Intelligent crust breaking and blanking control method for aluminum electrolysis cell

Abstract

The invention relates to the technical field of electrolytic aluminum intelligent crust breaking, in particular to an intelligent crust breaking blanking control method for an aluminum electrolysis cell, which comprises the following steps: collecting cylinder feedback voltage and pipe network pressure, the cylinder feedback voltage being used for representing a cylinder stroke state; identifying material blocking and bag sticking events based on the voltage and a preset identification rule; related historical data are counted and stored; a crust breaking time sequence is determined by combining pipe network pressure and historical data, and rated stroke crust breaking is sequentially executed according to priorities; after crust breaking is completed at a single crust breaking point, discharging operation is executed; and in the crust breaking and discharging process, if a material blocking event is recognized, light or heavy material blocking is divided based on the air cylinder feedback voltage, and the process is recovered after a corresponding grading treatment strategy is executed. According to the crust breaking device and method, accurate recognition and differentiation treatment of blockage are achieved, crust breaking force is more concentrated, energy waste is reduced, and crust breaking and discharging collaboration and production continuity are improved.

Description

Technical Field

[0001] This invention relates to the field of intelligent shelling technology for electrolytic aluminum, and specifically to an intelligent shelling and feeding control method for aluminum electrolytic cells. Background Technology

[0002] In electrolytic aluminum production, shelling and feeding are key steps to ensure continuous and stable production. The core objective is to ensure that alumina raw materials enter the electrolytic cell in a timely and uniform manner to maintain the balance of the electrolyte system.

[0003] Traditional aluminum electrolysis cell shell-breaking control methods have the following shortcomings: 1. Fixed shell-breaking mode, often using multiple points to break shells simultaneously, resulting in drastic fluctuations in pipeline pressure, dispersed shell-breaking force, and a large waste of compressed air; 2. Delayed identification of material blockage, relying heavily on manual inspection or single parameter threshold judgment, and the handling methods after material blockage occurs are limited, which can easily lead to the expansion of material accumulation, triggering the anode effect and affecting production efficiency.

[0004] In existing technologies, some solutions achieve basic feedback control by collecting voltage and pressure signals, but these still fail to solve the problems of poor adaptability of shell-breaking parameters under dynamic operating conditions, lack of graded handling of material blockage, and unreasonable collaborative control of multiple shell-breaking points. Furthermore, some solutions use image recognition or single sensors for detection, which suffer from poor stability in high-temperature and strong electromagnetic electrolysis environments, making large-scale deployment difficult. Therefore, there is an urgent need for a dynamic single-point shell-breaking control method, where only one shell-breaking point performs the shell-breaking action at a time, and the execution sequence and interval of the shell-breaking points are dynamically adjusted based on real-time operating conditions and historical data. This would achieve precise matching of shell-breaking parameters with operating conditions, rapid response to material blockage, and improved production continuity and stability. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an intelligent shell-breaking and feeding control method for aluminum electrolytic cells. Through a dynamic single-point shell-breaking mode, it achieves dynamic adaptation of shell-breaking parameters and graded treatment of material blockage, reducing the frequency of sticking and blockage, improving production efficiency, and reducing energy waste.

[0006] The basic solution provided by this invention is an intelligent shell-breaking and feeding control method for aluminum electrolysis cells, comprising the following steps: S1. Collect multi-source data: Collect cylinder feedback voltage and pipeline pressure. The cylinder feedback voltage is used to characterize the cylinder stroke state. S2. Event Recognition: Identifies material blockage and sticking events based on cylinder feedback voltage and preset recognition rules; S3. Event Count Statistics: Count the total number of shell breaking events, the historical number of material blockage events, and the historical number of packaging sticking events; the historical number of material blockage events is the total number of material blockage events counted within a preset statistical period, and the historical number of packaging sticking events is the total number of packaging sticking events counted within a preset statistical period; establish a data storage unit to store the total number of shell breaking events, the historical number of material blockage events, and the historical number of packaging sticking events; S4. Single-point shell-breaking timing control: The shell-breaking timing is determined based on the pipeline pressure, the historical number of material blockages at the feeding point, and the historical number of packing sticking. The shell-breaking timing includes shell-breaking priority sorting and shell-breaking time interval. The rated stroke shell-breaking is executed sequentially according to the priority sorting. The shell-breaking time interval is the time from the completion of the shell-breaking action of the previous shell-breaking point to the start of the shell-breaking action of the next shell-breaking point. S5. Shelling and Unloading Command Execution: Based on the shelling timing, a shelling command is generated and sent to the cylinder. After receiving the shelling command, the cylinder performs the rated stroke shelling. After a single shelling point completes the shelling action, the cylinder returns to the initial state. When the cylinder feedback voltage is the initial state voltage, an unloading command is generated and sent to the unloading execution mechanism. After receiving the command, the unloading execution mechanism performs the unloading operation. S6. Blockage Status Classification and Grading: If a blockage event is detected during the shell breaking and material feeding process, it is classified into two blockage states, namely mild blockage or severe blockage, based on the cylinder feedback voltage and preset classification rules. The preset grading processing strategy is executed according to the blockage state. After the processing is completed, the shell breaking and material feeding commands are executed again.

[0007] The principle of this invention is as follows: Step S1 collects cylinder feedback voltage (representing stroke state) and pipeline pressure to provide real-time operating data support for subsequent control, wherein the cylinder feedback voltage is directly related to the cylinder stroke; Step S2 accurately identifies material blockage events and packing events based on cylinder feedback voltage and preset identification rules; Step S3 statistically analyzes historical data to provide data basis for shell-breaking timing optimization and ensures the targeted nature of control logic; Step S4 does not adopt the traditional multi-point simultaneous shell-breaking mode, but combines historical event data and real-time pipeline pressure to determine shell-breaking priority and time interval, and executes the rated stroke shell-breaking at each shell-breaking point in sequence to achieve shell-breaking force. Concentrated flow reduces pipeline pressure fluctuations; in step S5, after generating the shell-breaking instruction according to the shell-breaking sequence and completing the shell-breaking at one point, the cylinder returns to its initial state. At this time, the cylinder feedback voltage is the initial state voltage, and a feeding instruction is generated and sent to the feeding execution mechanism. After receiving the instruction, the feeding execution mechanism executes the feeding operation to ensure that the raw material is replenished in time after the shell is broken through, avoiding raw material accumulation or shortage caused by the asynchronous feeding and shell-breaking; in step S6, after identifying the blockage event, the degree of blockage is further divided based on the cylinder feedback voltage, and a targeted processing strategy is implemented to avoid inefficiency or excessive impact caused by a single processing method, and to ensure continuous production.

[0008] The beneficial effects of this invention are as follows: the dynamic single-point shell-breaking mode avoids the pressure dispersion problem of simultaneous shell-breaking at multiple points, making the shell-breaking force more concentrated and effectively reducing the dry-breaking rate; based on the cylinder feedback voltage to directly characterize the stroke state, combined with preset rules, material blockage events are quickly identified, avoiding the lag of manual inspection and reducing the risk of material accumulation expansion; the material blockage classification and treatment strategy can adaptively respond according to the severity of the blockage, balancing the treatment effect and production continuity, and reducing the impact on normal production.

[0009] Furthermore, the preset identification rules in S2 include a material blockage event identification rule and a packing sticking event identification rule. The material blockage event identification rule is: when the cylinder feedback voltage is not within the preset full stroke voltage standard range, it is determined to be a material blockage event. The packing sticking event identification rule is: after the shell-breaking action is completed, when the cylinder feedback voltage rises from the preset full stroke voltage standard range to the preset initial voltage range during the cylinder return stroke, the time is greater than the preset return stroke time threshold, it is determined to be a packing sticking event. The preset initial voltage range is the reasonable fluctuation range of the cylinder feedback voltage in the initial state of the cylinder, and the preset full stroke voltage standard range is the reasonable fluctuation range of the cylinder feedback voltage when the cylinder reaches the rated stroke. Both are determined based on manual preset.

[0010] Clearly define the quantitative identification criteria for material blockage and packaging sticking events. By pre-setting voltage ranges to accommodate sensor errors or minor fluctuations, the risk of misjudgment in threshold determination can be avoided. At the same time, accurate statistics of historical events provide reliable data support for subsequent shell-opening timing optimization.

[0011] Furthermore, the strategy for determining the priority of shell breaking in S4 includes: sorting each shell breaking point from high to low according to the number of historical material blockages; when the number of historical material blockages is the same, sorting it from low to high according to the number of historical material sticking; when both the number of historical material blockages and the number of historical material sticking are the same, sorting it from low to high according to the shell breaking point number; the strategy for determining the shell breaking time interval includes: preset high-pressure network pressure threshold and medium-pressure network pressure threshold; when the network pressure is greater than or equal to the high-pressure network pressure threshold, a first time interval is used; when the network pressure is greater than the medium-pressure network pressure threshold but less than the high-pressure network pressure threshold, a second time interval is used; the first time interval is less than the second time interval.

[0012] The shell-breaking priority ranking focuses on high-risk points of material blockage, prioritizing the treatment of easily blocked points to prevent the expansion of material accumulation, while also taking into account the risk of sticking to the packaging to avoid secondary failures; the shell-breaking time interval is dynamically adapted to the pipeline pressure, shortening the interval when the pressure is sufficient to improve production efficiency, and extending the interval when the pressure is insufficient to ensure shell-breaking force, achieving a balance between efficiency and effectiveness, and reducing pipeline pressure fluctuations.

[0013] Furthermore, the preset blockage state classification rules in S6 include: based on the negative correlation between cylinder feedback voltage and cylinder stroke formed by the conversion circuit, a preset blockage threshold voltage is established, which serves as the cylinder feedback voltage boundary distinguishing between mild and severe blockage; when the cylinder feedback voltage is not within the preset full stroke voltage range and is less than the blockage threshold voltage, it is classified as mild blockage; when the cylinder feedback voltage is greater than or equal to the blockage threshold voltage, it is classified as severe blockage; the graded processing strategy includes: when classified as mild blockage, the feeding process is not interrupted, and a preset number of short pulse rated stroke shelling operations are performed simultaneously, with the interval between two adjacent pulse shelling operations being the preset short pulse interval; when classified as severe blockage, the feeding process is immediately interrupted, and a preset duration of continuous rated stroke shelling is performed. After the execution, the cylinder feedback voltage is re-detected; if it is within the preset full stroke voltage range, feeding is resumed; otherwise, an abnormal alarm is triggered.

[0014] Based on the negative correlation between cylinder feedback voltage and stroke, the severity of material blockage is accurately classified. For mild blockage, both material feeding and unblocking are addressed to avoid production stoppages. For severe blockage, efforts are concentrated on breaking through stubborn blockages. If continuous rated stroke punching still cannot resolve the blockage, an alarm mechanism is used to remind manual intervention to prevent long-term unresolved blockages from affecting production. The differentiated treatment strategy improves the efficiency of unblocking while reducing the wear and tear on the equipment caused by excessive punching. Attached Figure Description

[0015] Figure 1 This is a logic diagram of an embodiment of an intelligent shell-breaking and feeding control method for aluminum electrolysis cells according to the present invention. Detailed Implementation

[0016] The following detailed description illustrates the specific implementation method: The basic implementation examples are as follows: Figure 1 As shown: A smart shell-breaking and feeding control method for aluminum electrolysis cells includes the following steps: S1. Collect multi-source data: Collect cylinder feedback voltage and pipeline pressure. The cylinder feedback voltage is used to characterize the cylinder stroke state. S2. Event Recognition: Identifies material blockage and sticking events based on cylinder feedback voltage and preset recognition rules; S3. Event Count Statistics: Count the total number of shell breaking events, the historical number of material blockage events, and the historical number of packaging sticking events; the historical number of material blockage events is the total number of material blockage events counted within a preset statistical period, and the historical number of packaging sticking events is the total number of packaging sticking events counted within a preset statistical period; establish a data storage unit to store the total number of shell breaking events, the historical number of material blockage events, and the historical number of packaging sticking events; S4. Single-point shell-breaking timing control: The shell-breaking timing is determined based on the pipeline pressure, the historical number of material blockages at the feeding point, and the historical number of packing sticking. The shell-breaking timing includes shell-breaking priority sorting and shell-breaking time interval. The rated stroke shell-breaking is executed sequentially according to the priority sorting. The shell-breaking time interval is the time from the completion of the shell-breaking action of the previous shell-breaking point to the start of the shell-breaking action of the next shell-breaking point. S5. Shelling and Unloading Command Execution: Based on the shelling timing, a shelling command is generated and sent to the cylinder. After receiving the shelling command, the cylinder performs the rated stroke shelling. After a single shelling point completes the shelling action, the cylinder returns to the initial state. When the cylinder feedback voltage is the initial state voltage, an unloading command is generated and sent to the unloading execution mechanism. After receiving the command, the unloading execution mechanism performs the unloading operation. S6. Blockage Status Classification and Grading: If a blockage event is detected during the shell breaking and material feeding process, it is classified into two blockage states, namely mild blockage or severe blockage, based on the cylinder feedback voltage and preset classification rules. The preset grading processing strategy is executed according to the blockage state. After the processing is completed, the shell breaking and material feeding commands are executed again.

[0017] Furthermore, the preset identification rules in S2 include a material blockage event identification rule and a packing sticking event identification rule. The material blockage event identification rule is: when the cylinder feedback voltage is not within the preset full stroke voltage standard range, it is determined to be a material blockage event. The packing sticking event identification rule is: after the shell-breaking action is completed, when the cylinder feedback voltage rises from the preset full stroke voltage standard range to the preset initial voltage range during the cylinder return stroke, the time is greater than the preset return stroke time threshold, it is determined to be a packing sticking event. The preset initial voltage range is the reasonable fluctuation range of the cylinder feedback voltage in the initial state of the cylinder, and the preset full stroke voltage standard range is the reasonable fluctuation range of the cylinder feedback voltage when the cylinder reaches the rated stroke. Both are determined based on manual preset.

[0018] Furthermore, the strategy for determining the priority of shell breaking in S4 includes: sorting each shell breaking point from high to low according to the number of historical material blockages; when the number of historical material blockages is the same, sorting it from low to high according to the number of historical material sticking; when both the number of historical material blockages and the number of historical material sticking are the same, sorting it from low to high according to the shell breaking point number; the strategy for determining the shell breaking time interval includes: preset high-pressure network pressure threshold and medium-pressure network pressure threshold; when the network pressure is greater than or equal to the high-pressure network pressure threshold, a first time interval is used; when the network pressure is greater than the medium-pressure network pressure threshold but less than the high-pressure network pressure threshold, a second time interval is used; the first time interval is less than the second time interval.

[0019] Furthermore, the preset blockage state classification rules in S6 include: based on the negative correlation between cylinder feedback voltage and cylinder stroke formed by the conversion circuit, a preset blockage threshold voltage is established, which serves as the cylinder feedback voltage boundary distinguishing between mild and severe blockage; when the cylinder feedback voltage is not within the preset full stroke voltage range and is less than the blockage threshold voltage, it is classified as mild blockage; when the cylinder feedback voltage is greater than or equal to the blockage threshold voltage, it is classified as severe blockage; the graded processing strategy includes: when classified as mild blockage, the feeding process is not interrupted, and a preset number of short pulse rated stroke shelling operations are performed simultaneously, with the interval between two adjacent pulse shelling operations being the preset short pulse interval; when classified as severe blockage, the feeding process is immediately interrupted, and a preset duration of continuous rated stroke shelling is performed. After the execution, the cylinder feedback voltage is re-detected; if it is within the preset full stroke voltage range, feeding is resumed; otherwise, an abnormal alarm is triggered.

[0020] In this embodiment, a GLMVIII type tank control machine and a Jefuli energy-saving cylinder are used as the core hardware carriers. The Jefuli energy-saving cylinder can convert the cylinder stroke into cylinder feedback voltage through a pressure sensor and conversion circuit, thereby achieving accurate detection of the cylinder state. The cylinder feedback voltage corresponds to 24V in the initial state of the cylinder, and 0V when the cylinder reaches its rated stroke (i.e., full stroke). The rated stroke of the cylinder is 0.65m, and the preset parameters are as follows: Voltage range: The preset full-stroke voltage range is 0V~0.2V (to accommodate sensor errors and minor stroke fluctuations, ensuring accurate full-stroke determination); the preset initial voltage range is 23.8V~24.2V (corresponding to the voltage fluctuation range in the initial, un-exploded state of the cylinder). Event judgment threshold: The preset return time threshold is 6s (used to judge the sticking event); the preset blockage threshold voltage is 5V (the voltage boundary that distinguishes between light and heavy blockage). Timing and processing parameters: The preset statistical period is 30 days, which is used to accumulate the historical number of blockages and the historical number of sticking at each shelling point, providing data support for shelling priority ranking; the preset high-pressure network pressure threshold is 0.7MPa and the medium-pressure network pressure threshold is 0.5MPa, the first time interval is 2.5s (when the network pressure is sufficient) and the second time interval is 4s (when the network pressure is moderate). Material blockage handling parameters: The preset number of times is 3, that is, the preset number of short pulse shelling is 3 when the material blockage is mild; the preset short pulse interval is 500ms, that is, the interval between two adjacent pulse shelling is 500ms; the preset duration is 30s, that is, the preset continuous shelling duration is 30s when the material blockage is severe; the abnormal alarm includes buzzer alarm and warning light alarm (the buzzer sounds at a fixed frequency and the warning light flashes red light) to remind manual intervention to resolve stubborn material blockage.

[0021] Two identical 350kA prebaked electrolytic cells (cell numbers 2532 and 2533) were selected for a 30-day comparative experiment. The production load and raw material quality of the two electrolytic cells were completely identical, with the only difference being the shell-forming control scheme. 2532 tank (ordinary tank): adopts traditional shell-breaking control method, equipped with Jefuli energy-saving shell-breaking cylinder (diameter 160mm, rated stroke 0.65m), and adopts multi-point simultaneous shell-breaking mode; 2533 Tank (Experimental Tank): Using the control method of this invention, a Jefuli energy-saving shell-breaking cylinder (diameter 160mm, rated stroke 0.65m) is configured. A dynamic single-point shell-breaking mode is adopted, and single-point shell-breaking timing control and blockage classification are performed according to the above preset parameters.

[0022] The comparison results of the performance indicators of the ordinary tank and the experimental tank during the experiment are shown in Table 1 below: Table 1 Comparison Results of Indicators

[0023] According to the experimental comparison results, the number of times the packing and the number of times the material blocked in the experimental cell decreased significantly, and the number of times the anode effect occurred in the experimental cell also decreased. Therefore, based on the synergistic effect of dynamic single-point shelling timing control and graded treatment of material blockage, this invention can reduce the frequency of packing and material blockage by accurately collecting working condition data, quantitatively optimizing shelling parameters, and prioritizing the treatment of high-risk shelling points, thereby improving the continuity and stability of electrolytic aluminum production.

[0024] The above are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A method for intelligent shell-breaking and feeding control in aluminum electrolytic cells, characterized in that, Includes the following steps: S1. Collect multi-source data: Collect cylinder feedback voltage and pipeline pressure. The cylinder feedback voltage is used to characterize the cylinder stroke state. S2. Event Recognition: Identifies material blockage and sticking events based on cylinder feedback voltage and preset recognition rules; S3. Event Count Statistics: Count the total number of shell breaking events, the historical number of material blockage events, and the historical number of packaging sticking events; the historical number of material blockage events is the total number of material blockage events counted within a preset statistical period, and the historical number of packaging sticking events is the total number of packaging sticking events counted within a preset statistical period; establish a data storage unit to store the total number of shell breaking events, the historical number of material blockage events, and the historical number of packaging sticking events; S4. Single-point shell-breaking timing control: The shell-breaking timing is determined based on the pipeline pressure, the historical number of material blockages at the feeding point, and the historical number of packing sticking. The shell-breaking timing includes shell-breaking priority sorting and shell-breaking time interval. The rated stroke shell-breaking is executed sequentially according to the priority sorting. The shell-breaking time interval is the time from the completion of the shell-breaking action of the previous shell-breaking point to the start of the shell-breaking action of the next shell-breaking point. S5. Shelling and Unloading Command Execution: Based on the shelling timing, a shelling command is generated and sent to the cylinder. After receiving the shelling command, the cylinder performs the rated stroke shelling. After a single shelling point completes the shelling action, the cylinder returns to the initial state. When the cylinder feedback voltage is the initial state voltage, an unloading command is generated and sent to the unloading execution mechanism. After receiving the command, the unloading execution mechanism performs the unloading operation. S6. Blockage Status Classification and Grading: If a blockage event is detected during the shell breaking and material feeding process, it is classified into two blockage states, namely mild blockage or severe blockage, based on the cylinder feedback voltage and preset classification rules. The preset grading processing strategy is executed according to the blockage state. After the processing is completed, the shell breaking and material feeding commands are executed again.

2. The intelligent shell-breaking and feeding control method for aluminum electrolytic cells according to claim 1, characterized in that, The preset identification rules in S2 include rules for identifying material blockage events and rules for identifying packaging sticking events. The rule for identifying material blockage events is: when the cylinder feedback voltage is not within the preset full-stroke voltage standard range, it is determined to be a material blockage event. The rule for identifying packaging sticking events is: after the shell-breaking action is completed, when the cylinder feedback voltage rises from the preset full-stroke voltage standard range to the preset initial voltage range during the cylinder return stroke, the time is greater than the preset return stroke time threshold, it is determined to be a packaging sticking event. The preset initial voltage range is the reasonable fluctuation range of the cylinder feedback voltage when the cylinder is in its initial state, and the preset full-stroke voltage standard range is the reasonable fluctuation range of the cylinder feedback voltage when the cylinder reaches its rated stroke. Both are determined based on manual preset.

3. The intelligent shell-breaking and feeding control method for aluminum electrolytic cells according to claim 2, characterized in that, The strategy for determining the priority of shell breaking in S4 includes: sorting each shell breaking point from high to low according to the number of historical material blockages; when the number of historical material blockages is the same, sorting it from low to high according to the number of historical packing sticks; when both the number of historical material blockages and the number of historical packing sticks are the same, sorting it from low to high according to the shell breaking point number; the strategy for determining the shell breaking time interval includes: setting a high-pressure network pressure threshold and a medium-pressure network pressure threshold; when the network pressure is greater than or equal to the high-pressure network pressure threshold, a first time interval is used; when the network pressure is greater than the medium-pressure network pressure threshold but less than the high-pressure network pressure threshold, a second time interval is used; the first time interval is less than the second time interval.

4. The intelligent shell-breaking and feeding control method for aluminum electrolytic cells according to claim 3, characterized in that, The preset blockage state classification rules in S6 include: based on the negative correlation between cylinder feedback voltage and cylinder stroke formed by the conversion circuit, a preset blockage threshold voltage is established, which serves as the cylinder feedback voltage boundary distinguishing between mild and severe blockage; when the cylinder feedback voltage is not within the preset full stroke voltage range and is less than the blockage threshold voltage, it is classified as mild blockage; when the cylinder feedback voltage is greater than or equal to the blockage threshold voltage, it is classified as severe blockage; the graded processing strategy includes: when classified as mild blockage, the feeding process is not interrupted, and a preset number of short pulse rated stroke shelling operations are performed simultaneously, with the interval between two adjacent pulse shelling operations being the preset short pulse interval; when classified as severe blockage, the feeding process is immediately interrupted, and a preset duration of continuous rated stroke shelling is performed. After the execution, the cylinder feedback voltage is re-detected. If it is within the preset full stroke voltage range, feeding is resumed; otherwise, an abnormal alarm is triggered.

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