Method for accurately checking the weight of undissolved copper

Abstract

The application relates to the technical field of chemical production control, and discloses a method for accurately checking the weight of undissolved copper, which comprises a copper dissolving tank provided with a weighing sensor at the bottom and an external circulation system connected with the copper dissolving tank, wherein the external circulation system comprises a circulating tank and a circulating pump; when checking is needed, most of the copper sulfate solution in the copper dissolving tank is led out to the circulating tank through the circulating pump, so that the copper dissolving tank mainly contains undissolved copper and residual copper sulfate solution; the total weight of the undissolved copper and the residual copper sulfate solution is measured through the weighing sensor; and the weight of the undissolved copper is obtained through calculation according to a preset empty tank weight and a constant residual liquid weight. The method realizes accurate checking without interrupting the production process, avoids shutdown loss, provides a new means for closed-loop control of the production process through monitoring of the weight change rate, and significantly improves process stability and accuracy of inventory data.

Description

Technical Field

[0001] This invention relates to the field of chemical production control technology, specifically a method for accurately counting the weight of unmelted copper. Background Technology

[0002] In the production of chemical products such as copper sulfate, a key step is to place solid copper material (such as scrap copper or copper blocks) in a copper dissolving tank and dissolve it by circulating sulfuric acid solution. For effective production scheduling, cost accounting, and inventory management, it is essential to periodically and accurately monitor the weight of the remaining, undissolved copper material in the dissolving tank.

[0003] However, current technological practices have significant shortcomings in the methods for obtaining this crucial data. The most common inventory method involves shutting down the production line, completely halting production, pumping out all copper sulfate solution from the tank, manually scooping out and weighing the remaining solid copper, and then returning it to the tank to resume production. The drawbacks of this method are obvious: it forcibly interrupts the continuous production process, resulting in significant wasted labor hours and lost capacity, and the entire process is time-consuming, labor-intensive, and cumbersome.

[0004] As an alternative to downtime inventory checks, some factories use empirical estimation methods. This involves calculating the remaining copper quantity based on the total amount of raw materials fed, production time, and a theoretical average melting rate. However, the actual copper dissolution rate is complexly affected by various dynamic factors such as solution temperature, acid concentration, circulation rate, copper surface area, and packing morphology. This often leads to significant and unpredictable discrepancies between the theoretical estimate and the actual remaining quantity. This inaccuracy in the data severely distorts inventory information, failing to provide a reliable basis for lean production and cost control.

[0005] Therefore, when conducting inventory checks on ongoing copper melting reactions, existing technologies always face a dilemma: either sacrifice production efficiency for accuracy or maintain production but accept severely inaccurate data. There is a lack of an effective solution that can balance production continuity and data accuracy. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a method for accurately counting the weight of unmelted copper, solving the problems of requiring machine shutdown and inaccurate data in existing technologies.

[0007] To achieve the above objectives, the present invention provides a method for accurately counting the weight of unmelted copper, comprising the following steps:

[0008] Based on a copper melting tank with a weighing sensor installed at the bottom, and an external circulation system connected to the copper melting tank, the external circulation system includes a circulation tank and a circulation pump;

[0009] When an inventory check is required, most of the copper sulfate solution in the copper dissolving tank is discharged to the circulation tank through the circulation pump, so that the copper dissolving tank mainly contains undissolved copper and residual copper sulfate solution.

[0010] The total weight of the inventory, including undissolved copper and residual copper sulfate solution, was measured by the weighing sensor.

[0011] The weight of the undissolved copper is calculated based on the preset empty tank weight and the constant residual liquid weight.

[0012] Preferably, the step of exporting most of the copper sulfate solution in the copper dissolving tank to the circulation tank specifically involves:

[0013] The circulating pump is controlled to operate at a preset low and constant inventory speed to form a stable and repeatable residual copper sulfate solution state.

[0014] Preferably, an initialization calibration step is also included before the inventory count:

[0015] When no undissolved copper is added to the copper dissolving tank, the circulating pump is controlled to run at the inventory speed. The weight at this time is measured and recorded by the weighing sensor. After subtracting the preset weight of the empty tank, the difference is determined as the constant residual liquid weight.

[0016] Preferably, the method further includes the step of monitoring the copper melting rate during normal production:

[0017] The total weight change of the copper melting tank is continuously monitored by the weighing sensor;

[0018] The actual dissolution rate is obtained by calculating the decrease in the total weight per unit time.

[0019] Preferably, the method further includes a step of closed-loop feedback adjustment based on the actual dissolution rate:

[0020] The actual dissolution rate is compared with the preset target dissolution rate;

[0021] Based on the comparison results, the process parameters are automatically adjusted to make the actual dissolution rate approach the target dissolution rate.

[0022] Preferably, the process parameters include the production speed of the circulating pump or the power of the heater in the external circulation system.

[0023] Preferably, the step of calculating the weight of the undissolved copper based on a preset empty tank weight and a constant residual liquid weight specifically involves:

[0024] The weight of the undissolved copper is obtained by subtracting the weight of the empty tank and the weight of the constant residual liquid from the total inventory weight.

[0025] Preferably, the circulating pump is a variable frequency circulating pump, and the disk rotation speed is achieved by adjusting its operating frequency.

[0026] Preferably, the pipeline in the external circulation system is also equipped with a filter for filtering impurities in the copper sulfate solution.

[0027] Preferably, a heater is also provided on the pipeline of the external circulation system for adjusting the temperature of the copper sulfate solution.

[0028] This invention provides a method for accurately counting the weight of undissolved copper. It has the following beneficial effects:

[0029] 1. This invention integrates a weighing sensor with a copper dissolving tank and combines it with an external circulation system. During inventory checks, most of the copper sulfate solution can be transferred to the circulation tank, allowing the weighing sensor to primarily measure the weight of undissolved copper and a small amount of residual liquid. By subtracting the preset weight of the empty tank and the constant weight of the residual liquid, the net weight of the undissolved copper can be accurately calculated. The entire process is completed online without stopping the core copper dissolving reaction, thus avoiding production losses and waste of manpower and resources caused by downtime for inventory checks.

[0030] 2. This invention utilizes a weighing sensor to continuously and in real-time monitor the total weight of the copper dissolution tank, and by calculating the rate of change of the total weight over time, it achieves direct quantification of the actual copper dissolution rate. In addition, the actual dissolution rate can be used as a core process parameter, and after being compared with the target rate, a closed-loop feedback is formed to automatically adjust the heating power or the speed of the circulating pump, etc., so that the production process is transformed from traditional open-loop estimation control to precise closed-loop control, which significantly improves the stability of the production process.

[0031] 3. This invention precisely calibrates the constant residual liquid weight under specific working conditions, transforming the largest variable in inventory calculation into a stable and repeatable constant. This ensures that each inventory count is conducted under a consistent measurement benchmark, greatly improving the accuracy and reliability of the calculation results. This enables companies to reduce unnecessary copper wire safety stock and reduce capital occupation. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the device structure of the present invention;

[0033] Figure 2 This is a flowchart of the online inventory method of the present invention;

[0034] Figure 3 This is a flowchart of the closed-loop control method of the present invention;

[0035] Figure 4 This is a block diagram of the control system signal flow of the present invention. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Please see the appendix Figure 1 - Appendix Figure 4 This invention provides a method for accurately counting the weight of unmelted copper, comprising:

[0038] Based on a copper melting tank with a weighing sensor installed at the bottom, and an external circulation system connected to the copper melting tank, the external circulation system includes a circulation tank and a circulation pump;

[0039] When an inventory check is required, most of the copper sulfate solution in the copper dissolving tank is discharged to the circulation tank through the circulation pump, so that the copper dissolving tank mainly contains undissolved copper and residual copper sulfate solution.

[0040] The total weight of the inventory, including undissolved copper and residual copper sulfate solution, was measured by the weighing sensor.

[0041] The weight of the undissolved copper is calculated based on the preset empty tank weight and the constant residual liquid weight.

[0042] In this embodiment, one or more weighing sensors are installed at the bottom of the weighing copper melting tank. The weighing sensors are used to measure the total weight of the weighing copper melting tank and all the materials inside it in real time and continuously, and send the measured weight data to a central control module.

[0043] The method also includes an external circulation system connected to the weighing copper melting tank. This external circulation system includes a separate circulation tank, a variable frequency circulation pump, and a piping system for connecting the various components. The bottom outlet of the weighing copper melting tank is connected to the inlet of the circulation tank via a pipe, the outlet of the circulation tank is connected to the inlet of the variable frequency circulation pump via a pipe, and the outlet of the variable frequency circulation pump is then connected to a spray device at the top of the weighing copper melting tank via a pipe.

[0044] The external circulation system also includes a process auxiliary module. Specifically, a heater is installed on the pipeline between the outlet of the variable frequency circulating pump and the spray device to regulate the temperature of the pumped-back copper sulfate solution. Additionally, a filter is installed; for example, a bypass pipeline with a filter is led out from the circulation tank, and the filtered solution is returned to the circulation tank to remove solid impurities from the copper sulfate solution.

[0045] The method further includes a central control module. Its physical entity can be a PLC (Programmable Logic Controller) or an industrial control computer. The signal input terminals of the central control module are electrically connected to the weighing sensor to receive real-time weight data. The control output terminals of the central control module are electrically connected to the frequency converter of the variable frequency circulating pump and the heater, respectively, to send control commands to adjust the operating frequency of the variable frequency circulating pump and the power of the heater.

[0046] For the following steps: When an inventory check is required, most of the copper sulfate solution in the copper dissolving tank is discharged to the circulation tank through the circulation pump, so that the copper dissolving tank mainly contains undissolved copper and residual copper sulfate solution.

[0047] First, to achieve accurate calculations, this method requires a one-time initialization calibration process before formal production to determine the baseline parameters needed for subsequent calculations. This process is automatically executed by the central control module. The constant residual liquid weight W... liquid_residual The calibration is the foundation for achieving accurate inventory procedures.

[0048] Specifically, under the conditions that the weighing copper dissolving tank is clean and only copper sulfate solution is added, with no undissolved copper added, the central control module initiates the calibration program. This module sends a specific frequency control command to the inverter of the variable frequency circulating pump, causing the pump to operate at a preset, low, and constant speed. This speed is defined as the inventory speed S. inv Here we take stock of the rotational speed S. inv At this point, the pumped solution flow rate is small, only sufficient to maintain a continuous but small amount of liquid outflow from the top spray device. At this time, the liquid level in the weighing copper dissolving tank, the thickness of the liquid film adhering to the tank wall, and the amount of liquid retained at the bottom due to flow all reach a stable and repeatable physical state. After the weighing sensor reading stabilizes, the central control module records the total weight at this moment and subtracts the known empty tank weight W. tare The difference is then determined as the constant residual liquid weight W. liquid_residual And store.

[0049] During normal production operation of the equipment, when a manual or preset inventory command is received, the central control module will begin to execute the online inventory process corresponding to the above steps.

[0050] The central control module first sends a control command to the inverter of the variable frequency circulating pump, changing its operating frequency from the high-efficiency production speed S. prod The corresponding frequency smoothly decreases to the disk rotation speed S. inv The corresponding frequency.

[0051] As the speed of the variable frequency circulating pump decreases to the inventory speed S inv The flow rate of the solution pumped to the top of the weighing copper dissolving tank is significantly reduced. At this time, most of the copper sulfate solution inside the weighing copper dissolving tank will naturally flow back and collect in the circulation tank, which does not participate in the weighing, because its gravity is greater than the lift provided by the circulation pump.

[0052] After a brief, preset stabilization period, the state of the residual copper sulfate solution in the weighing copper dissolving tank reached the same level as in the aforementioned calibration process, determined by the inventory rotation speed S. inv The stable state determined by this alone. This completes the preparatory steps for inventorying the copper solution, leaving the copper dissolving tank primarily containing undissolved copper and precisely quantifiable residual copper sulfate solution, thus laying the physical foundation for subsequent accurate weighing.

[0053] For the step: the total weight of the inventory, including undissolved copper and residual copper sulfate solution, is measured by the weighing sensor;

[0054] After completing the aforementioned steps to achieve a stable inventory state in the weighing copper melting tank, the method of the present invention then performs a precise weight measurement step.

[0055] Specifically, the central control module continuously receives and processes real-time weight data transmitted from the weighing sensors at a set high frequency (e.g., once per second). This occurs when the variable frequency circulating pump switches to the inventory speed S. inv After running for a period of time, the central control module will start a monitoring program for the stable weighing status.

[0056] In this monitoring program, the central control module performs real-time analysis on a series of weight data collected within a continuous time window (e.g., the most recent 5 seconds). Specifically, it can calculate the standard deviation of this series of data, or the difference between the maximum and minimum values. When the calculated result is less than a preset stability threshold that indicates the readings have essentially stabilized, the central control module determines that the device has reached a stable weighing state where accurate measurements can be performed.

[0057] Once a stable weighing state is determined, the central control module immediately executes a data acquisition command. To eliminate random errors from single-point sampling, this command specifically acquires all weight data output by the weighing sensor within a short subsequent measurement cycle (e.g., 2 seconds) and calculates the arithmetic mean of the acquired data points.

[0058] The calculated arithmetic mean is determined to be the total inventory weight, including all undissolved copper and stable residual copper sulfate solution in the tank. This value is assigned the symbol W. total The data is locked and stored in its internal storage unit by the central control module, serving as the direct basis for subsequent final weight calculations.

[0059] For the following steps: The weight of the undissolved copper is calculated based on the preset empty tank weight and the constant residual liquid weight;

[0060] After obtaining the total weight W of the aforementioned inventory count total The method of the present invention then performs a final weight calculation step to determine the net weight of the unmelted copper.

[0061] Specifically, the central control module immediately retrieves the total inventory weight W, which was determined in the aforementioned steps, from its internal storage unit. total And the empty slot weight W that has been preset and stored in the initialization calibration process. tare and constant residual liquid weight W liquid_residual These three parameters.

[0062] The calculation follows the established physical model formula:

[0063] W copper =W total -W tare -W liquid_residual ;

[0064] In this formula, the physical meaning of each parameter is explicitly defined: W copper The final calculated target result is the net weight of unmelted copper inside the weighing copper melting tank at the current moment, W total In the previous measurement step, the load cell was used to measure the rotational speed S of the inventory. inv W is the total weight of all materials in the tank, measured under steady-state conditions. tare and W liquid_residual These are the empty tank weight and the constant residual liquid weight, which are precisely determined in advance during the initialization calibration process and stored as constant correction values.

[0065] After the central control module performs the subtraction operation, the calculated result W is obtained. copper It can be displayed directly on its human-machine interface, or uploaded to the upper-level production execution system (MES) or enterprise resource planning (ERP) system through the communication interface for inventory recording and cost accounting.

[0066] While completing this calculation step, the central control module has changed the speed of the variable frequency circulating pump from the inventory speed S. invRestore to production speed S prod This completes the entire inventory process, allowing the equipment to seamlessly return to normal production operation.

[0067] To further disclose the technical solution of the present invention, the method of the present invention also includes a continuous monitoring and closed-loop adjustment process for the copper dissolution rate during normal production operation.

[0068] In this process, the central control module continuously receives and records the total weight data W measured by the weighing sensor at a fixed high frequency. total (t). The central control module performs real-time differential calculations on continuously collected weight data and calculates the actual dissolution rate V according to the following formula. actual (t):

[0069]

[0070] The negative sign indicates that the weight decreases over time. In practical discrete-time calculations, a difference form can be used, that is, the weight decrease ΔW over a very short time interval Δt can be used as an approximation, i.e., V. actual ≈-ΔW / Δt.

[0071] The central control module has a preset target melting rate V. target The module will calculate V in real time. actual (t) and V target Continuous comparisons are performed, and adjustment signals are generated based on the PID control algorithm.

[0072] When V actual (t) <V target If the dissolution rate is too slow, the central control module will output a control signal to increase the heater power to raise the solution temperature, or, within the allowable process range, appropriately increase the production speed S of the variable frequency circulating pump. prod This enhances the flushing force, thereby increasing the dissolution rate.

[0073] When V actual (t)>V target When the dissolution rate is too fast, the central control module will perform the opposite adjustment.

[0074] This closed-loop control process can precisely maintain the copper melting rate near the target value, thereby ensuring the stability of production efficiency and product quality.

[0075] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for accurately counting the weight of undissolved copper, characterized in that, Includes the following steps: Based on a copper melting tank with a weighing sensor installed at the bottom, and an external circulation system connected to the copper melting tank, the external circulation system includes a circulation tank and a variable frequency circulation pump; Before the inventory count, an initialization calibration step is also included: when no undissolved copper is added to the copper dissolving tank, the variable frequency circulating pump is controlled to run at a preset low-speed constant inventory count speed. The weight at this time is measured and recorded by the weighing sensor. After subtracting the preset empty tank weight, the difference is determined as the constant residual liquid weight. When inventory is required, the operating frequency of the variable frequency circulating pump is used to achieve the inventory rotation speed, and most of the copper sulfate solution in the copper dissolving tank is exported to the circulating tank, so that the copper dissolving tank mainly contains undissolved copper and residual copper sulfate solution, forming a stable and repeatable residual copper sulfate solution state. The total weight of the inventory, including undissolved copper and residual copper sulfate solution, was measured by the weighing sensor. The weight of the undissolved copper is calculated based on the preset empty tank weight and the constant residual liquid weight.

2. The method for accurately counting the weight of undissolved copper according to claim 1, characterized in that, The method also includes the step of monitoring the copper dissolution rate during normal production: The total weight change of the copper melting tank is continuously monitored by the weighing sensor; The actual dissolution rate is obtained by calculating the decrease in the total weight per unit time.

3. The method for accurately counting the weight of undissolved copper according to claim 2, characterized in that, The method further includes a closed-loop feedback adjustment step based on the actual dissolution rate: The actual dissolution rate is compared with the preset target dissolution rate; Based on the comparison results, the process parameters are automatically adjusted to make the actual dissolution rate approach the target dissolution rate.

4. The method for accurately counting the weight of undissolved copper according to claim 3, characterized in that, The process parameters include the production speed of the variable frequency circulating pump or the power of the heater in the external circulation system.

5. The method for accurately counting the weight of undissolved copper according to claim 1, characterized in that, The step of calculating the weight of undissolved copper based on the preset empty tank weight and constant residual liquid weight is as follows: The weight of the undissolved copper is obtained by subtracting the weight of the empty tank and the weight of the constant residual liquid from the total inventory weight.

6. The method for accurately counting the weight of undissolved copper according to claim 1, characterized in that, The external circulation system is also equipped with a filter on the pipeline to filter out impurities in the copper sulfate solution.

7. The method for accurately counting the weight of undissolved copper according to claim 1, characterized in that, A heater is also installed on the pipeline of the external circulation system to regulate the temperature of the copper sulfate solution.

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