail (201). 1), the lifting plate (203) is driven by a linear motor to rise and fall along the linear guide rail (201), the laser ranging module (204) is fixed on the upper surface of the lifting plate (203), the laser ranging module (204) is arranged perpendicular to one end of the electrolytic cell (1), the laser ranging module (204) corresponds to the position of the cell core to be measured (101) and the standard detection block (3), respectively, and the linear motor, the laser ranging module (204) and the HMI touch screen (202) are all connected to the PLC controller (205) for communication.

2. The electrolytic cell core stacking consistency detection device according to claim 1, characterized in that: The two laser distance measuring modules (204) are symmetrically arranged on both sides of the upper end of the lifting plate (203).

3. The electrolytic cell core stacking consistency detection device according to claim 1, characterized in that: The lifting plate (203) is L-shaped, the vertical portion of the lifting plate (203) is lifted and lowered along the linear guide rail (201), and the laser ranging module (204) is fixed to the horizontal portion of the lifting plate (203).

4. The off-line detection method using the electrolytic cell core stack consistency detection device according to claim 1 is characterized in that: The following steps are involved: Step 1) Install the detection device (2) at the position of the electrolytic cell (1) to be measured, fix the standard detection block (3) to the edge of one side of the lower end plate (103), and respectively position the two laser ranging modules (204) corresponding to the measurement position of the electrolytic cell (1) and the position of the standard detection block (3); Step 2) the detection device (2) is turned on, the PLC controller (205) performs automatic calibration, and obtains reference point cloud data by scanning with the laser ranging module (204), and the PLC controller (205) extends this data as a virtual reference line Z0; Step 3) The linear motor drives the laser distance measurement module (204) to move along the Z axis for dynamic scanning detection, and the PLC controller (205) collects the actual distance values ​​Z of N discrete points on the surface of the slot core (101) to be measured. n ; Step 4) The PLC controller (205) calculates ΔZ according to the formula n =Z n -Z0 calculates the relative deviation of each discrete point and uses the shielding optimization algorithm to generate the stacking consistency parameters; Step 5) The PLC controller (205) processes the stacking consistency data of the slot core (101) and converts it into a line graph, generates a test report including a maximum deviation value and consistency parameters, and displays it on the HMI touch screen (202).

5. An online detection method using the electrolytic cell core stacking consistency detection device according to claim 1, characterized in that: The following steps are involved: Step 1) Install the detection device (2) at the position of the electrolytic cell (1) to be measured, fix the standard detection block (3) to the edge of one side of the lower end plate (103), and respectively position the two laser ranging modules (204) corresponding to the measurement position of the electrolytic cell (1) and the position of the standard detection block (3); Step 2) The detection device (2) is turned on, and the PLC controller (205) performs automatic calibration, and obtains reference point cloud data by scanning through the laser ranging module (204), and the PLC controller (205) extends this data as a virtual reference line Z0; Step 3) During the assembly process, the PLC controller (205) performs online detection, drives the laser distance measurement module (204) along the Z axis through the linear motor, and collects the actual distance value Z on the surface of the single-section slot core (101). n When a significant difference in distance is detected (e.g., >5 mm), it is determined that the detection of the single-section slot core (101) is completed; Step 4) The PLC controller (205) uses the formula ΔZ n =Z n -Z0 calculates the relative deviation of each point and uses a shielding optimization algorithm to generate the stacking consistency during the assembly process of a single-section slot core (101); Step 5) The PLC controller (205) gives a judgment result, such as NG, based on a given judgment basis, and gives an adjustment prompt, such as using a fully automatic assembly device, outputting an adjustment signal, and displaying it on the HMI touch screen (202).

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