Problem tracing method, device and equipment for production process and medium
By obtaining and evaluating the physical and chemical indicators in the alumina production process, the problem of accurate traceability in existing technologies has been solved, and accurate traceability and quality improvement of problems in the alumina production process have been achieved.
Patent Information
- Application Number
- CN202510831053.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-20
- Publication Date
- 2025-09-26
AI Technical Summary
Existing technologies are unable to accurately trace the problems arising during the alumina production process, resulting in the inability to improve product quality and process performance.
By obtaining the physical and chemical indicators of each process in the alumina production process, including physical and chemical indicators, we can evaluate whether the process is qualified and trace the problem to the source if it is unqualified.
It has achieved accurate traceability of problems in the alumina production process and improved product quality and production efficiency.
Smart Images
Figure CN120706803A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of computer technology, and in particular to a production process problem tracing device, equipment and medium. Background Art
[0002] The production process of α-alumina calcined in a rotary kiln primarily includes multiple steps, including washing and filtration, high-temperature calcination, and homogenization and packaging. The control, monitoring, and management of each step determine the yield of the alumina produced. Therefore, monitoring and managing the entire α-alumina calcination process in a rotary kiln is crucial for improving alumina product quality and enhancing process performance.
[0003] At present, the monitoring and management of the alumina production process only monitors the discrete quality of products after being processed in each process. If, based on the discrete quality of the products detected in each process, it is found that the quality of the product after being processed in a certain process is poor, and one wants to trace the cause of the poor quality of the product generated by this process, the discrete quality of the product of this process cannot be accurately traced to the source of the problem, and thus cannot provide a reference for process improvement, and further cannot improve the production quality of alumina products. Therefore, how to accurately trace the problems arising in the alumina production process is a technical problem that needs to be solved urgently. Summary of the Invention
[0004] In view of the above problems, the present application is proposed to provide a method, device, equipment and medium for tracing problems in the production process to solve the above problems, which can accurately trace the problems generated in the alumina production process.
[0005] In a first aspect, the present application provides a method for tracing problems in a production process, the method comprising: obtaining a process product of a target material after it has been processed through at least two production processes, wherein the target material is a material for producing alumina; and the production processes are the processes required to produce alumina;
[0006] For each production process, test the physical and chemical indicators of the process product corresponding to the current production process; wherein the physical and chemical indicators include at least one of the physical indicators and chemical indicators of the process product, and the physical and chemical indicators are used to evaluate whether the corresponding production process is qualified;
[0007] In the case that a target production process fails to meet the standards in the production process, the problem of the target production process is traced to the source based on the physical and chemical indicators corresponding to the target production process.
[0008] In one embodiment, the method further comprises:
[0009] For each product in the process products corresponding to the current production process, determining production quality evaluation information of the current production process based on the physical and chemical indicators of the product;
[0010] Determining target evaluation information of production quality of the current production process based on the evaluation information corresponding to each product;
[0011] The target evaluation information is used to evaluate whether the corresponding production process is qualified.
[0012] In one embodiment, determining the production quality assessment information of the current production process based on the physical and chemical indicators of the product includes:
[0013] Obtaining at least one of the standard physical and chemical indicators, indicator deviation thresholds, and indicator weights of each indicator in the ideal indicator corresponding to the product;
[0014] Based on the standard physical and chemical indicators corresponding to the products, the indicator deviation threshold and at least one of the indicator weights of each indicator in the ideal indicator, and the physical and chemical indicators corresponding to the products, the production quality evaluation information of the current production process is calculated.
[0015] In one embodiment, the production quality assessment information of the current production process is calculated based on at least one of the standard physical and chemical indicators corresponding to the products, the indicator deviation threshold, and the indicator weight of each indicator in the ideal indicator, and the physical and chemical indicators corresponding to the products, including:
[0016] When the current production process is a washing and filtration process or a high-temperature calcination process, a quality coefficient of the production quality of the current production process is calculated based on the standard physical and chemical indicators of the product, the indicator deviation threshold, the indicator weight of each indicator in the ideal indicator, and the corresponding ideal indicator, and the quality coefficient is used as the evaluation information;
[0017] When the current production process is a homogenization packaging process, the quality coefficient of the production quality of the current production process is calculated based on the standard physical and chemical indicators of the sample, the indicator weights of each indicator in the ideal indicators, and the corresponding ideal indicators, and the quality coefficient is used as the evaluation information.
[0018] In one embodiment, the detecting of the physical and chemical indicators of the process product corresponding to the current production process includes:
[0019] Sampling the process products corresponding to the current production process to obtain process product samples;
[0020] Testing the physical and chemical indicators of product samples from the process;
[0021] The sampling of the process products corresponding to the current production process includes:
[0022] Based on the preset weight and the preset sampling period, part of the process products at each sampling point with the preset weight is obtained, and the part of the products is used as the process product sample; the collection points are set on the product conveyor belt according to the preset sampling distance, and the product conveyor belt is used to convey the process products corresponding to the current production process.
[0023] In one embodiment, when the production process is a washing and filtration process, the chemical indicators include at least one of sodium oxide content, moisture content, and pH value; when the production process is a high-temperature calcination process, the physical indicators include at least one of powder particle size and original crystal particle size; when the production process is a homogenization and packaging process, the chemical indicators include at least one of sodium oxide content, iron oxide content, and silicon dioxide content.
[0024] In one embodiment, the method further comprises:
[0025] Associate and store all physical and chemical indicators corresponding to each production process and the corresponding target evaluation information;
[0026] Sending target evaluation information corresponding to each production process to a quality management device, so that the quality management device determines whether the corresponding production process is qualified based on the target evaluation information;
[0027] The problem tracing of the target production process based on the physical and chemical indicators corresponding to the target production process includes:
[0028] receiving an information acquisition instruction sent by the quality management device when the target production process is determined to be unqualified based on the target evaluation information;
[0029] Based on the information acquisition instruction, all physical and chemical indicators corresponding to the target production process that are pre-associated and stored are acquired;
[0030] All physical and chemical indicators corresponding to the target production process are sent to the quality management device, so that the quality management device can trace the problem of the target production process based on all physical and chemical indicators corresponding to the target production process.
[0031] In a second aspect, the present application provides a device for tracing problems in a production process, the device comprising:
[0032] An acquisition module is used to acquire a process product of a target material after being processed through at least two production processes, wherein the target material is a material for producing alumina; and the production processes are the processes required to produce alumina;
[0033] A detection module is used to detect the physical and chemical indicators of the process products corresponding to the current production process for each production process; wherein the physical and chemical indicators include at least one of the physical indicators and chemical indicators of the process products, and the physical and chemical indicators are used to evaluate whether the corresponding production process is qualified;
[0034] The traceability module is used to trace the problem of the target production process based on the physical and chemical indicators corresponding to the target production process when the target production process is unqualified in the production process.
[0035] In a third aspect, the present application provides an electronic device comprising: a memory and a processor, wherein the memory and the processor are communicatively connected to each other, computer instructions are stored in the memory, and the processor executes the method described in the first aspect by executing the computer instructions.
[0036] In a fourth aspect, the present application provides a computer-readable storage medium, wherein the computer-readable storage medium stores computer instructions, and the computer instructions are used to enable the computer to execute the method described in the first aspect.
[0037] The technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:
[0038] The embodiments of the present application provide a method, device, equipment and medium for tracing problems in a production process. The present application obtains a process product of a target material after being processed through at least two production processes, wherein the target material is a material for producing alumina; the production process is a process required to produce alumina; for each production process, the physical and chemical indicators of the process product corresponding to the current production process are detected, which is equivalent to being able to follow and monitor the physical and chemical indicators of the products in the alumina production process, rather than just detecting the discrete quality of the products. The physical and chemical indicators are used to evaluate whether the corresponding production process is qualified. Therefore, when the target production process is unqualified in the production process, the problems in the target production process can be traced based on the physical and chemical indicators corresponding to the target production process. Compared with the method of tracing problems in the production process based on the discrete quality of the product, the physical and chemical indicators of the products in the alumina production process can measure the physical properties and chemical properties of the products. The present application can more accurately trace the problems generated in the alumina production process based on the physical and chemical indicators.
[0039] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS
[0040] 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:
[0041] Figure 1 This is a method for tracing problems in a production process provided by an embodiment of the present application;
[0042] Figure 2 This is a schematic diagram of the structure of an intelligent management system provided by an embodiment of the present application;
[0043] Figure 3 This is a schematic diagram of the structure of a production process problem tracing device provided in an embodiment of the present application;
[0044] Figure 4 This is a schematic diagram of the structure of the electronic device of this application. DETAILED DESCRIPTION
[0045] In order to make the purpose, technical solutions and advantages of the present application clearer, the implementation methods of the present application will be further described in detail below with reference to the accompanying drawings. It should be understood that the embodiments of the present disclosure and the specific features in the embodiments are detailed descriptions of the technical solutions of the present application, rather than limitations on the technical solutions of the present application. In the absence of conflict, the embodiments of the present application and the technical features in the embodiments can be combined with each other.
[0046] Figure 1 This is a flow chart of a method for tracing the source of problems in a production process provided by an embodiment of the present application. Figure 1 As shown, the method includes:
[0047] Step S101: Obtain a process product of a target material after it has been processed through at least two production processes, wherein the target material is a material for producing alumina; and the production process is a process required to produce alumina;
[0048] If the above-mentioned rotary kiln calcined α alumina production process mainly includes multiple steps such as washing and filtration, high-temperature calcination, homogenization and packaging, then the production steps include washing and filtration steps, high-temperature calcination steps, or homogenization and packaging steps.
[0049] The target material needs to be processed through at least two production processes with a processing sequence. The process product after being processed in a certain production process will be used as the target material of the next production process and will be transported to the next production process for processing. The product after the target material is processed through each production process is the process product. For example, the target material is processed through the washing and filtration process to obtain the filter cake product, and the filter cake product is processed through the high-temperature calcination process to obtain the kiln head product, and the kiln head product is then processed through the homogenization and packaging process to obtain the finished alumina product.
[0050] Step S102: For each production process, detecting the physical and chemical indicators of the process product corresponding to the current production process; wherein the physical and chemical indicators include at least one of the physical indicators and chemical indicators of the process product, and the physical and chemical indicators are used to evaluate whether the corresponding production process is qualified;
[0051] For each production process, the physical and chemical indicators of the process products corresponding to the current production process are tested. Physical and chemical indicators refer to a series of quantitative data or descriptive information obtained by testing and analyzing substances through physical and chemical methods, which can reflect the properties, composition, structure, purity, stability, etc. of the substances. Specifically, physical and chemical indicators include physical indicators and chemical indicators of process products.
[0052] Since the physical and chemical indicators include the physical indicators and chemical indicators of the process products, it can be understood that whether the corresponding production process is qualified can be evaluated based on the physical indicators and chemical indicators of the process products.
[0053] Step S103: When a target production process fails to meet the standards in the production process, the problem of the target production process is traced based on the physical and chemical indicators corresponding to the target production process.
[0054] The intelligent management system can evaluate whether the corresponding production process is qualified based on the physical and chemical indicators of the products of each process. If the production process is unqualified, the production process will be used as the target production process;
[0055] Alternatively, the intelligent management system may send the physical and chemical index evaluation of the products of each process to the production, technology and management system of the rotary kiln calcined α alumina, and the production, technology and management system will evaluate whether the corresponding production process is qualified based on the physical and chemical indicators of the products of each process, and feed back the evaluation results to the intelligent management system.
[0056] In the case that the target production process fails to meet the standards in the production process, the present application can trace the problem of the target production process based on the physical and chemical indicators corresponding to the target production process. The physical and chemical indicators of the products in the alumina production process can measure the physical properties and chemical properties of the products. If there are problems with the physical properties and chemical properties of the process products, the problems in the corresponding production process can be traced based on the problematic physical properties or chemical properties. The problems in the alumina production process can be accurately traced, instead of tracing the problem of the production process based on the discrete quality of the products detected in each process as in the prior art, that is, the problem can only be traced based on the final quality of the process products, and the specific problems in the production process cannot be known.
[0057] The present application obtains a process product after a target material has been processed through at least two production processes, wherein the target material is a material for producing alumina; the production process is a process required to produce alumina; for each production process, the physical and chemical indicators of the process product corresponding to the current production process are detected, which is equivalent to being able to follow and monitor the physical and chemical indicators of the products in the alumina production process, rather than just detecting the discrete quality of the products. The physical and chemical indicators are used to evaluate whether the corresponding production process is qualified, so that when the target production process is unqualified in the production process, the problems in the target production process can be traced based on the physical and chemical indicators corresponding to the target production process. Compared with the method of tracing the problems of the production process based on the discrete quality of the product, the physical and chemical indicators of the products in the alumina production process can measure the physical properties and chemical properties of the products. The present application can more accurately trace the problems in the alumina production process based on the physical and chemical indicators.
[0058] In one embodiment, the method further includes: determining, for each product in the process products corresponding to the current production process, the production quality evaluation information of the current production process based on the physical and chemical indicators of the product; and determining the target evaluation information of the production quality of the current production process based on the evaluation information corresponding to each product; wherein the target evaluation information is used to evaluate whether the corresponding production process is qualified.
[0059] In this embodiment, each production process may correspond to multiple process products, and each product in the process product is any one of the multiple process products;
[0060] The intelligent management system evaluates whether the corresponding production process is qualified based on the physical and chemical indicators of the products in each process, including:
[0061] For each of the multiple process products corresponding to the current production process, the intelligent management system can determine the production quality evaluation information of the current production process based on the physical and chemical indicators of the product; for example: there are 100 process products, based on the physical and chemical indicators of each process product, the production quality evaluation information of the current production process can be evaluated and obtained, and 100 pieces of evaluation information can be determined for the 100 process products.
[0062] Based on the evaluation information corresponding to multiple products, a comprehensive evaluation is performed to obtain the target evaluation information of the production quality of the current production process. Then, the intelligent management system can evaluate whether the corresponding production process is qualified based on the target evaluation information.
[0063] The above production, technology and management systems evaluate whether the corresponding production process is qualified based on the physical and chemical indicators of the products of each process, including:
[0064] Similarly, the intelligent management system comprehensively evaluates and obtains the target evaluation information of the production quality of the current production process, and then sends the target evaluation information to the production, technology and management systems. The production, technology and management systems evaluate whether the corresponding production process is qualified based on the target evaluation information, and feed back the evaluation results to the intelligent management system.
[0065] In one embodiment, the determining of the production quality evaluation information of the current production process based on the physical and chemical indicators of the product includes: obtaining at least one of the standard physical and chemical indicators, indicator deviation thresholds, and indicator weights of each indicator in the ideal indicators corresponding to the product; and calculating the production quality evaluation information of the current production process based on the standard physical and chemical indicators, indicator deviation thresholds, and at least one of the indicator weights of each indicator in the ideal indicators corresponding to the products, and the physical and chemical indicators corresponding to the products.
[0066] In this embodiment, the standard physical and chemical indicators corresponding to the product refer to the pre-set physical and chemical indicators when the product is qualified; the indicator deviation threshold refers to the difference threshold between the physical and chemical indicators of the product and the standard physical and chemical indicators corresponding to the product;
[0067] The number of physical and chemical indicators of a product can be one or more. Each indicator in the ideal indicator is any one of multiple physical and chemical indicators. Each physical and chemical indicator has a corresponding, pre-set indicator weight, and each physical and chemical indicator has a one-to-one corresponding standard physical and chemical indicator.
[0068] In one embodiment, based on the standard physical and chemical indicators corresponding to the products, the indicator deviation threshold, and at least one of the indicator weights of each indicator in the ideal indicators, and the physical and chemical indicators corresponding to the products, the evaluation information of the production quality of the current production process is calculated, including: when the current production process is a washing and filtration process or a high-temperature calcination process, based on the standard physical and chemical indicators of the products, the indicator deviation threshold, the indicator weights of each indicator in the ideal indicators, and the corresponding ideal indicators, the quality coefficient of the production quality of the current production process is calculated, and the quality coefficient is used as the evaluation information; when the current production process is a homogenization and packaging process, based on the standard physical and chemical indicators of the samples, the indicator weights of each indicator in the ideal indicators, and the corresponding ideal indicators, the quality coefficient of the production quality of the current production process is calculated, and the quality coefficient is used as the evaluation information.
[0069] For any production process, for each product in the process products corresponding to the current production process, determine the quality coefficient corresponding to each product according to the above method, and use the quality coefficient as the evaluation information of the production quality of the current production process. Then, average the quality coefficients corresponding to each product to obtain the average quality coefficient, and use the average quality coefficient as the target evaluation information of the production quality of the current production process;
[0070] In one embodiment, when the production process is a washing and filtration process, the chemical indicator includes at least one of sodium oxide content, water content, and pH value.
[0071] Correspondingly, the specific implementation of testing the physical and chemical indicators of the process products corresponding to the washing and filtration process is as follows:
[0072] For each filter cake product sample (product from each washing and filtration step), the filter cake product sample is divided into three equal portions based on the principle of equal weight to obtain a first sub-sample, a second sub-sample, and a third sub-sample of the filter cake product sample. The process of sampling to obtain the filter cake product samples is described in the following embodiments.
[0073] The first subsample is placed at a set temperature and heated until the mass of the first subsample is stable. The mass difference of the first subsample before and after heating is compared to obtain the volatile water mass of the first subsample. The volatile water mass of the first subsample is divided by the mass of the first subsample to obtain the volatile water content of the first subsample. This is marked as the moisture content of the filter cake product sample, denoted as a i , i represents the number of the i-th filter cake product sample, and the value range of i is [1, n].
[0074] After drying the second subsample, take 0.3 g and put it into a platinum dish. Mix it evenly with 2 g of a specific solvent and place the platinum dish on a hot plate. Ash it for 20 minutes. Melt it in a high-temperature furnace at 1100°C for 10 minutes, then take it out and place it on a hot plate at 70 to 80°C. Add a small amount of boiling pure water until it is fully dissolved. Transfer the dissolved sample to a 250 ml beaker and heat the beaker on a hot plate at 70 to 80°C for 20 minutes. Remove the beaker and cool it to room temperature. Use a funnel stand to transfer it to a 100 ml volumetric flask, make up the volume, shake it well, filter it through medium-speed quantitative filter paper, and use atomic absorption method to detect the sodium oxide content to obtain the sodium oxide content of the second subsample of each filter cake product sample. Mark it as the sodium oxide content of the filter cake product sample, and record it as b i ,Similarly, i represents the number of the i-th filter cake product sample, and the value range of i is [1, n].
[0075] After drying the third subsample, take 10 g and put it into a beaker. Add a clean magnetic rod and stir it stably in a magnetic stirrer at room temperature for 30 minutes. Use a pH meter to detect the pH value to obtain the pH value of the third subsample. Mark it as the pH value of the filter cake product sample and record it as c i ,Similarly, i represents the number of the i-th filter cake product sample, and the value range of i is [1, n].
[0076] Correspondingly, the specific calculation formula of the average quality coefficient is as follows:
[0077] ;
[0078] Wherein, η1 is the average quality coefficient of the washing and filtration process, n represents the number of filter cake product samples (process products corresponding to the washing and filtration process), e represents a natural constant, a0, b0, and c0 represent the standard Na2O content, standard moisture content, and standard pH value of the filter cake product samples stored in the database, Δa, Δb, and Δc represent the preset index deviation thresholds of the Na2O content, moisture content, and pH value of the filter cake product samples, respectively, δ1, δ2, and δ3 represent the preset index weights of the Na2O content, moisture content, and pH value of the filter cake product samples, respectively, and a i 、b i and c i represent the Na2O content, moisture content, and pH value of the i-th filter cake product sample respectively.
[0079] In one embodiment, when the production process is a high-temperature calcination process, the physical indicators include at least one of the powder particle size and the original crystal particle size.
[0080] Correspondingly, the specific implementation of testing the physical and chemical indicators of the process products corresponding to the high-temperature calcination process is as follows:
[0081] The kiln head product after the high temperature calcination process is obtained and sampled, and each sample is obtained and marked as a kiln head product sample. The sampling process of the kiln head product is described in the following examples.
[0082] The powder particle size of each kiln head product sample is obtained by a laser particle size analyzer and recorded as D j , j represents the number of the j-th kiln head product sample, and the value range of j is [1, m].
[0083] The original grain size of each kiln head product sample is obtained by laser particle size analyzer and recorded as d j , j represents the number of the j-th kiln head product sample, and the value range of j is [1, m].
[0084] Correspondingly, the specific calculation formula of the average quality coefficient is as follows:
[0085]
[0086] Wherein, η2 is the average quality coefficient of the high-temperature calcination process, m represents the number of kiln head product samples (process products corresponding to the high-temperature calcination process), D0 and d0 represent the standard powder particle size and standard original crystal particle size of the kiln head product samples stored in the database, ΔD and Δd represent the index deviation thresholds of the preset powder particle size and original crystal particle size of the kiln head product samples, φ1 and φ2 represent the index weights of the preset powder particle size and original crystal particle size of the kiln head product samples, respectively. j and d j They represent the powder particle size and original crystal particle size of the i-th kiln product sample respectively.
[0087] In one embodiment, when the production process is a homogenization and packaging process, the chemical indicators include at least one of sodium oxide content, iron oxide content, and silicon dioxide content.
[0088] Correspondingly, the specific implementation of testing the physical and chemical indicators of the process products corresponding to the homogenization and packaging process is as follows:
[0089] The finished alumina product after the homogenization and packaging process is obtained and sampled. Samples of the finished alumina product after the homogenization and packaging process are obtained and marked as finished alumina product samples. The finished alumina product sampling process is described in the following examples.
[0090] For each finished alumina sample, 0.3 g of the finished alumina sample was obtained from the finished alumina sample and placed in a platinum dish. The sample was evenly mixed with 2 g of a specific solvent, and the platinum dish was placed on a hot plate for ashing for 20 minutes. The sample was melted in a high-temperature furnace at 1100°C for 10 minutes, and then taken out and placed on a hot plate at 70-80°C. A small amount of boiling pure water was added until the sample was fully dissolved. The dissolved sample was transferred to a 250 ml beaker, and the beaker was placed on a hot plate at 70-80°C and heated for 20 minutes. The beaker was removed and cooled to room temperature, and the sample was transferred to a 100 ml volumetric flask with a funnel stand, fixed to volume, shaken, filtered through medium-speed quantitative filter paper, and the sodium oxide content was detected by atomic absorption method to obtain the sodium oxide content of the finished alumina sample, which was marked as the sodium oxide content of the finished alumina sample, and recorded as r. k , k represents the number of the kth alumina finished product sample, and the value range of k is [1, q].
[0091] 0.5 g of the finished alumina sample was obtained and placed in a platinum dish. After being evenly mixed with 1.8 g of a specific solution, the platinum dish was placed in a high-temperature furnace. After melting in a high-temperature furnace at 1050°C for 20 minutes, the mixture was taken out and cooled. A small amount of boiling pure water was added and placed on a hot plate until fully dissolved. A specific amount of nitric acid of a specific concentration was transferred to a 250 ml beaker, and the dissolved sample was transferred to the beaker, shaken until clear, and transferred to a 100 ml volumetric flask with a funnel stand, fixed to volume, and shaken well; 50 ml was taken out and transferred to another 100 ml volumetric flask, a certain amount of ammonium molybdate was added, shaken, and allowed to stand for 15 minutes; a certain amount of tartaric acid solution and a certain amount of ascorbic acid solution were added to the volumetric flask, fixed to volume, shaken well, and allowed to stand for another 15 minutes; the silica content was detected by a spectrophotometer to obtain the silica content of the finished alumina sample, which was marked as the silica content of the finished alumina sample, recorded as s k , k represents the number of the kth alumina finished product sample, and the value range of k is [1, q].
[0092] 0.5 g of the finished alumina sample was obtained and placed in a platinum dish. The sample was mixed evenly with 1.8 g of a specific solvent, and the platinum dish was placed in a high-temperature furnace. After melting in a high-temperature furnace at 1050° C. for 20 minutes, the sample was taken out and cooled. A small amount of boiling pure water was added and the sample was placed on a hot plate until fully dissolved. A specific amount of nitric acid of a specific concentration was transferred to a 250 ml beaker, and the dissolved sample was transferred to the beaker. The sample was shaken until clear, and the sample was transferred to a 100 ml volumetric flask with a funnel stand, and the volume was fixed and shaken. 50 ml was taken out and transferred to another 100 ml volumetric flask. A certain amount of hydroxylamine hydrochloride, o-phenanthroline, and sodium acetate-glacial acetic acid buffer solution was added, the volume was fixed, shaken, and the sample was placed for 15 minutes. The iron oxide content was detected by a spectrophotometer to obtain the iron oxide content of the finished alumina sample, which was marked as the iron oxide content of the finished alumina sample and recorded as t k, k represents the number of the kth alumina finished product sample, and the value range of k is [1, q].
[0093] Correspondingly, the specific calculation formula of the average quality coefficient is as follows:
[0094]
[0095] Where η3 is the average quality coefficient of the homogenization and packaging process, q represents the number of finished product samples, r0, s0, and t0 represent the standard Na2O content, standard Fe2O3 content, and standard SiO2 content of the homogenization and packaging process stored in the database, ε1, ε2, and ε3 represent the preset indicator weights of the Na2O content, Fe2O3 content, and SiO2 content of the homogenization and packaging process, respectively. k 、s k and t k They represent the Na2O content, standard Fe2O3 content, and standard SiO2 content of the product of the i-th process respectively.
[0096] In one embodiment, the detecting of the physical and chemical indicators of the process product corresponding to the current production process includes:
[0097] Sampling the process products corresponding to the current production process to obtain process product samples; detecting the physical and chemical indicators of the process product samples; wherein, sampling the process products corresponding to the current production process includes: based on a preset weight and a preset sampling period, obtaining a portion of the process products at each sampling point with the preset weight, and using the portion of the products as the process product samples; the collection points are set on the product conveyor belt according to the preset sampling distance, and the product conveyor belt is used to convey the process products corresponding to the current production process.
[0098] Sampling points can be set at equal distances on the product conveyor belt, and sample extraction points can be set at equal depths at each sampling point to obtain process product samples of set weight;
[0099] For example, filter cakes of a set weight are extracted at each sampling point in the washing and filtration process to obtain samples after the washing and filtration process is completed, and are marked as filter cake product samples;
[0100] Extract the set weight of process products at each sampling point of the high-temperature calcination process to obtain the process products after the high-temperature calcination process is completed, and mark them as kiln head product samples;
[0101] A set weight of process product is extracted at each sampling point in the homogenization and packaging process to obtain the process product after the homogenization and packaging process is completed, and it is marked as a finished alumina product sample.
[0102] Then, the physical and chemical indicators of the process product samples are collected according to the method described in the above embodiment.
[0103] In one embodiment, the method further includes: associating and storing all physical and chemical indicators corresponding to each production process and corresponding target evaluation information; sending the target evaluation information corresponding to each production process to a quality management device, so that the quality management device determines whether the corresponding production process is qualified based on the target evaluation information;
[0104] The problem tracing of the target production process based on the physical and chemical indicators corresponding to the target production process includes:
[0105] Receive an information acquisition instruction sent by the quality management device when it is determined that the target production process is unqualified based on the target evaluation information; based on the information acquisition instruction, obtain all physical and chemical indicators corresponding to the target production process that are pre-associated and stored; send all physical and chemical indicators corresponding to the target production process to the quality management device, so that the quality management device can trace the problem of the target production process based on all physical and chemical indicators corresponding to the target production process.
[0106] The intelligent management system comprehensively evaluates the target quality assessment information for the current production process. It then establishes a one-to-one correspondence between all physical and chemical indicators and the corresponding target assessment information for each production process and stores this correspondence. The intelligent management system then sends this target assessment information to the production, technical, and management systems (i.e., quality management equipment). These systems then evaluate the corresponding production process based on the target assessment information and provide feedback to the intelligent management system.
[0107] When the quality management device determines that the target production process is unqualified based on the target evaluation information, the quality management device sends an information acquisition instruction to the intelligent management system, where the information acquisition instruction includes a process identifier of the target production process and is used to obtain all physical and chemical indicators corresponding to the production process;
[0108] The intelligent management system determines the corresponding target production process based on the process identifier, and then obtains all physical and chemical indicators corresponding to the target production process. The intelligent management system sends all the obtained physical and chemical indicators to the quality management equipment, and the quality management equipment traces the problem of the target production process based on all the physical and chemical indicators corresponding to the target production process. For example, when the target production process is a washing and filtration process, if there is a problem with the sodium oxide content of the filtered product sample, the cause of the problem in the sodium oxide content can be traced back to the washing and filtration process.
[0109] like Figure 2The figure shows an intelligent management system for the production control of α-alumina calcined in a rotary kiln, comprising: a comprehensive evaluation module for the production of α-alumina calcined in a rotary kiln, a washing and filtration control and analysis module, a high-temperature calcination control and analysis module, a homogenization and packaging control and analysis module, and a data storage unit;
[0110] The rotary kiln calcined α alumina production comprehensive evaluation module is connected to one end of the washing and filtration control analysis module, the high-temperature calcination control analysis module, and the homogenization and packaging control analysis module respectively, and the data storage unit is connected to the other end of the washing and filtration control analysis module, the high-temperature calcination control analysis module, and the homogenization and packaging control analysis module respectively;
[0111] Washing and filtration control and analysis module: used to obtain and sample the filter cake products from the washing and filtration process of α-alumina calcined in a rotary kiln, obtain each sample of the alumina filter cake after the washing and filtration process is completed, mark it as a filter cake product sample, obtain the Na2O content, moisture content, and pH value of each filter cake product sample, and analyze the average quality coefficient of the washing and filtration process.
[0112] High-temperature calcination control and analysis module: used to obtain and sample various samples of kiln head products after the high-temperature calcination process is completed, obtain various samples of kiln head products, mark them as kiln head product samples, obtain the powder particle size and original crystal particle size of each kiln head product sample, and analyze the average quality coefficient of the high-temperature calcination process.
[0113] Homogenization packaging control and analysis module: used to obtain and sample various samples of the finished alumina product after the homogenization packaging process is completed, obtain various samples of the finished alumina product after the homogenization packaging process is completed, mark them as finished alumina product samples, obtain the Na2O content, Fe2O3 content, and SiO2 content of each finished alumina product sample, and analyze the average quality coefficient of the homogenization packaging process.
[0114] Comprehensive evaluation module for rotary kiln calcined α-alumina production: used to feed back the average quality coefficient of the washing and filtration process, high-temperature calcination process, and homogenization and packaging process to the production, technology and management system of rotary kiln calcined α-alumina.
[0115] Data storage unit: used to store the Na2O content, moisture content, and pH value of the washing and filtration process, the powder particle size and original crystal particle size of the high-temperature calcination process, and the Na2O content, Fe2O3 content, and SiO2 content of the homogenization and packaging process.
[0116] It is understandable that the sampling of the process products corresponding to the production process and the testing of the physical and chemical indicators of the process product samples are all performed by the corresponding modules. For example, if the production process is a washing and filtration process, it is performed by the washing and filtration control and analysis module; if the production process is a high-temperature calcination process, it is performed by the high-temperature calcination control and analysis module; if the production process is a homogenization and packaging process, it is performed by the homogenization and packaging control and analysis module;
[0117] The above-mentioned step of determining target evaluation information of production quality of each production process is performed by the rotary kiln calcined α alumina production comprehensive evaluation module.
[0118] It can be seen that this application can monitor the entire life cycle production process of α-alumina calcined in a rotary kiln, obtain physical and chemical indicators, and provide guarantees for improving hourly output and product quality.
[0119] Based on the same application concept, the embodiment of the present invention also provides a device for tracing the source of problems in a production process. Figure 3 This is a structural block diagram of a production process problem tracing device provided by an embodiment of the present application, such as Figure 3 As shown, the device 300 includes:
[0120] An acquisition module 301 is used to acquire a process product of a target material after it has been processed through at least two production processes, wherein the target material is a material for producing alumina; and the production processes are the processes required to produce alumina;
[0121] The detection module 302 is used to detect the physical and chemical indicators of the process product corresponding to the current production process for each production process; wherein the physical and chemical indicators include at least one of the physical indicators and chemical indicators 303 of the process product, and the physical and chemical indicators are used to evaluate whether the corresponding production process is qualified;
[0122] The traceability module 303 is used to trace the problem of the target production process based on the physical and chemical indicators corresponding to the target production process when the target production process is unqualified in the production process.
[0123] In one embodiment, the device further includes a determination module, the determination module being configured to determine, for each product in the process products corresponding to the current production process, evaluation information of the production quality of the current production process based on the physical and chemical indicators of the product;
[0124] Determining target evaluation information of production quality of the current production process based on the evaluation information corresponding to each product;
[0125] The target evaluation information is used to evaluate whether the corresponding production process is qualified.
[0126] In one embodiment, when determining the production quality assessment information of the current production process based on the physical and chemical indicators of the product, the determination module is specifically configured to:
[0127] Obtaining at least one of the standard physical and chemical indicators, indicator deviation thresholds, and indicator weights of each indicator in the ideal indicator corresponding to the product;
[0128] Based on the standard physical and chemical indicators corresponding to the products, the indicator deviation threshold and at least one of the indicator weights of each indicator in the ideal indicator, and the physical and chemical indicators corresponding to the products, the production quality evaluation information of the current production process is calculated.
[0129] In one embodiment, when the determination module calculates the production quality assessment information of the current production process based on the standard physical and chemical indicators corresponding to the products, the indicator deviation threshold, and at least one of the indicator weights of each indicator in the ideal indicator, and the physical and chemical indicators corresponding to the products, the module is specifically configured to:
[0130] When the current production process is a washing and filtration process or a high-temperature calcination process, a quality coefficient of the production quality of the current production process is calculated based on the standard physical and chemical indicators of the product, the indicator deviation threshold, the indicator weight of each indicator in the ideal indicator, and the corresponding ideal indicator, and the quality coefficient is used as the evaluation information;
[0131] When the current production process is a homogenization packaging process, the quality coefficient of the production quality of the current production process is calculated based on the standard physical and chemical indicators of the sample, the indicator weights of each indicator in the ideal indicators, and the corresponding ideal indicators, and the quality coefficient is used as the evaluation information.
[0132] In one embodiment, when detecting the physical and chemical indicators of the process product corresponding to the current production process, the detection module 302 is specifically used to:
[0133] Sampling the process products corresponding to the current production process to obtain process product samples;
[0134] Testing the physical and chemical indicators of product samples from the process;
[0135] The detection module 302 is specifically used to:
[0136] Based on the preset weight and the preset sampling period, part of the process products at each sampling point with the preset weight is obtained, and the part of the products is used as the process product sample; the collection points are set on the product conveyor belt according to the preset sampling distance, and the product conveyor belt is used to convey the process products corresponding to the current production process.
[0137] In one embodiment, when the production process is a washing and filtration process, the chemical indicators include at least one of sodium oxide content, moisture content, and pH value; when the production process is a high-temperature calcination process, the physical indicators include at least one of powder particle size and original crystal particle size; when the production process is a homogenization and packaging process, the chemical indicators include at least one of sodium oxide content, iron oxide content, and silicon dioxide content.
[0138] In one embodiment, the apparatus further includes a storage module, the storage module being configured to: associate and store all physical and chemical indicators corresponding to each production process and corresponding target evaluation information; and send the target evaluation information corresponding to each production process to a quality management device, so that the quality management device determines whether the corresponding production process is qualified based on the target evaluation information;
[0139] When tracing the source of problems of the target production process based on the physical and chemical indicators corresponding to the target production process, the traceability module 303 is specifically used to: receive the information acquisition instruction sent by the quality management device when it determines that the target production process is unqualified based on the target evaluation information; based on the information acquisition instruction, obtain all the physical and chemical indicators corresponding to the target production process that are pre-associated and stored; and send all the physical and chemical indicators corresponding to the target production process to the quality management device, so that the quality management device can trace the source of problems of the target production process based on all the physical and chemical indicators corresponding to the target production process.
[0140] It can be understood that the device provided in the above embodiment is only illustrated by the division of the above functional modules. In actual applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above.
[0141] An embodiment of the present invention further provides an electronic device, which may include a processor 402 and a memory 401 , wherein the processor and the memory may be communicatively connected to each other via a bus or other means.
[0142] The processor 402 may be a central processing unit (CPU), or an application specific integrated circuit (ASIC), or may be configured to implement one or more integrated circuits of the embodiments of the present application, or may be other general-purpose processors, digital signal processors (DSP), application specific integrated circuits (ASIC), field programmable gate arrays (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, or a combination of the above chips.
[0143] Memory 401 may include a large capacity memory for data or instructions. By way of example and not limitation, the memory may include a hard disk drive (HDD), a floppy disk drive, a flash memory, an optical disk, a magneto-optical disk, a magnetic tape, or a universal serial bus (USB) drive, or a combination of two or more of these. Where appropriate, the memory may include removable or non-removable (or fixed) media. Where appropriate, the memory may be inside or outside the electronic device. In a particular embodiment, the memory may be a non-volatile solid-state memory.
[0144] In one embodiment, the memory 401 may be a read-only memory (ROM). In one embodiment, the ROM may be a mask-programmable ROM, a programmable ROM (PROM), an erasable PROM (EPROM), an electrically erasable PROM (EEPROM), an electrically rewritable ROM (EAROM), or a flash memory, or a combination of two or more of these.
[0145] The processor 402 implements any one of the production process problem tracing methods in the above embodiments by reading and executing computer program instructions stored in the memory.
[0146] In one example, the electronic device may further include a communication interface and a bus. The processor, memory, and communication interface are connected via the bus and communicate with each other. The communication interface is primarily used to enable communication between the various modules, devices, units, and / or devices in the embodiments of this application. Where appropriate, the bus may include one or more buses.
[0147] In addition, in conjunction with the production process problem tracing method described in the above embodiments, embodiments of the present invention may provide a computer-readable storage medium for implementation. The computer-readable storage medium stores computer program instructions; when executed by a processor, the computer program instructions implement any of the production process problem tracing methods described in the above embodiments.
[0148] Those skilled in the art will appreciate that all or part of the processes in the above-mentioned embodiments can be implemented by instructing the relevant hardware through a computer program. The program can be stored in a computer-readable storage medium. When the program is executed, it can include the processes of the embodiments of the above-mentioned methods. The storage medium can be a read-only memory (ROM), a random access memory (RAM), a flash memory, a hard disk drive (HDD), or a solid-state drive (SSD). The storage medium can also include a combination of the above-mentioned types of memory.
[0149] In the description provided herein, numerous specific details are described. However, it is understood that embodiments of the present invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques are not shown in detail so as not to obscure the understanding of this description.
[0150] Similarly, it should be understood that in order to streamline the present disclosure and aid in understanding one or more of the various inventive aspects, in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together into a single embodiment, figure, or description thereof. However, this disclosed method should not be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as reflected in the claims below, inventive aspects lie in less than all the features of the individual embodiments disclosed above. Accordingly, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of the invention.
[0151] It should be noted that the above embodiments illustrate rather than limit the invention, and that a person skilled in the art may devise alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between brackets should not be construed as limiting the claims. The word "comprising" does not exclude the presence of components or steps not listed in the claims. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. The present invention may be implemented by means of hardware comprising several different components and by means of a suitably programmed computer. In a unit claim enumerating several means, several of these means may be embodied by the same item of hardware. The use of the words first, second, and third etc. does not indicate any order. These words may be interpreted as names.
Claims
1. A method for tracing the source of problems in a production process, characterized in that: The method comprises: Obtaining a process product of a target material after being processed through at least two production processes, wherein the target material is a material for producing alumina; and the production processes are the processes required to produce alumina; For each production process, test the physical and chemical indicators of the process product corresponding to the current production process; wherein the physical and chemical indicators include at least one of the physical indicators and chemical indicators of the process product, and the physical and chemical indicators are used to evaluate whether the corresponding production process is qualified; In the case that a target production process fails to meet the standards in the production process, the problem of the target production process is traced to the source based on the physical and chemical indicators corresponding to the target production process.
2. The method according to claim 1, characterized in that The method further comprises: For each product in the process products corresponding to the current production process, determining production quality evaluation information of the current production process based on the physical and chemical indicators of the product; Determining target evaluation information of production quality of the current production process based on the evaluation information corresponding to each product; The target evaluation information is used to evaluate whether the corresponding production process is qualified.
3. The method according to claim 2, characterized in that The determining of the production quality evaluation information of the current production process based on the physical and chemical indicators of the product includes: Obtaining at least one of the standard physical and chemical indicators, indicator deviation thresholds, and indicator weights of each indicator in the ideal indicator corresponding to the product; Based on the standard physical and chemical indicators corresponding to the products, the indicator deviation threshold and at least one of the indicator weights of each indicator in the ideal indicator, and the physical and chemical indicators corresponding to the products, the production quality evaluation information of the current production process is calculated.
4. The method according to claim 3, characterized in that The production quality evaluation information of the current production process is calculated based on at least one of the standard physical and chemical indicators corresponding to the products, the indicator deviation threshold, and the indicator weight of each indicator in the ideal indicator, and the physical and chemical indicators corresponding to the products, including: When the current production process is a washing and filtration process or a high-temperature calcination process, a quality coefficient of the production quality of the current production process is calculated based on the standard physical and chemical indicators of the product, the indicator deviation threshold, the indicator weight of each indicator in the ideal indicator, and the corresponding ideal indicator, and the quality coefficient is used as the evaluation information; When the current production process is a homogenization packaging process, the quality coefficient of the production quality of the current production process is calculated based on the standard physical and chemical indicators of the sample, the indicator weights of each indicator in the ideal indicators, and the corresponding ideal indicators, and the quality coefficient is used as the evaluation information.
5. The method according to any one of claims 1 to 4, characterized in that The physical and chemical indicators of the process products corresponding to the current production process are detected, including: Sampling the process products corresponding to the current production process to obtain process product samples; Testing the physical and chemical indicators of product samples from the process; The sampling of the process products corresponding to the current production process includes: Based on the preset weight and the preset sampling period, part of the process products at each sampling point with the preset weight is obtained, and the part of the products is used as the process product sample; the collection points are set on the product conveyor belt according to the preset sampling distance, and the product conveyor belt is used to convey the process products corresponding to the current production process.
6. The method according to any one of claims 1 to 4, characterized in that When the production process is a washing and filtration process, the chemical indicators include at least one of the sodium oxide content, moisture content, and pH value; when the production process is a high-temperature calcination process, the physical indicators include at least one of the powder particle size and the original crystal particle size; when the production process is a homogenization and packaging process, the chemical indicators include at least one of the sodium oxide content, iron oxide content, and silicon dioxide content.
7. The method according to any one of claims 2 to 4, characterized in that The method further comprises: Associate and store all physical and chemical indicators corresponding to each production process and the corresponding target evaluation information; Sending target evaluation information corresponding to each production process to a quality management device, so that the quality management device determines whether the corresponding production process is qualified based on the target evaluation information; The problem tracing of the target production process based on the physical and chemical indicators corresponding to the target production process includes: receiving an information acquisition instruction sent by the quality management device when the target production process is determined to be unqualified based on the target evaluation information; Based on the information acquisition instruction, all physical and chemical indicators corresponding to the target production process that are pre-associated and stored are acquired; All physical and chemical indicators corresponding to the target production process are sent to the quality management device, so that the quality management device can trace the problem of the target production process based on all physical and chemical indicators corresponding to the target production process.
8. A device for tracing the source of problems in a production process, characterized in that: The device comprises: An acquisition module is used to acquire a process product of a target material after being processed through at least two production processes, wherein the target material is a material for producing alumina; and the production processes are the processes required to produce alumina; A detection module is used to detect the physical and chemical indicators of the process products corresponding to the current production process for each production process; wherein the physical and chemical indicators include at least one of the physical indicators and chemical indicators of the process products, and the physical and chemical indicators are used to evaluate whether the corresponding production process is qualified; The traceability module is used to trace the problem of the target production process based on the physical and chemical indicators corresponding to the target production process when the target production process is unqualified in the production process.
9. An electronic device, characterized in that: include: A memory and a processor, wherein the memory and the processor are communicatively connected to each other, the memory stores computer instructions, and the processor executes the method according to any one of claims 1 to 7 by executing the computer instructions.
10. A computer-readable storage medium, characterized in that The computer-readable storage medium stores computer instructions, and the computer instructions are used to enable the computer to execute the method according to any one of claims 1 to 7.