High-precision aluminum electrolysis cell guide rod equidistant pressure drop detection device
The high-precision equidistant voltage drop detection device solves the problems of accuracy and automation in the detection of voltage drop in aluminum electrolysis cell guide rods, enabling efficient and accurate detection in complex environments and optimizing electrolysis production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-27
- Publication Date
- 2026-03-31
AI Technical Summary
Existing methods for detecting voltage drop in aluminum electrolytic cell guide rods suffer from low precision, large errors, difficulty in achieving equidistant detection, poor accuracy of detection equipment in complex environments, and a lack of automation and unified data standards.
A high-precision aluminum electrolytic cell guide rod equidistant voltage drop detection device was designed, including a control system box, a touch screen and a moving detection device. It adopts a high-precision equidistant voltage drop acquisition probe, a temperature sensor and a signal amplification module, and combines a central processing unit to realize automated detection. Data is displayed and uploaded through a 485 communication line and a touch screen.
It significantly improves detection accuracy and efficiency, enabling accurate acquisition of conductor voltage drop and temperature data in high-temperature and strong magnetic environments, optimizing electrolytic production processes, reducing energy consumption, and improving production management efficiency.
Smart Images
Figure CN224066886U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of equidistant voltage drop detection technology for aluminum electrolytic cell guide rods, specifically a high-precision equidistant voltage drop detection device for aluminum electrolytic cell guide rods. Background Technology
[0002] In the aluminum electrolysis industry, the conductor rod is a key component for transmitting current, and its voltage drop directly affects the energy consumption, efficiency, and stability of electrolysis production. As the scale of aluminum electrolysis production expands and the requirements for energy conservation and consumption reduction increase, accurate detection of conductor rod voltage drop is becoming increasingly critical.
[0003] Traditional testing methods mostly rely on manual measurement, which suffers from low accuracy and large errors. Furthermore, it's difficult to achieve equidistant testing, failing to comprehensively and accurately reflect the voltage drop distribution of the guide rod. Currently, the automation level of parameter detection and control for aluminum electrolysis cell guide rods in China is relatively low. Intelligent manufacturing faces a series of problems, including a lack of top-level design, a lack of unified data standards, a lack of accurate mathematical models describing all elements, and insufficient equipment intelligence. In addition, the complex environment of aluminum electrolysis workshops, with factors such as high temperature, strong magnetic fields, and dust, can interfere with testing equipment and results, further reducing accuracy. Therefore, we propose a high-precision equidistant voltage drop detection device for aluminum electrolysis cell guide rods. Utility Model Content
[0004] (a) Technical problems to be solved
[0005] To address the shortcomings of existing technologies, this invention provides a high-precision aluminum electrolytic cell guide rod equidistant voltage drop detection device, which solves the aforementioned problems.
[0006] (II) Technical Solution
[0007] To achieve the above-mentioned objectives, this utility model provides the following technical solution: a high-precision aluminum electrolytic cell guide rod equidistant voltage drop detection device, comprising a control system box, a touch screen, and a moving detection device. The moving detection device is disposed outside the control system box and is connected to the control system box via a 485 communication line. The moving detection device is placed inside the electrolytic cell. The touch screen is disposed outside the control system box and is connected to the side wall of the control system box via an adapter screw. The touch screen is connected to the circuit board inside the control system box via a 485 communication line, which is the same as the 485 communication line.
[0008] Preferably, the control system box is equipped with a central processing unit, a motor drive module, an output interface module, a power interface module, a data storage module, a temperature sensor output module, a signal amplification module, etc.
[0009] Preferably, the power interface module is powered by a 12-24V DC switching power supply.
[0010] Preferably, the data storage module uses a 24C08 data storage chip with an SPI interface.
[0011] Preferably, the temperature sensor output module uses a MAX31865ATP with a high-precision temperature sensor chip, an RTD to digital output converter, and digital temperature reading with RTD fault detection and input voltage protection.
[0012] Preferably, the touch screen is provided with an RS-232 communication interface, which communicates with the central processing unit via the PELCO_D communication protocol to set and save parameters.
[0013] Preferably, the signal amplification module internally employs an AD8293G160 amplifier chip, a zero-drift instrumentation amplifier, a built-in filter, and an ADS1115IDGSR digital-to-analog converter chip, which is a 16-bit 860SPS4-channel Δ-Σ ADC with PGA, oscillator, VREF, comparator, and I2C.
[0014] Preferably, the moving detection device consists of three parts: a stepper motor, an equidistant voltage drop acquisition probe, and a slide rail. The main body of the moving detection device is the slide rail, and a stepper motor is provided at the end of the slide rail shaft. The stepper motor is fixedly connected to the slide rail by an adapter bolt, and the output shaft of the stepper motor passes through the interior of the slide rail. An equidistant voltage drop acquisition probe is provided inside the slide rail corresponding to the lead screw. A set of spring-type contacts with equal spacing is provided on the side of the equidistant voltage drop acquisition probe away from the stepper motor.
[0015] (III) Beneficial Effects
[0016] Compared with the prior art, this utility model provides a high-precision aluminum electrolytic cell guide rod equidistant voltage drop detection device, which has the following beneficial effects:
[0017] 1. This high-precision aluminum electrolysis cell guide rod equidistant voltage drop detection device greatly improves detection accuracy. Traditional manual detection is greatly affected by environmental interference and has low accuracy, making it difficult to fully reflect the voltage drop distribution of the guide rod. This device uses a high-precision equidistant voltage drop acquisition probe and temperature sensor, combined with a signal amplification module for precise processing of weak signals, and a central processing unit for efficient computing. It can accurately collect and analyze the equidistant voltage drop and temperature data of the guide rod. For example, in a high-temperature, strong magnetic aluminum electrolysis workshop, its specially designed spring-type contacts can closely fit the guide rod to obtain accurate voltage signals, providing a reliable basis for optimizing the electrolysis production process and reducing energy consumption.
[0018] 2. This high-precision aluminum electrolysis cell guide rod equidistant voltage drop detection device significantly improves detection efficiency and automation level. The device uses a touchscreen for parameter setting and real-time data display. Through a central processing unit and motor drive module, it precisely controls the stepper motor to automatically complete the movement and detection of the equidistant voltage drop acquisition probe, quickly acquiring multiple sets of data. Simultaneously, the data storage module automatically saves data and can also achieve rapid data upload and sharing through various communication interfaces. In large-scale aluminum electrolysis production, this greatly saves detection time, reduces labor costs, and improves production management efficiency. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the high-precision aluminum electrolytic cell guide rod equidistant voltage drop detection device of this utility model;
[0020] Figure 2 This is a block diagram of the internal control system of the control system box of this utility model;
[0021] Figure 3 This is a schematic diagram of the mobile detection device of this utility model;
[0022] Figure 4 This is a schematic diagram of the power supply circuit of this utility model;
[0023] Figure 5 This is a schematic diagram of the stepper motor drive circuit of this utility model;
[0024] Figure 6 This is a schematic diagram of the data storage circuit of this utility model;
[0025] Figure 7 This is a schematic diagram of the 485 communication circuit of this utility model;
[0026] Figure 8 This is a circuit diagram of the analog-to-digital conversion module of this utility model;
[0027] Figure 9 This is a schematic diagram of the temperature sensor circuit of this utility model;
[0028] Figure 10 This is a schematic diagram of the signal amplification module circuit of this utility model;
[0029] Figure 11 This is a schematic diagram of the main MCU circuit of this utility model.
[0030] In the diagram: 1. Control system box; 2. Touch screen; 3. Motion detection device; 4. Central processing unit; 5. Motor drive module; 6. Output interface module; 7. Power interface module; 8. Data storage module; 9. Temperature sensor output module; 10. Signal amplification module; 11. Stepper motor; 12. Equidistant voltage drop acquisition probe; 13. Slide rail; 14. Spring contact; 15. Lead screw; 16. 485 communication line. Detailed Implementation
[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0032] Please see Figure 1-11 A high-precision aluminum electrolytic cell guide rod equidistant voltage drop detection device includes a control system box 1, a touch screen 2, and a moving detection device 3. The moving detection device 3 is installed outside the control system box 1 and is connected to the control system box 1 via a 485 communication line 16. The moving detection device 3 is placed inside the electrolytic cell. The touch screen 2 is installed on the outside of the control system box 1 and is connected to the side wall of the control system box 1 by an adapter screw. The touch screen 2 is connected to the circuit board inside the control system box 1 via a 485 communication line, which is the same as the 485 communication line 16.
[0033] Furthermore, the control system box 1 is equipped with a central processing unit 4, a motor drive module 5, an output interface module 6, a power interface module 7, a data storage module 8, a temperature sensor output module 9, and a signal amplification module 10. The central processing unit 4 adopts a high-performance 32-bit STM32 microprocessor with an operating frequency of up to 72MHz. It has abundant external interface units, high cost performance, 64KB of FLASH space, 20KB of SRAM, and multiple communication interfaces. It can read and write simultaneously. When communicating with the human-machine interface via serial port, it adopts DMA data interaction mode, which does not occupy the MCU running time. The high-performance timer built into the central processing unit 4 realizes the control of the stepper motor 11. It is connected to the motor drive module 5 integrated in the device, which can realize the acceleration and deceleration control of the stepper motor 11, high-precision pulse data output, and control of the running direction. It realizes the trapezoidal acceleration and deceleration and S-curve acceleration and deceleration functions of the stepper motor 11.
[0034] Furthermore, the power interface module 7 is powered by a 12-24V DC switching power supply to power this device. Internally, the 12-24V voltage is isolated and converted into the 5V and 3.3V voltages required by the system circuit modules.
[0035] Furthermore, the data storage module 8 uses a 24C08 data storage chip with an SPI interface to save the basic operating parameters of the system, and can also be connected to an external high-capacity memory to enhance storage capacity.
[0036] Furthermore, the temperature sensor output module 9 uses a MAX31865ATP chip in conjunction with a high-precision temperature sensor chip and an RTD to digital output converter. It employs digital temperature reading with RTD fault detection and input voltage protection to realize real-time acquisition and data processing of the guide rod temperature.
[0037] Furthermore, the touch screen 2 is equipped with an RS-232 communication interface. This interface communicates with the central processing unit 4 via the PELCO_D communication protocol to set and save parameters, and displays the collected data such as the equidistant pressure drop of the guide rod, temperature, and calculated current in real time on the touch screen 2.
[0038] Furthermore, the signal amplification module 10 internally employs the AD8293G160 amplifier chip, a low-cost, zero-drift instrumentation amplifier with a built-in filter and a fixed gain G=160, as well as the ADS1115IDGSR digital-to-analog converter chip, a 16-bit 860SPS4-channel Δ-Σ ADC with PGA, oscillator, VREF, comparator, and I2C, which acquires the equidistant voltage drop signal of the guide rod in real time, and transmits the amplified and converted signal to the main control chip for further processing.
[0039] Furthermore, the moving detection device 3 consists of three parts: a stepper motor 11, an equidistant voltage drop acquisition probe 12, and a slide rail 13. The main body of the moving detection device 3 is the slide rail 13, with the stepper motor 11 mounted on the shaft end of the slide rail 13. The stepper motor 11 is fixedly connected to the slide rail 13 by an adapter bolt, and the output shaft of the stepper motor 11 passes through the interior of the slide rail 13. The lead screw 15 is mounted inside the slide rail 13 with the equidistant voltage drop acquisition probe 12. The equidistant voltage drop acquisition probe 12 has a set of equidistantly distributed spring contacts 14 on the side away from the stepper motor 11. The moving detection device 3, used to drive the detection probe to move on the guide rod of the aluminum electrolysis cell to achieve equidistant detection, adopts a high-precision guide rail and lead screw transmission system. The speed and rotation angle are controlled by a stepper motor 11, which can accurately control the moving distance and speed of the equidistant voltage drop acquisition probe 12 to ensure the accuracy and repeatability of the detection. The equidistant voltage drop acquisition probe 12 is designed with multiple equidistantly distributed spring-type contacts 14 to ensure equidistant detection on the guide rod. The special structure of the spring-type contacts 14 can automatically adapt to the unevenness of the guide rod surface to ensure close contact with the guide rod and obtain accurate voltage signals.
[0040] Structural Description:
[0041] Control System Box 1: The control system box 1 is the core part of the device. It integrates multiple modules internally and connects to the motion detection device 3 and the touch screen 2 externally, providing installation space and a stable operating environment for each module.
[0042] Touch screen 2: Touch screen 2 is installed on the outside of the control system box 1 and communicates with the central processing unit 4 through the RS-232 communication interface. It is used for parameter setting, data display and command operation.
[0043] Mobile detection device 3: The mobile detection device 3 consists of a stepper motor 11, an equidistant voltage drop acquisition probe 12 and a slide rail 13. It is placed inside the electrolytic cell to realize the mobile detection of the equidistant voltage drop of the guide rod.
[0044] Central Processing Unit 4: The Central Processing Unit 4 uses a 32-bit STM32 microprocessor with rich interfaces, controls the stepper motor 11, and processes the acquired data. It is the core of the device's control and data processing.
[0045] Motor drive module 5: Motor drive module 5 is connected to central processing unit 4 and uses MCU timer to control stepper motor 11 to realize its acceleration, deceleration, pulse output and direction control;
[0046] Output interface module 6: Output interface module 6 uses EL3H7 high-speed optocoupler to output abnormal signals of the drive module to the touch screen, so as to facilitate real-time understanding of the device's operating status;
[0047] Power interface module 7: Power interface module 7 connects to a 12-24V DC switching power supply, converts it to 5V and 3.3V voltages, and supplies power to the various modules of the device;
[0048] Data storage module 8: Data storage module 8 uses a 24C08 chip with an SPI interface to save system operating parameters, and can also be connected to an external memory to enhance storage capacity;
[0049] Temperature sensor output module 9: Temperature sensor output module 9 uses MAX31865ATP and a high-precision sensor chip to collect and process guide rod temperature data in real time;
[0050] Signal Amplification Module 10: The signal amplification module 10 uses AD8293G160 and ADS1115IDGSR chips to amplify and convert the equidistant voltage drop signal before transmitting it to the main control chip;
[0051] Stepper motor 11: Stepper motor 11 is mounted on the end of slide rail 13 and is controlled by motor drive module 5. It drives lead screw 15 to move equidistant voltage drop acquisition probe 12.
[0052] Equidistant pressure drop acquisition probe 12: The equidistant pressure drop acquisition probe 12 is mounted on the lead screw 15 and acquires the equidistant pressure drop signal of the guide rod through the spring contact 14 to ensure detection accuracy;
[0053] Slide rail 13: Slide rail 13 is the main body of the moving detection device 3, providing a moving track for the equidistant pressure drop acquisition probe 12 to ensure its smooth movement and detection accuracy;
[0054] Spring-type contact 14: The spring-type contact 14 is located on one side of the equidistant voltage drop acquisition probe 12, and can automatically adapt to the surface of the guide rod to make close contact and obtain accurate voltage signals;
[0055] Lead screw 15: The lead screw 15 is inside the slide rail 13 and is connected to the output shaft of the stepper motor 11, which drives the equidistant voltage drop acquisition probe 12 to achieve equidistant movement detection;
[0056] 485 communication line 16: 485 communication line 16 connects the mobile detection device 3 and the control system box 1, transmitting detection data and control signals to ensure the coordinated operation of all parts of the device.
[0057] Working Principle: Following the diagram, the high-precision aluminum electrolytic cell guide rod equidistant voltage drop detection device is correctly installed. During operation, the device first connects to a 12-24V DC switching power supply via the power interface module 7, converting it to 5V and 3.3V voltages to power the modules within the control system box 1 and the moving detection device 3, ensuring stable operation of the entire device. During startup, the device establishes communication and reads raw parameters. The operator interacts with the central processing unit 4 via the RS-232 communication interface on the touchscreen 2, according to the PELCO_D communication protocol, to complete parameter setting and saving. These parameters are then stored in the data storage module 8. The central processing unit 4 acts as... At its core, the device employs a high-performance 32-bit STM32 microprocessor, utilizing its built-in high-performance timer to coordinate with the motor drive module 5 to control the stepper motor 11. When a relevant operation button is activated on the touchscreen 2, the central processing unit 4 sends a pulse signal to the motor drive module 5 according to the instruction. The stepper motor 11 is mounted on the end of the slide rail 13 shaft. After starting, it drives the lead screw 15 to rotate, which in turn pushes the equidistant voltage drop acquisition probe 12 to move on the slide rail 13. The moving detection device 3, with its high-precision guide rail and lead screw transmission system, can accurately control the moving distance and speed of the equidistant voltage drop acquisition probe 12, achieving equidistant detection. The spring-type contact 14 on the equidistant voltage drop acquisition probe 12 contacts the aluminum electrolysis cell guide rod, and its special... The structure automatically adapts to uneven surfaces on the guide rod, ensuring tight contact and accurate voltage signal acquisition. Simultaneously, the temperature sensor output module 9, through the MAX31865ATP and a high-precision temperature sensor chip, performs real-time acquisition and data processing of the guide rod temperature. The voltage signal acquired by the equidistant voltage drop acquisition probe 12 and the temperature data acquired by the temperature sensor output module 9 are transmitted to the signal amplification module 10. The AD8293G160 amplifier chip and ADS1115IDGSR digital-to-analog converter chip inside the signal amplification module 10 work together to amplify and convert the voltage signal before transmitting the processed signal to the central processing unit 4. After receiving this data, the central processing unit 4... The system performs analysis and calculations to obtain data such as the working current of the guide rod. On one hand, it transmits the data to the touch screen 2 via the RS-485 communication line 16, where it displays data such as the equidistant voltage drop, temperature, and current of the guide rod in real time. On the other hand, it controls the extension and retraction of the stepper motor 11 via the RS-485 communication interface in the form of commands, and transmits the collected aluminum electrolysis cell guide rod data to the centralized monitor and digital cell control system. It can also send the data to the aluminum electrolysis plant server via the 4G, WIFI, or WLAN interface on the concentrator to realize data uploading and sharing. Throughout the process, the output interface module 6 monitors abnormal signals such as overheating and overcurrent of the drive module in real time and displays them on the touch screen 2 to ensure the safe and stable operation of the device.
[0058] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A high-precision aluminum electrolysis cell guide rod equidistance pressure drop detection device, comprising a control system box (1), a touch screen (2) and a mobile detection device (3), characterized in that: The control system box (1) is externally provided with a movement detection device (3), the movement detection device (3) is connected with the control system box (1) through a 485 communication line (16), and the movement detection device (3) is arranged in the electrolytic cell, a touch screen (2) is arranged on the outside of the control system box (1), the touch screen (2) is connected with the side wall of the control system box (1) through an adaptive screw, and the touch screen (2) is connected with the internal circuit board of the control system box (1) through the same 485 communication line as the 485 communication line (16), the movement detection device (3) is composed of three parts, namely a stepping motor (11), an equidistant pressure drop acquisition probe (12) and a slide rail (13), and the main body of the movement detection device (3) is the slide rail (13), the slide rail (13) is provided with the stepping motor (11) at the shaft end, the stepping motor (11) is fixedly connected with the slide rail (13) through an adaptive bolt, the output shaft of the stepping motor (11) penetrates into the slide rail (13), and the equidistant pressure drop acquisition probe (12) is arranged in the slide rail (13) in a corresponding manner, and a group of equidistantly distributed spring contacts (14) are arranged on the side, away from the stepping motor (11), of the equidistant pressure drop acquisition probe (12).
2. The high-precision aluminum electrolysis cell guide rod equidistance pressure drop detection device according to claim 1, characterized in that: The control system box (1) is internally provided with a central processing unit (4), a motor driving module (5), an output interface module (6), a power supply interface module (7), a data storage module (8), a temperature sensor output module (9) and a signal amplification module (10).
3. A high-precision aluminum electrolysis cell guide rod equidistance pressure drop detection device according to claim 2, characterized in that: The power supply interface module (7) is powered by a 12-24V direct-current switching power supply.
4. The high-precision aluminum cell guide rod equidistance pressure drop detection device according to claim 2, characterized in that: The data storage module (8) adopts a 24C08 data storage chip with an SPI interface.
5. The high-precision aluminum cell guide rod equidistance pressure drop detection device according to claim 2, characterized in that: The temperature sensor output module (9) adopts a MAX31865ATP cooperating with a high-precision temperature sensor chip, an RTD-to-digital output converter, and a digital temperature reading with RTD fault detection and input voltage protection.
6. The high-precision aluminum cell guide rod equidistance pressure drop detection device according to claim 2, characterized in that: An RS-232 communication interface is arranged on the touch screen (2), the interface performs parameter setting and saving on the central processing unit (4) through a PELCO_D communication protocol.
7. The high-precision aluminum cell guide rod equidistance pressure drop detection device according to claim 2, characterized in that: The signal amplification module (10) internally adopts an AD8293G160 amplifier chip, a zero-drift instrument amplifier, a built-in filter and an ADS1115IDGSR digital-analog conversion chip, and has PGA, oscillator, VREF, comparator, I2C 16-bit 860SPS4-channel delta-sigma ADC.