Aluminum cell tapping control system and method

Abstract

The application discloses an aluminum electrolysis cell aluminum tapping control system and method, the system comprises an aluminum electrolysis cell, a vacuum ladle, a crane actuator, an electromagnetic induction flow rate measuring module, a liquid level distance measuring module and a controller; the vacuum ladle sucks aluminum liquid from the aluminum electrolysis cell through a suction pipe; the crane actuator is used to drive the vacuum ladle and the suction pipe to complete alignment, pipe insertion and pipe extraction operations with the aluminum electrolysis cell; the suction pipe is used to collect the instantaneous flow rate of aluminum liquid in the suction pipe in real time; the top end of the vacuum ladle is provided with an observation window for light transmission and isolation of high-temperature aluminum liquid, dust and flue gas in the interior of the vacuum ladle; the liquid level distance measuring module uses laser or ultrasonic non-contact methods to detect the liquid level height of aluminum liquid in the interior of the vacuum ladle in real time; the controller is used to complete aluminum tapping amount fusion calculation, fault tolerance determination and vacuum valve self-adaptive adjustment based on the detection data of the electromagnetic induction flow rate measuring module and the liquid level distance measuring module. Through the application, the accuracy of aluminum tapping control of the aluminum electrolysis cell can be improved.

Description

Technical Field

[0001] This application belongs to the technical field of aluminum smelting, and particularly relates to a control system and method for aluminum electrolysis cell output. Background Technology

[0002] As the aluminum electrolysis industry continues to develop towards large-scale, refined, and unmanned operations, the aluminum tapping process, as a core production link maintaining stable aluminum levels and thermal balance in the electrolytic cell, directly determines the current efficiency, primary aluminum purity, and service life of the electrolytic cell through its metering accuracy and process stability. Currently, aluminum electrolysis tapping operations are gradually transitioning from manual to automated operations, generally adopting a metering structure of vacuum ladle lifting combined with overhead crane weighing, and achieving semi-automatic or automatic operation of the aluminum tapping process through vacuum valve regulation.

[0003] However, the harsh working conditions in electrolysis workshops, such as strong magnetic fields, high temperatures, dust, and dynamic equipment vibrations, easily cause magnetostrictive drift and electromagnetic interference errors in weighing sensors, resulting in generally high metering errors in conventional aluminum tapping. Furthermore, existing aluminum tapping control systems often rely on a single detection device as the sole metering basis, lacking redundant verification and fault tolerance mechanisms. Conditions such as long-term sensor drift, pipeline blockage, and abnormal liquid level fluctuations cannot be identified or tolerated in real time, leading to insufficient long-term operational reliability. In addition, traditional aluminum tapping control often employs fixed negative pressure and fixed flow rate control strategies, which cannot adaptively adjust based on individual tank aluminum liquid levels and tank conditions. This easily leads to problems such as fluctuations in aluminum tapping flow rate, slag inclusion, and exceeding or falling short of the target amount at the endpoint, making it difficult to meet the high-precision and high-stability production control requirements of modern electrolytic aluminum production.

[0004] Therefore, improving the accuracy of aluminum output control in aluminum electrolysis cells has become an urgent technical problem to be solved. Summary of the Invention

[0005] The embodiments of this application provide an aluminum electrolysis cell aluminum output control system and method, which can at least to some extent improve the accuracy of aluminum output control in aluminum electrolysis cells.

[0006] 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.

[0007] According to a first aspect of the embodiments of this application, an aluminum electrolysis cell aluminum discharge control system is provided. The system includes an aluminum electrolysis cell, a vacuum lifting ladle, an overhead crane actuator, an electromagnetic induction flow rate measurement module, a liquid level measuring module, and a controller. The vacuum lifting ladle draws molten aluminum from the aluminum electrolysis cell through a suction tube. The overhead crane actuator drives the vacuum lifting ladle and the suction tube to complete alignment, insertion, and removal operations with the aluminum electrolysis cell. The outer wall of the suction tube is provided with a positioning groove. The electromagnetic induction flow rate measurement module is a detachable clamp-type structure, which is limited and clamped at the positioning groove for real-time acquisition of the instantaneous flow rate of the molten aluminum in the suction tube. The top of the vacuum lifting ladle is provided with an observation window. The observation window is fitted with a sealed high-temperature resistant quartz glass to allow light to pass through while isolating the high-temperature molten aluminum, dust, and fumes inside the vacuum lifting package. The top of the vacuum lifting package also has a mounting hole, where the liquid level measuring module is installed. It uses a laser or ultrasonic non-contact method to detect the liquid level height of the molten aluminum inside the vacuum lifting package in real time. The controller is communicatively connected to both the electromagnetic induction flow velocity measurement module and the liquid level measuring module. It incorporates dual-source metering logic, cross-validation logic, volume adaptive compensation logic, and closed-loop control logic. Based on the detection data from the electromagnetic induction flow velocity measurement module and the liquid level measuring module, it performs aluminum output fusion calculations, fault tolerance judgment, and adaptive adjustment of the vacuum valve.

[0008] According to a second aspect of the embodiments of this application, an aluminum electrolysis cell aluminum output control method is provided. The method is applied to the aluminum electrolysis cell aluminum output control system of the first aspect described above. The method includes: acquiring the initial liquid level of the empty vacuum lifting package using a liquid level ranging module on the vacuum lifting package, recording the target aluminum output amount in the controller, and completing system parameter initialization; controlling the overhead crane actuator to complete the alignment of the aluminum electrolysis cell and insertion of the aluminum suction tube, and opening the vacuum valve in the aluminum suction tube; controlling the electromagnetic induction flow velocity measurement module on the aluminum suction tube and the liquid level ranging module to synchronously acquire detection data, calculating the flow velocity integral aluminum output amount and the liquid level converted aluminum output amount respectively; and comparing the results in real time. The deviation between the aluminum output by the flow rate integral and the aluminum output calculated by the liquid level is considered, and the operating status of the two detection branches is determined according to a preset deviation threshold. When the deviation is within the preset deviation threshold range, the controlled aluminum output is obtained through dynamic weighted fusion. When the deviation exceeds the preset deviation threshold range, a single detection branch is determined to be faulty, and the system automatically switches to the normally operating detection branch for single-source independent closed-loop control. The opening of the vacuum valve is dynamically adjusted according to the difference between the aluminum output progress and the target aluminum output. When the controlled aluminum output reaches the target aluminum output, the vacuum valve is closed, and the overhead crane actuator is controlled to complete the aluminum suction tube removal and vacuum lifting and resetting.

[0009] In some embodiments of this application, based on the foregoing scheme, the amount of aluminum produced by the flow rate integral is calculated according to the following formula:

[0010] In the formula, for The amount of aluminum is calculated by integrating the flow rate at any given time. The instantaneous flow rate of molten aluminum in the aluminum suction tube. This is the effective inner cross-sectional area of ​​the aluminum suction tube. The density of molten aluminum, This refers to the aluminum tapping time.

[0011] In some embodiments of this application, based on the foregoing scheme, the amount of aluminum is calculated from the liquid level using the following formula:

[0012] In the formula, for The amount of aluminum is calculated from the liquid level at a given time. for The level of molten aluminum inside the vacuum ladle at all times. This represents the initial liquid level height of the empty package during vacuum lifting. This represents the effective cross-sectional area of ​​the vacuum lifting package at the corresponding liquid level. This represents the density of the molten aluminum.

[0013] In some embodiments of this application, based on the foregoing scheme, the amount of aluminum produced is calculated according to the following formula:

[0014] In the formula, The amount of aluminum produced at time t is controlled. The amount of aluminum is calculated by integrating the flow rate at time t. The amount of aluminum is calculated from the liquid level at time t. The weighting coefficient corresponding to the amount of aluminum integrated from the flow rate has a value range of 0 to 1.

[0015] In some embodiments of this application, based on the aforementioned scheme, the automatic switching to the normally operating detection branch for single-source independent closed-loop control includes: when the data collected by the electromagnetic induction flow velocity measurement module is abnormal, switching to the liquid level ranging module to perform liquid level conversion measurement and closed-loop control independently; when the data collected by the liquid level ranging module is abnormal, switching to the electromagnetic induction flow velocity measurement module to perform flow velocity integration measurement and closed-loop control independently; and automatically restoring the dual-source fusion control mode after the fault is cleared.

[0016] In some embodiments of this application, based on the aforementioned scheme, the step of dynamically adjusting the opening of the vacuum valve according to the difference between the aluminum tapping progress and the target aluminum tapping amount includes: when the controlled aluminum tapping amount reaches a preset ratio range of the target aluminum tapping amount, reducing the opening of the vacuum valve, smoothly reducing the aluminum tapping flow rate from a first aluminum tapping flow rate to a second aluminum tapping flow rate, and simultaneously increasing the sampling frequency of the detection data.

[0017] In some embodiments of this application, based on the foregoing scheme, the method further includes: applying a high-order moving average filter to the collected flow velocity data to eliminate flow velocity pulsation errors caused by aluminum liquid turbulence and bubbles; and applying a median filter combined with a sliding steady-state filter to the collected liquid level data to filter out instantaneous liquid level jumps caused by crane movement and vacuum ladle swaying.

[0018] In some embodiments of this application, based on the foregoing scheme, the method further includes: dynamically correcting the effective cross-sectional area according to the shell accumulation condition of the inner wall of the vacuum lifting package to achieve volume adaptive compensation; and automatically resetting the volume calibration parameters after the vacuum lifting package completes shell cleaning and maintenance.

[0019] In some embodiments of this application, based on the foregoing scheme, the method further includes: after the aluminum tapping operation is completed, retrieving the weighing data from the weighing verification module in the aluminum electrolysis cell aluminum tapping control system to verify the final aluminum tapping quantity.

[0020] Based on the technical solution proposed in this application, by setting a positioning groove on the outer wall of the aluminum suction tube and cooperating with a detachable clamp-type electromagnetic induction flow velocity measurement module, standardized limiting installation of the flow velocity detection probe can be achieved. This unifies the detection position and installation gap of each lifting bale and each aluminum suction tube, eliminating the influence of manual clamping deviation on flow velocity detection and ensuring a stable and consistent detection benchmark for the instantaneous flow velocity data of the pipeline. Simultaneously, by setting an observation window with embedded high-temperature resistant quartz glass and a dedicated mounting hole for installing the liquid level measurement module at the top of the vacuum lifting bale, and using a laser or ultrasonic non-contact method to detect the aluminum liquid level from the top of the lifting bale, the liquid level detection can be kept away from the strong magnetic field area and the area of ​​liquid surface disturbance in the aluminum electrolysis cell, avoiding the influence of magnetic field interference and liquid surface fluctuations on liquid level measurement. Based on this, the controller uses two independent detection data from the electromagnetic induction flow velocity measurement module and the liquid level ranging module to calculate the aluminum quantity through dual-source metering logic. It compares the results of the two channels through cross-validation logic to determine the operating status, corrects the lifting volume parameters through volume adaptive compensation logic, and adaptively adjusts the vacuum valve opening through closed-loop control logic. This integrates the advantages of the two detection channels, reduces the metering error caused by signal drift or operating condition disturbances in a single detection method, and thus improves the overall accuracy of aluminum output control in the aluminum electrolysis cell. Attached Figure Description

[0021] 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: Figure 1 A schematic diagram of the aluminum electrolysis cell aluminum output control system in an embodiment of this application is shown; Figure 2 A flowchart of the aluminum electrolysis cell aluminum output control method in an embodiment of this application is shown; Figure 3 A schematic diagram of the controller in an embodiment of this application is shown. Detailed Implementation

[0022] 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.

[0023] 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.

[0024] 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. It should also be noted that, for the sake of simplicity, certain components in the drawings that do not affect the interpretation of the technical solution of this application have been appropriately omitted.

[0025] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it 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 actual situation.

[0026] In the description of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "multiple" means two or more.

[0027] This application proposes an aluminum electrolysis cell aluminum output control scheme, the purpose of which is to improve the accuracy of aluminum electrolysis cell aluminum output control, thereby meeting the production control requirements of modern electrolytic aluminum with high precision and high stability.

[0028] Next, this application will elaborate on the proposed aluminum electrolysis cell aluminum output control scheme.

[0029] First, it should be noted that in the aluminum electrolysis production process, the aluminum tapping process is a core and critical step that maintains the stability of the aluminum level and thermal balance in the electrolytic cell by periodically extracting liquid metallic aluminum from the cell. The accuracy of aluminum tapping measurement and the stability of the tapping process directly determine the current efficiency, the purity of the primary aluminum, and the service life of the electrolytic cell. Traditional aluminum tapping methods generally use vacuum ladle lifting combined with overhead crane hooks and weighing sensors for measurement. This method is greatly affected by the strong magnetic field of the electrolytic cell, the swaying of the flexible suspension of the ladle, and differences in manual operation, resulting in generally high measurement errors. Although existing automated aluminum tapping solutions can achieve automatic valve control, the core measurement method still uses a single-point weighing mode, lacking redundant detection and cross-verification mechanisms, resulting in insufficient long-term operational reliability. The aluminum electrolysis cell tapping control scheme proposed in this application is aimed at addressing the above-mentioned technical deficiencies, and aims to achieve high-precision, high-fault-tolerant fully automated aluminum tapping control through a dual-source fusion metering architecture.

[0030] First, this application proposes an aluminum electrolysis cell aluminum output control system. (Refer to...) Figure 1 The diagram shows a schematic diagram of the aluminum electrolysis cell aluminum output control system in an embodiment of this application.

[0031] Specifically, Figure 1 The system architecture of this application illustrates the connection relationships and spatial layout between the various components. The core concept of this application is to abandon the traditional single hook weighing measurement mode and construct a detection system with two independent principles and complementary working conditions. One system performs integral measurement based on the flow rate of aluminum liquid in the aluminum suction tube, and the other system performs conversion measurement based on the liquid level of aluminum liquid in the vacuum lifting ladle. The two data are cross-validated and fused in the controller, thereby fundamentally solving technical problems such as strong magnetic field interference, dynamic swaying error and poor reliability of single sensors. Figure 1 The component names corresponding to the labels in the accompanying drawings will be explained one by one in the following description.

[0032] like Figure 1 As shown, the aluminum electrolysis cell aluminum output control system may include an aluminum electrolysis cell 101, a vacuum lifting bag 102, a crane actuator 103, an electromagnetic induction flow rate measurement module 104, a liquid level distance measurement module 105, and a controller 106.

[0033] In this application, the above six components constitute the basic structure of the aluminum electrolysis cell aluminum output control system. The aluminum electrolysis cell 101 serves as the source carrier of the molten aluminum, the vacuum ladle 102 serves as the receiving carrier of the molten aluminum, the overhead crane actuator 103 serves as the main body for automated operation, the electromagnetic induction flow rate measurement module 104 and the liquid level ranging module 105 serve as two independent detection data sources, and the controller 106 serves as the command center of the entire system. The components work collaboratively through mechanical connections, communication connections, or fluid connections to jointly complete the entire aluminum output process from molten aluminum extraction to precise metering and automatic shutdown. It should be noted that the system described in this application may also include other auxiliary components, such as a weighing verification module 111, a high-pressure gas controller, a field control display device, and a management unit, etc. These auxiliary components will be described in the corresponding sections below.

[0034] This application sets up two independent detection devices, an electromagnetic induction flow velocity measurement module and a liquid level ranging module, which can complete the cross-verification and fusion calculation of dual-source data in the controller. This effectively reduces the measurement error caused by magnetic field interference, signal drift or mechanical shaking of a single detection device, and improves the accuracy of aluminum measurement and the reliability of system operation.

[0035] Specifically, in this application, the vacuum lifter 102 can draw molten aluminum from the aluminum electrolysis cell 101 through the aluminum suction tube 107. The vacuum lifter 102 is a large metal container with high temperature resistance and sealed liquid storage function, and its interior can form a negative pressure environment. When a negative pressure is formed inside the vacuum lifter 102, the molten aluminum in the aluminum electrolysis cell 101 is forced into the vacuum lifter 102 through the aluminum suction tube 107 under atmospheric pressure, thereby completing the extraction of molten aluminum. The aluminum suction tube 107 is usually made of high temperature resistant cast iron or cast steel, with one end inserted into the molten aluminum layer in the aluminum electrolysis cell 101, and the other end connected to the internal space of the vacuum lifter 102. The molten aluminum flows from bottom to top in the aluminum suction tube 107 and eventually flows into the bottom of the vacuum lifter 102.

[0036] In this application, the overhead crane actuator 103 can be used to drive the vacuum lifting package 102 and the aluminum suction tube 107 to complete the alignment, insertion and removal of the aluminum electrolysis cell 101.

[0037] The overhead crane actuator 103 is a large lifting and transport device deployed above the electrolysis workshop. It is typically equipped with a lifting mechanism, a traveling mechanism, and a rotating mechanism, enabling it to drive the vacuum ladle 102 and the aluminum suction tube 107 to perform lifting, translation, and alignment movements in three-dimensional space. Before the aluminum tapping operation begins, the overhead crane actuator 103 can lift the vacuum ladle 102 directly above the target aluminum electrolysis cell 101 and accurately insert the lower end of the aluminum suction tube 107 into the molten aluminum layer within the aluminum electrolysis cell 101; this process is called tube insertion. After the aluminum tapping operation is completed, the overhead crane actuator 103 can remove the aluminum suction tube 107 from the aluminum electrolysis cell 101 and lift the vacuum ladle 102 to the next workstation; this process is called tube removal. The automated operation of the overhead crane actuator 103 avoids alignment deviations and efficiency fluctuations caused by manual operation, adapting to the operational needs of standardized aluminum tapping workstations in the workshop.

[0038] This application utilizes a vacuum lifting and suction tube negative pressure structure to achieve closed-loop extraction of molten aluminum, preventing oxidation caused by contact with air during transfer. Simultaneously, the automated alignment and tube insertion / removal operations via the overhead crane actuator improve the efficiency and consistency of aluminum extraction, reducing operational discrepancies caused by manual intervention.

[0039] In this application, the outer wall of the aluminum suction tube 107 may be provided with a positioning groove 108. The electromagnetic induction flow velocity measurement module 104 is a detachable clamp-type structure, which is limited and clamped in the positioning groove 108, and can be used to collect the instantaneous flow velocity of the aluminum liquid in the aluminum suction tube 107 in real time. The electromagnetic induction flow velocity measurement module 104 is the first measurement source of this application, and its working principle is based on the law of electromagnetic induction. Liquid aluminum has good conductivity. When the aluminum liquid flows in the aluminum suction tube 107, it is equivalent to a conductor cutting magnetic field lines in a magnetic field, thereby generating an induced electromotive force inside the aluminum liquid. The electromagnetic induction flow velocity measurement module 104 can calculate the instantaneous flow velocity of the aluminum liquid in the aluminum suction tube 107 by applying a magnetic field to the outer wall of the aluminum suction tube 107 and detecting the magnitude of the induced electromotive force. Since this detection method is non-contact, the probe of the electromagnetic induction flow velocity measurement module 104 does not need to be in direct contact with the high-temperature aluminum liquid, thus avoiding damage to the sensor caused by high-temperature corrosion and aluminum liquid adhesion, and extending the service life of the equipment.

[0040] The electromagnetic induction flow velocity measurement module 104 adopts a detachable clamp-type structure, whose shape is adapted to the outer wall of the aluminum suction tube 107, and can clamp the aluminum suction tube 107 from the outside like a clamp. The advantage of this detachable design is that when the electromagnetic induction flow velocity measurement module 104 needs to be maintained, calibrated or replaced, it can be directly removed from the aluminum suction tube 107 without disassembling the aluminum suction tube 107 or the vacuum lifting package 102, making maintenance and operation convenient. At the same time, the clamp-type structure can ensure that the installation gap between the probe and the outer wall of the aluminum suction tube 107 remains consistent after each clamping, thereby reducing detection errors caused by differences in installation gap.

[0041] The positioning groove 108 is a groove structure machined at a pre-set fixed detection point on the outer wall of the aluminum suction tube 107. Its function is to provide a precise installation positioning reference for the electromagnetic induction flow velocity measurement module 104. In traditional clamping methods, each time the operator clamps the flow velocity probe onto the aluminum suction tube 107, the clamping position may shift vertically or rotate circumferentially, resulting in inconsistencies in the detection tube diameter, installation gap, and detection angle, thus introducing detection errors. The positioning groove 108 uniquely determines the clamping position of the electromagnetic induction flow velocity measurement module 104, fundamentally eliminating manual clamping deviations. In some embodiments, the inner diameter of the aluminum suction tube 107 can be 160mm, corresponding to an effective inner cross-sectional area of ​​approximately 0.0201. The density of molten aluminum can be taken as 2300 kg / m³. These parameters will be used in subsequent flow rate integral estimating formulas.

[0042] This application enables standardized installation of the flow rate detection probe by setting a positioning groove on the outer wall of the aluminum suction tube and using a detachable clamp-type electromagnetic induction flow rate measurement module. This unifies the detection position and benchmark for each lifting bag and each aluminum suction tube, eliminating measurement errors caused by manual clamping deviations. At the same time, the non-contact detection method can avoid corrosion damage to the sensor caused by high-temperature aluminum liquid, improving the service life and maintenance convenience of the detection device.

[0043] In this application, the top of the vacuum lifting bag 102 may be provided with an observation window 109, and the observation window 109 is fitted with a sealed high-temperature resistant quartz glass, which can be used to transmit light and isolate the high-temperature aluminum liquid, dust and flue gas inside the vacuum lifting bag 102. Specifically, the observation window 109 is a dedicated window located at the top of the vacuum ladle 102, and its interior is fitted with sealed high-temperature resistant quartz glass. Quartz glass possesses characteristics such as high light transmittance, good high-temperature resistance, and strong chemical stability, allowing it to remain transparent for extended periods in the high-temperature environment of hundreds of degrees Celsius inside the vacuum ladle 102, while also withstanding aluminum splashes and dust erosion without damage. The observation window 109 facilitates visual observation of the aluminum liquid collection within the vacuum ladle 102 during aluminum unloading operations, enabling timely detection of abnormal conditions. Furthermore, for the liquid level measuring module 105 employing laser ranging, the quartz glass at the observation window 109 provides a transparent channel for the laser beam, allowing it to penetrate the top wall of the vacuum ladle 102 and illuminate the surface of the internal aluminum liquid. In some embodiments, the diameter of the observation window 109 can be 100 mm to ensure sufficient light transmission area and observation field.

[0044] In this application, the top of the vacuum lifting pot 102 may also be provided with a mounting hole 110, and the liquid level measuring module 105 is installed in the mounting hole 110 to detect the liquid level height of the aluminum liquid inside the vacuum lifting pot 102 in real time using a non-contact method such as laser or ultrasound.

[0045] Mounting hole 110 is a small hole additionally opened at the top of vacuum lifting container 102 for fixing and mounting liquid level measuring module 105. In some embodiments, mounting hole 110 can be located about 100mm to the side of observation window 109, and the hole diameter can be 3mm. Liquid level measuring module 105 extends vertically downward into vacuum lifting container 102 from mounting hole 110, with its detection end facing the aluminum liquid surface at the bottom of vacuum lifting container 102. Liquid level measuring module 105 can be a high-temperature resistant laser height measuring instrument, which emits a laser beam and receives the echo signal reflected from the aluminum liquid surface. The distance from liquid level measuring module 105 to the aluminum liquid surface is calculated based on the laser flight time, and then combined with the installation height of liquid level measuring module 105, the liquid level height of aluminum liquid inside vacuum lifting container 102 can be calculated. Liquid level measuring module 105 can also be an ultrasonic distance measuring instrument, which realizes liquid level detection by emitting ultrasonic waves and receiving echoes. Both methods are non-contact detection, and the detection end does not need to be immersed in aluminum liquid, thus avoiding high-temperature corrosion and aluminum liquid adhesion problems.

[0046] The liquid level measuring module 105, as the second measurement source in this application, directly monitors the amount of molten aluminum extracted into the vacuum ladle 102, achieving metering verification from the aluminum outlet terminal. Because the liquid level measuring module 105 is installed on top of the vacuum ladle 102, away from the strong magnetic field area and the area of ​​liquid surface disturbance in the aluminum electrolysis cell 101, its detection data can completely avoid problems such as electrolysis cell crusting, liquid surface fluctuations, and strong magnetic field interference. The detection results are intuitive, accurate, and highly stable. This architecture, which measures from two independent dimensions—pipeline flow rate and ladle liquid level—forms an efficient redundant verification system, providing a foundation for high-precision metering and fault-tolerant control.

[0047] This application provides a transparent channel and fixed installation benchmark for non-contact liquid level detection by setting an observation window with high-temperature resistant quartz glass embedded in the top of the vacuum lifting pot and a mounting hole specifically for installing the liquid level measuring module. At the same time, the liquid level measuring module detects the aluminum liquid level from the top of the lifting pot, which can avoid the interference of the strong magnetic field of the electrolytic cell and the disturbance of the liquid surface in the cell. It forms a dual-source metering system with independent principle and complementary operating conditions with pipeline flow rate detection.

[0048] In this application, the controller 106 can be communicatively connected to the electromagnetic induction flow velocity measurement module 104 and the liquid level ranging module 105 respectively. It has built-in dual-source metering logic, cross-validation logic, volume adaptive compensation logic and closed-loop control logic. It can be used to complete the fusion calculation of aluminum output, fault tolerance judgment and adaptive adjustment of vacuum valve based on the detection data of the electromagnetic induction flow velocity measurement module 104 and the liquid level ranging module 105.

[0049] The controller 106 is the core processing unit of the aluminum electrolysis cell aluminum output control system of this application. Its hardware can be an industrial programmable logic controller (PLC) or an embedded industrial computer, and its deployment location can be set up in the overhead crane electrical room or the workshop control center. The controller 106 establishes data connections with the electromagnetic induction flow velocity measurement module 104 and the liquid level ranging module 105 via wired or wireless communication, respectively, and can receive flow velocity and liquid level data uploaded by the two detection modules in real time. The flow velocity data collected by the electromagnetic induction flow velocity measurement module 104 can be uploaded to the controller 106 via wireless communication to adapt to dynamic operation scenarios such as overhead crane movement and bag lifting.

[0050] The controller 106 incorporates dual-source metering logic to calculate two independent aluminum output rates based on flow rate and liquid level data, respectively. Cross-validation logic compares the deviations between the two output rates in real time and determines the operating status of the detection branch. Adaptive volume compensation logic dynamically corrects volume parameters based on the buildup conditions on the inner wall of the vacuum ladle 102. Closed-loop control logic automatically adjusts the vacuum valve opening based on the difference between the aluminum output progress and the target value. These four logics work together to enable the controller 106 to automate the entire aluminum output management process, from data acquisition, metering calculation, deviation verification, fault diagnosis to valve control, without requiring real-time manual intervention.

[0051] This application integrates four types of logic—dual-source metering, cross-verification, volume adaptive compensation, and closed-loop control—into the controller. This enables parallel processing and fusion calculation of two-channel detection data, automatically completing fault diagnosis and valve opening adjustment. As a result, it eliminates reliance on manual operation experience and improves the automation level and metering accuracy of aluminum control.

[0052] In this application, the positioning groove 108 can be an annular limiting groove, which is opened at the fixed calibration position of the aluminum suction tube 107. It is used to limit the electromagnetic induction flow velocity measurement module 104 in the whole circumference and fix the installation point, unify the detection gap, detection tube diameter and installation position, and eliminate manual clamping deviation.

[0053] Specifically, the annular limiting groove refers to a groove structure that extends continuously along the circumference of the outer wall of the aluminum suction tube 107. Its cross-section can be rectangular, trapezoidal, or arc-shaped. The groove width and depth are designed to match the size parameters of the clamp of the electromagnetic induction flow velocity measurement module 104. When the clamp of the electromagnetic induction flow velocity measurement module 104 is engaged in the annular limiting groove, the inner protrusion of the clamp forms mechanical interference with the side wall of the groove, preventing the electromagnetic induction flow velocity measurement module 104 from moving up and down along the axial direction of the aluminum suction tube 107, and also preventing it from rotating around the circumference of the aluminum suction tube 107, thereby achieving full circumferential limiting and fixed-point installation.

[0054] The fixed calibration position refers to the detection point predetermined during the design and manufacturing stage of the aluminum suction tube 107. This point is usually selected in the middle area of ​​the straight section of the aluminum suction tube 107, avoiding bends and interface sections, to ensure a relatively stable flow of molten aluminum and a relatively uniform flow velocity distribution at this location. Maintaining consistent fixed calibration positions for each aluminum suction tube 107 ensures a unified detection benchmark across different ladles and aluminum suction tubes. The detection gap refers to the distance between the probe of the electromagnetic induction flow velocity measurement module 104 and the outer wall of the aluminum suction tube 107. The detection tube diameter refers to the inner cross-sectional area of ​​the aluminum suction tube 107 at the detection position. The installation position refers to the specific axial position of the electromagnetic induction flow velocity measurement module 104 on the aluminum suction tube 107. These three parameters are kept highly consistent under the constraint of the annular limiting groove, thereby completely eliminating systematic errors caused by differences in manual clamping positions.

[0055] This application, by designing the positioning groove as an annular limiting groove and opening it at the fixed calibration position of the aluminum suction tube, can achieve full circumferential limiting and fixed-point installation of the electromagnetic induction flow velocity measurement module, unify the detection gap, detection pipe diameter and installation position, fundamentally eliminate the influence of manual clamping deviation on the flow velocity detection accuracy, and ensure that the detection data after clamping by different batches and different operators have good consistency and comparability.

[0056] In this application, the electromagnetic induction flow velocity measurement module 104 may be covered with a magnetic shield to shield the strong magnetic field interference of the aluminum electrolysis cell 101 and resist the influence of equipment shaking and dynamic displacement on flow velocity detection.

[0057] Aluminum electrolysis workshops are typical environments with strong magnetic fields. Taking a 500KA-class aluminum electrolysis cell as an example, the magnetic field strength around the cell can reach hundreds of Gauss, and at the edge of the end cell, the magnetic field strength can even reach 350 Gauss. Such a strong magnetic field will cause electromagnetic interference to the sensitive circuit inside the electromagnetic induction flow velocity measurement module 104, resulting in zero-point drift and noise superposition in the detection signal, and in severe cases, it may even cause the flow velocity reading to be completely distorted. In addition, the mechanical vibration and dynamic displacement during the overhead crane movement, bag lifting and lowering, and tube insertion and removal processes will also adversely affect the stability of the flow velocity detection.

[0058] The magnetic shield is a shell structure made of high magnetic permeability material, covering the exterior of the electromagnetic induction flow velocity measurement module 104. The high magnetic permeability material provides a low magnetic resistance bypass channel for external magnetic fields, allowing most of the magnetic field energy to be conducted along the shield shell without entering the internal space. This creates a relatively low magnetic field environment inside the shield, protecting the internal detection circuitry from strong magnetic field interference. The magnetic shield allows the electromagnetic induction flow velocity measurement module 104 to operate stably for extended periods in the strong magnetic field environment of an electrolysis workshop, with instantaneous fluctuations in flow velocity detection controlled within 0.02 meters per second. Simultaneously, the magnetic shield itself possesses certain structural strength and damping characteristics, absorbing some mechanical vibration energy and further improving the detection stability of the equipment under dynamic operating conditions.

[0059] This application effectively shields the electromagnetic interference of the strong magnetic field of the aluminum electrolysis cell on the detection circuit by covering the electromagnetic induction flow velocity measurement module with a magnetic shield, suppresses zero drift and signal noise, and resists the influence of equipment shaking and dynamic displacement on flow velocity detection. This ensures that the flow velocity detection data remains stable and reliable even under harsh working conditions, providing a high-quality data source for subsequent accurate measurement.

[0060] In this application, the vacuum lifting bag 102 can be a tank-type variable diameter tapered structure, with different effective cross-sectional areas corresponding to different liquid levels; the controller 106 has pre-stored standard volume parameters corresponding to each liquid level of the vacuum lifting bag 102, which can dynamically correct the effective cross-sectional area according to the internal shelling conditions, and supports the automatic reset of the volume parameters after the vacuum lifting bag 102 is cleaned.

[0061] The tank-type variable-diameter tapering structure refers to the fact that the inner cavity of the vacuum lifting ladle 102 is not a straight cylinder with equal diameters at the top and bottom, but rather a tank-like shape with a larger diameter at the bottom and gradually narrowing upwards. This structural design is beneficial for the containment and insulation of molten aluminum, but it also brings a measurement problem: the effective cross-sectional area of ​​the inner cavity varies with different liquid levels. If the volume of molten aluminum is simply calculated by multiplying a fixed cross-sectional area by the liquid level rise, significant measurement deviations will occur at high or low liquid levels. To solve this problem, the controller 106 pre-stores standard volume parameters for the entire liquid level range of the vacuum lifting ladle 102. These parameters record the effective cross-sectional area corresponding to each liquid level in the form of a data table or function relationship. When performing liquid level conversion measurement, the effective cross-sectional area at the corresponding liquid level can be called for calculation, thereby eliminating the measurement error caused by the variable-diameter structure.

[0062] Inner wall crusting is an unavoidable phenomenon during long-term use of the vacuum ladle 102. Electrolyte components in the molten aluminum gradually condense and adhere to the inner wall of the vacuum ladle 102 during temperature fluctuations, forming a hard crust layer. The presence of this crust layer gradually reduces the actual effective volume of the vacuum ladle 102, and the crust thickness is unevenly distributed at different heights. If the original standard volume parameters are still used for measurement, the aluminum quantity calculated from the liquid level will gradually deviate from the true value. The volume adaptive compensation logic on the controller 106 can dynamically correct the effective cross-sectional area corresponding to each liquid level height based on the actual crusting conditions on site, ensuring that the measurement parameters always match the actual volume of the vacuum ladle 102.

[0063] The electrolysis workshop typically performs regular shell cleaning and maintenance on the vacuum ladle 102 to remove the crust layer adhering to the inner wall and restore the ladle's designed volume. After the shell cleaning and maintenance is completed, the volume parameters of the vacuum ladle 102 are restored to their initial standard state. The controller 106 can automatically reset the volume calibration parameters to the pre-stored standard volume parameters, eliminating the need for manual recalibration by operators. This adapts to the workshop's routine shell cleaning and maintenance process, reducing the workload of manual calibration and human error.

[0064] This application, by adopting a tank-type variable diameter necking structure and pre-storing standard volume parameters for the entire liquid level range in the controller, can eliminate the influence of the lifting and variable diameter structure on liquid level conversion and measurement. At the same time, it dynamically corrects the volume changes caused by the inner wall shell through volume adaptive compensation logic, and automatically resets the parameters after shell cleaning and maintenance. This can keep the liquid level measurement accuracy at a high level at all times, eliminating the need for frequent manual calibration and reducing on-site operation and maintenance costs.

[0065] In this application, the top of the vacuum lifting bag 102 is also provided with a vent hole, which can be used to balance the air pressure inside and outside the vacuum lifting bag 102 and avoid air pressure changes from interfering with liquid level detection.

[0066] The vent is a micro-hole at the top of the vacuum ladle 102. Its small diameter ensures pressure communication between the inside of the vacuum ladle 102 and the external atmosphere without causing a large amount of high-temperature flue gas to leak out. During aluminum tapping, the internal pressure of the vacuum ladle 102 changes with the adjustment of the vacuum valve. Simultaneously, the molten aluminum occupies space after entering the ladle, compressing the internal gas. If the vacuum ladle 102 is completely sealed, fluctuations in internal pressure will affect the detection results of the liquid level ranging module 105. Specifically, for the liquid level ranging module 105 using ultrasonic ranging, pressure changes alter the speed of ultrasonic waves in the air, leading to deviations in the time-of-flight distance calculation. For the liquid level ranging module 105 using laser ranging, pressure changes cause slight changes in the air refractive index, which also slightly affects laser propagation. Furthermore, pressure fluctuations may also cause slight undulations on the surface of the molten aluminum inside the ladle, further interfering with liquid level detection.

[0067] The vent hole ensures that the internal air pressure of the vacuum lifting bag 102 remains balanced with the external atmospheric pressure, eliminating the interference of air pressure fluctuations on liquid level detection and making the detection data of the liquid level measuring module 105 more accurate and stable. In some embodiments, the vent hole can be integrated with the observation window 109 or the mounting hole 110, or it can be opened separately. Its diameter can be reasonably selected according to the lifting bag volume and air pressure balance requirements.

[0068] This application, by setting a vent at the top of the vacuum leveling bag, can balance the air pressure inside and outside the bag, eliminate the influence of air pressure fluctuations on the propagation speed and refractive index of ultrasonic or laser level detection, avoid the problem of falsely high or low level detection, and further improve the accuracy and reliability of level measurement data.

[0069] In this application, the system may also include a weighing verification module 111, which is installed between the overhead crane hook and the vacuum lifting bag 102. It is only used for final value traceability verification after aluminum is discharged and does not participate in real-time metering control.

[0070] The weighing verification module 111 is a weighing sensor installed between the overhead crane hook and the vacuum ladle 102. It can measure the total weight of the vacuum ladle 102 and the molten aluminum inside after the aluminum tapping operation is completed. Unlike the traditional aluminum tapping system that uses hook weighing as the sole real-time measurement basis, the weighing verification module 111 in this application only serves as the final value verification benchmark after aluminum tapping is completed and does not participate in real-time measurement and control during the aluminum tapping process. The reason for this design is that the hook weighing method is easily affected by strong magnetic field interference, ladle flexible suspension swaying, and dynamic impact of tube insertion and removal during the aluminum tapping process, resulting in large fluctuations in real-time readings, making it unsuitable as a basis for process control. However, after aluminum tapping is completed and the ladle comes to a standstill, the hook weighing reading is relatively stable and can serve as a third-party verification benchmark for the dual-source fusion measurement results.

[0071] After the aluminum tapping operation is completed, the controller 106 can retrieve the weighing data from the weighing verification module 111 and compare it with the aluminum tapping quantity calculated by the dual-source fusion to verify the accuracy of the aluminum tapping measurement. If the deviation between the two is within the allowable range, it indicates that the dual-source metering system is working normally; if the deviation exceeds the allowable range, an alarm can be triggered to prompt the operator to check the working status of the detection device. The weighing verification module 111 can also provide data traceability for production management. The measurement results and weighing verification results of each aluminum tapping operation can be recorded and archived, providing data support for subsequent process optimization and quality traceability.

[0072] This application, by setting up a weighing verification module solely for final value traceability verification, can provide a third-party independent verification benchmark for dual-source fusion measurement results without affecting real-time control accuracy, thereby achieving closed-loop traceability of data throughout the entire process. It also facilitates the timely detection of long-term drift issues in the detection device, further enhancing the reliability and traceability of the system's measurement.

[0073] In this application, the controller 106 may also have a built-in data filtering algorithm, which uses a high-order moving average filter for the flow velocity data collected by the electromagnetic induction flow velocity measurement module 104, and uses a median filter combined with a sliding steady-state filter for the liquid level data collected by the liquid level ranging module 105.

[0074] The complex operating conditions in the electrolysis workshop can cause different types of interference to the two detection data streams, thus requiring targeted filtering algorithms for processing. For the flow velocity data collected by the electromagnetic induction flow velocity measurement module 104, the main sources of interference are the turbulent pulsation and bubble disturbance of the molten aluminum in the aluminum suction tube 107. When the molten aluminum flows in the aluminum suction tube 107, turbulence is easily formed due to the high flow velocity and the presence of bends in the pipe, resulting in high-frequency pulsation of the instantaneous flow velocity; at the same time, tiny bubbles that may be entrained in the molten aluminum can also cause instantaneous jumps in the flow velocity reading. To address this type of high-frequency pulsation interference, the controller 106 uses a high-order moving average filter, which averages the flow velocity data from multiple sampling points within a sliding time window. The window length can be adjusted according to the actual interference frequency, thereby smoothing out the flow velocity pulsation error caused by turbulence and bubbles and preserving the true trend of flow velocity changes.

[0075] For the liquid level data collected by the liquid level measuring module 105, the main source of interference is the instantaneous liquid level jumps caused by the movement of the overhead crane and the slight shaking of the vacuum lifting pot 102. The overhead crane vibrates during its movement, and the vacuum lifting pot 102, as a flexible suspended load, oscillates. These mechanical disturbances cause instantaneous fluctuations on the surface of the molten aluminum inside the pot, resulting in isolated spikes or jumps in the liquid level reading. To address this type of pulse interference, the controller 106 employs a combined strategy of median filtering and sliding steady-state filtering. Median filtering, by taking the median within a sliding window, effectively eliminates isolated abnormal jump points; sliding steady-state filtering further smooths the data after median filtering, filtering out remaining small fluctuations. After the above filtering process, the fluctuation of the liquid level data can be controlled within ±0.8 mm, providing a stable data foundation for accurate measurement.

[0076] This application employs targeted filtering algorithms for flow rate and liquid level data, effectively eliminating interference from aluminum turbulence, bubble pulsation, and equipment shaking on both detection data. This ensures that both flow rate and liquid level data remain stable and accurate, providing high-quality input data for subsequent dual-source fusion metering and closed-loop control, thereby improving the overall accuracy of aluminum output metering.

[0077] Based on the same inventive concept, this application also proposes a method for controlling the aluminum output of an aluminum electrolysis cell. This method can be applied to the aluminum output control system of the aluminum electrolysis cell described above, that is, the method can be executed as follows: Figure 1 The controller 106 shown.

[0078] The aluminum electrolysis cell aluminum tapping control method proposed in this application belongs to the same inventive concept as the aforementioned aluminum electrolysis cell aluminum tapping control system. Each step in the method corresponds one-to-one with the function of each component in the system. The execution entity of the method can be the controller 106. The controller 106 completes the automated control of the entire aluminum tapping process by sending control commands to the electromagnetic induction flow rate measurement module 104, the liquid level ranging module 105, the overhead crane actuator 103, and the vacuum valve, and receiving feedback data. The following will combine... Figure 2 Each step of the method is explained in detail.

[0079] Reference Figure 2 The flowchart illustrates a method for controlling aluminum output from an aluminum electrolysis cell according to an embodiment of this application. For example... Figure 2 As shown, the method specifically includes steps 210 to 270: In step 210, the initial liquid level of the empty vacuum lifter is collected by the liquid level measuring module on the vacuum lifter, and the target aluminum output is entered into the controller to complete the system parameter initialization.

[0080] In this application, step 210 is the preparation stage for aluminum tapping, the purpose of which is to establish an initial benchmark for subsequent metering calculations. The initial empty ladle liquid level refers to the liquid level height of the molten aluminum inside the vacuum ladle 102 before the start of the aluminum tapping operation. In actual production, the vacuum ladle 102 may have a small amount of molten aluminum remaining after the previous aluminum tapping, or there may be a crust on the inner wall of the ladle causing a change in the bottom benchmark. Therefore, the initial empty ladle liquid level needs to be re-collected before each aluminum tapping as the starting benchmark for calculating the increase in the liquid level during this tapping. After completing self-check calibration before aluminum tapping, the liquid level measuring module 105 can quickly collect the initial empty ladle liquid level of the vacuum ladle 102 and upload it to the controller 106. The entire process does not require a long preheating time and is suitable for frequent and continuous aluminum tapping operations.

[0081] The target aluminum output refers to the total weight of molten aluminum to be extracted from the aluminum electrolysis cell 101 in this aluminum extraction operation. This value is determined by the production process personnel based on the aluminum level in the electrolysis cell and the production plan, and is entered into the controller 106. In some embodiments, the target aluminum output per cell can be 3680 kg or 3700 kg, with the specific value set according to the cell type and process requirements. System parameter initialization includes loading the standard volume parameters of the vacuum lifting baffle 102, confirming the normal communication status between the electromagnetic induction flow velocity measurement module 104 and the liquid level ranging module 105, and setting the deviation threshold and weighting coefficient. If the vacuum lifting baffle 102 has just completed shell cleaning and maintenance, the controller 106 can also automatically reset the volume parameters to the standard value during the initialization phase.

[0082] This application establishes an accurate starting benchmark for subsequent level conversion and measurement by collecting the initial liquid level of the empty package and recording the target aluminum output before aluminum tapping. At the same time, the system parameter initialization ensures that the volume parameters, communication status and control thresholds are in the correct state, laying the foundation for precise control of the entire aluminum tapping process.

[0083] Continue to refer to Figure 2 In step 220, the crane actuator is controlled to complete the alignment of the aluminum electrolysis cell and the insertion of the aluminum suction tube, and the vacuum valve in the aluminum suction tube is opened.

[0084] After the tube insertion is completed, the controller 106 opens the vacuum valve, connecting the inside of the vacuum lifting ladle 102 with the vacuum system. The air pressure inside the ladle rapidly decreases, creating a negative pressure. Under this negative pressure, the molten aluminum in the aluminum electrolysis cell 101 is forced into the vacuum lifting ladle 102 through the aluminum suction tube 107, and the aluminum tapping operation officially begins. The opening degree of the vacuum valve can be continuously adjusted by the controller 106. A larger opening degree results in a stronger negative pressure and a faster aluminum tapping flow rate, while a smaller opening degree results in a weaker negative pressure and a slower aluminum tapping flow rate. In the initial stage of aluminum tapping, the controller 106 can open the vacuum valve to a larger degree, allowing the molten aluminum to enter the ladle at a faster and more stable flow rate, thus improving the aluminum tapping efficiency.

[0085] This application uses a controller to automatically control the overhead crane actuator to complete the alignment and insertion of the tube and open the vacuum valve, which can realize the automated start of the aluminum tapping operation, avoid the influence of manual alignment deviation and valve operation differences on the aluminum tapping process, and at the same time, the continuously adjustable characteristics of the vacuum valve provide an execution basis for subsequent adaptive flow rate adjustment.

[0086] Continue to refer to Figure 2 In step 230, the electromagnetic induction flow velocity measurement module on the aluminum suction tube and the liquid level distance measurement module are controlled to synchronously collect detection data, and the amount of aluminum output by flow velocity integration and the amount of aluminum output by liquid level conversion are calculated respectively.

[0087] In this application, step 230 is the dual-source synchronous metering stage. After the vacuum valve is opened, the controller 106 simultaneously sends acquisition commands to the electromagnetic induction flow velocity measurement module 104 and the liquid level ranging module 105. The two detection modules start data acquisition synchronously with the same high-frequency sampling period. The significance of synchronous acquisition is that the two data streams are strictly aligned on the time axis, ensuring that when comparing deviations at any time, the two metering results are compared at the same time, avoiding false deviations introduced by time asynchrony. The controller 106 can process the two data streams in parallel, calculating the aluminum quantity integrated from the flow velocity and the aluminum quantity converted from the liquid level, respectively. The two calculation processes are independent of each other and do not affect each other.

[0088] In such Figure 1 In step 230 shown, the amount of aluminum produced by the flow rate integral can be calculated according to the following formula (1):

[0089] In the formula, for The amount of aluminum is calculated by integrating the flow rate at any given time. The instantaneous flow rate of molten aluminum in the aluminum suction tube. This is the effective inner cross-sectional area of ​​the aluminum suction tube. The density of molten aluminum, This refers to the aluminum tapping time.

[0090] The physical meaning of formula (1) is to multiply the instantaneous flow of molten aluminum in the aluminum suction tube 107 by the effective internal cross-sectional area of ​​the aluminum suction tube 107 to obtain the volume of molten aluminum flowing through the aluminum suction tube 107 per unit time, then multiply it by the density of molten aluminum to obtain the mass flow rate of molten aluminum per unit time, and finally integrate and accumulate over time to obtain the mass flow rate of molten aluminum from the start of aluminum discharge to the end of the discharge. The cumulative aluminum output at any given moment. This calculation method accurately reflects the change in the instantaneous aluminum output flow rate in the pipeline and can capture the dynamic fluctuations in the aluminum output velocity. In some embodiments, the effective inner cross-sectional area A of the aluminum suction pipe 107 can be 0.0201. The density ρ of molten aluminum can be 2300 kg / m³. The sampling period can be set to the millisecond level according to the control accuracy requirements.

[0091] In such Figure 1 In step 230 shown, the amount of aluminum can be calculated by converting the liquid level into the amount of aluminum using the following formula (2):

[0092] In the formula, for The amount of aluminum is calculated from the liquid level at a given time. for The level of molten aluminum inside the vacuum ladle at all times. This represents the initial liquid level height of the empty package during vacuum lifting. This represents the effective cross-sectional area of ​​the vacuum lifting package at the corresponding liquid level. This represents the density of the molten aluminum.

[0093] In formula (2), the liquid level rise is equal to The real-time liquid level height at any given moment minus the initial liquid level height of the empty ladle collected before aluminum tapping reflects the time from the start of aluminum tapping to... The calculation measures the rise in aluminum molten liquid level within the vacuum ladle 102. Since the vacuum ladle 102 is a tank-type variable-diameter, constricted-mouth structure, the effective cross-sectional area varies with different liquid level heights. Therefore, the calculation requires referencing the effective cross-sectional area parameters pre-stored in the controller 106 at the corresponding liquid level height. Multiplying the liquid level rise by the effective cross-sectional area at the corresponding liquid level height yields the volume of newly added aluminum molten liquid, which is then multiplied by the aluminum molten liquid density to convert it into the mass of aluminum molten liquid entering the ladle. This calculation method directly measures the aluminum molten liquid inventory from the aluminum outlet terminal, complementing the principle of pipeline flow rate measurement. It should be noted that the effective cross-sectional area can be dynamically corrected based on the internal wall crusting conditions.

[0094] This application collects data synchronously through two detection modules and calculates the aluminum content according to the flow rate integral formula and the liquid level conversion formula respectively. It can construct two physically independent and complementary measurement systems. The results of the two channels can be mutually verified and checked, providing a reliable data foundation for subsequent deviation judgment and fusion control, and effectively solving the problem of insufficient reliability of a single detection method.

[0095] Continue to refer to Figure 2 In step 240, the deviation between the aluminum quantity integrated from the flow rate and the aluminum quantity calculated from the liquid level is compared in real time, and the operating status of the two detection branches is determined according to the preset deviation threshold.

[0096] In this application, step 240 is the dual-source deviation verification stage. The controller 106 calculates the deviation between the aluminum quantity integrated from the flow rate and the aluminum quantity calculated from the liquid level in real time during each sampling cycle. The deviation value can be the absolute value of the difference between the two data streams. A preset deviation threshold is a pre-set upper limit for allowable deviation in the controller 106. When the deviation of both meters is within this threshold range, both detection branches are considered to be working normally; when the deviation exceeds this threshold, at least one detection branch is considered to have malfunctioned.

[0097] Setting the preset deviation threshold requires comprehensive consideration of the normal error range of the two detection methods and the sensitivity of fault judgment. If the threshold is set too low, random fluctuations under normal operating conditions may trigger false fault judgments; if the threshold is set too high, real faults may not be identified in time. In some embodiments, the preset deviation threshold can be set according to 1% to 2% of the target aluminum output of a single tank. For example, when the target aluminum output is 3700 kg, the deviation threshold can be set to 50 kg, which is approximately 1.35% of the target aluminum output. This threshold can tolerate slight differences between the two detection methods under normal operating conditions, while also being able to trigger fault judgment in a timely manner when there is significant drift or signal abnormality in the detection branch.

[0098] This application can automatically determine the operating status of the two detection branches by comparing the deviation of the aluminum output from the two channels in real time and comparing it with a preset threshold, thereby realizing real-time fault diagnosis and avoiding control based on distorted data when the detection device is abnormal, thus ensuring the accuracy of aluminum output measurement and the continuity of operation.

[0099] Continue to refer to Figure 2 In step 250, when the deviation is within the preset deviation threshold range, the controlled aluminum output is obtained through dynamic weighted fusion. When the deviation exceeds the preset deviation threshold range, a single-channel detection branch is determined to be faulty, and the system automatically switches to the normally operating detection branch for single-source independent closed-loop control.

[0100] In this application, step 250 is the adaptive fusion and fault-tolerant control stage, where the controller 106 executes two different control strategies based on the deviation determination result of step 240. When the deviations of the two metering channels are within the preset threshold range, it indicates that both the electromagnetic induction flow velocity measurement module 104 and the liquid level ranging module 105 are working normally. At this time, the controller 106 uses a dynamic weighted fusion algorithm to merge the two aluminum output quantities into a single controlled aluminum output quantity, which serves as the basis for subsequent valve adjustment and shutdown determination. The advantage of dynamic weighted fusion is that it can combine the accuracy advantages of the two detection channels and offset the random errors and system deviations existing in single detection channels by reasonably allocating weights, resulting in a more accurate metering result than any single detection channel.

[0101] In such Figure 1 In step 250 shown, the amount of aluminum produced can be calculated according to the following formula (3):

[0102] In the formula, The amount of aluminum produced at time t is controlled. The amount of aluminum is calculated by integrating the flow rate at time t. The amount of aluminum is calculated from the liquid level at time t. The weighting coefficient corresponding to the amount of aluminum integrated from the flow rate has a value range of 0 to 1.

[0103] In formula (3), the weighting coefficient α determines the proportion of aluminum output from the flow rate integral in the fusion result, while the weight of aluminum output from the liquid level conversion is 1 minus α, and the sum of the two is 1. The weighting coefficient α can be dynamically allocated according to the difference in steady-state detection accuracy between the two detection modules, and the module with higher accuracy can be assigned a larger weight. In some embodiments, after long-term industrial production big data calibration, the steady-state error of electromagnetic flow rate detection can be 0.20%, and the steady-state error of liquid level measurement can be 0.15%. Since the liquid level measurement accuracy is slightly higher, the flow rate weight α can be set to 0.45, and the corresponding liquid level weight is 0.55. Under the steady-state production conditions of a 500KA electrolytic cell, when the target aluminum output is 3680kg, after dual-source fusion using the above weights, the actual aluminum output can reach 3678.8kg, and the overall measurement error is as low as 0.03%, which is significantly better than the accuracy level of single-channel detection.

[0104] When the deviation between the two metering channels exceeds the preset deviation threshold, the controller 106 determines that one of the detection channels has a fault such as drift, obstruction, or signal abnormality. Continuing to use the data from the faulty channel for fusion calculation would distort the controlled aluminum output. The controller 106 can automatically alarm and seamlessly switch to the normally operating detection channel, using the individual metering data from that channel as the control benchmark for single-source independent closed-loop control, ensuring uninterrupted aluminum output and accurate metering. The fault switching process is transparent to the aluminum output operation and requires no manual intervention or operation suspension.

[0105] In such Figure 1 In step 250, the automatic switching to the normally operating detection branch for single-source independent closed-loop control can be performed according to steps 251 to 253 as follows: Step 251: When the data collected by the electromagnetic induction flow velocity measurement module is abnormal, switch to the liquid level ranging module to perform liquid level conversion measurement and closed-loop control independently.

[0106] Step 252: When the data collected by the liquid level measuring module is abnormal, switch to the electromagnetic induction flow velocity measuring module to perform flow velocity integration measurement and closed-loop control independently.

[0107] Step 253: After the fault is cleared, the dual-source fusion control mode will be automatically restored.

[0108] When the electromagnetic induction flow velocity measurement module 104 experiences abnormalities such as signal jumps, data distortion, or communication interruptions, the aluminum output from the flow velocity integral will deviate from the true value, causing the deviation between the two paths to exceed the threshold. After determining that the flow velocity branch is abnormal, the controller 106 can automatically switch to the liquid level measurement module 105 for independent measurement and control. The liquid level measurement module 105, relying on real-time liquid level data and variable diameter lifting volume compensation parameters, can accurately calculate the mass of the aluminum liquid entering the ladle, and immediately shut down the valve and stop the machine after the target is met. In some embodiments, when the target aluminum output is 3700 kg and the flow velocity detection branch experiences signal loosening or electromagnetic interference causing data distortion, after switching to the liquid level single-source control mode, the actual aluminum output can reach 3692.3 kg, with a measurement error of 0.21%. Good aluminum output accuracy can still be guaranteed under abnormal operating conditions, and the entire production process is uninterrupted and without measurement loss of control.

[0109] When the liquid level measuring module 105 experiences abnormalities such as dust obstruction of the observation window or instantaneous drift distortion of the liquid level signal, the calculated aluminum quantity will deviate from the true value. After determining that the liquid level branch is abnormal, the controller 106 can automatically switch to the electromagnetic induction flow velocity measurement module 104 to perform flow velocity integration measurement and closed-loop control independently. Flow velocity integration measurement relies on stable pipeline flow velocity detection data to complete the entire closed-loop aluminum tapping operation. In some embodiments, when the observation window is obstructed by dust, causing the liquid level signal to be distorted, switching to the single-source flow velocity control mode can achieve an actual aluminum output of 3690.8 kg with a measurement error of 0.25%, thus ensuring the continuous and stable operation of the aluminum tapping process.

[0110] Once the abnormal state of the fault detection branch is resolved, such as when the flow rate signal stabilizes, dust in the observation window is cleaned, or the liquid level signal returns to normal, the metering deviation between the two channels will fall back to within the preset threshold range. At this time, the controller 106 can automatically resume the dual-source fusion control mode and recalculate the controlled aluminum output using the dynamic weighted fusion algorithm, without requiring manual recalibration or system restart by the operator. This automatic recovery mechanism ensures that the system always operates in the optimal dual-source fusion state, maximizing the complementary advantages of the two detection channels.

[0111] This application employs a dynamic weighted fusion algorithm when the deviation is normal, automatically switches to the normal branch for single-source control when the deviation exceeds the limit, and automatically restores the dual-source mode after the fault is cleared. This can ensure metering accuracy while achieving fault tolerance, avoid work interruption or metering distortion caused by single-path detection anomalies, and greatly improve the system's operational reliability and continuous operation capability under complex working conditions.

[0112] Continue to refer to Figure 2 In step 260, the opening degree of the vacuum valve is dynamically adjusted according to the difference between the aluminum tapping progress and the target aluminum tapping amount.

[0113] In this application, step 260 is the valve adaptive adjustment stage. The controller 106 dynamically and continuously adjusts the opening of the vacuum valve based on the difference between the real-time controlled aluminum output and the target aluminum output, ensuring the aluminum output flow rate remains within a reasonable range. In the initial stage of aluminum output, when the controlled aluminum output differs significantly from the target value, the controller 106 can maintain the vacuum valve at a larger opening, allowing aluminum output to proceed at a higher, more stable flow rate, thus improving aluminum output efficiency. As the aluminum output progresses and gradually approaches the target value, the controller 106 can gradually reduce the vacuum valve opening, lowering the aluminum output flow rate and preventing problems such as aluminum turbulence, slag inclusion, or pipeline turbulence caused by excessively high flow rates. This method of continuously adjusting the valve opening according to the aluminum output progress ensures a smooth transition in the aluminum output flow rate, guaranteeing the stability of the aluminum output process.

[0114] In such Figure 1 In step 260, the dynamic adjustment of the vacuum valve opening based on the difference between the aluminum tapping progress and the target aluminum tapping amount can be performed as follows: step 261: Step 261: When the controlled aluminum output reaches the preset ratio range of the target aluminum output, reduce the opening of the vacuum valve to smoothly reduce the aluminum output flow rate from the first aluminum output flow rate to the second aluminum output flow rate, and at the same time increase the sampling frequency of the detection data to achieve low-speed fine metering at the end.

[0115] In this application, step 261 is an end-stage creep flow rate control strategy. The preset proportional range refers to the range within which low-speed control is triggered when the aluminum quantity approaches the target value, and can be set to 85% to 95% of the target aluminum quantity. When the controlled aluminum quantity reaches this proportional range, it indicates that the aluminum tapping operation has entered the final stage, at which point more precise flow rate control is required to ensure the accuracy of the final measurement. The controller 106 reduces the opening of the vacuum valve, so that the aluminum tapping flow rate smoothly decreases from the first aluminum tapping flow rate in the normal aluminum tapping stage to a lower second aluminum tapping flow rate. The first aluminum tapping flow rate can be 180 kg / min, and the second aluminum tapping flow rate can be 50 kg / min. The process of reducing the flow rate is a smooth transition, avoiding sudden changes in flow rate that could cause aluminum tumbling.

[0116] Simultaneously, the controller 106 increases the sampling frequency of the electromagnetic induction flow velocity measurement module 104 and the liquid level ranging module 105, increasing the number of sampling points per unit time, resulting in higher metering resolution at the end stage and enabling more accurate capture of the moment when the aluminum quantity approaches the target value. The end-stage low-speed creeping mode can effectively stabilize the fluid state in the pipeline and the aluminum liquid state on the tank surface, eliminating slag suction and inclusion quality defects caused by sudden changes in flow velocity at the aluminum discharge end. In some embodiments, when the target aluminum discharge is 3680 kg and the dual-source fusion metering value reaches 95% of the target value, the end-stage creeping control is activated. The actual aluminum discharge on site can reach 3678.6 kg, with a metering error of only 0.04%. At the same time, it can stably ensure the quality of primary aluminum, reduce the fluctuation of aluminum discharge in a single tank, and maintain the stability of the material and thermal balance of the electrolytic cell.

[0117] This application dynamically adjusts the opening of the vacuum valve according to the aluminum tapping progress and adopts a creeping flow stabilization control strategy at the end of the aluminum tapping process. This allows the aluminum tapping flow rate to maintain a smooth transition throughout the process, avoiding aluminum liquid turbulence and slag suction problems caused by sudden changes in flow rate. At the same time, it achieves fine metering by increasing the sampling frequency at the end, thereby significantly improving the accuracy of the final metering and the quality of the primary aluminum while ensuring aluminum tapping efficiency.

[0118] Continue to refer to Figure 2 In step 270, when the controlled aluminum output reaches the target aluminum output, the vacuum valve is closed, and the overhead crane actuator is controlled to complete the aluminum suction tube removal and vacuum lifting and resetting.

[0119] In this application, step 270 is the precise shutdown and operation reset stage. The controller 106 continuously monitors and controls the change in the aluminum output. When the controlled aluminum output precisely reaches the preset target output, it immediately sends a closing command to the vacuum valve, instantly terminating the aluminum output operation. Because low-speed creep control and high-frequency sampling are used in the final stage, the controller 106 can precisely close the valve the instant the aluminum output reaches the target value, completely eliminating problems of exceeding tolerances or falling short of the target output. After the valve closes, the negative pressure inside the vacuum lifting ladle 102 gradually disappears, the molten aluminum in the aluminum suction tube 107 stops flowing, and the aluminum output operation officially ends.

[0120] After the vacuum valve is closed, the controller 106 sends a tube-pulling command to the overhead crane actuator 103. The overhead crane actuator 103 drives the aluminum suction tube 107 to rise and be pulled out of the aluminum electrolysis cell 101. Subsequently, it drives the vacuum lifting package 102 to move to the reset position or the next station. The detachable electromagnetic induction flow rate measurement module 104 can be removed from the aluminum suction tube 107 and stored for future use. The entire shutdown and reset process is automatically controlled by the controller 106 without manual intervention.

[0121] This application achieves precise control of the aluminum tapping endpoint by immediately closing the vacuum valve and automatically completing the tube resetting when the aluminum tapping amount reaches the target value, completely eliminating problems of exceeding tolerances and under-tapping. At the same time, the automated resetting operation can improve the overall efficiency and safety of the aluminum tapping operation.

[0122] In this application, steps 281 to 282 may also be performed: Step 281: Apply a high-order moving average filter to the collected flow velocity data to eliminate flow velocity fluctuation errors caused by aluminum turbulence and bubbles.

[0123] Step 282: The collected liquid level data is subjected to median filtering combined with sliding steady-state filtering to filter out instantaneous liquid level jumps caused by the crane movement and the swaying of the vacuum lifting bag.

[0124] In this application, step 281 is a software filtering process for the flow velocity data, which can be performed before the flow velocity integral calculation in step 230. The core idea of ​​high-order moving average filtering is to take the arithmetic mean of the flow velocity data of the most recent N sampling points within a sliding time window of length N, and use this as the filtered flow velocity value at the current moment. The window length N can be selected according to the actual interference frequency; the higher the interference frequency, the larger the window length can be. Moving average filtering can effectively smooth out the high-frequency pulsations caused by turbulence and bubbles in molten aluminum, while preserving the overall trend of flow velocity changes. After filtering, the instantaneous fluctuation of the pipeline flow velocity can be controlled within ±0.02 meters per second.

[0125] In this application, step 282 is a software filtering process for the liquid level data, which can be performed before the liquid level conversion calculation in step 230. The median filtering method involves sorting the sampled data by size within a sliding window and taking the median value as the filter output. This method is particularly effective in removing isolated spikes, as abnormal liquid level values ​​caused by crane movement or bag-lifting swaying typically manifest as isolated pulse signals. The sliding steady-state filtering further smooths the data based on the median filtering, eliminating remaining small fluctuations. After combined filtering, the fluctuation of the liquid level data can be controlled within ±0.8 mm, providing a stable data foundation for accurate liquid level conversion and measurement.

[0126] This application employs high-order moving average filtering and median combined moving steady-state filtering on flow velocity and liquid level data respectively, which can specifically eliminate different types of interference in the two detection data. This ensures that the flow velocity and liquid level data remain stable and accurate even under harsh conditions such as strong magnetic fields, equipment vibration, and turbulent aluminum flow, thereby providing high-quality input data for dual-source fusion metering and closed-loop control.

[0127] In this application, steps 283 to 284 may also be performed: Step 283: Dynamically adjust the effective cross-sectional area according to the shell-forming conditions of the inner wall of the vacuum lifting package to achieve volume adaptive compensation.

[0128] Step 284: After the vacuum lifting package completes the shell cleaning and maintenance, the volume calibration parameters are automatically reset.

[0129] In this application, step 283 is a volume adaptive compensation step. During long-term use, electrolyte crusts gradually adhere to the inner wall of the vacuum ladle 102, causing the actual effective cross-sectional area to be smaller than the design value. The controller 106 can determine the degree of crusting by the deviation trend of dual-source metering data. When the aluminum quantity calculated from the liquid level is consistently higher than the aluminum quantity calculated from the flow rate integral and the deviation shows a cumulative increase, it indicates that the crusting on the inner wall of the ladle is causing a reduction in the effective cross-sectional area. The controller 106 can gradually adjust the effective cross-sectional area parameters corresponding to each liquid level height according to a certain correction strategy, so that the liquid level calculation result is rematched with the actual amount of aluminum liquid entering the ladle. This dynamic correction method can adapt to the real-time changes in the ladle volume and does not require manual calibration during shutdown.

[0130] In this application, step 284 is the automatic parameter reset step after shell cleaning. The electrolysis workshop regularly performs shell cleaning maintenance on the vacuum lifting package 102 to remove the crust layer adhering to the inner wall. After shell cleaning, the volume of the vacuum lifting package 102 is restored to the design standard state. At this time, the controller 106 can automatically reset the volume calibration parameters to the pre-stored standard volume parameters, so that the liquid level conversion measurement is recalculated based on the standard cross-sectional area. The automatic reset mechanism can adapt to the workshop's routine shell cleaning and maintenance process, avoid the workload and human error caused by manual recalibration, and ensure that the system can maintain high-precision measurement before and after shell cleaning.

[0131] This application dynamically corrects the effective cross-sectional area based on the shelling conditions and automatically resets the volume parameters after shelling, which ensures that the liquid level conversion measurement always matches the actual volume state of the vacuum lifting package, eliminates the measurement drift caused by the variable diameter structure and the inner wall shelling, and reduces the frequency of manual calibration, thereby lowering on-site operation and maintenance costs.

[0132] In this application, step 285 may also be performed: Step 285: After the aluminum tapping operation is completed, retrieve the weighing data from the weighing verification module in the aluminum electrolysis cell aluminum tapping control system to verify the final aluminum tapping amount, so as to achieve closed-loop traceability of data throughout the entire process.

[0133] Step 285 is the final value weighing and verification step, which can be performed after the tube removal and reset in step 270. After the aluminum tapping operation is completed and the vacuum lifting ladle 102 is in a stationary state, the controller 106 retrieves the weighing data from the weighing verification module 111 installed between the overhead crane hook and the vacuum lifting ladle 102, and compares and verifies the final value of aluminum tapping obtained by weighing with the amount of aluminum tapped calculated by dual-source fusion. If the deviation between the two is within the allowable range, it indicates that the dual-source metering result of this aluminum tapping is accurate and reliable; if the deviation exceeds the allowable range, the controller 106 can trigger an alarm to prompt the operator to check the working status or calibration parameters of the detection device.

[0134] Each aluminum tapping operation's dual-source metering data, valve adjustment records, fault switching information, and weighing verification results can be stored in the controller 106 or the host computer, forming a complete aluminum tapping operation data archive. This data can provide support for subsequent process optimization, equipment maintenance, and quality traceability, achieving closed-loop data management throughout the entire process from aluminum tapping preparation to final value verification.

[0135] This application provides an independent third-party verification benchmark for the dual-source fusion metering results by retrieving data from the weighing verification module after aluminum tapping is completed, which can promptly detect long-term drift problems of the detection device. At the same time, the full-process data recording can support process optimization and quality traceability, and realize closed-loop data management of aluminum tapping operations.

[0136] In this application, the preset deviation threshold can be set according to 1% to 2% of the target aluminum output of a single tank.

[0137] In this application, the preset deviation threshold is a key parameter used in step 240 to determine the operating status of the two detection branches. Its value directly affects the sensitivity of fault determination and the fault tolerance of the system. Setting the threshold to 1% to 2% of the target aluminum output per tank is a reasonable range determined after comprehensively considering the inherent error range of the two detection methods under normal operating conditions and the fault identification requirements. Within this range, the deviation caused by random fluctuations in the two detections under normal operating conditions will not trigger false alarms. However, when one detection shows obvious drift, obstruction, or signal abnormality, the deviation will quickly exceed the threshold and be identified in a timely manner.

[0138] Taking a target aluminum output of 3700 kg as an example, the threshold range corresponding to 1% to 2% is 37 kg to 74 kg. In practical applications, 50 kg can be selected as the preset deviation threshold. This threshold can ensure that the system operates stably in dual-source fusion mode under normal working conditions, and can also trigger fault switching in a timely manner when an abnormality occurs in the detection branch, thus balancing metering accuracy and operational reliability.

[0139] This application achieves a reasonable balance between normal measurement error and fault identification sensitivity by setting the preset deviation threshold to 1% to 2% of the target aluminum output of a single cell. This avoids false alarms caused by normal fluctuations and can trigger fault-tolerant switching in a timely manner when a real abnormality occurs in the detection branch, ensuring the stable operation of the system under various working conditions.

[0140] In this application, references Figure 3 The diagram shows a schematic of the controller in an embodiment of this application. The controller includes one or more memories 304, one or more processors 302, and at least one computer program (computer program instruction) stored in the memory 304 and executable on the processor 302. When the processor 302 executes the computer program, it implements the aluminum electrolysis cell aluminum output control method as described above.

[0141] 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.

[0142] The functions described herein can be implemented in hardware, software executed by a processor, firmware, or any combination thereof. When implemented in software executed by a processor, the functions can 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 can be implemented using software executed by a processor, hardware, firmware, hardwired, or any combination thereof. Furthermore, the functional units can be integrated into a single processing unit, or each unit can exist physically separately, or two or more units can be integrated into a single unit.

[0143] 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.

[0144] 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.

[0145] When 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 computer program instructions, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0146] 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 control system for aluminum electrolysis cell output, characterized in that, The system includes an aluminum electrolysis cell, a vacuum lifting ladle, an overhead crane actuator, an electromagnetic induction flow velocity measurement module, a liquid level distance measurement module, and a controller. The vacuum lifting bag draws molten aluminum from the aluminum electrolysis cell through an aluminum suction tube; The overhead crane actuator is used to drive the vacuum lifting package and the aluminum suction tube to complete the alignment, insertion and removal operations with the aluminum electrolysis cell; The outer wall of the aluminum suction tube is provided with a positioning groove, and the electromagnetic induction flow rate measurement module is a detachable clamp-type structure, which is limited and clamped in the positioning groove to collect the instantaneous flow rate of the aluminum liquid in the aluminum suction tube in real time. The top of the vacuum lifting package is provided with an observation window, which is fitted with sealed high-temperature resistant quartz glass to allow light to pass through while isolating the high-temperature molten aluminum, dust and fumes inside the vacuum lifting package. The top of the vacuum lifting bag is also provided with a mounting hole, and the liquid level measuring module is installed in the mounting hole to detect the liquid level height of the aluminum liquid inside the vacuum lifting bag in real time using a non-contact method such as laser or ultrasound. The controller is communicatively connected to the electromagnetic induction flow velocity measurement module and the liquid level ranging module, and has built-in dual-source metering logic, cross-validation logic, volume adaptive compensation logic and closed-loop control logic. It is used to perform aluminum output fusion calculation, fault tolerance judgment and vacuum valve adaptive adjustment based on the detection data of the electromagnetic induction flow velocity measurement module and the liquid level ranging module.

2. A method for controlling aluminum output from an aluminum electrolysis cell, characterized in that, The method is applied to the aluminum electrolysis cell aluminum output control system as described in claim 1, and the method includes: The initial liquid level of the empty vacuum lifter is collected by the liquid level ranging module on the vacuum lifter, and the target aluminum output is entered into the controller to complete the system parameter initialization. The crane actuator is controlled to complete the alignment of the aluminum electrolysis cell and the insertion of the aluminum suction tube, and the vacuum valve in the aluminum suction tube is opened; The electromagnetic induction flow velocity measurement module on the aluminum suction tube and the liquid level distance measurement module are controlled to collect detection data synchronously, and the aluminum quantity integrated by the flow velocity and the aluminum quantity converted by the liquid level are calculated respectively. The deviation between the aluminum quantity integrated from the flow rate and the aluminum quantity calculated from the liquid level is compared in real time, and the operating status of the two detection branches is determined according to the preset deviation threshold. When the deviation is within the preset deviation threshold range, the controlled aluminum output is obtained through dynamic weighted fusion; when the deviation exceeds the preset deviation threshold range, a single detection branch is determined to be faulty, and the system automatically switches to the normally operating detection branch for single-source independent closed-loop control. The opening degree of the vacuum valve is dynamically adjusted according to the difference between the aluminum tapping progress and the target aluminum tapping amount; When the controlled aluminum output reaches the target aluminum output, the vacuum valve is closed, and the overhead crane actuator is controlled to complete the aluminum suction tube removal and vacuum lifting and resetting.

3. The method according to claim 2, characterized in that, The amount of aluminum produced by integrating the flow rate is calculated using the following formula: In the formula, for The amount of aluminum is calculated by integrating the flow rate at each moment. The instantaneous flow rate of molten aluminum in the aluminum suction tube. This is the effective inner cross-sectional area of ​​the aluminum suction tube. The density of molten aluminum, This refers to the aluminum tapping time.

4. The method according to claim 2, characterized in that, The amount of aluminum can be calculated by converting the liquid level into the following formula: In the formula, for The amount of aluminum is calculated from the liquid level at a given time. for The level of molten aluminum inside the vacuum ladle at all times. This represents the initial liquid level height of the empty package in the vacuum lifting assembly. This represents the effective cross-sectional area of ​​the vacuum lifting package at the corresponding liquid level. This represents the density of the molten aluminum.

5. The method according to claim 2, characterized in that, The aluminum output should be calculated and controlled using the following formula: In the formula, The amount of aluminum produced at time t is controlled. The amount of aluminum is calculated by integrating the flow rate at time t. The amount of aluminum is calculated from the liquid level at time t. The weighting coefficient corresponding to the amount of aluminum integrated from the flow rate has a value range of 0 to 1.

6. The method according to claim 2, characterized in that, The automatic switching to the normally operating detection branch for single-source independent closed-loop control includes: When the data collected by the electromagnetic induction flow velocity measurement module is abnormal, the system switches to the liquid level ranging module to perform liquid level conversion measurement and closed-loop control independently. When the data collected by the liquid level ranging module is abnormal, the system switches to the electromagnetic induction flow velocity measurement module to perform flow velocity integral measurement and closed-loop control independently. The dual-source fusion control mode will be automatically restored after the fault is resolved.

7. The method according to claim 2, characterized in that, The step of dynamically adjusting the opening of the vacuum valve based on the difference between the aluminum tapping progress and the target aluminum tapping amount includes: When the controlled aluminum output reaches the preset ratio range of the target aluminum output, the opening of the vacuum valve is reduced, and the aluminum output flow rate is smoothly reduced from the first aluminum output flow rate to the second aluminum output flow rate, while the sampling frequency of the detection data is increased.

8. The method according to claim 2, characterized in that, The method further includes: The collected flow velocity data were filtered using a high-order moving average to eliminate flow velocity fluctuation errors caused by turbulence and bubbles in the molten aluminum. The collected liquid level data is filtered using a combination of median filtering and sliding steady-state filtering to filter out instantaneous liquid level jumps caused by the crane's movement and the swaying of the vacuum lifting bag.

9. The method according to claim 2, characterized in that, The method further includes: The effective cross-sectional area is dynamically adjusted according to the shell-forming conditions of the inner wall of the vacuum lifting bag to achieve volume adaptive compensation. After the vacuum lifting package completes the shell cleaning and maintenance, the volume calibration parameters are automatically reset.

10. The method according to claim 2, characterized in that, The method further includes: After the aluminum tapping operation is completed, the weighing data from the weighing verification module in the aluminum electrolysis cell aluminum tapping control system is retrieved to verify the final aluminum tapping quantity.

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