An abnormal visualization alarm device for a lower outlet of an aluminum electrolytic cell and a method thereof

Abstract

The application discloses an abnormal visualization alarm device for a discharging port of an aluminum electrolysis cell and a method thereof, and relates to the field of automatic monitoring of aluminum electrolysis production. The device comprises a detection unit, a control unit and an execution unit. The detection unit comprises a metal trigger ring, a first sensor and a second sensor. The first sensor is used to detect the position signal of the metal trigger ring when the piston rod is completely retracted, and the second sensor is used to detect the position signal of the metal trigger ring when the piston rod is completely extended. The control unit is used to receive the position signal and determine whether the working state of the crust-breaking hammer head is normal according to a preset timing logic. When it is determined that the working state is abnormal, an alarm instruction is generated. The execution unit is provided with a plurality of independently controlled indicator lights, which are one-to-one corresponding to the discharging ports of the aluminum electrolysis cell. The execution unit is used to receive the alarm instruction and light up the indicator light corresponding to the discharging port to realize visual alarm. The application can realize real-time, automatic and accurate detection of abnormal states such as "clamping and blocking" and "jamming" of the discharging port of the aluminum electrolysis cell.

Description

Technical Field

[0001] This application relates to the field of automated monitoring in aluminum electrolysis production, and in particular to a visual alarm device and method for abnormal discharge port of aluminum electrolysis cell. Background Technology

[0002] In the aluminum electrolysis production process, a stable alumina feed rate is crucial for maintaining the thermal and material balance of the electrolytic cell. The shell-breaking and feeding system is responsible for periodically breaking up the electrolyte crust and adding alumina. Aluminum electrolysis is a complex electrochemical process, the core of which lies in maintaining the material and thermal balance of the electrolytic cell. A stable alumina concentration in the electrolyte is the primary condition for ensuring the efficient operation of the electrolytic cell. The alumina concentration not only directly determines the resistance within the cell but is also closely related to key indicators such as the frequency of the anodic effect and current efficiency.

[0003] However, due to fluctuations in alumina concentration within the electrolytic cell causing overheating, the hammerhead often develops an excessively large clump of complexed ions formed by the electrolyte and alumina adhering to it. This clump can become stuck at the feed inlet during the downward or upward movement of the hammerhead, or it can fall off and block the feed inlet, or the cooling of the electrolytic cell can cause severe condensation at the feed inlet. If these faults are not addressed promptly, they will lead to blockage of the corresponding feed inlet, preventing the addition of alumina and causing a series of adverse consequences. According to the resistance-alumina concentration characteristic curve within the electrolytic cell, when the alumina concentration drops below 1.5%~2.0%, the resistance within the cell will rise sharply, causing an increase in the electrolytic cell voltage and energy consumption. If the concentration continues to drop below 1.0%, the electrolytic cell will inevitably experience an anode effect. During the anode effect, not only will strong greenhouse gases CF4 and C2F6 be generated in the anode gas, but it will also cause a sudden rise in electrolyte temperature and a large amount of fluoride salt volatilization, severely damaging the internal structure of the cell and leading to a significant decrease in current efficiency. Therefore, blockage at the feed port is not a simple equipment failure, but a major potential process accident that can trigger a chain reaction.

[0004] Currently, there is no widely used automated visual monitoring solution for this type of fault in the industry. The closest approach is to rely entirely on the operator's sensory experience and manual inspection. Specifically: Auditory judgment: Experienced operators can judge by listening to the sound when the shell is being punched – a crisp striking sound is normal, while a dull or no sound indicates a blockage.

[0005] Visual observation: Observe whether the cylinder rod swings smoothly and whether it stops in an abnormal position.

[0006] Regular inspections: In accordance with the inspection system, all discharge ports of all tanks are inspected at regular intervals, which is subject to delays.

[0007] The existing solution relies entirely on human factors for detection and judgment, which has the following problems: (1) Due to the noisy environment in the electrolysis workshop (high background noise), the reliability of judging by sound (auditory) is low and it is easy to miss the judgment; (2) Because manual inspections are intermittent, while the shell-breaking action occurs periodically, faults that occur during the inspection interval cannot be detected immediately, resulting in a serious lag in fault diagnosis. From the occurrence of a fault to its discovery, tens of minutes or even an hour may have passed, at which point the discharge port is completely blocked; (3) Due to the reliance on personal experience, the technical level and sense of responsibility of different operators vary, resulting in inconsistent judgment standards for the same phenomenon, which has a great deal of randomness; (4) When a fault occurs, the operator needs to check each one to locate the specific abnormal material port, which is inefficient and prolongs the recovery time of the tank. Summary of the Invention

[0008] The purpose of this application is to provide a visual alarm device and method for abnormalities at the feed port of an aluminum electrolysis cell, which can realize real-time, automatic and accurate detection of abnormal states such as "blockage" and "jamming" at the feed port of the aluminum electrolysis cell, and immediately inform the operator of the abnormal information in an intuitive visual manner.

[0009] To achieve the above objectives, this application provides the following solution: In a first aspect, this application provides a visual alarm device for abnormalities at the feed port of an aluminum electrolysis cell, comprising: The detection unit includes a metal trigger ring fixed to the piston rod of the cylinder, a first sensor mounted on the upper part of the cylinder body, and a second sensor mounted on the lower part of the cylinder body; the first sensor is used to detect the position signal of the metal trigger ring when the piston rod is fully retracted, and the second sensor is used to detect the position signal of the metal trigger ring when the piston rod is fully extended. The control unit, connected to the first and second sensors, is used to receive the position signal and determine whether the working status of the shell-breaking hammer is normal according to the preset timing logic. When it is determined to be abnormal, an alarm command is generated. The execution unit is equipped with multiple independently controlled indicator lights, each corresponding to a feeding port of the aluminum electrolysis cell. These indicator lights are used to receive alarm commands and illuminate the corresponding feeding port indicator lights for visual alarm purposes.

[0010] Secondly, this application provides a method for visually alarming abnormalities at the aluminum electrolytic cell discharge port using the aforementioned visual alarm device, comprising: Collect multiple normal shelling cycle times and calculate the sliding average of multiple normal shelling cycle times as the benchmark normal cycle time; The alarm time threshold is set based on the aforementioned baseline normal cycle time; The position signal of the metal trigger ring is detected when the piston rod is fully retracted, and the position signal of the metal trigger ring is detected when the piston rod is fully extended; Based on the alarm time threshold and the position signal, the working status of the shell-breaking hammer is judged according to the preset timing logic. When it is judged to be abnormal, an alarm command is generated. The alarm command controls the indicator light to emit an alarm signal, providing a visual alarm.

[0011] According to the specific embodiments provided in this application, this application has the following technical effects: (1) This application uses upper and lower dual sensors (i.e., the first sensor and the second sensor) in conjunction with a metal trigger ring to collect the timing signal of the piston rod limit position. The objective electrical signal replaces the manual listening judgment in the noisy workshop, is not affected by environmental noise, and the reliability of fault detection is greatly improved. It synchronously follows the shelling cycle for real-time continuous monitoring, eliminates the time blind spot of manual intermittent inspection, and identifies faults immediately when they occur, thus preventing long-term blockage of the discharge port.

[0012] (2) This application relies on the timing logic preset by the control unit to automatically determine the working state of the shell-breaking hammer. The judgment standard is unified and quantified, eliminating the randomness of judgment caused by the difference in operator experience, and the fault identification results are stable and consistent.

[0013] (3) Set up independent indicator lights corresponding to each feeding port for visual alarm, which can directly and accurately locate the faulty feeding port, save the manual inspection of each port, shorten the fault handling time, and quickly restore alumina feeding.

[0014] (3) Through visual alarm, staff can clear blockages in the feed inlet in advance, ensure a stable supply of alumina, maintain the alumina concentration in the tank within a reasonable range, avoid the anode effect caused by excessively low concentration, reduce greenhouse gas emissions, fluoride loss, tank damage, stabilize tank voltage and current efficiency, and reduce energy consumption and overall production cost of electrolysis production.

[0015] (4) This application can realize automated and visual monitoring of abnormalities at the feed port, filling the gap in the industry where there is no mature automated monitoring solution. The hardware structure of the whole device is simple, suitable for the harsh working conditions of high temperature and dust in the electrolysis workshop, and facilitates the batch promotion and application of the whole series of electrolytic cells. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments 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.

[0017] Figure 1This is a schematic diagram of the structure of an abnormal visual alarm device for the feed port of an aluminum electrolysis cell provided in one embodiment of this application; Figure 2 This is a flowchart illustrating a visual alarm method for abnormal discharge port of an aluminum electrolysis cell, provided in one embodiment of this application. Detailed Implementation

[0018] 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.

[0019] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, this application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0020] In one exemplary embodiment, an abnormal visual alarm device for the feed port of an aluminum electrolysis cell is provided, including a detection unit, a control unit, and an execution unit. Each unit is described in detail below.

[0021] (1) Detection unit.

[0022] like Figure 1 As shown, the detection unit includes a metal trigger ring 2 fixed to the piston rod 5 of the shell-breaking cylinder 6, a first sensor 4 mounted on the upper part of the cylinder body, and a second sensor 3 mounted on the lower part of the cylinder body. The first sensor 4 is used to detect the position signal of the metal trigger ring 1 when the piston rod 5 is fully retracted, and the second sensor 3 is used to detect the position signal of the metal trigger ring 1 when the piston rod 5 is fully extended. The extended end of the piston rod 5 is sleeved in the protective connecting sleeve 1.

[0023] Both the first sensor 4 and the second sensor 3 are inductive displacement sensors. Inductive displacement sensors can detect the approach of a metal object in a non-contact manner and output a switching signal. The operating environment of an aluminum electrolysis cell is extremely harsh, with strong magnetic fields, high temperatures, and high dust levels. Inductive displacement sensors have advantages such as high temperature resistance (operating temperature up to 125℃), resistance to electromagnetic interference (insensitive to constant magnetic fields), and resistance to dust pollution (non-contact detection, no optical window), enabling them to operate stably for extended periods in this environment.

[0024] (2) Control unit.

[0025] The control unit, connected to the first sensor 4 and the second sensor 3, is used to receive the position signal and determine whether the working status of the shell-breaking hammer is normal according to the preset timing logic. When it is determined to be abnormal, an alarm command is generated.

[0026] The control unit is a programmable logic controller, which is the brain of the device. It receives the switching signals from all sensors and stores preset logic programs and timing parameters.

[0027] (3) Execution unit.

[0028] The execution unit is equipped with multiple independently controlled indicator lights, each corresponding to a feeding port of the aluminum electrolysis cell. These indicator lights are used to receive alarm commands and illuminate the corresponding feeding port indicator lights for visual alarm purposes.

[0029] The execution unit is a visual lighting panel, which is installed at the aluminum outlet and flue end of the aluminum electrolysis cell. The visual lighting panel is equipped with multiple LED indicator lights, each corresponding to a feeding port (such as the 6 feeding ports of a 500kA cell).

[0030] Based on the above apparatus, in an exemplary embodiment, such as Figure 2 As shown, a visual alarm method for abnormalities at the feed port of an aluminum electrolysis cell is provided, including the following steps.

[0031] S1: Collect multiple normal shelling cycle times and calculate the sliding average of multiple normal shelling cycle times as the benchmark normal cycle time.

[0032] Monitoring Startup. The monitoring cycle begins when the PLC receives the "start shelling" command from the tank controller or detects an electrical signal indicating that the cylinder has started operating. During the initial commissioning phase, the system learns and records the complete normal shelling cycle time T through multiple normal shelling actions. normal (e.g., 3 seconds), and based on this, set a reasonable alarm time threshold T. alarm (For example, 5 seconds). To address the drift in normal operating cycle time caused by compressed air pressure fluctuations, cylinder wear, etc., the PLC has an adaptive reference learning function: after the initial installation and commissioning of the system, or during the stable operation of the electrolytic cell (such as early morning each day), the PLC automatically collects 10-20 complete normal shelling cycle times, removes the maximum and minimum values, and calculates its sliding average value as the reference normal cycle time T for the current state. normal In order to achieve intelligentization.

[0033] S2: Set the alarm time threshold based on the benchmark normal cycle time.

[0034] Alarm time threshold T alarm According to T normal Dynamic calculation, for example, set to T alarm =k×T normal , where k is the safety factor, which can be set to 1.5~2.0.

[0035] S3: Detects the position signal of the metal trigger ring when the piston rod is fully retracted, and detects the position signal of the metal trigger ring when the piston rod is fully extended.

[0036] S4: Based on the alarm time threshold and the position signal, determine whether the working status of the shell-breaking hammer is normal according to the preset timing logic. When it is determined to be abnormal, generate an alarm command. Specifically, this includes: S41: Analyze the position signal to obtain the trigger timing sequence of the metal trigger ring during the shell-breaking action cycle; the trigger timing sequence includes the first trigger event, the intermediate trigger event, and the last trigger event.

[0037] Normal state path: Initial trigger event: The piston rod moves downward, and the metal ring triggers the first sensor first.

[0038] Intermediate trigger event: Continuing downwards, the metal ring subsequently triggers the second sensor.

[0039] Last trigger event: The piston rod moves upward, and the metal ring triggers the first sensor again, completing one shell-breaking cycle.

[0040] The entire shell-breaking process cycle T cycle ≤T alarm .

[0041] S42: Based on the alarm time threshold and the integrity of the trigger timing sequence, identify abnormal signal characteristics. Specifically, this includes: S421: When the trigger timing sequence is complete and the shell-breaking action cycle is greater than the alarm time threshold, it is identified as an action timeout abnormal signal feature.

[0042] When the trigger sequence is complete, that is, the first trigger event, intermediate trigger events, and last trigger event are completed, but T cycle >T alarm This indicates that the hammer head is moving slowly, is severely obstructed, and the action is timed out.

[0043] S422: When the trigger timing sequence is incomplete and no intermediate trigger event is detected within the alarm time threshold after the first trigger event is detected, it is identified as a downlink obstruction abnormal signal feature.

[0044] The metal ring triggered the first sensor, but in T alarm The second sensor was not triggered. This indicates that the hammer did not hit the designated position during its descent, the feed inlet was blocked, and the descent was obstructed.

[0045] S423: When the trigger timing sequence includes a first trigger event and an intermediate trigger event, but no final trigger event is detected within the alarm time threshold after the intermediate trigger event is detected, it is identified as a reset failure abnormal signal feature.

[0046] The metal ring triggered the second sensor, but in T alarm The system failed to return to trigger the first sensor within the specified time. This indicates that the hammer head was stuck during the upward reset, resulting in a reset failure.

[0047] S43: When the abnormal signal feature is detected in 2-3 consecutive shelling operation cycles, an alarm command is generated.

[0048] To further improve alarm accuracy and avoid false alarms caused by single signal jitter or transient external interference, continuous anomaly detection logic is added: when the PLC first detects an anomaly, it does not immediately output an alarm, but continues to monitor the next fault cycle. If the anomaly is detected for 2-3 consecutive cycles, it is confirmed as a genuine fault, and an alarm signal is output.

[0049] S5: Control the indicator light to emit an alarm signal according to the alarm command to provide a visual alarm.

[0050] Once the PLC determines any of the above abnormal situations, it immediately sends a command to the visual lighting panel, causing the LED indicator corresponding to the abnormal material inlet to flash yellow.

[0051] This application also includes an alarm reset mechanism: Manual reset mode: After the operator has dealt with the abnormality, a reset command can be sent through the operating button installed on the tank control machine or on site to control the indicator light to turn off.

[0052] Automatic Reset Mode: After outputting an alarm, the PLC continues to monitor subsequent expulsion cycles. If 3-5 consecutive normal cycles occur, the PLC automatically determines that the fault has been cleared and automatically turns off the indicator light, thus automatically resetting the alarm.

[0053] This application has the following advantages: (1) Real-time and accurate: Since this application uses sensors to collect signals in real time for each shelling cycle and the PLC performs millisecond-level logic operations, it can detect abnormalities immediately. This overcomes the intermittency of manual inspection and solves the problem of judgment lag.

[0054] (2) Reliable and objective: Since this application uses a unified and quantifiable electrical signal and time threshold as the judgment standard, it completely replaces the subjective feelings that vary from person to person, making the detection results consistent and reliable, and solving the problem of randomness in manual judgment.

[0055] (3) High efficiency and intuitiveness: Since this application adopts a visual light panel and each indicator light is bound to a specific material port, the operator can locate the fault point at a glance from a distance, realizing "what you see is what you get", eliminating the trouble of checking one by one, and greatly improving maintenance efficiency.

[0056] (4) Simple structure and easy to implement: The core components of this application are all industrial standard parts (inductive sensors, PLC, LED lights), with mature technology and low cost. The modification can be completed on existing electrolytic cells through simple mechanical installation and electrical wiring, making it highly applicable.

[0057] (5) In-depth diagnosis and prevention: By identifying abnormalities such as "action timeout", this application can indirectly reflect abnormal heat balance in the tank such as "process-type crust", providing operators and process personnel with a more comprehensive basis for decision-making, which helps to take process adjustment measures in the incipient stage of the fault and avoid the fault from worsening.

[0058] (6) Strong self-adaptation and stable reliability: This application has an adaptive benchmark learning function, which can dynamically adapt to changes in working conditions such as cylinder aging and air pressure fluctuations; at the same time, through continuous abnormal judgment logic, it effectively filters out occasional interference, ensures the accuracy of alarms, and greatly reduces the false alarm rate.

[0059] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0060] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A visual alarm device for abnormal discharge port of an aluminum electrolysis cell, characterized in that, include: The detection unit includes a metal trigger ring fixed to the piston rod of the cylinder, a first sensor mounted on the upper part of the cylinder body, and a second sensor mounted on the lower part of the cylinder body; the first sensor is used to detect the position signal of the metal trigger ring when the piston rod is fully retracted, and the second sensor is used to detect the position signal of the metal trigger ring when the piston rod is fully extended. The control unit, connected to the first and second sensors, is used to receive the position signal and determine whether the working status of the shell-breaking hammer is normal according to the preset timing logic. When it is determined to be abnormal, an alarm command is generated. The execution unit is equipped with multiple independently controlled indicator lights, each corresponding to a feeding port of the aluminum electrolysis cell. These indicator lights are used to receive alarm commands and illuminate the corresponding feeding port indicator lights for visual alarm purposes.

2. The visual alarm device for abnormal aluminum electrolytic cell discharge port according to claim 1, characterized in that, Both the first sensor and the second sensor are inductive displacement sensors.

3. The visual alarm device for abnormal aluminum electrolytic cell discharge port according to claim 1, characterized in that, The control unit is a programmable logic controller.

4. The visual alarm device for abnormal aluminum electrolytic cell discharge port according to claim 1, characterized in that, The execution unit is a visual lighting panel.

5. The aluminum electrolysis cell feed port abnormality visual alarm device according to claim 4, characterized in that, The visualization light panel is installed at the aluminum outlet end and the flue end of the aluminum electrolysis cell.

6. A method for visually alarming abnormalities at the aluminum electrolytic cell discharge port using the visual alarm device for abnormalities at the aluminum electrolytic cell discharge port as described in any one of claims 1-5, characterized in that, The method includes: Collect multiple normal shelling cycle times and calculate the sliding average of multiple normal shelling cycle times as the benchmark normal cycle time; The alarm time threshold is set based on the aforementioned baseline normal cycle time; The position signal of the metal trigger ring is detected when the piston rod is fully retracted, and the position signal of the metal trigger ring is detected when the piston rod is fully extended; Based on the alarm time threshold and the position signal, the working status of the shell-breaking hammer is judged according to the preset timing logic. When it is judged to be abnormal, an alarm command is generated. The alarm command controls the indicator light to emit an alarm signal, providing a visual alarm.

7. The visual alarm method for abnormal aluminum electrolytic cell discharge port according to claim 6, characterized in that, Based on the alarm time threshold and the position signal, the working status of the shell-breaking hammer is determined according to a preset timing logic. When an abnormality is detected, an alarm command is generated, specifically including: The position signal is analyzed to obtain the trigger timing sequence of the metal trigger ring during the shell-breaking action cycle; the trigger timing sequence includes the first trigger event, intermediate trigger events, and the last trigger event. Based on the alarm time threshold and the integrity of the trigger timing sequence, abnormal signal characteristics are identified; When the abnormal signal characteristics are detected within 2-3 consecutive shelling cycles, an alarm command is generated.

8. The visual alarm method for abnormal aluminum electrolytic cell discharge port according to claim 7, characterized in that, Based on the alarm time threshold and the integrity of the trigger timing sequence, abnormal signal characteristics are identified, specifically including: When the trigger timing sequence is complete and the shell-breaking action cycle is greater than the alarm time threshold, it is identified as an action timeout abnormal signal feature; When the trigger timing sequence is incomplete and no intermediate trigger event is detected within the alarm time threshold after the first trigger event is detected, it is identified as a downlink obstruction abnormal signal feature. When the trigger timing sequence includes an initial trigger event and an intermediate trigger event, but no final trigger event is detected within the alarm time threshold after the intermediate trigger event is detected, it is identified as a reset failure abnormal signal feature.

9. The visual alarm method for abnormal aluminum electrolytic cell discharge port according to claim 6, characterized in that, After the abnormality is handled, the indicator light is turned off according to the reset command; the reset command is sent through the operation button installed on the tank control machine or on site.

10. The visual alarm method for abnormal aluminum electrolytic cell discharge port according to claim 6, characterized in that, If subsequent monitoring shows that the shell-breaking process is in a normal state for 3-5 consecutive cycles, the indicator light will turn off.

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