Early warning method for abnormal inter-electrode distance in aluminum discharge stage of aluminum electrolysis cell

Abstract

The invention belongs to the technical field of aluminum electrolysis production, and particularly provides an early warning method for abnormal electrode spacing in the aluminum discharge stage of an aluminum electrolysis cell, and the method comprises the following steps: obtaining set parameters, operation parameters and anode action parameters of the aluminum electrolysis cell; determining a real-time resistance sequence of the aluminum electrolysis cell based on the operation parameters; a resistance reference value is determined based on the set parameters, and whether the inter-electrode distance is abnormal or not is judged based on the resistance reference value, the real-time resistance sequence and the anode action parameters; if it is judged that the inter-electrode distance is abnormal, the abnormal level of the inter-electrode distance is judged based on the resistance reference value, the real-time resistance sequence and the anode action parameters, and a corresponding early warning signal is sent out based on the abnormal level. According to the technical scheme provided by the invention, the accuracy of early warning of the abnormal inter-electrode distance in the aluminum discharge stage of the aluminum electrolysis cell can be improved.

Description

Technical Field

[0001] This application belongs to the field of aluminum electrolysis production technology, and in particular relates to an early warning method for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell. Background Technology

[0002] Aluminum electrolysis is the core production process of aluminum smelting, and the aluminum tapping operation, as a crucial link, directly determines the continuity and stability of electrolysis production. During electrolysis, molten aluminum continuously accumulates at the bottom of the electrolytic cell and needs to be periodically extracted and transported to downstream processing. Prebaked cells typically require a large-scale aluminum tapping operation once a day. During the tapping operation, as the molten aluminum is extracted, the electrolyte interface gradually decreases. The cell control box needs to adjust the anode in real time according to voltage changes to maintain stable operating voltage and ensure the safe operation of the electrolytic cell. However, the existing aluminum tapping process lacks electrode spacing monitoring methods, making it impossible to accurately detect and warn of abnormal electrode spacing during the aluminum tapping stage of the aluminum electrolytic cell. When the anode action does not follow the set cycle and threshold to adjust according to the target voltage, it can easily cause the anode to detach from the electrolyte, potentially leading to major safety accidents such as explosions. Therefore, improving the accuracy of the early warning of abnormal electrode spacing during the aluminum tapping stage of the aluminum electrolytic cell is an urgent technical problem to be solved. Summary of the Invention

[0003] The embodiments of this application provide a method, device, program product, readable storage medium, and electronic device for early warning of abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell, thereby improving the accuracy of early warning of abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell.

[0004] Other features and advantages of this application will become apparent from the following detailed description, or may be learned in part from practice of this application.

[0005] According to a first aspect of the embodiments of this application, a method for early warning of abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell is provided. The method comprises: acquiring setting parameters, operating parameters, and anode action parameters of the aluminum electrolysis cell; the setting parameters including a setting voltage and a setting current of the aluminum electrolysis cell; the operating parameters including the operating voltage and operating current during the operation of the aluminum electrolysis cell; and the anode action parameters including the descent contactor status parameters and the cumulative anode descent time of the aluminum electrolysis cell; determining a real-time resistance sequence of the aluminum electrolysis cell based on the operating parameters; determining a resistance reference value based on the setting parameters; and determining whether there is an abnormality in the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters; if an abnormality is determined in the electrode spacing, determining the abnormality level of the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters, and issuing a corresponding early warning signal based on the abnormality level.

[0006] In some embodiments of this application, based on the foregoing scheme, before obtaining the setting parameters, operating parameters and anode action parameters of the aluminum electrolytic cell, the method further includes: real-time monitoring of the operating status of each aluminum electrolytic cell; if the operating status of each aluminum electrolytic cell is aluminum output, then triggering an abnormal detection action of the electrode spacing of each aluminum electrolytic cell.

[0007] In some embodiments of this application, based on the foregoing scheme, determining the real-time resistance sequence of the aluminum electrolytic cell based on the operating parameters includes: determining the real-time resistance value of the aluminum electrolytic cell based on the operating voltage and the operating current; collecting the real-time resistance value of the aluminum electrolytic cell according to a preset time window length and a preset acquisition frequency to obtain an initial resistance sequence; and filtering the initial resistance sequence according to a preset time granularity to obtain a real-time resistance sequence.

[0008] In some embodiments of this application, based on the foregoing scheme, determining whether the electrode spacing is abnormal based on the resistance reference value, the real-time resistance sequence, and the anode action parameters includes: determining whether the resistance of the aluminum electrolytic cell is abnormal based on the resistance reference value and the real-time resistance sequence; if the resistance of the aluminum electrolytic cell is abnormal, determining whether the aluminum electrolytic cell has an anode reduction action based on the anode action parameters; if the aluminum electrolytic cell does not have an anode reduction action, determining that the electrode spacing is abnormal; if the aluminum electrolytic cell has an anode reduction action and the real-time resistance of the aluminum electrolytic cell does not decrease, determining that the electrode spacing is abnormal.

[0009] In some embodiments of this application, based on the foregoing scheme, determining whether the resistance of the aluminum electrolytic cell is abnormal based on the resistance reference value and the real-time resistance sequence includes: performing a first-order backward difference on the real-time resistance sequence to determine the instantaneous slope sequence of the real-time resistance sequence; if any subsequence in the instantaneous slope sequence is an increasing sequence, and the number of instantaneous slopes in any subsequence is greater than or equal to a first preset number, then the resistance of the aluminum electrolytic cell is determined to be abnormal; determining the deviation rate between each real-time resistance in the real-time resistance sequence and the resistance reference value; if there is a deviation rate greater than a first preset deviation rate threshold among the deviation rates corresponding to each real-time resistance, then the resistance of the aluminum electrolytic cell is determined to be abnormal.

[0010] In some embodiments of this application, based on the aforementioned scheme, determining whether the aluminum electrolytic cell has anode-lowering action based on the anode action parameters includes: if the state parameter of the lowering contactor is 1, or the cumulative anode lowering time continues to increase, then it is determined that the aluminum electrolytic cell has anode-lowering action; if the state parameter of the lowering contactor is 0, then it is determined that the aluminum electrolytic cell does not have anode-lowering action.

[0011] In some embodiments of this application, based on the foregoing scheme, the step of determining the anomaly level of the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters, and issuing a corresponding early warning signal based on the anomaly level, includes: if there is a deviation rate greater than a first preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the first preset deviation rate threshold is greater than a second preset number, and the aluminum electrolysis cell does not have an anode reduction action, then the anomaly level of the electrode spacing is determined to be a Level 1 anomaly, and a Level 1 early warning signal of the first category is issued; if there is a deviation rate greater than a second preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the second preset deviation rate threshold is greater than a third preset number, If the aluminum electrolytic cell does not have an anode reduction action, then the abnormality level of the electrode spacing is determined to be a level two abnormality, and a level two warning signal of the first category is issued. The second preset deviation rate threshold is greater than the first preset deviation rate threshold, and the severity of the level two abnormality is greater than the severity of the level one abnormality. If there is a deviation rate greater than the third preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the third preset deviation rate threshold is greater than the fourth preset number, and the aluminum electrolytic cell does not have an anode reduction action, then the abnormality level of the electrode spacing is determined to be a level three abnormality, and a level three warning signal of the first category is issued. The third preset deviation rate threshold is greater than the second preset deviation rate threshold, and the severity of the level three abnormality is greater than the severity of the level two abnormality.

[0012] In some embodiments of this application, based on the foregoing scheme, the method further includes: if there is a deviation rate greater than a first preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the first preset deviation rate threshold is greater than a second preset number, and the aluminum electrolytic cell is undergoing anode reduction action, then the abnormality level of the electrode spacing is determined to be a level one abnormality, and a level one warning signal of the second category is issued; if there is a deviation rate greater than a second preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the second preset deviation rate threshold is greater than a third preset number, and the aluminum electrolytic cell is undergoing anode reduction action. If the action is detected, the abnormality level of the electrode spacing is determined to be Level 2 abnormality, and a Level 2 warning signal of the second category is issued; if there is a deviation rate greater than a third preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the third preset deviation rate threshold is greater than a fourth preset number, and the aluminum electrolysis cell is performing anode reduction action, then the abnormality level of the electrode spacing is determined to be Level 3 abnormality, and a Level 3 warning signal of the second category is issued; if the instantaneous slope in the instantaneous slope sequence is positive, and the aluminum electrolysis cell is performing anode reduction action, then the abnormality level of the electrode spacing is determined to be Level 3 abnormality, and a Level 3 warning signal of the third category is issued.

[0013] According to a second aspect of the embodiments of this application, an early warning device for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell is provided. The device comprises: an acquisition unit, configured to acquire setting parameters, operating parameters, and anode action parameters of the aluminum electrolysis cell; the setting parameters include a setting voltage and a setting current of the aluminum electrolysis cell; the operating parameters include the operating voltage and operating current during the operation of the aluminum electrolysis cell; and the anode action parameters include the descent contactor status parameters and the cumulative anode descent time of the aluminum electrolysis cell; a determination unit, configured to determine a real-time resistance sequence of the aluminum electrolysis cell based on the operating parameters; a judgment unit, configured to determine a resistance reference value based on the setting parameters, and to determine whether an abnormality exists in the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters; and an early warning unit, configured to, if an abnormality is determined in the electrode spacing, determine the abnormality level of the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters, and issue a corresponding early warning signal based on the abnormality level.

[0014] According to a third aspect of the embodiments of this application, a computer program product is provided, the computer program product including computer instructions stored in a computer-readable storage medium and adapted to be read and executed by a processor to cause a computer device having the processor to perform an operation as described in any of the embodiments of the first aspect above.

[0015] According to a fourth aspect of the embodiments of this application, a computer-readable storage medium is provided, the computer-readable storage medium storing at least one computer program instruction, the at least one computer program instruction being loaded and executed by a processor to perform the operation performed by the method described in any of the embodiments of the first aspect above.

[0016] According to a fifth aspect of the present application, an electronic device is provided, the electronic device including one or more processors and one or more memories, the one or more memories storing at least one computer program instruction, the at least one computer program instruction being loaded and executed by the one or more processors to perform the operation performed by the method as described in any of the first aspect embodiments above.

[0017] Based on the technical solution proposed in this application, by simultaneously collecting three types of data—setting parameters, operating parameters, and anode action parameters—it can cover not only benchmark data reflecting the standard state but also dynamic data reflecting actual operation and feedback data reflecting anode adjustment actions. This allows multi-dimensional data to complement each other, thus comprehensively covering various scenarios of inter-electrode spacing anomalies and avoiding accidents caused by missed inter-electrode spacing anomalies due to missing data. At the same time, using real-time resistance sequence as the core analysis indicator, based on the physical correlation between resistance and inter-electrode spacing, it can more accurately capture subtle changes and trend fluctuations in inter-electrode spacing compared to other indirect indicators. This reduces the interference of non-correlated factors such as short-term voltage fluctuations on anomaly judgment and improves the accuracy of anomaly identification.

[0018] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0019] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort. In the drawings:

[0020] Figure 1 A flowchart of an early warning method for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell, according to one embodiment of this application, is shown. Figure 2 A block diagram of an early warning device for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell, according to one embodiment of this application, is shown. Figure 3 A schematic diagram of the structure of an electronic device according to one embodiment of this application is shown. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0023] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0024] The flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily have to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.

[0025] It should also be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such uses of these terms can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described.

[0026] Aluminum electrolysis is the core production process of aluminum smelting, and the aluminum tapping operation, as a key link, directly determines the continuity and stability of electrolysis production. During electrolysis, molten aluminum continuously accumulates at the bottom of the electrolytic cell and needs to be periodically extracted and transported to downstream processing. Prebaked cells typically require a large-scale aluminum tapping operation once a day. During the tapping operation, as the molten aluminum is extracted, the electrolyte interface gradually decreases. The cell control box needs to lower the anode in real time according to voltage changes to maintain stable operating voltage and ensure the safe operation of the electrolytic cell. However, existing aluminum tapping processes lack electrode spacing monitoring methods, making it impossible to accurately detect and warn of abnormal electrode spacing during the aluminum tapping stage of the aluminum electrolytic cell. When the anode action does not follow the target voltage adjustment according to the set cycle and threshold, it is very easy to cause the anode to detach from the electrolyte, which can lead to major safety accidents such as explosions. Based on this, this application proposes an early warning method for abnormal electrode spacing during the aluminum tapping stage of the aluminum electrolytic cell to improve the accuracy of the early warning for abnormal electrode spacing during the aluminum tapping stage of the aluminum electrolytic cell.

[0027] Next, we will combine Figure 1This application provides a detailed description of the early warning method for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell.

[0028] See Figure 1 The flowchart illustrates a method for early warning of abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell, as shown in one embodiment of this application. Figure 1 As shown, the method may include at least the following steps 110 to 140: Step 110: Obtain the setting parameters, operating parameters, and anode action parameters of the aluminum electrolytic cell. The setting parameters include the setting voltage and setting current of the aluminum electrolytic cell. The operating parameters include the operating voltage and operating current of the aluminum electrolytic cell during operation. The anode action parameters include the descent contactor status parameters and the cumulative anode descent time of the aluminum electrolytic cell.

[0029] Step 120: Determine the real-time resistance sequence of the aluminum electrolytic cell based on the operating parameters.

[0030] Step 130: Determine the resistance reference value based on the set parameters, and determine whether there is an abnormality in the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters.

[0031] Step 140: If it is determined that there is an abnormality in the electrode spacing, the abnormality level of the electrode spacing is determined based on the resistance reference value, the real-time resistance sequence and the anode action parameters, and a corresponding warning signal is issued based on the abnormality level.

[0032] In this application, the setting parameters include the setting voltage and setting current of the aluminum electrolytic cell, which are the standard values ​​for normal operation of the aluminum electrolytic cell. They are the main basis for establishing resistance references and judging whether the operating state deviates from the normal range, and can directly determine the quantitative standard of the normal state. The operating parameters can include the operating voltage and operating current during the actual operation of the aluminum electrolytic cell, which can directly reflect the actual working state and operating conditions of the aluminum electrolytic cell. The anode action parameters include the descent contactor status parameters and the cumulative anode descent time. The descent contactor status parameters can be used to determine whether the anode performs a descent action, while the cumulative anode descent time can reflect the duration of the anode descent action.

[0033] In this application, the operating current can specifically be a series current, that is, a series of unified operating currents for aluminum electrolytic cells composed of multiple aluminum electrolytic cells. This application does not make specific limitations in this regard.

[0034] In this application, based on Ohm's law, there is a quantitative relationship between resistance, voltage, and current. Therefore, the real-time resistance value of the aluminum electrolytic cell can be calculated by real-time acquisition of the operating voltage and operating current. The change in the electrode spacing directly changes the distance between the anode and cathode in the electrolytic cell, thereby changing the length of the conductive path in the electrolytic cell and thus causing a change in resistance. Therefore, the real-time resistance value of the aluminum electrolytic cell can reflect the real-time state of the electrode spacing.

[0035] In this application, the real-time resistance sequence is not the resistance value at a single point in time, but a series of real-time resistance data collected continuously. Therefore, the sequence can reflect the trend of the resistance of the aluminum electrolytic cell over time, thereby avoiding the randomness of data at a single point in time and providing a data basis for subsequent judgment on whether there is an abnormality in the resistance.

[0036] In this application, the resistance reference value can be obtained by dividing the set voltage by the set current. The resistance reference value is the standard resistance value of the electrolytic cell when it is operating normally and the electrode spacing is within a reasonable range. The degree of deviation between the real-time resistance and the reference value can reflect the deviation of the current electrode spacing of the aluminum electrolytic cell from the normal state.

[0037] In this application, the difference between the real-time resistance and the reference value is not used to determine whether there is an abnormality in the electrode spacing. Instead, a comprehensive analysis is conducted by combining the changing characteristics of the actual resistance sequence and the anode action parameters. On the one hand, the dynamic change trend of the resistance is observed through the real-time resistance sequence to determine whether the real-time resistance continuously deviates from the reference value and whether the deviation exceeds a reasonable range. On the other hand, the anode action parameters are used to determine whether the anode has decreased, so as to determine whether the continuous deviation of the resistance from the reference value is caused by the anode action or whether the anode action is used to intervene, thereby determining whether there is an abnormality in the electrode spacing.

[0038] In this application, by simultaneously collecting three types of data—setting parameters, operating parameters, and anode action parameters—it can cover not only benchmark data reflecting standard conditions but also dynamic data reflecting actual operation and feedback data reflecting anode adjustment actions. This multi-dimensional data complements each other, thus comprehensively covering various scenarios of inter-electrode spacing anomalies and avoiding accidents caused by missed inter-electrode spacing anomalies due to missing data. At the same time, using real-time resistance sequence as the core analysis indicator, based on the physical correlation between resistance and inter-electrode spacing, it can more accurately capture subtle changes and trend fluctuations in inter-electrode spacing compared to other indirect indicators. This reduces the interference of non-correlated factors such as short-term voltage fluctuations on anomaly judgment and improves the accuracy of anomaly identification.

[0039] Based on the technical solution proposed in this application, before step 110 above, the method can also be performed according to the following steps 101 to 102: Step 101: Monitor the operating status of each aluminum electrolysis cell in real time.

[0040] Step 102: If the operating state of each aluminum electrolytic cell is aluminum output, then trigger the abnormal electrode spacing detection action for each aluminum electrolytic cell.

[0041] In this application, the operating state may include roasting start-up state, aluminum tapping state, normal electrolysis state, electrode switching, bus lifting state, fault shutdown and maintenance state, etc. Among them, the aluminum tapping state is the trigger condition for subsequent key judgment of abnormal electrode spacing detection. It can be judged by the status signal fed back by the control system of the electrolytic cell (such as the cell control system). When the electrolytic cell starts aluminum tapping operation, the control system will output the aluminum tapping status indicator simultaneously, indicating that the aluminum electrolytic cell has entered the processing state.

[0042] In this application, a real-time monitoring method is adopted to establish a stable communication connection (such as TCP protocol) with the control system of each electrolytic cell, and to obtain status feedback at preset short intervals to ensure that the switching of the electrolytic cell from the non-aluminum output state to the aluminum output state can be monitored in a timely manner, so as to avoid the failure of abnormal detection start-up due to monitoring delay, which could lead to safety accidents.

[0043] In this application, triggering the inter-electrode spacing anomaly detection action for each aluminum electrolytic cell when the electrolytic cell is in the aluminum tapping state can avoid continuously starting the full-process detection during non-aluminum tapping periods, which would occupy processor computing power and consume storage resources, thus significantly improving overall operating efficiency. At the same time, by monitoring in real time whether the aluminum electrolytic cell has switched to the aluminum tapping state, anomaly detection can be initiated in a timely manner after the aluminum tapping operation begins, ensuring the safety of the aluminum tapping operation process.

[0044] In step 120 above, determining the real-time resistance sequence of the aluminum electrolysis cell based on the operating parameters can be specifically performed according to steps 121 to 123 as follows: Step 121: Determine the real-time resistance value of the aluminum electrolysis cell based on the operating voltage and the operating current.

[0045] Step 122: Collect the real-time resistance value of the aluminum electrolytic cell according to the preset time window length and preset acquisition frequency to obtain the initial resistance sequence.

[0046] Step 123: Filter the initial resistance sequence according to a preset time granularity to obtain a real-time resistance sequence.

[0047] In this application, the real-time resistance value of the aluminum electrolytic cell is determined based on the operating voltage and the operating current. Specifically, according to Ohm's law, the resistance value is directly proportional to the voltage and inversely proportional to the current. The real-time resistance value of the aluminum electrolytic cell is obtained by dividing the operating voltage by the operating current.

[0048] In this application, the change in the real-time resistance value of the aluminum electrolytic cell can reflect the change in the electrode spacing of the aluminum electrolytic cell, because the electrode spacing is a key factor affecting the resistance of the electrolytic cell. The larger the electrode spacing, the longer the current conduction path and the greater the resistance, and the resistance value increases accordingly. If the electrode spacing is within the normal range, the resistance value will be stable within a reasonable range.

[0049] In this application, the operating voltage and operating current used to determine the real-time resistance value of the aluminum electrolytic cell are real-time dynamic data during the operation of the electrolytic cell. This is because during the aluminum tapping stage, the continuous reduction of aluminum liquid leads to continuous changes in the electrolyte interface, which in turn causes changes in the electrode spacing. Therefore, it is necessary to collect voltage and current data in real time to accurately determine the resistance value at the corresponding moment and ensure the synchronization between the resistance value and the electrode spacing state.

[0050] In this application, the preset time window length refers to the time range covered by a single analysis. It can be used to define an effective analysis interval, avoid incomplete trends in real-time resistance due to a short time span, and avoid data redundancy and analysis lag due to a long time span. Specifically, the preset time window length can be 60s or 120s. It can be adjusted according to the production rhythm. This application does not make specific limitations on this.

[0051] In this application, the preset acquisition frequency refers to the number of times the real-time resistance value is acquired per unit time. It can be determined according to the rate of change of the real-time resistance value, or it can be set to a fixed value. Specifically, the preset acquisition frequency can be acquired once per second, once every 2 seconds, or once every 3 seconds. This application does not make any specific limitation on this.

[0052] In this application, the real-time resistance value of the aluminum electrolytic cell is collected according to a preset time window length and a preset acquisition frequency to obtain an initial resistance sequence. Specifically, the real-time resistance value is continuously collected within a preset time window according to the set acquisition frequency, and these discrete single values ​​are arranged in chronological order to form an initial resistance sequence. For example, if the time window is set to 60 seconds and the acquisition frequency is once per second, the initial resistance sequence contains 60 resistance values ​​arranged in chronological order.

[0053] In this application, a single real-time resistance value can only reflect the inter-electrode spacing correlation state at a certain instant, which is easily affected by random factors and cannot reflect the trend of change. However, the initial resistance sequence integrates continuous data in the time dimension, transforming discrete resistance values ​​into a trend-based data set, which can clearly show whether the resistance value is continuously increasing, fluctuating steadily, or gradually decreasing, providing a basis for subsequent judgment on whether the inter-electrode spacing is abnormal.

[0054] In this application, the preset time granularity refers to the time interval between two adjacent data points in the real-time resistance sequence after filtering. Its function is to normalize the sampling of the initial resistance sequence, avoid computational redundancy caused by excessively dense data points, and ensure that the sequence can retain key change trends.

[0055] In this application, the filtering process can be performed on the sub-data groups divided by time granularity in the initial resistance sequence according to a preset filtering algorithm (such as moving average filtering, Kalman filtering, etc.). Specifically, if the time granularity is set to 3 seconds and the sampling frequency is once per second, then each time granularity contains 3 initial resistance values. The stable value (such as average value, median value, etc.) of the sub-group is calculated by the filtering algorithm and used as the resistance data corresponding to the time granularity.

[0056] In this application, the initial resistance sequence may contain instantaneous spikes (such as abnormal resistance peaks caused by sudden voltage fluctuations) or random noise (such as minor fluctuations caused by equipment signal transmission interference). These data are unrelated to the change in electrode spacing and will interfere with the accuracy of subsequent analysis. By filtering, these fluctuations can be smoothed out, abnormal spikes can be removed, and by normalizing the time granularity, a real-time resistance sequence with uniform data intervals and stable trends can be formed. This ensures that the sequence can truly reflect the gradual change in electrode spacing and improves the accuracy of early warning of abnormal electrode spacing during the aluminum electrolysis cell's aluminum tapping stage.

[0057] In step 130 above, determining whether there is an abnormality in the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters can be specifically performed according to steps 131 to 134 below: Step 131: Based on the resistance reference value and the real-time resistance sequence, determine whether there is an abnormality in the resistance of the aluminum electrolysis cell.

[0058] Step 132: If the resistance of the aluminum electrolytic cell is abnormal, determine whether the aluminum electrolytic cell has a de-anode action based on the anode action parameters.

[0059] Step 133: If the aluminum electrolysis cell does not have anode reduction action, it is determined that the electrode spacing is abnormal.

[0060] Step 134: If the aluminum electrolytic cell has a deanode reduction action and the real-time resistance of the aluminum electrolytic cell does not decrease, then it is determined that the electrode spacing is abnormal.

[0061] In this application, the electrode spacing is a key factor affecting the resistance of the aluminum electrolytic cell, and the two are directly related. When the electrode spacing increases, the current conduction path is lengthened and the resistance increases, and the resistance value will increase accordingly. When the electrode spacing is within the normal range, the resistance value will stabilize in the range that matches the reference value. Therefore, whether the resistance is abnormal is the core indicator of whether the electrode spacing is abnormal. By first determining whether the resistance of the aluminum electrolytic cell is abnormal, the high probability scenario of electrode spacing abnormality can be quickly identified.

[0062] In this application, anode reduction is a means of adjusting the electrode spacing in aluminum electrolysis cell production. By lowering the anode position, the electrode spacing can be directly reduced, thereby reducing the resistance. Whether anode reduction action exists can reflect whether the system or operators have intervened in abnormal resistance or potential electrode spacing abnormalities.

[0063] In this application, if the resistance has been preliminarily determined to be abnormal, and verification confirms that there is no anode reduction action, it indicates that the potential risk of abnormal electrode spacing has not been addressed and the abnormal state persists. Therefore, it is directly determined that there is an abnormality in the electrode spacing. If the resistance has been preliminarily determined to be abnormal, and verification confirms that there is anode reduction action, but the real-time resistance sequence does not show a downward trend, it indicates that the anode reduction action has not achieved the effect of reducing the electrode spacing and lowering the resistance. There may be other factors causing the abnormality in the electrode spacing. If the resistance has been preliminarily determined to be abnormal and the anode reduction action has been initiated, and the real-time resistance sequence shows a significant downward trend, it indicates that the abnormality in the electrode spacing has been alleviated through adjustment and the resistance has returned to normal. Therefore, it is determined that there is no abnormality in the electrode spacing.

[0064] In this application, an initial judgment is made based on resistance anomalies, followed by verification using anode reduction actions, to ultimately determine whether the electrode spacing is abnormal. This makes the judgment of electrode spacing anomalies more rigorous and significantly reduces the probability of misjudgment and missed judgment. At the same time, this scheme can not only identify obvious anomalies such as resistance anomalies without anode reduction actions, but also identify latent anomalies such as resistance anomalies with anode reduction actions, but the anode reduction actions are ineffective. This can cover different development stages and handling states of electrode spacing anomalies, thereby improving the accuracy of electrode spacing anomaly early warning during the aluminum electrolysis cell's aluminum tapping stage.

[0065] In step 131 above, determining whether there is an abnormality in the resistance of the aluminum electrolysis cell based on the resistance reference value and the real-time resistance sequence can be performed according to steps 1311 to 1314 below: Step 1311: Perform a first-order backward difference on the real-time resistance sequence to determine the instantaneous slope sequence of the real-time resistance sequence.

[0066] Step 1312: If any subsequence in the instantaneous slope sequence is an increasing sequence, and the number of instantaneous slopes in any subsequence is greater than or equal to a first preset number, then it is determined that the resistance of the aluminum electrolysis cell is abnormal.

[0067] Step 1313: Determine the deviation rate between each real-time resistor in the real-time resistance sequence and the resistance reference value.

[0068] Step 1314: If any deviation rate among the deviation rates corresponding to each real-time resistor is greater than the first preset deviation rate threshold, then it is determined that the resistance of the aluminum electrolysis cell is abnormal.

[0069] In this application, the step of performing a first-order backward difference on the real-time resistance sequence to calculate the instantaneous slope can specifically be, for the first... n The instantaneous slope of a data point can be determined by the following formula (1): (1) in, Indicates the first in the real-time resistance sequence n The instantaneous slope of each data point. Indicates the first in the real-time resistance sequence n Real-time resistance values ​​at each data point Indicates the first in the real-time resistance sequence Real-time resistance values ​​at each data point Indicates the first n The data point and the first The time difference between data points; by calculating the instantaneous slope sequence with the same length as the real-time resistance sequence for each data point in the sequence.

[0070] In this application, the instantaneous slope can reflect the rate and direction of change of resistance between two adjacent moments. When the slope is positive, it indicates that the resistance is increasing; when the slope is negative, it indicates that the resistance is decreasing; when the slope is 0, it indicates that the resistance remains stable. Compared with simply comparing the resistance value, the slope can more intuitively show the dynamic change of the resistance and provide a basis for judging whether the resistance is abnormal.

[0071] In this application, if any subsequence in the instantaneous slope sequence is an increasing sequence, and the number of positive instantaneous slopes in any subsequence is greater than or equal to a first preset number, then the resistance of the aluminum electrolytic cell is determined to be abnormal. Specifically, for example, a continuous subsequence can be extracted from the instantaneous slope sequence, and it can be determined whether the subsequence is an increasing sequence, that is, the subsequent slope in the subsequence is greater than the previous slope, and the number of positive instantaneous slopes in the subsequence is determined to be greater than or equal to the first preset number, for example, it can be 5, 4, or 2. This application does not make specific limitations on this. If the subsequence simultaneously satisfies the conditions of being an increasing sequence and the number of positive instantaneous slopes being greater than or equal to the first preset number, then the resistance can be determined to be abnormal.

[0072] In this application, if the subsequence is an increasing sequence, it means that the rate of increase of resistance is constantly accelerating and the abnormal situation is intensifying. If the number of instantaneous slopes is greater than or equal to the first preset number, it can be said that the increase of resistance is not an accidental single fluctuation, but a stable trend that lasts for a period of time. This can eliminate false signals caused by instantaneous interference and ensure the accuracy of the judgment of abnormal trends.

[0073] In this application, the deviation rate between each real-time resistor in the real-time resistance sequence and the resistance reference value can be determined by the following formula (2): (2) in, Indicates the first in the real-time resistance sequence n Deviation rate of each data point Indicates the first in the real-time resistance sequence n Real-time resistance values ​​at each data point This indicates the reference value for resistance.

[0074] In this application, the first preset deviation rate threshold can be determined based on production data statistics. It represents the upper limit of normal resistance fluctuation. Exceeding this threshold indicates that the deviation of the resistance from the standard state has exceeded the reasonable range. Even if it does not show a continuous upward trend, it is still an abnormal situation.

[0075] In this application, the presence of resistance anomalies can be determined both by the instantaneous slope change trend and by the deviation rate, thus covering different manifestations of resistance anomalies and improving the accuracy of the judgment. Simultaneously, by using first-order backward differential to quantify the rate of change of resistance, the scientific rigor and accuracy of the judgment can be improved. Furthermore, determining the deviation rate between each real-time resistor in the real-time resistance sequence and the resistance reference value can eliminate the influence of differences in reference resistances between different electrolytic cells, making the amplitude judgment more objective, and thereby improving the accuracy of early warning of abnormal electrode spacing during the aluminum electrolysis cell's aluminum tapping stage.

[0076] In step 132 above, determining whether the aluminum electrolysis cell has anode-lowering action based on the anode action parameters can be specifically performed according to steps 1321 to 1322 as follows: Step 1321: If the state parameter of the descent contactor is 1, or the cumulative descent time of the anode continues to increase, it is determined that the aluminum electrolysis cell has an anode descent action.

[0077] Step 1322: If the state parameter of the lowering contactor is 0, it is determined that there is no anode lowering action in the aluminum electrolysis cell.

[0078] In this application, the descent contactor is the actuator in the aluminum electrolytic cell that controls the descent of the anode. Its status parameters directly reflect whether the action has been initiated. When the descent contactor status parameter is 1, it indicates that the contactor has been activated and the anode descent drive mechanism has been activated. At this time, it can be directly determined that the aluminum electrolytic cell is performing the anode descent action. This method of determining whether the aluminum electrolytic cell is performing the anode descent action has a rapid response, direct determination, and can complete the identification at the same time as the action is initiated, without delay.

[0079] In this application, the cumulative anode descent time is a record of the total descent time of the anode from its initial position to its current position. It is a process feedback parameter for the anode lowering action. As long as the anode is in a continuous descent state, this time will continuously increase over time; if the anode is not lowering, this time remains constant. When the cumulative anode descent time is detected to be continuously increasing, it can be indirectly determined that an anode lowering action exists even without directly obtaining the status signal of the lowering contactor.

[0080] In this application, the timing module only accumulates the time when the anode drive mechanism actually performs the descent action, and the cumulative descent time of the anode will increase. For example, if the anode performs the first descent from the 5th to the 8th minute of the aluminum tapping operation and the second descent from the 12th to the 17th minute, then the cumulative descent time of the anode at the 17th minute of the aluminum tapping operation is 3+5=8 minutes.

[0081] In some specific embodiments of this application, the first preset deviation rate threshold is set to 3%, and the second preset number is set to 8. When the aluminum electrolysis cell is in the aluminum output state, there are 9 cells in the real-time resistance sequence with a deviation rate greater than 3%, indicating that the resistance is abnormal. However, the anode action parameters are 0, and the cumulative anode descent time remains unchanged at 6 minutes. Therefore, it is determined that the aluminum electrolysis cell does not have an anode descent action, indicating that there is an abnormal electrode spacing.

[0082] In this application, by using both the contactor status parameters and the cumulative anode descent time for judgment, it can be ensured that there are any small-scale anomalies in the equipment signal transmission, and the anode descent action can be accurately identified, thereby improving the accuracy of anomaly detection.

[0083] In step 140 above, the abnormality level of the electrode spacing is determined based on the resistance reference value, the real-time resistance sequence, and the anode action parameters, and a corresponding warning signal is issued based on the abnormality level. Specifically, this can be performed according to steps 141 to 143 as follows: Step 141: If there is a deviation rate greater than the first preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the first preset deviation rate threshold is greater than the second preset number, and there is no anode reduction action in the aluminum electrolysis cell, then the abnormal level of the electrode spacing is determined to be a level one abnormality, and a first-class warning signal of the first category is issued.

[0084] Step 142: If there is a deviation rate greater than the second preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the second preset deviation rate threshold is greater than the third preset number, and there is no anode reduction action in the aluminum electrolysis cell, then the abnormality level of the electrode spacing is determined to be a level two abnormality, and a level two warning signal of the first category is issued, wherein the second preset deviation rate threshold is greater than the first preset deviation rate threshold, and the severity of the level two abnormality is greater than the severity of the level one abnormality.

[0085] Step 143: If there is a deviation rate greater than the third preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the third preset deviation rate threshold is greater than the fourth preset number, and there is no anode reduction action in the aluminum electrolysis cell, then the abnormality level of the electrode spacing is determined to be a level three abnormality, and a first-category level three warning signal is issued, wherein the third preset deviation rate threshold is greater than the second preset deviation rate threshold, and the severity of the level three abnormality is greater than the severity of the level two abnormality.

[0086] In this application, the first-level anomaly is a minor anomaly, which requires the simultaneous fulfillment of three conditions. First, in the real-time resistance sequence, at least one real-time resistor has a deviation rate greater than a first preset deviation rate threshold, for example, 2.5% or 3%, which can be determined based on the specific production situation. Second, among all the deviation rates corresponding to real-time resistors, the number of deviation rates greater than the first preset deviation rate threshold exceeds a second preset number, for example, 3 or 4, which can be adjusted according to the acquisition frequency. Third, the aluminum electrolysis cell does not have an anode lowering action, i.e., the lowering contactor state parameter is 0, and the cumulative anode lowering time has not increased. If the above conditions are met, it indicates a minor anomaly in the electrode spacing that has not been adjusted, and the risk is in the initial accumulation stage. Operators should be alerted to pay close attention, but no emergency action is required, and a first-level warning signal of the first category should be issued.

[0087] In this application, the secondary anomaly is a moderate anomaly, requiring the simultaneous fulfillment of three conditions. First, in the real-time resistance sequence, at least one real-time resistor has a deviation rate greater than a second preset deviation rate threshold, for example, 3.75% or 4%, depending on the specific production situation. Second, among all real-time resistors, the number of deviation rates greater than the second preset deviation rate threshold exceeds a third preset number, specifically 5 or 4, adjustable according to the acquisition frequency. Third, the aluminum electrolysis cell does not exhibit anode-lowering action, i.e., the contactor state parameter is 0, and the cumulative anode-lowering time has not increased. Meeting these conditions indicates a significant anomaly in the electrode spacing without any adjustment action, indicating a rapid accumulation of risk. Without timely intervention, the situation may worsen, requiring operators to initiate targeted measures and issuing a first-category secondary warning signal.

[0088] In this application, the Level 3 anomaly is a severe anomaly, requiring the simultaneous fulfillment of three conditions. First, in the real-time resistance sequence, at least one real-time resistor has a deviation rate greater than a third preset deviation rate threshold, for example, 5% or 5.25%, corresponding to a severe deviation of the electrode spacing from the normal range. Second, among all real-time resistors, the number of deviation rates greater than the third preset deviation rate threshold exceeds a fourth preset number, the specific number of which can be determined based on actual production conditions. Third, the aluminum electrolysis cell does not exhibit anode-lowering action, i.e., the contactor state parameter is 0, and the cumulative anode-lowering time has not increased. Meeting these conditions indicates a severe anomaly in the electrode spacing, with no adjustment measures implemented. In this case, there is a significant safety risk, such as anode detachment from the electrolyte and potential explosion, constituting an emergency scenario requiring immediate emergency measures from the operator, triggering a Level 3 warning signal (Category 1).

[0089] In this application, all warning signals without anode reduction action belong to the first category. That is, the warning content of the first category will clearly indicate that the electrode spacing is abnormal and adjustment has not been initiated, so that when the operator receives the warning, he / she can quickly know the background of the abnormality and the action to be taken first (such as initiating anode reduction operation), avoiding processing delays caused by ambiguous information.

[0090] In step 140 above, the step of determining the abnormality level of the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters, and issuing a corresponding warning signal based on the abnormality level, can also be performed according to steps 144 to 147 below: Step 144: If there is a deviation rate greater than the first preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the first preset deviation rate threshold is greater than the second preset number, and the aluminum electrolysis cell is performing anode reduction action, then the abnormal level of the electrode spacing is determined to be a level one abnormality, and a level one warning signal of the second category is issued.

[0091] Step 145: If there is a deviation rate greater than the second preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the second preset deviation rate threshold is greater than the third preset number, and the aluminum electrolysis cell is performing anode reduction action, then the abnormal level of the electrode spacing is determined to be a level two abnormality, and a level two warning signal of the second category is issued.

[0092] Step 146: If there is a deviation rate greater than the third preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the third preset deviation rate threshold is greater than the fourth preset number, and the aluminum electrolysis cell has an anode reduction action, then the abnormal level of the electrode spacing is determined to be a level three abnormality, and a level three warning signal of the second category is issued.

[0093] Step 147: If the instantaneous slope in the instantaneous slope sequence is positive and the aluminum electrolysis cell has anode reduction action, then the abnormality level of the electrode spacing is determined to be level three abnormality, and a level three warning signal of the third category is issued.

[0094] In this application, if the aluminum electrolysis cell has a deanode reduction action, and the deviation rate corresponding to each real-time resistor gradually decreases with the deanode reduction action until it is lower than the first preset deviation rate threshold, then the warning signal can be canceled.

[0095] In this application, the second category of Level 1 warning signals corresponds to Level 1 anomalies and must simultaneously meet three conditions. First, in the real-time resistance sequence, at least one real-time resistor has a deviation rate greater than a first preset deviation rate threshold, for example, it could be 2.5% or 3%, depending on the specific production situation. Second, among all the deviation rates corresponding to real-time resistors, the number of deviation rates greater than the first preset deviation rate threshold exceeds a second preset number, for example, it could be 3 or 4, adjustable according to the acquisition frequency. Third, the aluminum electrolysis cell exhibits anode reduction action, i.e., the contactor status parameter is 1, or the cumulative anode reduction time increases, indicating a slight abnormality in the electrode spacing. Although the anode reduction action has been initiated, the expected adjustment effect has not been achieved, possibly due to insufficient action amplitude or an initial fault. Operators need to monitor the adjustment effect and, if necessary, increase the adjustment intensity.

[0096] In this application, the second category of level-two warning signals corresponds to level-two anomalies and must simultaneously meet three conditions. First, in the real-time resistance sequence, at least one real-time resistor has a deviation rate greater than a second preset deviation rate threshold, for example, it could be 3.75% or 4%, depending on the specific production situation. Second, among all the deviation rates corresponding to real-time resistors, the number of deviation rates greater than the second preset deviation rate threshold exceeds a third preset number, specifically it could be 5 or 4, adjustable according to the acquisition frequency. Third, the aluminum electrolysis cell exhibits anode-lowering action, i.e., the contactor status parameter is 1, or the cumulative anode descent time increases, indicating a significant abnormality in the electrode spacing. The anode-lowering action has not effectively mitigated the problem, and the abnormal risk is still accumulating. There may be faults such as abnormal command transmission in the cell control system, requiring operators to check the equipment's operating status and adjust the handling strategy.

[0097] In this application, the second category of level three warning signals corresponds to level three anomalies and requires the simultaneous fulfillment of three conditions. First, in the real-time resistance sequence, at least one real-time resistor has a deviation rate greater than a third preset deviation rate threshold, for example, 5% or 5.25%, corresponding to a severe deviation of the electrode spacing from the normal range. Second, among all the deviation rates corresponding to real-time resistors, the number of deviation rates greater than the third preset deviation rate threshold exceeds a fourth preset number, the specific number of which can be determined based on actual production conditions. Third, the aluminum electrolysis cell exhibits anode-lowering action, i.e., the contactor status parameter is 1, or the cumulative anode descent time increases, indicating a severe electrode spacing anomaly, rendering the anode-lowering action completely ineffective, and highly suggesting a serious equipment malfunction (such as a reversed three-phase sequence causing the anode to rise instead of fall), posing significant safety risks such as electrode separation and explosion, requiring immediate shutdown and emergency handling by operators.

[0098] In this application, the warning content in the second category of warnings must clearly indicate that a deanode action has been taken, but the action is ineffective, so that when operators receive the warning, they can quickly understand the abnormal background and the action that needs to be taken first, thereby improving processing efficiency.

[0099] In this application, the third category of early warning is an emergency early warning based on instantaneous slope. When the instantaneous slope in the instantaneous slope sequence is positive and the aluminum electrolytic cell is undergoing anode reduction, it is directly judged as a level three anomaly, and a level three early warning signal of the third category is issued. The fact that the instantaneous slope in the instantaneous slope sequence is positive and the aluminum electrolytic cell is undergoing anode reduction indicates that the anode reduction action not only failed to alleviate the anomaly but also made the electrode spacing anomaly more serious, indicating that there is a serious fault in the equipment, such as anode mechanical jamming, reverse command execution, and the electrode spacing is rapidly expanding. The risk has reached an emergency state, and extreme measures such as immediate shutdown and power cut-off must be taken to avoid a major accident.

[0100] Based on the technical solution proposed in this application, by simultaneously collecting three types of data—setting parameters, operating parameters, and anode action parameters—it can cover not only benchmark data reflecting the standard state but also dynamic data reflecting actual operation and feedback data reflecting anode adjustment actions. This allows multi-dimensional data to complement each other, thus comprehensively covering various scenarios of inter-electrode spacing anomalies and avoiding accidents caused by missed inter-electrode spacing anomalies due to missing data. At the same time, using real-time resistance sequence as the core analysis indicator, based on the physical correlation between resistance and inter-electrode spacing, it can more accurately capture subtle changes and trend fluctuations in inter-electrode spacing compared to other indirect indicators. This reduces the interference of non-correlated factors such as short-term voltage fluctuations on anomaly judgment and improves the accuracy of anomaly identification.

[0101] The technical solution proposed in this application will be described below with reference to some specific embodiments.

[0102] Example 1: Taking a 200KA series electrolytic cell 1101 as an example, the cell's status is obtained from the cell control system as aluminum output state. The set voltage (4V), set current (200KA), and series current (200KA) of the cell are acquired. The target resistance of the cell is calculated: target resistance = set voltage / set current = 20μΩ, which serves as the dynamic reference value for the cell's resistance. Data such as the cell voltage, descent contactor status, and anode descent time are read from the PLC, one data point per second. The analysis time window is set to 60 seconds and the time granularity to 3 seconds, forming a time-series data sequence. The cell resistance time-series data sequence is filtered using an exponential moving average and analysis begins. The acquired voltage value drops from 3.944V to 3.910V, and the calculated cell resistance drops from 19.72μΩ to 19.55μΩ. The instantaneous slope of the resistance is -0.17, indicating that the resistance has not increased and remains within the normal range. Assuming the R deviation rate threshold is set to three levels: 2.5%, 3.75%, and 5%, the calculated tank resistance deviation rate of -2.25% is within the normal range and no alarm is needed.

[0103] Example 2: Taking a 200KA series electrolytic cell 1101 as an example, the cell's status is obtained from the cell control system as aluminum output state. The set voltage (4V), set current (200KA), and series current (200KA) of the cell are acquired. The target resistance of the cell is calculated to be 20μΩ, which is used as the dynamic reference value for the cell's resistance. Data such as the cell voltage, the status of the drop contactor, and the anode drop time are read from the PLC, one data point per second. The analysis time window is set to 60 seconds and the time granularity to 3 seconds, forming a time-series data sequence. The cell resistance time-series data sequence is filtered using an exponential moving average and analysis begins. The acquired voltage value changes from 3.998V to 4.020V, and the cell resistance is calculated to increase from 19.99μΩ to 20.1μΩ. The instantaneous slope of the resistance is 0.11, and the number of times the resistance continuously increases is recorded once. Assuming the R deviation rate threshold is set to three levels: 2.5%, 3.75%, and 5%, the calculated tank resistance deviation rate of 0.55% is within the normal range and no alarm is needed. Further analysis shows that the voltage changes from 4.020V to 4.160V, and the resistance changes from 20.1Ω to 20.8Ω, with an instantaneous slope of 0.7. The number of times the resistance continuously increases is recorded twice, resulting in a deviation rate of 4%. A deviation rate greater than 3.75% triggers the secondary alarm threshold. It is determined that the contactor status is 0, and the cumulative anode descent time remains unchanged, triggering an early warning: "2024.11.15 15:33:20 The electrode spacing of tank 1101 is significantly abnormal and there is no anode descent action." Further analysis shows that the voltage changes from 4.160V to 4.050V, and the resistance returns to normal; the early warning signal is canceled.

[0104] Example 3: Taking a 200KA series electrolytic cell 1101 as an example, the cell's status is obtained from the cell control system as aluminum output state. The set voltage (4V), set current (200KA), and series current (200KA) of the cell are acquired. The target resistance of the cell is calculated to be 20μΩ, which is used as the dynamic reference value for the cell's resistance. Data such as the cell voltage, the status of the drop contactor, and the anode drop time are read from the PLC, one data point per second. The analysis time window is set to 60 seconds and the time granularity to 3 seconds, forming a time-series data sequence. The cell resistance time-series data sequence is filtered using an exponential moving average and analysis begins. The acquired voltage value changes from 4.005V to 4.050V, and the cell resistance is calculated to increase from 20.025μΩ to 20.25μΩ. The instantaneous slope of the resistance is 0.225, and the number of times the resistance continuously increases is recorded once. Assuming the R deviation rate threshold is set to three levels: 2.5%, 3.75%, and 5%, the calculated tank resistance deviation rate of 1.125% is within the normal range and no alarm is needed. Continuing the analysis, the voltage changes from 4.050V to 4.120V, and the resistance changes from 20.25 to 20.6, with an instantaneous slope of 0.35. The number of times the resistance continuously increases is recorded twice, resulting in a deviation rate of 3%. A deviation rate greater than 2.5% triggers a level one alarm threshold. It is determined that the contactor status is 0, and the cumulative anode descent time has not changed, thus issuing a warning: "2024.11.17 10:20:10 Tank No. 1101 may have excessive electrode spacing and no anode descent action." Continuing the analysis, the voltage changed from 4.120V to 4.150V, and the resistance changed from 20.6Ω to 20.75Ω, with an instantaneous slope of 0.15. The number of times the resistance continuously increased was recorded three times, with a deviation rate of 3.75%. A deviation rate greater than or equal to 3.75% triggers a level two alarm: "2024.11.17 10:20:12 The electrode spacing of slot 1101 is significantly abnormal and there is no anode reduction action." Further analysis determined that the contactor status was 1. Further analysis of the anode resistance showed a reduction action until the resistance returned to 4.01Ω, at which point the alarm signal was canceled.

[0105] The following describes an embodiment of the apparatus described in this application, which can be used to execute the early warning method for abnormal electrode spacing during the aluminum electrolysis cell tapping stage in the above embodiments of this application. For details not disclosed in the apparatus embodiments of this application, please refer to the embodiments of the early warning method for abnormal electrode spacing during the aluminum electrolysis cell tapping stage described above in this application.

[0106] Figure 2 A block diagram of an early warning device for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell, according to one embodiment of this application, is shown.

[0107] Reference Figure 2 An early warning device 200 for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell according to one embodiment of this application includes: an acquisition unit 201, a determination unit 202, a judgment unit 203, and an early warning unit 204.

[0108] The system includes: an acquisition unit 201, used to acquire the setting parameters, operating parameters, and anode action parameters of the aluminum electrolytic cell; the setting parameters include the setting voltage and setting current of the aluminum electrolytic cell; the operating parameters include the operating voltage and operating current during the operation of the aluminum electrolytic cell; and the anode action parameters include the descent contactor status parameters and the cumulative anode descent time of the aluminum electrolytic cell. A determination unit 202 is used to determine the real-time resistance sequence of the aluminum electrolytic cell based on the operating parameters. A judgment unit 203 is used to determine a resistance reference value based on the setting parameters, and to determine whether there is an abnormality in the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters. An early warning unit 204 is used to determine the abnormality level of the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters if an abnormality is determined, and to issue a corresponding early warning signal based on the abnormality level.

[0109] In some embodiments of this application, based on the foregoing scheme, the device further includes a monitoring unit, which is configured to: monitor the operating status of each aluminum electrolytic cell in real time; if the operating status of each aluminum electrolytic cell is aluminum output, then trigger an abnormal detection action of the inter-electrode spacing of each aluminum electrolytic cell.

[0110] In some embodiments of this application, based on the foregoing scheme, the determining unit 202 is configured to: determine the real-time resistance value of the aluminum electrolytic cell based on the operating voltage and the operating current; collect the real-time resistance value of the aluminum electrolytic cell according to a preset time window length and a preset acquisition frequency to obtain an initial resistance sequence; and filter the initial resistance sequence according to a preset time granularity to obtain a real-time resistance sequence.

[0111] In some embodiments of this application, based on the foregoing scheme, the judgment unit 203 is configured to: determine whether the resistance of the aluminum electrolytic cell is abnormal based on the resistance reference value and the real-time resistance sequence; if the resistance of the aluminum electrolytic cell is abnormal, determine whether the aluminum electrolytic cell has an anode reduction action based on the anode action parameters; if the aluminum electrolytic cell does not have an anode reduction action, determine that the electrode spacing is abnormal; if the aluminum electrolytic cell has an anode reduction action and the real-time resistance of the aluminum electrolytic cell does not decrease, determine that the electrode spacing is abnormal.

[0112] In some embodiments of this application, based on the foregoing scheme, the judgment unit 203 is further configured to: perform a first-order backward difference on the real-time resistance sequence to determine the instantaneous slope sequence of the real-time resistance sequence; if any subsequence in the instantaneous slope sequence is an increasing sequence, and the number of instantaneous slopes in any subsequence is greater than or equal to a first preset number, then determine that the resistance of the aluminum electrolytic cell is abnormal; determine the deviation rate between each real-time resistance in the real-time resistance sequence and the resistance reference value; if there is a deviation rate greater than a first preset deviation rate threshold among the deviation rates corresponding to each real-time resistance, then determine that the resistance of the aluminum electrolytic cell is abnormal.

[0113] In some embodiments of this application, based on the foregoing scheme, the judgment unit 203 is further configured to: if the state parameter of the lowering contactor is 1, or the cumulative lowering time of the anode continues to increase, then determine that the aluminum electrolytic cell has an anode lowering action; if the state parameter of the lowering contactor is 0, then determine that the aluminum electrolytic cell does not have an anode lowering action.

[0114] In some embodiments of this application, based on the foregoing scheme, the early warning unit 204 is configured as follows: if there is a deviation rate greater than a first preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the first preset deviation rate threshold is greater than a second preset number, and the aluminum electrolytic cell does not have an anode reduction action, then the abnormality level of the electrode spacing is determined to be a level one abnormality, and a first-class level one early warning signal is issued; if there is a deviation rate greater than a second preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the second preset deviation rate threshold is greater than a third preset number, and the aluminum electrolytic cell does not have an anode reduction action, then the abnormality level of the electrode spacing is determined to be a level one abnormality. The anomaly level is classified as Level 2, and a Level 2 warning signal of the first category is issued. The second preset deviation rate threshold is greater than the first preset deviation rate threshold, and the severity of the Level 2 anomaly is greater than the severity of the Level 1 anomaly. If any deviation rate among the deviation rates corresponding to each real-time resistor exceeds a third preset deviation rate threshold, and the number of deviation rates exceeding the third preset deviation rate threshold is greater than a fourth preset number, and the aluminum electrolysis cell does not exhibit anode reduction action, then the anomaly level of the electrode spacing is determined to be Level 3, and a Level 3 warning signal of the first category is issued. The third preset deviation rate threshold is greater than the second preset deviation rate threshold, and the severity of the Level 3 anomaly is greater than the severity of the Level 2 anomaly.

[0115] In some embodiments of this application, based on the foregoing scheme, the early warning unit 204 is further configured as follows: if there is a deviation rate greater than a first preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the first preset deviation rate threshold is greater than a second preset number, and the aluminum electrolytic cell is experiencing anode reduction action, then the abnormality level of the electrode spacing is determined to be a first-level abnormality, and a second-category first-level early warning signal is issued; if there is a deviation rate greater than a second preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the second preset deviation rate threshold is greater than a third preset number, and the aluminum electrolytic cell is experiencing anode reduction action, then the abnormality level of the electrode spacing is determined to be a first-level abnormality, and a second-category first-level early warning signal is issued; If the anode reduction action is performed, the abnormality level of the electrode spacing is determined to be Level 2 abnormality, and a Level 2 warning signal of the second category is issued; if there is a deviation rate greater than a third preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the third preset deviation rate threshold is greater than a fourth preset number, and the aluminum electrolysis cell is undergoing anode reduction action, the abnormality level of the electrode spacing is determined to be Level 3 abnormality, and a Level 3 warning signal of the second category is issued; if the instantaneous slope in the instantaneous slope sequence is positive, and the aluminum electrolysis cell is undergoing anode reduction action, the abnormality level of the electrode spacing is determined to be Level 3 abnormality, and a Level 3 warning signal of the third category is issued.

[0116] As another embodiment of this application, a computer program product or computer program is also provided, which includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the methods described in the above embodiments.

[0117] As another embodiment of this application, a computer-readable storage medium is also provided. This computer-readable storage medium may be included in the electronic device described in the above embodiments; or it may exist independently and not assembled into the electronic device. The aforementioned computer-readable storage medium carries one or more programs, which, when executed by the electronic device, cause the electronic device to perform the methods described in the above embodiments.

[0118] Based on the same inventive concept, embodiments of this application also provide an electronic device. (Reference) Figure 3 The diagram illustrates the structure of an electronic device according to one embodiment of this application. The electronic device includes one or more memories 304, one or more processors 302, and at least one computer program (program code) stored in the memories 304 and executable on the processors 302. When the processors 302 execute the computer program, they implement the method described above.

[0119] Among them, Figure 3 In this document, a bus architecture (represented by bus 300) is used. Bus 300 may include any number of interconnected buses and bridges, linking various circuits including one or more processors represented by processor 302 and memory represented by memory 304. Bus 300 may also link various other circuits such as peripheral devices, voltage regulators, and power management circuits, which are well known in the art and therefore will not be described further herein. Bus interface 305 provides an interface between bus 300 and receiver 301 and transmitter 303. Receiver 301 and transmitter 303 may be the same element, i.e., a transceiver, providing a unit for communicating with various other devices over a transmission medium. Processor 302 is responsible for managing bus 300 and general processing, while memory 304 can be used to store data used by processor 302 during operation.

[0120] The functions described herein may be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed by a processor, the functions may be stored as one or more instructions or codes on or transmitted via a computer-readable medium. Other examples and embodiments are within the scope and spirit of this application and the appended claims. For example, due to the nature of software, the functions described above may be implemented using software executed by a processor, hardware, firmware, hardwired, or any combination thereof. Furthermore, the functional units may be integrated into a single processing unit, or each unit may exist physically separately, or two or more units may be integrated into a single unit.

[0121] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. The device embodiments described above are merely illustrative; for example, the division of units can be a logical functional division, and in actual implementation, there may be other division methods. For instance, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling, direct coupling, or communication connection may be through some interfaces; the indirect coupling or communication connection between units or modules may be electrical or other forms.

[0122] The units described as separate components may or may not be physically separate. Similarly, the components of the control device may or may not be physical units; they may be located in one place or distributed across multiple units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0123] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as a USB flash drive, read-only memory (ROM), random access memory (RAM), portable hard drive, magnetic disk, or optical disk.

[0124] The above description is merely an embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A method for early warning of abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell, characterized in that, The method includes: The setting parameters, operating parameters, and anode action parameters of the aluminum electrolysis cell are obtained. The setting parameters include the setting voltage and setting current of the aluminum electrolysis cell. The operating parameters include the operating voltage and operating current of the aluminum electrolysis cell during operation. The anode action parameters include the descent contactor status parameters and the cumulative anode descent time of the aluminum electrolysis cell. The real-time resistance sequence of the aluminum electrolytic cell is determined based on the operating parameters. The resistance reference value is determined based on the set parameters, and the presence of any abnormality in the electrode spacing is determined based on the resistance reference value, the real-time resistance sequence, and the anode action parameters. If an abnormality is determined in the electrode spacing, the abnormality level of the electrode spacing is determined based on the resistance reference value, the real-time resistance sequence, and the anode action parameters, and a corresponding warning signal is issued based on the abnormality level.

2. The method according to claim 1, characterized in that, Before obtaining the setting parameters, operating parameters, and anode action parameters of the aluminum electrolysis cell, the method further includes: Real-time monitoring of the operating status of each aluminum electrolysis cell; If the operating state of each aluminum electrolytic cell is aluminum output, then an abnormal electrode spacing detection action is triggered for each aluminum electrolytic cell.

3. The method according to claim 1, characterized in that, Determining the real-time resistance sequence of the aluminum electrolysis cell based on the operating parameters includes: Based on the operating voltage and the operating current, the real-time resistance value of the aluminum electrolysis cell is determined; The real-time resistance value of the aluminum electrolytic cell is collected according to the preset time window length and preset acquisition frequency to obtain the initial resistance sequence; The initial resistance sequence is filtered according to a preset time granularity to obtain a real-time resistance sequence.

4. The method according to claim 1, characterized in that, The step of determining whether there is an abnormality in the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters includes: Based on the resistance reference value and the real-time resistance sequence, determine whether there is an abnormality in the resistance of the aluminum electrolysis cell; If the resistance of the aluminum electrolytic cell is abnormal, it is determined whether the aluminum electrolytic cell has a de-anode action based on the anode action parameters; If the aluminum electrolysis cell does not have anode reduction action, then the electrode spacing is determined to be abnormal; If the aluminum electrolytic cell experiences a drop in anode position and the real-time resistance of the aluminum electrolytic cell does not decrease, then the electrode spacing is determined to be abnormal.

5. The method according to claim 4, characterized in that, The step of determining whether the resistance of the aluminum electrolysis cell is abnormal based on the resistance reference value and the real-time resistance sequence includes: Perform a first-order backward difference on the real-time resistance sequence to determine the instantaneous slope sequence of the real-time resistance sequence; If any subsequence in the instantaneous slope sequence is an increasing sequence, and the number of instantaneous slopes in any subsequence is greater than or equal to a first preset number, then it is determined that the resistance of the aluminum electrolytic cell is abnormal. Determine the deviation rate between each real-time resistor in the real-time resistance sequence and the resistance reference value; If any of the deviation rates corresponding to the real-time resistors exceeds the first preset deviation rate threshold, then the resistance of the aluminum electrolysis cell is determined to be abnormal.

6. The method according to claim 4, characterized in that, The step of determining whether the aluminum electrolysis cell has anode reduction action based on the anode action parameters includes: If the state parameter of the descent contactor is 1, or the cumulative descent time of the anode continues to increase, it is determined that the aluminum electrolysis cell is experiencing anode descent. If the state parameter of the descent contactor is 0, it is determined that there is no anode reduction action in the aluminum electrolysis cell.

7. The method according to claim 5, characterized in that, The step of determining the anomaly level of the electrode spacing based on the resistance reference value, the real-time resistance sequence, and the anode action parameters, and issuing a corresponding early warning signal based on the anomaly level, includes: If there is a deviation rate greater than the first preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the first preset deviation rate threshold is greater than the second preset number, and there is no anode reduction action in the aluminum electrolysis cell, then the abnormal level of the electrode spacing is determined to be a level one abnormality, and a first-class warning signal of the first category is issued. If there is a deviation rate greater than the second preset deviation rate threshold among the deviation rates corresponding to each real-time resistor, and the number of deviation rates greater than the second preset deviation rate threshold is greater than the third preset number, and there is no anode reduction action in the aluminum electrolysis cell, then the abnormality level of the electrode spacing is determined to be a level two abnormality, and a level two warning signal of the first category is issued, wherein the second preset deviation rate threshold is greater than the first preset deviation rate threshold, and the severity of the level two abnormality is greater than the severity of the level one abnormality; If any deviation rate among the deviation rates corresponding to each real-time resistor is greater than a third preset deviation rate threshold, and the number of deviation rates greater than the third preset deviation rate threshold is greater than a fourth preset number, and the aluminum electrolysis cell does not have an anode reduction action, then the abnormality level of the electrode spacing is determined to be a level three abnormality, and a first-category level three warning signal is issued, wherein the third preset deviation rate threshold is greater than the second preset deviation rate threshold, and the severity of the level three abnormality is greater than the severity of the level two abnormality.

8. The method according to claim 7, characterized in that, The method further includes: If there is a deviation rate greater than the first preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the first preset deviation rate threshold is greater than the second preset number, and the aluminum electrolysis cell is performing anode reduction action, then the abnormal level of the electrode spacing is determined to be a first-level abnormality, and a second-category first-level warning signal is issued. If there is a deviation rate greater than the second preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the second preset deviation rate threshold is greater than the third preset number, and the aluminum electrolysis cell is performing anode reduction action, then the abnormal level of the electrode spacing is determined to be a level two abnormality, and a level two warning signal of the second category is issued. If there is a deviation rate greater than the third preset deviation rate threshold among the deviation rates corresponding to each of the real-time resistors, and the number of deviation rates greater than the third preset deviation rate threshold is greater than the fourth preset number, and the aluminum electrolysis cell has an anode reduction action, then the abnormal level of the electrode spacing is determined to be a level three abnormality, and a level three warning signal of the second category is issued. If the instantaneous slope in the instantaneous slope sequence is positive and the aluminum electrolysis cell has anode reduction action, then the abnormality level of the electrode spacing is determined to be level three abnormality, and a level three warning signal of the third category is issued.

9. A warning device for abnormal electrode spacing during the aluminum tapping stage of an aluminum electrolysis cell, characterized in that, The device includes: The acquisition unit is used to acquire the setting parameters, operating parameters and anode action parameters of the aluminum electrolytic cell. The setting parameters include the setting voltage and setting current of the aluminum electrolytic cell. The operating parameters include the operating voltage and operating current of the aluminum electrolytic cell during operation. The anode action parameters include the descent contactor status parameters and the cumulative anode descent time of the aluminum electrolytic cell. A determining unit is used to determine the real-time resistance sequence of the aluminum electrolytic cell based on the operating parameters; The judgment unit is used to determine the resistance reference value based on the set parameters, and to determine whether there is an abnormality in the electrode spacing based on the resistance reference value, the real-time resistance sequence and the anode action parameters; The early warning unit is used to determine the abnormality level of the electrode spacing based on the resistance reference value, the real-time resistance sequence and the anode action parameters if it is determined that there is an abnormality in the electrode spacing, and to issue a corresponding early warning signal based on the abnormality level.

10. An electronic device, characterized in that, The electronic device includes one or more processors and one or more memories, wherein at least one piece of program code is stored in the one or more memories, and the at least one piece of program code is loaded and executed by the one or more processors to implement the method as described in any one of claims 1 to 8.

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