Submerged arc furnace electrode automatic adjusting method and system

Abstract

The invention discloses a submerged arc furnace electrode automatic adjusting method and system, and relates to the field of submerged arc furnace smelting equipment. The method comprises the steps of data acquisition, thermal expansion compensation amount calculation, collapse detection, density scanning of a subsidence area, risk grading decision, anti-collision control and the like. The system comprises a data acquisition module, a thermal expansion compensation module, a collapse detection module, a density scanning module, a risk decision module, an anti-collision control module and an abnormity monitoring module. The thermal expansion compensation amount is calculated by collecting data such as the electrode temperature and the immersion length so as to correct an electrode lifting instruction; the collapse of the furnace charge is detected by multi-sensor fusion; risk indexes are calculated based on microwave radar density scanning and voiceprint analysis, risk grading is carried out, and corresponding treatment measures are taken. According to the method, the thermal expansion influence can be accurately compensated, the collapse detection accuracy is improved, intelligent risk grading and self-adaptive anti-collision control are achieved, electrode damage is effectively reduced, and the system reliability and the smelting efficiency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ore smelting furnace equipment, in particular to an automatic electrode adjusting method and system for ore smelting furnace. BACKGROUND

[0002] In the smelting process of the ore smelting furnace, the electrode is the core component for converting electric energy into heat energy. Through the electrode, electric energy is input into the furnace, so that the furnace charge undergoes chemical reactions at high temperature to complete the smelting process.

[0003] However, during the heating process of the furnace charge, due to uneven internal temperature distribution of the furnace charge, gas escape caused by chemical reactions, and other reasons, the furnace charge is prone to local collapse. The collapse of the furnace charge will cause damage to the electrode, especially the electrode joint part. At present, the commonly used solution in the industry is to lift the electrode out of the furnace charge when the furnace charge collapses, but this method has the following problems:

[0004] Firstly, the system lifts the electrode according to the preset value when the furnace charge collapses, but the electrode will expand due to heat in the high-temperature environment, resulting in insufficient actual lifting amount. Since the electrode cannot completely escape from the collapsed area of the furnace charge, the collapsed furnace charge will continue to exert lateral extrusion force on the electrode joint, which will cause the electrode joint to loosen and the seal to fail over a long period of time, thereby causing the electrode to lose its conductivity and even causing the joint to break, resulting in the electrode being scrapped.

[0005] Secondly, the collapsed area contains un-melted hard blocks, and the electrode will directly impact the hard material when it is pressed down to compensate, which will cause damage to the electrode. The violent impact of the electrode and the un-melted hard blocks will generate strong mechanical impact, which will cause cracks and chunks on the end of the electrode. In severe cases, it will cause the electrode body to break; at the same time, the vibration generated by the impact will be transmitted to the electrode joint, causing fatigue damage to the joint connection part and shortening the service life of the electrode. SUMMARY

[0006] In view of the deficiencies of the prior art, the present application provides an automatic electrode adjusting method and system for ore smelting furnace, which solves the problems of insufficient lifting amount caused by high-temperature thermal expansion of the electrode and damage caused by impact on un-melted hard blocks when the electrode is pressed down.

[0007] To achieve the above purpose, the present application realizes the following technical scheme: an automatic electrode adjusting method and system for ore smelting furnace, comprising the following steps:

[0008] S1, data acquisition, real-time reading of the current temperature of the electrode, measurement of the length of the electrode immersed in the furnace charge, and acquisition of a preset electrode lifting value;

[0009] S2, thermal expansion compensation amount calculation, calculation of the length change amount caused by thermal expansion, and generation of a new electrode lifting instruction value;

[0010] S3, collapse detection, real-time monitoring of sensors, and determination of the collapse condition of the furnace charge;

[0011] S4, collapse area density scanning, using microwave radar to scan the collapse area, measuring the material density and transmitting the data to the processor, and calculating the risk index;

[0012] S5, risk classification decision, allowing normal pressing when the risk is low, starting voiceprint detection when the risk is medium or high, and activating the anti-collision protocol when the risk is high;

[0013] S6, anti-collision control, setting safe pressing parameters, and pressing step by step according to the safe displacement, real-time monitoring of pressure changes, emergency withdrawal and starting vibration crushing when the limit is exceeded;

[0014] At the same time, continuous anomaly detection is carried out throughout the process.

[0015] Preferably, the actual displacement calculation formula of the electrode in S1 is as follows:

[0016] D 实际 =D 指令 -ΔE

[0017] Where: D 实际 : actual displacement of the electrode tip; D 指令 : hydraulic system command displacement;

[0018] ΔE: thermal expansion compensation.

[0019] Preferably, the thermal expansion compensation calculation formula in S2 is as follows:

[0020] ΔE=a·(T-T0)·L

[0021] Where: a represents the thermal expansion coefficient; T represents the electrode expansion coefficient;

[0022] T0 represents the reference temperature; L represents the electrode immersion length;

[0023] Control logic:

[0024] Collapse instruction correction:

[0025] D 新指令 =D 预设 +ΔE 当前 .

[0026] Preferably, the sensors in S3 include electrical parameter sensors, position sensors, and acoustic sensors, the electrical parameter sensors are used to monitor the electrode voltage and current in real time, the position sensors are used to detect the real-time electrode position, and the acoustic sensors are used to detect the noise energy of specific frequency bands inside the furnace.

[0027] The formula for detecting the charge collapse by the sensor in S3 preferably comprises:

[0028] The basis for judging the electrical mutation

[0029] ΔPF = |cosφ t -cosφ t-0.5g |>0.15

[0030] Symbolic explanation: ΔP k ; represents the instantaneous power change rate; P t ; represents the total three-phase power at the current moment;

[0031] P avg represents the ten-second sliding average power; ΔPF represents the power factor change; cosφ t represents the current power factor;

[0032] The determination condition: ΔP K >0.2 and ΔPF>0.15.

[0033] The formula for detecting the charge collapse by the sensor in S3 preferably comprises:

[0034] The basis for judging the position mutation

[0035]

[0036] Symbolic explanation:

[0037] υdown represents the electrode sinking speed; D t represents the absolute position of the electrode at t moment.

[0038] The formula for detecting the charge collapse by the sensor in S3 preferably comprises:

[0039] The basis for judging the voiceprint energy

[0040]

[0041] Symbolic explanation:

[0042] E collapse represents the collapse characteristic frequency band energy; S(f) represents the sound pressure spectral density;

[0043] E bg represents the background noise energy, the average of the first 30 seconds.

[0044] The formula for calculating the risk index of the collapsed material in S4 is as follows:

[0045] The formula of the density risk index

[0046]

[0047] wherein:

[0048] R d denotes the density risk index; pmeasured denotes the microwave radar measured density;

[0049] pbase denotes the normal melt density;

[0050] Vocalprint risk index formula;

[0051]

[0052] wherein:

[0053] R g denotes the vocalprint risk index; SPLmeasured denotes the sonar array measured sound pressure level;

[0054] SPLbase denotes the normal melt sound pressure.

[0055] Preferably, the risk classification in S5, and its corresponding risk condition and control actions are as follows:

[0056] Low risk: R d < 1.5, normal depression is allowed, maintain standard depression speed, pressure upper limit: 100% pnormal;

[0057] Medium risk: R d ≥ 1.5 and Rs< 1.2, restricted depression mode, start vocalprint verification, depression speed reduced to 30%, pressure upper limit: 50% pnormal;

[0058] High risk: R d ≥ 1.5 and Rs≥ 1.2, trigger anti-collision protocol, step depression, activate vibration obstacle clearing, pressure upper limit: 30% pnormal.

[0059] Preferably, the anti-collision control model in S6 is as follows:

[0060] Safe depression pressure formula:

[0061]

[0062] wherein:

[0063] p safe denotes the allowed maximum pressure; pnormal denotes the standard melting pressure;

[0064] k denotes the safety factor;

[0065] Step depression displacement formula

[0066]

[0067] wherein:

[0068] delta d represents single step down displacement; d max delta d represents single step down displacement; d

[0069] Emergency braking condition:

[0070]

[0071] P>1.2P safe

[0072] Symbol summary

[0073] The symbols and their physical meanings are as follows:

[0074] D represents displacement amount; delta E represents thermal expansion compensation amount; a represents thermal expansion coefficient;

[0075] T represents temperature; L represents electrode immersion length; Rd represents density risk index;

[0076] rho represents material density; R g SPL represents sound pressure level;

[0077] P represents electrode pressure; delta d represents single step down displacement; k represents safety factor.

[0078] The beneficial effects possessed are as follows:

[0079] 1. A thermal expansion compensation amount calculation formula is established to correct the electrode lifting command in real time, solving the problem of insufficient actual lifting amount at high temperature, avoiding loosening, oxidation and fracture of the electrode joint due to continuous extrusion, and prolonging the service life of the electrode.

[0080] 2. Multi-dimensional collapse detection: a multi-sensor detection method combining electrical parameters, position changes and voiceprint energy is used, combined with a quantitative judgment formula, to improve the accuracy and timeliness of the furnace charge collapse identification, providing a basis for subsequent control.

[0081] 3. Intelligent risk grading: a risk index model is constructed based on microwave radar density scanning and voiceprint analysis to realize risk grading decision-making, avoid electrode impact damage caused by blind down pressure, ensure smelting efficiency at low risk, and ensure equipment safety at medium and high risk.

[0082] 4. Adaptive anti-collision control: through safety parameter setting, step down pressure and pressure monitoring, combined with emergency retreat and vibration crushing function, effectively deal with the unmelted hard block in the collapse area, reduce the risk of electrode end crack, block falling and body fracture, and improve the safety of system operation. BRIEF DESCRIPTION OF DRAWINGS

[0083] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description only constitute some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of these drawings.

[0084] Figure 1 The overall structure flowchart of the present application is shown in the figure. Figure 2 The data collection schematic diagram of the present application is shown in the figure. Figure 3 The sensor type schematic diagram of the present application is shown in the figure. Figure 4 The collapse schematic diagram of the present application is shown in the figure. Figure 5 The risk level schematic diagram of the present application is shown in the figure. Figure 6 The automatic adjustment system module schematic diagram of the present application is shown in the figure. DETAILED DESCRIPTION

[0089] In order to make the purpose, technical solutions and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application are described clearly and completely. Obviously, the described embodiments are some embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the protection scope of the present application.

[0090] In order to better understand the above technical solutions, the above technical solutions will be described in detail in the following in combination with the drawings in the specification and specific embodiments.

[0091] The embodiments of the present application disclose a self-adjusting method and system for electrodes of a submerged arc furnace, according to the attached Figures 1-3 The method comprises the following steps:

[0092] S1, data collection, real-time reading of the current temperature of the electrode, measurement of the length of the electrode immersed in the charge, and acquisition of a preset electrode lifting value;

[0093] S2, calculation of the thermal expansion compensation amount, calculation of the length change amount caused by thermal expansion, and generation of a new electrode lifting instruction value;

[0094] S3, collapse detection, real-time monitoring of the sensor, and judgment of the charge collapse condition;

[0095] S4, collapse area density scanning, using microwave radar to scan the collapse area, measure the material density and transmit the data to the processor, calculate the risk index;

[0096] S5, risk classification decision, low risk allows normal down pressure, high risk when starting voiceprint detection, confirm high risk when activated anti-collision protocol;

[0097] S6, anti-collision control, set the safe down pressure parameters, and step down pressure according to the safety displacement, real-time monitoring of pressure changes, over-limit emergency withdrawal and start vibration crushing;

[0098] At the same time, continuous anomaly detection is carried out throughout the process.

[0099] The electrode actual displacement calculation formula in S1 is as follows:

[0100] D 实际 = D 指令 - ΔE

[0101] Where: D 实际 : actual displacement of electrode tip; D 指令 : hydraulic system command displacement;

[0102] ΔE: thermal expansion compensation amount.

[0103] The thermal expansion compensation amount calculation formula in S2 is as follows:

[0104] ΔE = a · (T-T0) · L

[0105] Where:

[0106] α represents the coefficient of thermal expansion; T represents the electrode expansion coefficient;

[0107] T0 represents the reference temperature; L represents the electrode immersion length;

[0108] Control logic:

[0109] Collapse instruction correction:

[0110] D 新指令 = D 预设 + ΔE 当前 .

[0111] The sensors in S3 include electrical parameter sensors, position sensors and acoustic sensors, the electrical parameter sensors are used to monitor the electrode voltage and current in real time, the position sensors are used to detect the real-time electrode position, and the acoustic sensors are used to detect the specific frequency band noise energy inside the furnace body.

[0112] In this embodiment, the temperature sensor: mainly measures the current temperature of the electrode, the measurement range is 0-1200℃, the measurement accuracy is ±1℃, and provides temperature data for the calculation of thermal expansion compensation;

[0113] Laser range finder: measures the distance from the top of the electrode to itself, combined with the total length of the electrode, the length of the electrode immersed in the charge can be calculated, the measurement range is 0-5m, the measurement error is ≤0.5mm;

[0114] Current sensor: measures the working current of the electrode, the measurement range is 0-5000A, the accuracy is 0.5 level;

[0115] Voltage transmitter: measures the working voltage of the electrode, the measurement range is 0-1000V;

[0116] Position sensor: measures the absolute position of the electrode, through continuous measurement, the position change and moving speed of the electrode can be obtained, the measurement range is 0-10m, the resolution is 0.1mm;

[0117] Microphone array: collects the noise signal inside the furnace body, and after processing, the energy of the collapse characteristic frequency band can be obtained, the measurement range is 40-120dB;

[0118] Microwave radar: measures the density of the material in the collapse area, the measurement range is 1-5g / cm 3 , the measurement accuracy is ±2%.

[0119] According to the drawings shown in Figure 1 、 4 Further, the following steps are included:

[0120] S1, data acquisition, real-time reading of the current temperature of the electrode, and measurement of the length of the electrode immersed in the charge, obtaining the preset electrode lifting value;

[0121] S2, thermal expansion compensation calculation, calculating the length change caused by thermal expansion, and generating a new electrode lifting instruction value;

[0122] S3, collapse detection, real-time monitoring of the sensor, and judging the collapse condition of the charge;

[0123] S4, density scanning of the collapse area, using the microwave radar to scan the collapse area, measuring the material density and transmitting the data to the processor, and calculating the risk index;

[0124] S5, risk classification decision, allowing normal pressing when the risk is low, starting voiceprint detection when the risk is medium or high, and activating the anti-collision protocol when the risk is high;

[0125] S6, anti-collision control, setting the safe pressing parameters, and pressing according to the safe displacement step, real-time monitoring the pressure change, and when the limit is exceeded, emergency withdrawal and starting vibration crushing;

[0126] At the same time, continuous anomaly detection is carried out throughout the process.

[0127] The formula for detecting charge collapse by the sensor in S3 includes:

[0128] The basis for judging electrical mutation

[0129] ΔPF = |cosφ t -cosφ t-0.5g |>0.15

[0130] Symbol explanation:

[0131] ΔP k ; represents the instantaneous power change rate; P t ; represents the total three-phase power at the current time;

[0132] P avg represents the ten-second sliding average power; ΔPF represents the power factor change;

[0133] cosφ t represents the current power factor;

[0134] Judgment condition: ΔP K >0.2 and ΔPF>0.15.

[0135] The formula for detecting charge collapse by the sensor in S3 also includes:

[0136] The basis for judging position mutation

[0137]

[0138] Symbol explanation:

[0139] υdown represents the electrode sinking speed; D t represents the absolute position of the electrode at t.

[0140] The formula for detecting charge collapse by the sensor in S3 also includes:

[0141] The basis for judging voiceprint energy

[0142]

[0143] Symbol explanation:

[0144] E collapse represents the collapse characteristic frequency band energy; S(f) represents the sound pressure spectral density;

[0145] E bg represents the background noise energy, the average of the previous 30 seconds.

[0146] The formula of the S4 collapsed material risk index is as follows:

[0147] Density risk index formula

[0148]

[0149] Wherein:

[0150] R d represents the density risk index; p detected represents the microwave radar measured density;

[0151] p reference represents the normal melt density;

[0152] Voiceprint risk index formula

[0153]

[0154] Wherein:

[0155] R g represents the voiceprint risk index; SPL detected represents the sonar array measured sound pressure level;

[0156] SPL reference represents the normal melt sound pressure.

[0157] In this embodiment, the collapse monitoring is carried out in a multi-sensor fusion manner, and the specific process is as follows:

[0158] First, the electrical parameter sensor monitors the voltage and current of the electrode in real time, and calculates the three-phase total power and power factor according to the voltage and current. The instantaneous power change rate and power factor change amount are calculated once every 1 second, and when the instantaneous power change rate > 20% and the power factor change amount > 0.15, it is preliminarily judged that the furnace charge collapse may occur.

[0159] Second, the position sensor monitors the position of the electrode in real time, and records the absolute position of the electrode once every 1 second. The sinking speed of the electrode is obtained by calculating the ratio of the difference between the positions of two adjacent times to the time. When the absolute value of the electrode sinking speed > the preset value, the judgment of the furnace charge collapse is further supported.

[0160] Finally, the acoustic sensor collects the noise energy inside the furnace body, and calculates the background noise energy once every 30 seconds. The difference between the collapse characteristic band energy and the background noise energy is calculated in real time. When the difference > the preset value, the judgment results of the electrical parameters and the position change are comprehensively considered, and the furnace charge collapse is finally confirmed.

[0161] According to the accompanying drawings Figure 1 , 5 , 6, further comprising the following steps:

[0162] S1, data acquisition, real-time reading of the current temperature of the electrode, and measuring the length of the electrode immersed in the charge, obtaining the preset electrode lifting value;

[0163] S2, thermal expansion compensation calculation, calculating the length change caused by thermal expansion, and generating a new electrode lifting instruction value;

[0164] S3, collapse detection, real-time monitoring of the sensor, and judging the collapse of the charge;

[0165] S4, collapse area density scanning, using microwave radar to scan the collapse area, measuring the material density and transmitting the data to the processor, and calculating the risk index;

[0166] S5, risk classification decision, allowing normal pressing when the risk is low, starting voiceprint detection when the risk is medium or high, and activating the anti-collision protocol when the risk is high;

[0167] S6, anti-collision control, setting the safe pressing parameters, and pressing according to the safe displacement step, real-time monitoring the pressure change, emergency withdrawal and starting vibration crushing when the limit is exceeded;

[0168] At the same time, continuous abnormal detection is carried out throughout the process.

[0169] The risk classification in S5, and the corresponding risk conditions and control actions are as follows:

[0170] Low risk: R d <1.5, allowing normal pressing, maintaining the standard pressing speed, and the upper limit of the pressure: 100% p normal;

[0171] Medium risk: R d ≥1.5 and Rs<1.2, limited pressing mode, starting voiceprint verification, pressing speed reduced to 30%, and the upper limit of the pressure: 50% p normal;

[0172] High risk: R d ≥1.5 and Rs≥1.2, triggering the anti-collision protocol, step pressing, activating vibration obstacle removal, and the upper limit of the pressure: 30% p normal.

[0173] The anti-collision control model in S6 is as follows:

[0174] Safe pressing pressure formula:

[0175]

[0176] Where:

[0177] p safe represents the maximum allowable pressure; p 正常 represents the standard smelting pressure;

[0178] k represents the safety factor;

[0179] Step-down displacement formula

[0180]

[0181] Wherein:

[0182] δd represents single step-down displacement; d max represents the maximum allowed step length, default 5mm;

[0183] Emergency braking condition:

[0184]

[0185] P>1.2P safe

[0186] Symbol summary

[0187] The symbols and their physical meanings are as follows:

[0188] D represents displacement amount; ΔE represents thermal expansion compensation amount; a represents thermal expansion coefficient;

[0189] T represents temperature; L represents electrode immersion length; Rd represents density risk index;

[0190] ρ represents material density; R g represents voiceprint risk index; SPL represents sound pressure level;

[0191] P represents electrode pressure; δd represents single step-down displacement; k represents safety factor.

[0192] In this embodiment, the risk classification is mainly based on the calculated comprehensive risk index, as follows:

[0193] Low risk: when the density risk index <1.5, it is determined as low risk. At this time, the electrode is allowed to be normally pressed down, the standard pressing-down speed is maintained, and the upper limit of the pressure is 100% of the normal pressure. In this case, the material in the collapsed area is relatively loose, there are fewer unfused hard blocks, the resistance encountered during electrode pressing-down is smaller, and the risk of damage is lower, so the operation can be carried out according to the normal smelting rhythm.

[0194] Medium risk: when the density risk index >1.5 and the voiceprint risk index <1.2, it is determined as medium risk. At this time, the system starts voiceprint verification, that is, further collects the voiceprint signal of the collapsed area through the microphone array to confirm whether there are unfused hard blocks. At the same time, the pressing-down speed of the electrode is reduced to 30% of the standard speed, and the upper limit of the pressure is set to 50% of the normal pressure. This is because in the medium risk case, there may be a certain number of unfused hard blocks in the collapsed area, and reducing the pressing-down speed and the upper limit of the pressure can reduce the intensity of the electrode and hard block impact, avoiding electrode damage.

[0195] High risk: when the density risk index is ≥1.5 and the voiceprint risk index is ≥1.2, it is determined as high risk. At this time, the anti-collision protocol is triggered, and the electrode adopts the step-down pressure mode, and the single-step displacement is corrected according to the risk index, and the default maximum step length is 5mm. At the same time, the vibration obstacle removal function is activated, and the electrode is vibrated by the vibration motor to make the unfused hard block loose or broken. The upper limit of the pressure is set to 30% of the normal pressure (3MPa), and in the process of step-down pressure, the pressure change is monitored in real time, and when the pressure exceeds the upper limit, the electrode is withdrawn 50mm in emergency, and the vibration obstacle removal continues. After the pressure drops to a safe range, continue to press down. This processing method can maximize the avoidance of violent impact between the electrode and the unfused hard block, and protect the electrode from damage.

[0196] Working principle: after the system is started, initialization is performed first, and each module is self-checked to ensure that the temperature sensor, laser range finder, current sensor, voltage transmitter, position sensor, microphone array, microwave radar and other devices can work normally, and the communication connection between the modules is smooth. If there is a fault, an alarm will be sent out immediately and the fault position will be displayed.

[0197] After initialization is completed, enter the normal operation stage, and the data acquisition module continues to work, the temperature sensor reads the current temperature of the electrode in real time, the laser range finder continuously measures the length of the electrode immersed in the charge, and at the same time obtains the preset electrode lifting value and the displacement instruction of the hydraulic system, and transmits these data to the thermal expansion compensation module.

[0198] After receiving the data, the thermal expansion compensation module calculates the length change caused by thermal expansion according to the thermal expansion compensation formula, and then generates a new electrode lifting instruction value according to the actual displacement calculation formula of the electrode to control the electrode to lift. In the process of electrode operation, the collapse detection module is always in working state, and the electrical parameter sensor, position sensor and microphone array collect data according to their respective measurement frequencies and methods, and analyze according to the corresponding judgment conditions. When the detection results of the three sensors all meet the collapse judgment condition, the system confirms that the charge has collapsed, and transmits the collapse signal to the density scanning module.

[0199] After receiving the collapse signal, the density scanning module controls the microwave radar to scan the collapsed area and measure the material density, while the microphone array collects the sound pressure level data of the area and transmits the data to the processor. The processor calculates two risk indexes according to the density risk index formula and the voiceprint risk index formula respectively, and then obtains the comprehensive risk index. After receiving the comprehensive risk index, the risk decision module makes a judgment according to the risk classification standard. If it is low risk, a normal down-pressing instruction is issued, and the electrode down-presses according to the standard down-pressing speed and the upper limit of the normal pressure; if it is medium risk, the voiceprint verification is started, and the electrode down-presses at 30% of the standard speed and 50% of the normal pressure upper limit; if it is high risk, the anti-collision protocol is triggered, the electrode enters the step-down-pressing mode, and the vibration obstacle removal function is activated, and the upper limit of the pressure is set to 30% of the normal pressure. During the electrode down-pressing process, the anti-collision control module monitors the pressure change in real time, and when the pressure exceeds the pressure upper limit corresponding to the current risk level, the electrode is immediately controlled to retreat urgently, and the vibration crushing is continuously started. When the pressure drops to a safe range, the down-pressing operation is continued according to the risk level.

[0200] During the whole process, the abnormality monitoring module continuously monitors the data of each sensor, the calculation results of each module and the running state of the electrode. If data anomalies, calculation results exceeding limits or abnormal conditions of the electrode running are found, an alarm is issued in time, and appropriate processing measures are taken according to the degree of abnormality, such as suspending the electrode operation, switching to backup sensors, etc., to ensure the safe and stable operation of the system. When the smelting work of the electric furnace is completed, the system receives the stop command, controls the electrode to reset, and each module stops working, completing a complete operation process.

[0201] The installation position of each device of the system and the vibration obstacle removal structure and principle are as follows:

[0202] The temperature sensor is installed at the middle part of the electrode close to the joint, which can accurately measure the real-time temperature of the electrode in the high temperature environment;

[0203] The length measuring device is a laser range finder, which is installed outside the furnace wall of the electric furnace. Its laser beam can irradiate on the reflector at the top of the electrode, so as to accurately measure the length of the electrode immersed in the furnace charge;

[0204] The motor voltage transformer includes a current sensor and a voltage transmitter. The current sensor is sleeved on the power cable of the electrode, and the voltage transmitter is connected in the power supply circuit of the electrode, which is used to monitor the voltage and current of the electrode;

[0205] The position sensor is a wire displacement sensor, one end of which is fixed on the furnace body frame, and the other end is connected to the lifting mechanism of the electrode, which can monitor the position change of the electrode in real time;

[0206] The acoustic sensor is a microphone array installed in the reserved mounting hole of the sidewall of the furnace body, which can collect noise energy of a specific frequency band inside the furnace body;

[0207] The microwave radar is installed at the top inside the furnace body, and the microwave signal emitted thereby can cover most of the area inside the furnace, so as to perform density scanning on the collapsed area;

[0208] The risk decision module, the anti-collision control module and the abnormality monitoring module are integrated in a control cabinet installed outside the operating room of the electric arc furnace, so as to facilitate the monitoring and operation of the operator.

[0209] The vibration obstacle removing structure mainly comprises a vibration motor, an eccentric block and a connecting bracket. The vibration motor is fixed on the upper part of the electrode through the connecting bracket, and the eccentric block is installed on the output shaft of the vibration motor. The working principle is that when the vibration obstacle removing function is activated, the vibration motor is started to drive the eccentric block to rotate. Since the center of gravity of the eccentric block is not on the center line of the output shaft of the motor, centrifugal force is generated during rotation, so that the electrode vibrates. The vibration is transmitted to the part of the electrode in contact with the unmelted hard block, so that the unmelted hard block is loosened or broken, facilitating the smooth downward pressing of the electrode.

[0210] The data acquisition module is used for executing the data acquisition in S1.

[0211] The thermal expansion compensation module is connected with the data acquisition module and is used for executing the calculation of the thermal expansion compensation amount and the actual displacement in S2.

[0212] The collapse detection module integrates various sensors and is used for executing the collapse detection in S3.

[0213] The density scanning module is equipped with a microwave radar and is used for executing the density scanning and risk index calculation in S4.

[0214] The risk decision module is connected with the density scanning module and is used for executing the risk classification decision in S5.

[0215] The anti-collision control module is linked with the risk decision module and is used for executing the anti-collision control in S6.

[0216] The abnormality monitoring module is used for continuous abnormality detection in the whole process.

[0217] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting; it is not intended to exclude myriad other embodiments of the present application that other inventors can develop based on the description herein. A person skilled in the art will recognize that the functions explained herein can be combined in alternate configurations in accordance with the principles of this disclosure, and that the illustrated configurations are only one of many that can provide a practical use of the principles of this disclosure. Other embodiments can be understood by persons skilled in the art upon reading and understanding the attached documents. It is intended that the disclosure encompasses these and other alternatives, modifications and equivalents. It is intended that the scope of the present application encompass all technical equivalents that operate like the recited embodiments to produce the same technical result. Thus, the above-described embodiments are merely meant to be illustrative and not limiting. The scope of the disclosure should be determined by a fair reading of the appended claims and their legal equivalents, along with the full range of equivalents to which the claims are entitled.

[0218] The foregoing is considered as illustrative only of the principles of the application. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the application to the exact construction and practice described. Accordingly, all such variations are intended to be included within the scope of the present application as defined in the following claims, along with the full range of equivalents to which such claims are entitled.

Claims

1. A method for automatic regulation of a smelting furnace electrode, characterized in that, The method comprises the following steps: S1, data acquisition, real-time reading of the current temperature of the electrode, and measurement of the length of the electrode immersed in the furnace charge to obtain a preset electrode lifting value; S2, calculation of the thermal expansion compensation amount, calculation of the length change amount caused by thermal expansion, and generation of a new electrode lifting instruction value; S3, collapse detection, real-time monitoring of the sensor, and judgment of the furnace charge collapse situation; S4, collapse area density scanning, scanning of the collapse area using a microwave radar, measurement of the material density and transmission of the data to the processor, and calculation of the risk index; S5, risk classification decision, allowing normal pressing down in the case of low risk, starting voiceprint detection in the case of medium and high risk, and activating the anti-collision protocol in the case of high risk; S6, anti-collision control, setting of the safe pressing down parameters, and pressing down step by step according to the safe displacement, real-time monitoring of the pressure change, emergency withdrawal and starting of vibration crushing when the limit is exceeded; At the same time, continuous abnormality detection is carried out throughout the process.

2. The automatic regulating system for the electrode of the ore-smelting furnace according to claim 1, characterized in that, The electrode actual displacement calculation formula in S1 is as follows: D 实际 = D 指令 - ΔE Wherein: D 实际 : actual displacement of electrode tip; D 指令 : hydraulic system command displacement ΔE: thermal expansion compensation amount.

3. The automatic regulating system for the electrode of the ore-smelting furnace according to claim 1, characterized in that, The thermal expansion compensation amount calculation formula in S2 is as follows: ΔE=a·(T-T0)·L Wherein: α represents the thermal expansion coefficient; T represents the electrode expansion coefficient; T0 represents the reference temperature; L represents the electrode immersion length; Control logic: Collapse instruction correction: D 新指令 = D 预设 + ΔEcurrent.

4. The automatic regulating system for the electrode of the ore-smelting furnace according to claim 1, characterized in that, The sensors in S3 include electrical parameter sensors, position sensors and acoustic sensors, the electrical parameter sensors are used for real-time monitoring of the electrode voltage and current, the position sensors are used for detecting the real-time electrode position, and the acoustic sensors are used for detecting the noise energy of specific frequency bands inside the furnace body.

5. The automatic regulating system for the electrode of the ore-smelting furnace according to claim 1, characterized in that, The sensor detection formula for detecting the furnace charge collapse in S3 includes: Electrical mutation judgment basis ΔPF = |cosφ t -cosφ t-0.5g |>0.15 Symbol explanation: ΔP k ; represents instantaneous power change rate; P t ; represents total three-phase power at current time P avg represents the first ten seconds moving average power; ΔPF represents the power factor change amount; cosφ t represents the current power factor; Decision condition: ΔP K > 0.2 and ΔPF > 0.

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6. A self-regulating system for electrodes of an electric arc furnace according to claim 5, characterized in that, The sensor detection formula for detecting the furnace charge collapse in S3 also includes: Position mutation judgment basis Symbol explanation: υsink represents the electrode sinking speed; D t represents the absolute position of the electrode at time t.

7. A self-regulating system for electrodes of an electric arc furnace according to claim 5, characterized in that, The sensor detection formula for detecting the furnace charge collapse in S3 also includes: Voiceprint energy judgment basis Symbol explanation: E collapse represents the collapsed feature band energy; S(f) represents the sound pressure spectral density; E bg represents background noise energy, mean of first 30 seconds.

8. The automatic regulating system for the electrode of the ore-smelting furnace as claimed in claim 5, wherein The formula for calculating the risk index of the collapsed material in S4 is as follows: Density risk index formula Wherein: R d denotes the density risk index; pmeas denotes the microwave radar measured density; ρbase represents the normal molten material density; Voiceprint risk index formula Wherein: R g represents the voiceprint risk index; SPL measured represents the measured sound pressure level of the sonar array; SPLbase represents the normal molten sound pressure.

9. The automatic regulating system for the electrode of the ore-smelting furnace according to claim 1, characterized in that, The risk classification in S5, the corresponding risk conditions and control actions are as follows: Low risk: R d <1.5, normal depression allowed, standard depression speed maintained, pressure upper limit: 100% p normal; Medium risk: R d ≥ 1.5 and Rs < 1.2, restricted press-down mode, voiceprint verification initiated, press-down speed reduced to 30%, upper pressure limit: 50% p normal; High risk: R d ≥ 1.5 and Rs ≥ 1.2, trigger collision avoidance protocol, step down, activate vibration clear, pressure upper limit: 30% p normal.

10. The automatic regulating system for the electrode of the ore-smelting furnace according to claim 1, characterized in that, The anti-collision control model in S6 is as follows: Safe pressing down pressure formula: Wherein: p safe denotes the allowed maximum pressure; p 正常 denotes the standard smelting pressure; k represents the safety factor; Stepwise pressing down displacement formula Wherein: δd represents the single step down displacement; d max represents the maximum allowed step size, default 5 mm; emergency braking condition: P>1.2P safe Symbol summary The symbols and their physical meanings are as follows: D represents displacement; ΔE represents thermal expansion compensation amount; a represents thermal expansion coefficient; T represents temperature; L represents electrode immersion length; Rd represents density risk index; ρ represents material density; Rs represents voiceprint risk index; SPL represents sound pressure level; P represents electrode pressure; δd represents single-step pressing down displacement; k represents safety factor.

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