A method and a device for measuring the position of an electrode in an electric arc furnace

Abstract

This invention provides a method for measuring the position of an electrode in a submerged arc furnace, relating to the field of measurement technology. The method includes: S1, installing a weighing device and a position detection device; S2, installing the electrode onto a holder and obtaining its initial weight using the weighing device; S3, lowering the electrode to its lowest position within the furnace chamber using a high-pressure cylinder, obtaining initial position information; S4, during production, the weighing device and position detection device continuously monitor the real-time weight of the holder and the real-time position information of the electrode. If the real-time weight remains unchanged compared to the initial weight, the electrode position can be determined based on the initial and real-time position information. If the real-time weight changes compared to the initial weight, the electrode position needs to be determined by combining the initial weight, the real-time weight, the initial position information, and the real-time position information. This invention can accurately determine the electrode's embedment depth and end position within the furnace, directly influencing the furnace's thermal field distribution and energy utilization efficiency calculations.

Description

Technical Field

[0001] This invention relates to the field of measurement technology, and in particular to a method for measuring the position of electrodes in a submerged arc furnace. Background Technology

[0002] As a core high-temperature smelting equipment in the metallurgical production of ferroalloys, industrial silicon, and calcium carbide, the embedment depth and end position of the electrodes in the furnace charge of an electric arc furnace directly determine the heat field distribution, energy utilization efficiency, product quality, and production safety within the furnace. Currently, the industry relies on methods such as calculating the electrode lifting stroke or judging by human experience to measure the electrode position in electric arc furnaces.

[0003] The above measurement method has the following problems:

[0004] 1. The measurement method is too indirect and cannot reflect the true position. It relies solely on the stroke of the electrode lifting mechanism for calculation, without considering the actual working conditions such as electrode burn-out, bending, furnace charge collapse, and crusting. This results in a serious discrepancy between the external stroke and the actual electrode position inside the furnace, leading to distorted measurement results. If the position is too low, it is easy to corrode the furnace lining and cause the risk of furnace leakage.

[0005] 2. Human experience-based judgment is highly subjective and prone to errors. It relies on operators to subjectively judge the electrode position based on phenomena such as flames, smoke, and current. It lacks quantitative standards, and the judgment results are unstable and inconsistent, making it impossible to achieve precise control.

[0006] 3. Poor real-time performance, making it difficult to meet the dynamic process control requirements. Traditional methods cannot continuously and in real time reflect the dynamic position changes of the electrode during the high-temperature melting process. The lag is obvious, and it is impossible to respond in time to sudden working conditions such as material collapse, sparking, and load fluctuations.

[0007] 4. Lack of closed-loop control foundation makes it difficult to achieve intelligent upgrades. Due to the lack of accurate and reliable real-time electrode position signals, it is impossible to form a closed-loop control with the electrode lifting and pressing system, which limits the automation, intelligence and green upgrading of the electric arc furnace. Summary of the Invention

[0008] To address the aforementioned technical problems, this invention provides a method for measuring the electrode position in a submerged arc furnace. This method accurately determines the electrode's embedment depth and end position within the furnace, directly influencing the furnace's thermal field distribution and energy utilization efficiency calculations. Accurate electrode position determination resolves issues such as exposed electric arcs, low thermal efficiency, high power consumption, and furnace top scorching and material collapse. This invention also discloses a device for measuring the electrode position in a submerged arc furnace.

[0009] The technical solution adopted in this invention is:

[0010] A method for measuring the electrode position of a submerged arc furnace, comprising:

[0011] S1. Install a weighing device and a position detection device. The weighing sensor is installed at the high-pressure cylinder of the gripper, and the position detection device is installed on the shelf of the high-pressure cylinder.

[0012] S2. Install the electrode onto the holder and obtain the initial weight using a weighing device;

[0013] S3. After the high-pressure cylinder drives the electrode down to the lowest position in the furnace, the zero position information in the furnace, the position information of the position detection device, and the stroke information of the high-pressure cylinder are obtained. The zero position information, position information, and stroke information are the initial position information.

[0014] S4. During the production process, the weighing device and the position detection device detect the real-time weight of the holder and the real-time position information of the electrode. If the real-time weight does not change compared with the initial weight, the position of the electrode can be obtained based on the initial position information and the real-time position information. If the real-time weight changes compared with the initial weight, the position of the electrode needs to be obtained by combining the initial weight, the real-time weight, the initial position information and the real-time position information.

[0015] Optionally, the initial weight in step S2 is the weight of all electrodes or the weight of all electrodes plus the weight of the holder.

[0016] Optionally, the position detection device is installed on the shelf or at a distance of 1-2 meters from the shelf.

[0017] Optionally, after the real-time weight changes compared to the initial weight in step S4, the following steps are included:

[0018] S41. After resetting the holder to the initial position, install a new electrode and re-measure the total weight. If the total weight is greater than the initial weight, subtract the difference between the total weight and the initial weight to obtain the new initial weight. If the total weight is less than the initial weight, proceed to step S41.

[0019] S42. The position sensing device re-detects the position information and records it as secondary position information. Based on the secondary position information and the total weight, the stroke adjustment information of the heavy-duty cylinder is obtained. Based on the stroke adjustment information, the position information of the electrode is adjusted so that the electrode is at the zero position.

[0020] Optionally, in step S41, a preset weight change threshold is set, and when the weight change reaches the preset weight change threshold, the process proceeds to step S42.

[0021] Optionally, when the real-time weight changes compared to the initial weight in step S4, the consumed length of the electrode is calculated based on the consumed electrode weight and the electrode density.

[0022] The specific calculation formula is: Electrode weight consumed / Electrode density = Consumed length.

[0023] A device for measuring the electrode position of a submerged arc furnace, comprising:

[0024] A shelf, wherein an exposed opening is provided on the shelf;

[0025] The holder is installed inside the exposed opening;

[0026] A high-pressure cylinder is installed on the shelf and connected to the gripper, used to drive the gripper to reciprocate along the exposed opening;

[0027] The load cell is installed on the heavy-duty cylinder.

[0028] A position sensor is mounted on the shelf.

[0029] The controller is electrically connected to the heavy-duty cylinder, the weighing sensor, and the position sensor.

[0030] Optionally, the position sensor is mounted on the top of the shelf via a mounting bracket, and the distance between the position sensor and the shelf is 1-2 meters after the position sensor is mounted on the mounting bracket.

[0031] Compared with the prior art, the beneficial effects of the present invention are:

[0032] 1. This method can accurately determine the embedment depth and end position of the electrode in the furnace, directly determining the thermal field distribution and energy utilization efficiency conversion in the furnace.

[0033] 2. Accurately determine the electrode position to solve problems such as exposed electric arc, low thermal efficiency, high power consumption, and furnace top fire and material collapse.

[0034] 3. Eliminate the risk of furnace leakage caused by the erosion of the furnace lining due to the low position.

[0035] 4. Accurate electrode positioning can improve automation applications and enable automatic power distribution and electrode pressing / discharging operations. Attached Figure Description

[0036] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0037] Figure 1 This is a schematic diagram of the process structure for measuring the electrode position of a submerged arc furnace.

[0038] Figure 2 This is a schematic diagram of the electrode position measuring device for an electric arc furnace.

[0039] Figure label:

[0040] 1. Shelves;

[0041] 2. Holder;

[0042] 3. Heavy-duty cylinder;

[0043] 4. Weighing sensor;

[0044] 5. Position sensor;

[0045] 6. Controller. Detailed Implementation

[0046] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0047] In the description of this invention, it should be understood that the terms "upper," "lower," "vertical," "top," "bottom," "axial," "radial," "circumferential," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used to facilitate the description of this invention and to simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0048] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0049] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0050] The following disclosure provides many different embodiments or examples for implementing various structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, examples of various specific processes and materials are provided in this invention, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0051] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0052] like Figure 1 and Figure 2 As shown, an embodiment of the present invention provides a method for measuring the position of electrodes in a submerged arc furnace, comprising:

[0053] S1. Install a weighing device (i.e., weighing sensor 4) and a position detection device (i.e., position sensor 5). The weighing sensor 4 is installed at the high-pressure cylinder 3 of the handle 2, and the position detection device is installed on the shelf 1 of the high-pressure cylinder 3. The position detection device is installed on the shelf 1 or at a distance of 1-2 meters from the shelf 1.

[0054] S2. Install the electrodes onto the holder 2 and obtain the initial weight using a weighing device; the initial weight is the weight of all electrodes or the weight of all electrodes plus the weight of the holder 2.

[0055] S3. After the high-pressure cylinder 3 drives the electrode down to the lowest position in the furnace, the zero position information in the furnace, the position information of the position detection device, and the stroke information of the high-pressure cylinder 3 are obtained. The zero position information, position information, and stroke information are the initial position information.

[0056] S4. During the production process, the weighing device and the position detection device detect the real-time weight of the holder 2 and the real-time position information of the electrode. If the real-time weight does not change compared to the initial weight, the position of the electrode can be obtained based on the initial position information and the real-time position information. If the real-time weight changes compared to the initial weight, the position of the electrode needs to be obtained by combining the initial weight, the real-time weight, the initial position information and the real-time position information.

[0057] S41. After resetting the holder 2 to the initial position, install the new electrode and remeasure the total weight. If the total weight is greater than the initial weight, subtract the difference between the total weight and the initial weight to obtain the new initial weight. If the total weight is less than the initial weight, proceed to step S41. A preset weight change threshold is set. When the weight change reaches the preset weight change threshold, proceed to step S42.

[0058] S42. The position sensing device re-detects the position information and records it as secondary position information. Based on the secondary position information and the total weight, the stroke adjustment information of the heavy-duty cylinder 3 is obtained. Based on the stroke adjustment information, the position information of the electrode is adjusted so that the electrode is at the zero position.

[0059] In one embodiment, when the real-time weight changes compared to the initial weight in step S4, the consumed length of the electrode is calculated based on the consumed electrode weight and the electrode density.

[0060] The specific calculation formula is: Electrode weight consumed / Electrode density = Consumed length.

[0061] In use, the weighing device is installed on the heavy-duty cylinder 3, and the position detection device is installed on the shelf 1. The weight of the single electrode holder 2 is calculated using the weighing device. Then, the electrodes are connected. After connection (standard is 7 electrodes), the weight of the entire holder 2, i.e., the initial weight (including the weight of the equipment and motor), is obtained. The total length of the connected electrodes is determined based on the electrode specifications and weight. The connected electrodes are lowered to the lowest position in the furnace, and this position is marked as zero position information. The position detection device is installed on the shelf 1 at a distance of 19.5 meters from the lowest position in the furnace (this position is the position information, i.e., the positioning mark). After the electrodes are lowered to the lowest position in the furnace, the position detection device detects the distance between the electrodes and this positioning mark. Simultaneously, the system records the stroke information of the heavy-duty cylinder 3.

[0062] During normal production, the electrodes, as consumables, gradually decrease in size, and their weight and length change. In order to facilitate the determination of the electrode's position information during use, the electrode's position is calculated by using the weight change and position information.

[0063] In actual production, the lower the electrode position, the higher the displayed current value (the highest current value is when the electrode is at its initial position at the bottom of the furnace, i.e., when the high-pressure cylinder 3 drives the holder 2 to the zero position). Under normal operating conditions (standard gear, load), record the current value of the electrode at different positions (record once every 10mm increase). Measure the current change value at elevations of 100mm-500mm as a reference record.

[0064] During the production process of an electric arc furnace, the electrode is consumed due to process reactions. The weight change of the consumed electrode is measured by a weighing device, and the length of the consumed electrode is calculated. Subtracting the consumed length from the total length gives a preliminary indication of the electrode's position within the furnace. Combining this with the displayed current value, a comprehensive value is obtained to determine the precise position of the electrode.

[0065] For example:

[0066] The total weight of a single electrode is 33.6 tons (7 electrodes, the total weight of the electrodes obtained by subtracting the weight of the handle 2 from the weighing device, i.e., the initial weight). The manufacturer's electrode specifications are: length 2.3 meters, weight 4.8 tons (resulting in an electrode density of 2.09 tons / meter).

[0067] After one shift of operation of the electric arc furnace, the weighing device detected that the weight of the electrode was 33 tons. The reduction in electrode weight is the initial weight minus the real-time weight, i.e., 22.6 - 33 = 0.6 tons. According to the formula, the electrode consumption is calculated to be 0.6 / 2.09 = 0.29 meters. Therefore, it is determined that the overall electrode is reduced by 290 mm, and the working end is shortened.

[0068] After the working end is shortened, electrodes need to be added. Adding electrodes will change the weight of the electrodes, so the weight of the electrodes needs to be adjusted to match the initial weight. For example, if the total weight of the added electrodes is 35 tons, the excess 1.4 tons needs to be subtracted from the system weight.

[0069] Simultaneously, the length will also change, and the position information of the electrode is detected by a position detection device. If the length is greater than the position information detected by the position detection device, the initial position information does not need to be changed.

[0070] When the weight of the electrode changes, and the electrode is not fully installed or not fully installed to reach its initial weight, the reduced weight is fed back to the system.

[0071] The system compares the real-time position information detected by the position detection device with the original position information to calculate the difference in length. The stroke of the high-pressure cylinder 3 is used to compensate for the difference in length, ensuring that the electrode is always at the zero position at the start of production.

[0072] During production, the distance between the electrode and the lowest position in the furnace is adjusted according to the magnitude of the current. The position of the electrode is adjusted by the high-pressure cylinder 3.

[0073] During production, due to the production process principle, the position of the electrode will be adjusted according to the consumption. Therefore, it is necessary to compare the position information (i.e., 19.5 meters) with the value of the drop height and the value of the weight reduction. If the error is within 5%, the average value is taken as the final consumption of the electrode (the position in the furnace remains unchanged, that is, the zero position information remains unchanged).

[0074] During production, the electrode's position adjusts according to the current value. Therefore, it's necessary to refer to the position information (i.e., 19.5 meters) to confirm the rise value as the electrode's lifting height. This height needs to be added to the weight reduction value to arrive at the final electrode position. If the electrode weight remains constant, the rise height is the final electrode position. If the weight changes, the consumption amount needs to be added to arrive at the final electrode position.

[0075] like Figure 2 As shown, to facilitate the implementation of the above method, the present invention also includes an electrode position measuring device for a submerged arc furnace, comprising: a shelf plate 1, a holder 2, a high-pressure cylinder 3, a weighing sensor 4, a position sensor 5, and a controller 6. The shelf plate 1 has an exposed opening. The holder 2 is installed within the exposed opening. The high-pressure cylinder 3 is installed on the shelf plate 1 and connected to the holder 2, for driving the holder 2 to reciprocate along the height direction. The weighing sensor 4 is installed at the connection between the high-pressure cylinder 3 and the holder 2, for detecting the weight of the holder 2. The position sensor 5 is installed on the shelf plate 1. The controller 6 is electrically connected to the high-pressure cylinder 3, the weighing sensor 4, and the position sensor 5.

[0076] The heavy-duty cylinder 3 is vertically installed on the shelf 1. A weighing sensor 4 is movably mounted on the heavy-duty cylinder 3 and is connected to the handle 2. The position sensor 5 is installed on the shelf 1, and after installation, it is 19.5 meters away from the lowest position inside the electric arc furnace.

[0077] During production preparation, seven electrodes are installed inside the holder 2. After installation, the weight of the electrodes is detected by the load cell 4, and this data is recorded and fed back to the controller 6. The controller 6 (the control system of the electric arc furnace) records this data as the initial weight. The control cylinder 3 lowers the holder 2 to the lowest position inside the electric arc furnace, and this position information is recorded as the zero position information. At the same time, the stroke information of the control cylinder 3 at this time is recorded. Combined with the position information of the position sensor 5, the initial position information of the electrodes is obtained.

[0078] When the weighing sensor 4 does not detect a change in the weight of the electrode, it is only necessary to record the real-time position information. The real-time position of the electrode can be determined by comparing the real-time position information with the initial position information.

[0079] When the load cell 4 detects a decrease in the weight of the motor, the difference in weight is obtained by subtracting the real-time weight from the initial weight. The position of the electrode is then calculated based on this difference. For example, if the weighing device detects that the electrode weighs 33 tons, the decrease in electrode weight is the initial weight minus the real-time weight, i.e., 22.6 - 33 = 0.6 tons. According to the formula, the electrode consumption is calculated to be 0.6 / 2.09 = 0.29 meters. Therefore, it is determined that the overall electrode length has decreased by 290 mm, and the working end has become shorter.

[0080] After the working end is shortened, the controller 6 controls the high-pressure cylinder 3 to adjust the stroke, so that the real-time position information of the electrode matches the zero-position information. Then, the position of the electrode is adjusted according to the magnitude of the current.

[0081] More specifically, when the electrode length is reduced by 290mm, the stroke of the high-power cylinder 3 is supplemented by 290mm.

[0082] When the working end is shortened and the stroke adjustment of the heavy-duty cylinder 3 is no longer sufficient to meet production requirements, a new electrode needs to be installed. After installation, the weight of the electrode is monitored in real time by the weighing sensor 4. If the weight of the electrode is greater than the initial weight, the excess weight needs to be deducted. Then, the position information is determined by the position sensor 5, and the stroke information and zero position information of the heavy-duty cylinder 3 are recorded simultaneously.

[0083] If the weight of the electrode is less than the initial weight, the consumption of the electrode is calculated based on the difference, and it is determined how many millimeters the electrode has been reduced. The compensation is then made through the stroke of the high-power cylinder 3.

[0084] In one embodiment, to facilitate the adjustment of the position sensor 5, the position sensor 5 is mounted on the top of the shelf 1 by a mounting bracket. When the position sensor 5 is mounted on the mounting bracket, the distance between the position sensor 5 and the shelf 1 is 1 meter to 2 meters.

[0085] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for measuring the electrode position of a submerged arc furnace, characterized in that, Includes the following steps: S1. Install a weighing device and a position detection device. The weighing sensor is installed at the high-pressure cylinder of the gripper, and the position detection device is installed on the shelf of the high-pressure cylinder. S2. Install the electrode onto the holder and obtain the initial weight using a weighing device; S3. After the high-pressure cylinder drives the electrode down to the lowest position in the furnace, the zero position information in the furnace, the position information of the position detection device, and the stroke information of the high-pressure cylinder are obtained. The zero position information, position information, and stroke information are the initial position information. S4. During the production process, the weighing device and the position detection device detect the real-time weight of the holder and the real-time position information of the electrode. If the real-time weight does not change compared with the initial weight, the position of the electrode can be obtained based on the initial position information and the real-time position information. If the real-time weight changes compared with the initial weight, the position of the electrode needs to be obtained by combining the initial weight, the real-time weight, the initial position information and the real-time position information.

2. The method for measuring the electrode position of a submerged arc furnace according to claim 1, characterized in that, The initial weight in step S2 is the weight of all electrodes or the weight of all electrodes plus the weight of the holder.

3. The method for measuring the electrode position of a submerged arc furnace according to claim 1, characterized in that, The position detection device is installed on the shelf or at a distance of 1-2 meters from the shelf.

4. The method for measuring the electrode position of a submerged arc furnace according to claim 1, characterized in that, After the real-time weight changes compared to the initial weight in step S4, the following steps are included: S41. After resetting the holder to the initial position, install a new electrode and re-measure the total weight. If the total weight is greater than the initial weight, subtract the difference between the total weight and the initial weight to obtain the new initial weight. If the total weight is less than the initial weight, proceed to step S42. S42. The position sensing device re-detects the position information and records it as secondary position information. Based on the secondary position information and the total weight, the stroke adjustment information of the heavy-duty cylinder is obtained. Based on the stroke adjustment information, the position information of the electrode is adjusted so that the electrode is at the zero position.

5. The method for measuring the electrode position of a submerged arc furnace according to claim 1, characterized in that, In step S41, a preset weight change threshold is set. When the weight change reaches the preset weight change threshold, the process proceeds to step S42.

6. The method for measuring the electrode position of a submerged arc furnace according to claim 1, characterized in that, When the real-time weight changes compared to the initial weight in step S4, the consumed length of the electrode is calculated based on the consumed electrode weight and the electrode density. The specific calculation formula is: Electrode weight consumed / Electrode density = Consumed length.

7. A device for measuring the electrode position of a submerged arc furnace, characterized in that, include: A shelf, wherein an exposed opening is provided on the shelf; The holder is installed inside the exposed opening; A high-pressure cylinder is installed on the shelf and connected to the gripper, used to drive the gripper to reciprocate along the exposed opening; The load cell is installed on the heavy-duty cylinder. A position sensor is mounted on the shelf. The controller is electrically connected to the heavy-duty cylinder, the weighing sensor, and the position sensor.

8. The electrode position measuring device for a submerged arc furnace according to claim 7, characterized in that, The position sensor is mounted on the top of the shelf via a mounting bracket. When the position sensor is mounted on the mounting bracket, the distance between the position sensor and the shelf is 1-2 meters.

Images