Aluminum electrolysis material control system based on intelligent crust breaking

Abstract

The invention discloses an aluminum electrolysis material control system based on intelligent crust breaking, which comprises a main control module and a human-computer interaction interface module, and is characterized in that the main control module comprises an acquisition task module, an aluminum electrolysis production process module and a production operation execution module; a single-point closed-loop blanking control system is realized by combining an acquisition task module, an aluminum electrolysis production process module, a production operation execution module and a human-computer interaction interface module with an intelligent air cylinder, and the intelligent crust breaking and blanking system has the functions of single-point crust breaking, blanking, controllable crust breaking depth and the like during electrolytic cell machining operation. According to the system, aluminum oxide or villiaumite can be uniformly fed into a moderate position in electrolyte to accelerate the dissolution of the aluminum oxide or villiaumite, the service lives of the crust breaking cylinder and the hammer head can be prolonged, the whole system improves the intelligent production level of aluminum electrolysis, improves the electrolysis efficiency in aluminum electrolysis production, and saves the cost.

Description

Technical Field

[0001] This invention relates to the field of aluminum electrolysis production technology, and in particular to an aluminum electrolysis material control system based on intelligent shell forming. Background Technology

[0002] For aluminum electrolysis control systems, the control equipment in the aluminum electrolysis production process achieves a better material and thermal balance in the entire electrolytic cell by controlling the amount of alumina and fluoride salts and adjusting the electrode spacing, thus maximizing its efficiency. Therefore, the uniformity of the feeding directly affects the electrolysis efficiency of the electrolytic cell. Currently, traditional systems control the shell-breaking and feeding structure using multi-point simultaneous shell-breaking and feeding or alternating shell-breaking and feeding methods. That is, shell-breaking and feeding are controlled by two solenoid valves, each controlling two or three cylinders. The shell-breaking and feeding operations are completed simultaneously or alternately at one or two points. Under such feeding methods, if a blockage or uneven feeding occurs at one feeding point, it will cause overfeeding or underfeeding at other feeding points, causing sudden effects or increasing sedimentation at the furnace bottom. Based on simulation and testing of the flow field distribution in the electrolyzer, the electrolyte flow rate at each feeding point in the electrolyzer is not the same, and the solubility varies greatly. Therefore, the two-point feeding method will inevitably cause uneven concentration distribution at each feeding point in the electrolyzer and irregular furnace bottom. This can easily lead to misjudgment of the internal conditions of the electrolyzer by the control equipment or personnel, resulting in the sending of incorrect control commands and causing the operation of the electrolyzer to deteriorate, thus affecting the electrolysis efficiency of the electrolyzer.

[0003] From a production perspective, current aluminum electrolysis control systems employ open-loop control, only issuing commands for material feeding and anode distance control. They are unclear about whether alumina has actually entered the electrolytic cell or the electrolyte. Controlling the alumina concentration in such a system is like the blind men and the elephant; the result is that electrolytic cells with smooth material feeding have better performance, while those with obstructed feeding have weaker performance. Furthermore, production suffers from uneven current distribution leading to current deviation, furnace bottom sedimentation, hammerhead blockage, and packing adhesion problems. Summary of the Invention

[0004] The purpose of this invention is to solve the problems in the prior art and to propose an aluminum electrolysis material control system based on intelligent shell breaking.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: The aluminum electrolysis material control system based on intelligent shell breaking includes: a main control module and a human-machine interface module; The main control module includes a data acquisition module, which is used to acquire the cell voltage and cell current parameters of the electrolytic cell, and calculate the cell resistance of the electrolytic cell based on the acquired cell voltage and cell current. The aluminum electrolysis production process module is used to calculate the slope, cumulative tilt, needle vibration and oscillation value of the electrolysis cell based on the cell resistance using a first-order substitution filtering algorithm, and to generate aluminum anode lowering command, anode lifting command and feeding cycle conversion command. And the production operation execution module, which is used to control the execution of shell breaking, material feeding, electrode changing, sedimentation treatment and hammerhead blocking actions according to the anode lifting command, the preset shell breaking and material feeding action time, and the shell breaking, material feeding, electrode changing, sedimentation treatment and hammerhead blocking commands sent by the human-machine interface module. The human-computer interaction interface module includes a key scanning subroutine module for acquiring key information; The page display subroutine module is used to view and operate the content displayed on the page, and to generate instructions for shell breaking, material feeding, electrode changing, sedimentation treatment, and hammerhead jamming.

[0006] Furthermore, the data acquisition task module includes the following steps: Step 11: Initialize the pulse input capture interrupt function; Step 12: Periodically collect the cell voltage and cell current pulse count of the electrolytic cell; Step 13: Based on the cell voltage and cell current pulse count obtained in Step 11, calculate the cell voltage and cell current values ​​of the electrolytic cell, then calculate the cell resistance based on the cell voltage and cell current values, and then return to the previous step.

[0007] Furthermore, the aluminum electrolysis production process module includes the following steps: Step 21: Initialize parameters; Step 22: If the preset task suspension time is met, proceed to the next step; Step 23: If the delay time is not greater than 500ms, perform a first-order substitution filter calculation on the acquisition task module to obtain the filter resistance, and determine whether the acquisition task module obtains the slot voltage greater than the preset voltage. If yes, record the effect and send an automatic effect extinguishing command, and then return to step 22. Otherwise, directly return to step 22. If the delay time is not greater than 500ms, proceed to the next step. Step 24: If the delay time is not greater than 2s, perform a first-order substitution filter calculation on the filter resistor to obtain the smoothing resistor, and then return to step 22. If the delay time is not greater than 2s, proceed to the next step. Step 25: If the delay time is no more than 10s, calculate the slope, cumulative tilt, needle vibration and oscillation value of the electrolytic cell based on the cell resistance, filter resistance and smoothing resistance, and determine whether aluminum is being tapped. If so, generate an aluminum tapping anode drop command based on the slope and cumulative tilt of the electrolytic cell, and return to step 22. Otherwise, return directly to step 22. If the delay time is not greater than 10s, proceed to the next step. Step 26: If the delay time is not greater than 30s, generate an anode lifting command based on the filter resistor and smoothing resistor, generate a feeding cycle conversion command based on the slope and cumulative slope of the electrolytic cell, and then return to step 22. Otherwise, directly return to step 22.

[0008] Furthermore, the production operation execution module includes the following steps: Step 31: Hardware and parameter initialization; Step 32: If the preset task suspension time is met, proceed to the next step; Step 33: If the preset shell-breaking and unloading action time is reached, the intelligent cylinder control module controls the cylinder to drive the shell-breaking hammer to perform the shell-breaking action. If the shell-breaking action is completed, the shell-breaking action ends, the unloading action is performed, and then the process returns to step 32. Otherwise, the process returns directly to step 32. If the preset shell-breaking and unloading action time is not reached, the process proceeds to the next step. Step 34: Determine whether an anode lifting command has been received. If received, execute the anode lifting command and return to step 32. If not received, proceed to the next step. Step 35: Determine whether shelling and unloading instructions have been received. If received, execute the shelling action, then execute the unloading action. After the unloading action is completed, return to step 32. If not received, proceed to the next step. Step 36: Determine if a pole-switching operation instruction has been received. If received, execute the pole-switching operation and return to step 32. If not received, proceed to the next step. Step 37: Determine if a settlement treatment instruction has been received. If received, execute the settlement treatment and return to step 32. If not received, proceed to the next step. Step 38: Determine if a hammer head jamming handling instruction has been received. If received, execute the hammer head jamming handling and return to step 32. If not received, return directly to step 32.

[0009] Furthermore, the specific steps of the intelligent cylinder control module controlling the cylinder to drive the shell-breaking hammer to perform the shell-breaking action include: Step 331: Set the shell-breaking action time and the number of inspections, then proceed to the next step; Step 332: If the set number of inspections is reached, the cylinder action time will be set according to the cylinder check blockage time set inside the control machine to perform the shell breaking operation, and then proceed to the next step. If the set number of inspections is not reached, the shell breaking operation will be performed according to the set shell breaking action time, and then proceed to the next step. Step 333: If the cylinder upper limit switch signal is detected, the inspection count is reset to zero. When the inspection count is less than the set inspection count, the fault information is cleared. If the cylinder upper limit switch signal is not detected, the inspection count is incremented by 1, and then proceed to the next step. Step 334: If the number of inspections equals the set number of inspections, the cylinder presses down, stops the material once, increments the number of inspections by 1, and then proceeds to the next step. Step 335: If the number of inspections exceeds the set number of inspections, the shelling action time will be executed according to the internally set shelling action time, and the number of inspections will not be cleared. At the same time, a cylinder fault audible and visual signal will be issued, and then return to step 332. If the cylinder upper limit switch signal is detected, the number of inspections will be cleared, and then return to step 332.

[0010] Furthermore, the page display subroutine module includes: an electrolytic cell operating status parameter interface, used to display the electrolytic cell voltage, cell current, cell number, 24-hour feed rate, guided aluminum output, operation information, and fault information; The production control parameter interface is used to display commonly used parameters in aluminum electrolysis production; The pole-switching processing model is used to select the pole-switching position and send it to the main control board flag bit, so that the main control board generates a pole-switching processing command. The precipitation treatment model is used to select the precipitation location and precipitation status and send them to the main control board flag, so that the main control board generates precipitation treatment instructions; The shell-breaking cylinder depth setting model is used to set the stroke of the shell-breaking cylinder when it is working. The main control board generates shell-breaking and unloading instructions based on the set stroke of the shell-breaking cylinder when it is working. The hammerhead jamming setting model is used to determine the location where the hammerhead jams and send it to the main control board, so that the main control board generates a hammerhead jamming command.

[0011] Furthermore, the specific steps of the polarization processing model in selecting the polarization position and sending it to the main control board flag include: Step 41: Select the polarity change selection interface by touching the upper or lower parameter button; Step 42: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the pole switching position selection function, then touch the butterfly valve open or butterfly valve close button to select the desired pole switching point location and use it as the setting point. Step 43: After selecting the setting point, press and hold the manual button until the setting point turns green, then press the pole switching button until the setting point turns red, and send the selected pole switching position to the main control board flag.

[0012] Furthermore, the specific steps of the precipitation treatment model in selecting the precipitation location and precipitation status and sending them to the main control board flag include: Step 51: Touch the up button or down button of the parameters to select the sedimentation treatment interface; Step 52: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the sedimentation treatment and sedimentation degree selection function. Touch the butterfly valve open or butterfly valve close button to select the desired sedimentation treatment and sedimentation degree location, and use it as the setting point. Step 53: After selecting the setting point, press and hold the Yangjiang button until the setting point turns green, then press the processing button below until the setting point turns red. Select the sedimentation location and sedimentation status and send it to the main control board flag.

[0013] Furthermore, the specific steps for setting the stroke of the shell-breaking cylinder during operation using the shell-breaking cylinder depth setting model include: Step 61: Use the up or down button to select the shelling depth setting interface; Step 62: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the shell-breaking cylinder depth setting function. Touch the butterfly valve open or butterfly valve close button to select the location of the depth point to be modified, and use it as the setting point. Step 63: After selecting the setting point, press the anode rise or anode fall button to select the parameter to modify, then press and hold the manual button until the setting point turns red, then the stroke of the shell-opening cylinder is set.

[0014] Furthermore, the specific steps for determining the location of hammerhead jamming using the hammerhead jamming setting model include: Step 71: Use the up or down button on the touch parameter to select the hammer head processing selection interface; Step 72: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the shell head jamming position selection function, touch the butterfly valve open or butterfly valve close button to select the desired hammer head jamming point location, and use it as the setting point; Step 73: After selecting the setting point, press and hold the manual button until the setting point turns red, then the location where the hammer head is stuck has been confirmed.

[0015] Compared with existing technologies, the advantages of this invention are: 1. This invention integrates a task acquisition module, an aluminum electrolysis production process module, a production operation execution module, and a human-machine interface module with an intelligent cylinder to realize a single-point closed-loop feeding control system. This intelligent shell-breaking and feeding system features single-point shell breaking, feeding, and controllable shell breaking depth during electrolytic cell processing. It not only ensures that alumina or fluoride is evenly delivered to the appropriate position in the electrolyte to accelerate its dissolution, but also extends the service life of the shell-breaking cylinder and hammer. The entire system improves the level of intelligent aluminum electrolysis production, increases electrolysis efficiency, and saves costs.

[0016] 2. The present invention also collects the intelligent cylinder stroke pulse signal through the intelligent cylinder control module and converts it into cylinder stroke to control the intelligent operation of the cylinder. For example, it immediately retracts after the shell is in place, and continues to press the shell if the shell is not in place, so as to ensure that the shell surface is opened while reducing the sticking of the hammer head. Attached Figure Description

[0017] Figure 1 The flowchart of the main control board of the main control module in the aluminum electrolysis material control system based on intelligent shell breaking proposed in this invention is shown.

[0018] Figure 2 The present invention presents a flowchart of the data acquisition task module of the aluminum electrolysis material control system based on intelligent shell breaking.

[0019] Figure 3 The flowchart of the aluminum electrolysis production process algorithm task program in the aluminum electrolysis production process module of the aluminum electrolysis material control system based on intelligent shelling proposed in this invention is shown.

[0020] Figure 4 The present invention provides a flowchart of the production operation execution program for the production operation execution module of the aluminum electrolysis material control system based on intelligent shell forming.

[0021] Figure 5 The present invention presents a flowchart of the intelligent cylinder control module in the intelligent cylinder control module of the aluminum electrolysis material control system based on intelligent shell breaking.

[0022] Figure 6 The main program flow of the human-machine interaction program in the human-machine interaction interface module of the aluminum electrolysis material control system based on intelligent shell breaking proposed in this invention.

[0023] Figure 7 The present invention proposes a flowchart of the page display and key scanning process in the key scanning subroutine module and the page display subroutine module of the aluminum electrolysis material control system based on intelligent shelling.

[0024] Figure 8 The flowchart of the electrode switching interface program in the electrode switching processing model of the aluminum electrolysis material control system based on intelligent shell breaking proposed in this invention.

[0025] Figure 9 This invention proposes a precipitation treatment interface program flow in the precipitation treatment model of an aluminum electrolysis material control system based on intelligent shell breaking.

[0026] Figure 10 The flowchart of the interface program for setting the shelling depth of the cylinder in the precipitation treatment model of the aluminum electrolysis material control system based on intelligent shelling proposed in this invention is shown.

[0027] Figure 11 The flowchart of the hammerhead jamming setting interface program in the hammerhead jamming setting model of the aluminum electrolysis material control system based on intelligent shell breaking proposed in this invention. Detailed Implementation

[0028] The invention will now be further explained with reference to the accompanying drawings.

[0029] This invention provides an aluminum electrolysis material control system based on intelligent shell breaking, comprising: a main control module and a human-machine interface module.

[0030] The main control module includes a data acquisition module, which is used to acquire the cell voltage and cell current parameters of the electrolytic cell, and calculate the cell resistance based on the acquired cell voltage and cell current.

[0031] The aluminum electrolysis production process module is used to calculate the slope, cumulative tilt, needle vibration, and oscillation value of the electrolysis cell based on the cell resistance using a first-order substitution filtering algorithm, and to generate aluminum anode lowering instructions, anode lifting instructions, and feeding cycle conversion instructions.

[0032] The production operation execution module is used to control and execute shell-breaking, material feeding, electrode replacement, sedimentation treatment, and hammerhead blocking actions based on the anode lifting command, the preset shell-breaking and material feeding action time, and the shell-breaking, material feeding, electrode replacement, sedimentation treatment, and hammerhead blocking commands sent by the human-machine interface module.

[0033] The human-computer interaction interface module includes a key scanning subroutine module, which is used to obtain key information.

[0034] The page display subroutine module is used to view and operate the content displayed on the page, and to generate instructions for shell breaking, material feeding, electrode changing, sedimentation treatment, and hammerhead jamming.

[0035] like Figure 1 As shown, in order to improve CPU operating efficiency and program stability, the main control module's motherboard control program adopts the FreeRTOS operating system. First, the operating system and various functional peripherals are initialized. Tasks for each functional module are created using different priorities and time slices, including VF acquisition tasks, production operation execution tasks, aluminum electrolysis process algorithm tasks, serial communication tasks, and industrial Ethernet communication tasks. Timers and the operating system are started, and the running status of each task is dynamically monitored. In addition, the hardware watchdog circuit is enabled to monitor the program's running status in real time. If an error occurs, the program is reset and restarted to ensure reliable operation of the program in harsh production environments.

[0036] like Figure 2As shown, the acquisition task module executes once every 500ms. First, it initializes the pulse input capture interrupt function, periodically acquires the number of pulses of the cell voltage and cell current of the electrolytic cell, calculates the values ​​of the cell voltage and cell current of the electrolytic cell, and calculates the cell resistance based on the cell voltage and cell current.

[0037] like Figure 3 As shown, the aluminum electrolysis production process algorithm task is executed every 500ms, and the process algorithm task is divided into 500ms subroutines, 2s subroutines, 10s subroutines, and 30s subroutines. In the 500ms subroutines, the cell voltage calculated by the VF task is used to determine if an effect is detected. If an effect occurs, it is recorded and related automatic effect extinguishing operations are performed. Then, the cell resistance calculated by the VF task is subjected to a first-order substitution filter to obtain the filter resistance. In the 2s subroutines, a second first-order substitution filter is performed on the filtered electrolysis to calculate the smoothing resistance. Within the 10-second subroutine, the slope and cumulative slope of the electrolytic cell concentration change trend are calculated based on the cell resistance, filter resistance, and smoothing resistance, respectively. The needle vibration and oscillation values ​​of the electrolytic cell stability are judged to realize the automatic anode action judgment for aluminum output and send the anode action command. The 30-second subroutine performs a preliminary analysis of anode adjustment based on the filter resistance, sends the anode increase or decrease command, and analyzes the electrolytic cell concentration based on the slope and cumulative slope. It controls the switching operations of normal cycle, under-load cycle, over-load cycle, and automatic stop during the electrolytic cell feeding process to achieve the equilibrium of alumina concentration in the electrolytic cell.

[0038] The specific steps include the following: Step 21: Initialize parameters; Step 22: If the preset task suspension time is met, proceed to the next step; Step 23: If the delay time is not greater than 500ms, perform a first-order substitution filter calculation on the acquisition task module to obtain the filter resistance, and determine whether the acquisition task module obtains the slot voltage greater than the preset voltage. If yes, record the effect and send an automatic effect extinguishing command, and then return to step 22. Otherwise, directly return to step 22. If the delay time is not greater than 500ms, proceed to the next step. Step 24: If the delay time is not greater than 2s, perform a first-order substitution filter calculation on the filter resistor to obtain the smoothing resistor, and then return to step 22. If the delay time is not greater than 2s, proceed to the next step. Step 25: If the delay time is no more than 10s, calculate the slope, cumulative tilt, needle vibration and oscillation value of the electrolytic cell based on the cell resistance, filter resistance and smoothing resistance, and determine whether aluminum is being tapped. If so, generate an aluminum tapping anode drop command based on the slope and cumulative tilt of the electrolytic cell, and return to step 22. Otherwise, return directly to step 22. If the delay time is not greater than 10s, proceed to the next step. Step 26: If the delay time is not greater than 30s, generate an anode lifting command based on the filter resistor and smoothing resistor, generate a feeding cycle conversion command based on the slope and cumulative slope of the electrolytic cell, and then return to step 22. Otherwise, directly return to step 22.

[0039] The task suspension time is generally 120 seconds. The task suspension occurs when the electrolytic cell takes effect, and there are no special operations such as aluminum tapping or anode replacement.

[0040] like Figure 4 As shown, the aluminum electrolysis production operation is executed every 100ms. According to the set feeding interval (NB), the shell-breaking and feeding actions are automatically controlled. During the shell-breaking action, the cylinder stroke signal is collected to determine whether the shell-breaking action is completed. If it is not completed, the cylinder is blocked to ensure that the cylinder shell-breaking is completed. The anode lifting command generated in the aluminum electrolysis process algorithm is executed. The operation commands such as shell-breaking, feeding, electrode changing, precipitation treatment, and hammer blocking sent by the human-machine interface are received and executed. The fault status of the intelligent control system is judged through signal feedback.

[0041] The specific steps include the following: Step 31: Hardware and parameter initialization.

[0042] Step 32: If the preset task suspension time is met, proceed to the next step.

[0043] Step 33: If the preset shell-breaking and unloading action time is reached, the intelligent cylinder control module controls the cylinder to drive the shell-breaking hammer to perform the shell-breaking action. If the shell-breaking action is completed, the shell-breaking action ends, the unloading action is performed, and then the process returns to step 32. Otherwise, the process returns directly to step 32. If the preset shell-breaking and unloading action time is not reached, the process proceeds to the next step.

[0044] Step 34: Determine whether an anode lifting command has been received. If received, execute the anode lifting command and return to step 32. If not received, proceed to the next step.

[0045] Step 35: Determine whether shelling and unloading instructions have been received. If received, execute the shelling action, then execute the unloading action. After the unloading action is completed, return to step 32. If not received, proceed to the next step.

[0046] Step 36: Determine if a pole-switching operation instruction has been received. If received, execute the pole-switching operation and return to step 32. If not received, proceed to the next step.

[0047] Step 37: Determine if a settlement treatment instruction has been received. If received, execute the settlement treatment and return to step 32. If not received, proceed to the next step.

[0048] Step 38: Determine if a hammer head jamming handling instruction has been received. If received, execute the hammer head jamming handling and return to step 32. If not received, return directly to step 32.

[0049] During the single-point shell-breaking and feeding control of the electrode change, the controller performs timed increases and decreases in feeding every half hour. After half an hour, an additional voltage of 50mV is added, and after another half hour, the voltage returns to the normal setting. At the same time, the feeding point corresponding to the anode replacement is subject to material control, while other feeding points are adjusted according to normal concentration control. The material control process is as follows: Half an hour after the electrode change begins, feeding is stopped for one hour, or even longer, depending on the actual situation of the electrolytic cell. After one hour of stopping feeding, the feeding point starts feeding at a 60% reduction, and after two hours, feeding is reduced by 30%. After another two hours, processing is carried out with normal feeding to complete the entire electrode change operation.

[0050] Since the electrode switching point can be determined, and based on the non-conductive characteristic of the new electrode after switching, the material quantity can be independently controlled by a single-point shelling and feeding method without affecting the normal shelling and feeding at other points, so as to achieve the purpose of electrode switching. Practice has proven that this electrode switching control method can not only achieve the alumina concentration balance at other feeding points and ensure the stability of the electrolytic cell, but also reduce the additional voltage and time during the electrode switching process and reduce power consumption.

[0051] During sedimentation treatment, the electrolysis worker first checks the sedimentation situation at the bottom of the furnace, determining its location and extent. Using the human-machine interface (HMI) for bottom sedimentation treatment, the worker selects the corresponding feed point and its severity, then touches the processing button to execute the sedimentation treatment. If the sedimentation setting is "small," the feed rate at the corresponding feed point is reduced by 20%, continuing for three hours before returning to normal. If the sedimentation setting is "medium," the feed rate at the corresponding feed point is reduced by 40%, continuing for three hours before reducing by 20%, and returning to normal after three hours. If the sedimentation setting is "large," the feed rate at the corresponding feed point is first stopped for half an hour, then reduced by 60%, continuing for two hours before reducing by 40%, continuing for three hours before reducing by 20%, and returning to normal after three hours. This method ensures that the bottom sediment is gradually consumed while maintaining stable cell conditions, with minimal impact on the electrolysis efficiency of the electrolytic cell.

[0052] like Figure 5As shown, the intelligent cylinder control module sets the single-point shell-breaking action time and inspection count through the intelligent cylinder interface. When the tank control machine determines that a shell-breaking and unloading operation is required based on the on-site process control program, it sends a shell-breaking cylinder control signal, and the cylinder begins the shell-breaking action. Before the inspection count is reached, the shell-breaking action is completed according to the single-point shell-breaking time set on the LCD interface. Simultaneously, the upper limit switch signal is collected during the shell-breaking process. If the upper limit switch is collected during the shell-breaking process (the corresponding point MOS has an output), it indicates that the cylinder has reached the correct position, and the inspection count is cleared. If the upper limit switch signal is not collected, the inspection count is incremented by 1. When the inspection count reaches the set inspection count, the cylinder action time is adjusted according to the cylinder check. The slot control machine uses a pre-set cylinder check time (over 6 seconds) to perform the shell-breaking operation. If no upper limit switch signal is detected within 6 seconds, it indicates a blockage. The machine will handle this automatically, but the cylinder will not retract, and material will be stopped at that point until the next shell-breaking operation (during which the cylinder remains in the shell-pressing stage). Only when the machine detects the cylinder's upper limit signal does it indicate the blockage has been resolved, the inspection count is reset to zero, and material feeding resumes, entering the next inspection cycle. If the upper limit signal is still not detected during this process, the cylinder retracts, the self-handling of the blockage fails, a voice alarm is broadcast, the cylinder fault indicator illuminates, and material feeding resumes. Until the blockage is resolved, the inspection count is not reset to zero, and each shell-breaking operation is performed according to the internally set shell-breaking time. The fault persists until the blockage is resolved, the inspection count is reset to zero, the fault is cleared, and the inspection count is recalculated.

[0053] like Figure 6 As shown, in the human-machine interface module, the main program first initializes the parameters and obtains the button information, then enters the relevant page display subroutine. In the page display subroutine, the relevant parameters are set and the relevant production operations are enabled. The serial communication program sends the relevant setting parameters and receives the data from the main controller. The data is then displayed in the relevant display interface program in the display subroutine. Finally, a software watchdog protection program is designed to monitor the stability of the program. If an error occurs, the software watchdog is reset to make the CPU run again.

[0054] like Figure 7As shown, the human-machine interface module includes a key scanning subroutine module and a page display subroutine module. Both the page display and key scanning subroutines execute every 100ms. The key scanning subroutine module obtains key information, while the page display subroutine module is used to view and operate the displayed content. The page display subroutine module consists of an electrolytic cell operating status parameter interface, a production control parameter interface, an electrode switching treatment model, a precipitation treatment model, a shell-breaking cylinder depth setting model, and a hammerhead jamming setting model. The cell voltage operating status parameter interface displays the electrolytic cell voltage, cell current, cell number, and 24... The system includes information on hourly feed rate, aluminum output guidance, operation information, and fault information. The production control parameter interface displays 26 commonly used parameters in production, such as setting NB interval, setting voltage, target voltage, fluoride salt interval, needle vibration, and oscillation. The anode replacement processing model is used to select the anode position to be replaced and send it to the main control board flag. The precipitation processing model is used to select the precipitation position and precipitation status and send it to the main control board flag. The shell-breaking cylinder depth setting model is used to set the stroke of the shell-breaking cylinder during operation. The hammer head jamming operation setting model is used to determine the position of the hammer head to be processed and send it to the main control board.

[0055] The interface for the operating status parameters of the electrolytic cell is shown in Table 1 below:

[0056] Table 1 The production control parameter interface is shown in Table 2:

[0057] Table 2 like Figure 8 As shown, in the pole-switching processing model, the pole-switching selection interface is accessed by touching the parameter up or parameter down button. On this interface, simultaneously press and hold the butterfly valve open and butterfly valve close buttons (for approximately 5 seconds). The first setting point will then begin flashing, indicating entry into the pole-switching position selection function. Touch the butterfly valve open or butterfly valve close button to select the location of the pole-switching point. When a setting point is selected, press and hold the manual button until the text color turns green. When it is green, confirm the selection is correct. If the pole-switching button is pressed correctly, the selected pole-switching point will change from green to red, indicating successful setting and pole-switching processing. Pressing and holding the manual or timer reset buttons will cancel the pole-switching.

[0058] like Figure 9As shown, in the sedimentation treatment model, the sedimentation treatment interface is selected by touching the parameter up button or parameter down button. On this interface, simultaneously press and hold the butterfly valve open and butterfly valve close buttons (for approximately 5 seconds). The first setting point will then begin flashing, entering the function to select the location for sedimentation treatment and the degree of sedimentation. Touch the butterfly valve open or butterfly valve close button to select the location for sedimentation treatment and the desired degree of sedimentation. When a setting point is selected, press and hold the anode descending button until the text color turns green. When it is green, confirm the selection is correct. If correct, press the processing button below. When the selected polarity point changes from green to red, the setting is successful, and polarity switching treatment will begin. Pressing and holding the anode rising and timer reset buttons will cancel the sedimentation treatment operation.

[0059] like Figure 10 As shown, the shell-breaking cylinder depth setting model can be accessed by touching the parameter up button or parameter down button to select the shell-breaking depth setting interface. In this interface, press and hold the butterfly valve open and butterfly valve close buttons simultaneously (for about 5 seconds). The first setting point will turn white, entering the depth setting function. Touch the butterfly valve open button to select the location of the depth point to be modified. When the setting point is selected, press the anode up or anode down button. The corresponding value (the depth point corresponding to the white text) will increase or decrease. After successful setting, press and hold the manual button to confirm. The text will change from white to red, indicating successful modification. If no modification is needed, touch the timer reset button.

[0060] like Figure 11 As shown, the hammerhead jamming setting model allows you to select the hammerhead processing selection interface by touching the parameter up or parameter down button. On this interface, simultaneously press and hold the butterfly valve open and butterfly valve close buttons (for approximately 5 seconds). The first setting point will then flash, indicating the entry point for selecting the desired hammerhead jamming location. Touch the butterfly valve open or butterfly valve close button to select the desired hammerhead jamming point. Once a setting point is selected, press and hold the manual button until the text turns red, indicating successful setting and initiating hammerhead jamming processing. Pressing and holding the timer reset button cancels the hammerhead jamming operation. During hammerhead jamming processing, the hammerhead at that point is locked, and material feeding at that point is stopped for a maximum of 10 minutes. After processing, press and hold the manual button (for 5 seconds) to end the hammerhead locking function.

[0061] This invention acquires the cell voltage and current parameters of the electrolytic cell through a task acquisition module, calculates the cell resistance based on the acquired voltage and current, and uses an aluminum electrolysis production process module to estimate parameters such as the slope, cumulative tilt, needle vibration, and oscillation of the cell resistance after first-order filtering. This allows for the determination of the alumina concentration, electrode spacing, and stability of the electrolytic cell, generating corresponding instructions for the aluminum electrolysis production process module. This enables precise control of the electrolytic cell's shell-breaking, feeding, and anode actions. Simultaneously, it acquires the shell-breaking stroke signal, determines whether the cylinder's shell-breaking action has been completed based on the stroke, automatically handles shell head blockage, and ensures that each feeding is in place, maintaining material balance within the electrolytic cell. The invention also sends relevant electrolytic cell parameters and production control parameters to the human-machine interface module via a serial port, receives operation commands from the human-machine interface, including commands for shell-breaking, feeding, anode lifting, electrode switching, precipitation treatment, and hammer head blockage treatment, and executes the received commands accordingly. In addition, data is transmitted to the host computer via industrial Ethernet or industrial CAN communication so that the host computer can record and analyze the electrolytic cell status, and at the same time realize remote monitoring of the electrolytic cell operation and production management.

[0062] As is known from common technical knowledge, this invention can be implemented through other embodiments that do not depart from its spirit or essential characteristics. Therefore, the disclosed embodiments described above are merely illustrative and not exhaustive. All modifications within the scope of this invention or its equivalents are included in this invention.

Claims

1. An aluminum electrolysis material control system based on intelligent shell-breaking, characterized in that, include: Main control module and human-computer interaction interface module; The main control module includes a data acquisition module, which is used to acquire the cell voltage and cell current parameters of the electrolytic cell, and calculate the cell resistance of the electrolytic cell based on the acquired cell voltage and cell current. The aluminum electrolysis production process module is used to calculate the slope, cumulative tilt, needle vibration and oscillation value of the electrolysis cell based on the cell resistance using a first-order substitution filtering algorithm, and to generate aluminum anode lowering command, anode lifting command and feeding cycle conversion command. And the production operation execution module, which is used to control the execution of shell breaking, material feeding, electrode changing, sedimentation treatment and hammerhead blocking actions according to the anode lifting command, the preset shell breaking and material feeding action time, and the shell breaking, material feeding, electrode changing, sedimentation treatment and hammerhead blocking commands sent by the human-machine interface module. The human-computer interaction interface module includes a key scanning subroutine module for acquiring key information; The page display subroutine module is used to view and operate the content displayed on the page, and to generate instructions for shell breaking, material feeding, electrode changing, sedimentation treatment, and hammerhead jamming.

2. The aluminum electrolysis material control system based on intelligent shell-breaking as described in claim 1, characterized in that, The data acquisition module includes the following steps: Step 11: Initialize the pulse input capture interrupt function; Step 12: Periodically collect the cell voltage and cell current pulse count of the electrolytic cell; Step 13: Based on the cell voltage and cell current pulse count obtained in Step 11, calculate the cell voltage and cell current values ​​of the electrolytic cell, then calculate the cell resistance based on the cell voltage and cell current values, and then return to the previous step.

3. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 1, characterized in that, The aluminum electrolysis production process module includes the following steps: Step 21: Initialize parameters; Step 22: If the preset task suspension time is met, proceed to the next step; Step 23: If the delay time is not greater than 500ms, perform a first-order substitution filter calculation on the acquisition task module to obtain the filter resistance, and determine whether the acquisition task module obtains the slot voltage greater than the preset voltage. If yes, record the effect and send an automatic effect extinguishing command, and then return to step 22. Otherwise, directly return to step 22. If the delay time is not greater than 500ms, proceed to the next step. Step 24: If the delay time is not greater than 2s, perform a first-order substitution filter calculation on the filter resistor to obtain the smoothing resistor, and then return to step 22. If the delay time is not greater than 2s, proceed to the next step. Step 25: If the delay time is no more than 10s, calculate the slope, cumulative tilt, needle vibration and oscillation value of the electrolytic cell based on the cell resistance, filter resistance and smoothing resistance, and determine whether aluminum is being tapped. If so, generate an aluminum tapping anode drop command based on the slope and cumulative tilt of the electrolytic cell, and return to step 22. Otherwise, return directly to step 22. If the delay time is not greater than 10s, proceed to the next step. Step 26: If the delay time is not greater than 30s, generate an anode lifting command based on the filter resistor and smoothing resistor, generate a feeding cycle conversion command based on the slope and cumulative slope of the electrolytic cell, and then return to step 22. Otherwise, directly return to step 22.

4. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 1, characterized in that, The production operation execution module includes the following steps: Step 31: Hardware and parameter initialization; Step 32: If the preset task suspension time is met, proceed to the next step; Step 33: If the preset shell-breaking and unloading action time is reached, the intelligent cylinder control module will drive the shell-breaking hammer to perform the shell-breaking action. If the shell-breaking action is completed, the shell-breaking action will end, the unloading action will be performed, and then return to step 32. Otherwise, return directly to step 32. If the preset shell-breaking and unloading action time is not reached, proceed to the next step. Step 34: Determine whether an anode lifting command has been received. If received, execute the anode lifting command and return to step 32. If not received, proceed to the next step. Step 35: Determine whether shelling and unloading instructions have been received. If received, execute the shelling action, then execute the unloading action. After the unloading action is completed, return to step 32. If not received, proceed to the next step. Step 36: Determine if a pole-switching operation instruction has been received. If received, execute the pole-switching operation and return to step 32. If not received, proceed to the next step. Step 37: Determine if a settlement treatment instruction has been received. If received, execute the settlement treatment and return to step 32. If not received, proceed to the next step. Step 38: Determine if a hammer head jamming handling instruction has been received. If received, execute the hammer head jamming handling and return to step 32. If not received, return directly to step 32.

5. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 4, characterized in that, The intelligent cylinder control module controls the cylinder to drive the shell-breaking hammer to perform the shell-breaking action. The specific steps include: Step 331: Set the shell-breaking action time and the number of inspections, then proceed to the next step; Step 332: If the set number of inspections is reached, the cylinder action time will be set according to the cylinder check blockage time set inside the control machine to perform the shell breaking operation, and then proceed to the next step. If the set number of inspections is not reached, the shell breaking operation will be performed according to the set shell breaking action time, and then proceed to the next step. Step 333: If the cylinder upper limit switch signal is detected, the inspection count is reset to zero. When the inspection count is less than the set inspection count, the fault information is cleared. If the cylinder upper limit switch signal is not detected, the inspection count is incremented by 1, and then proceed to the next step. Step 334: If the number of inspections equals the set number of inspections, the cylinder presses down, stops the material once, increments the number of inspections by 1, and then proceeds to the next step. Step 335: If the number of inspections exceeds the set number of inspections, the shelling action time will be executed according to the internally set shelling action time, and the number of inspections will not be cleared. At the same time, a cylinder fault audible and visual signal will be issued, and then return to step 332. If the cylinder upper limit switch signal is detected, the number of inspections will be cleared, and then return to step 332.

6. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 1, characterized in that, The page display subroutine module includes: an electrolytic cell operating status parameter interface, used to display the electrolytic cell voltage, cell current, cell number, 24-hour feed rate, aluminum output guide, operation information, and fault information; The production control parameter interface is used to display commonly used parameters in aluminum electrolysis production; The pole-switching processing model is used to select the pole-switching position and send it to the main control board flag bit, so that the main control board generates a pole-switching processing command. The precipitation treatment model is used to select the precipitation location and precipitation status and send them to the main control board flag, so that the main control board generates precipitation treatment instructions; The shell-breaking cylinder depth setting model is used to set the stroke of the shell-breaking cylinder when it is working. The main control board generates shell-breaking and unloading instructions based on the set stroke of the shell-breaking cylinder when it is working. The hammerhead jamming setting model is used to determine the location where the hammerhead jams and send it to the main control board, so that the main control board generates a hammerhead jamming command.

7. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 6, characterized in that, The specific steps for the polarization processing model to select the polarization position and send it to the main control board flag include: Step 41: Select the polarity change selection interface by touching the upper or lower parameter button; Step 42: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the pole switching position selection function, then touch the butterfly valve open or butterfly valve close button to select the desired pole switching point location and use it as the setting point. Step 43: After selecting the setting point, press and hold the manual button until the setting point turns green, then press the pole switching button until the setting point turns red, and send the selected pole switching position to the main control board flag.

8. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 6, characterized in that, The specific steps for the precipitation treatment model to select the precipitation location and precipitation status and send them to the main control board flag include: Step 51: Touch the up button or down button of the parameters to select the sedimentation treatment interface; Step 52: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the sedimentation treatment and sedimentation degree selection function. Touch the butterfly valve open or butterfly valve close button to select the desired sedimentation treatment and sedimentation degree location, and use it as the setting point. Step 53: After selecting the setting point, press and hold the Yangjiang button until the setting point turns green, then press the processing button below until the setting point turns red. Select the sedimentation location and sedimentation status and send it to the main control board flag.

9. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 6, characterized in that, The specific steps for setting the stroke of the shell-breaking cylinder during operation using the shell-breaking cylinder depth setting model include: Step 61: Use the up or down button to select the shelling depth setting interface; Step 62: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the shell-breaking cylinder depth setting function. Touch the butterfly valve open or butterfly valve close button to select the location of the depth point to be modified, and use it as the setting point. Step 63: After selecting the setting point, press the anode rise or anode fall button to select the parameter to modify, then press and hold the manual button until the setting point turns red, then the stroke of the shell-opening cylinder is set.

10. The aluminum electrolysis material control system based on intelligent shell-breaking according to claim 6, characterized in that, The specific steps for determining the location of hammerhead jamming using the hammerhead jamming setting model include: Step 71: Use the up or down button on the touch parameter to select the hammer head processing selection interface; Step 72: Press and hold the butterfly valve open and butterfly valve close buttons simultaneously to enter the shell head jamming position selection function, touch the butterfly valve open or butterfly valve close button to select the desired hammer head jamming point location, and use it as the setting point; Step 73: After selecting the setting point, press and hold the manual button until the setting point turns red, then the location where the hammer head is stuck has been confirmed.

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