技术领域technical field
本发明属于铝电解技术领域，具体涉及一种铝电解槽智能打壳系统和方法。The invention belongs to the technical field of aluminum electrolysis, and in particular relates to an intelligent shelling system and method for an aluminum electrolytic cell.
背景技术Background technique
铝电解生产中，打壳下料是重要的工艺过程，该过程对铝电解的稳定生产影响很大。现有的打壳过程是由槽控系统控制的，需要打壳时，槽控系统向电磁阀通电一段时间，控制气缸带动锤头向下运行，实现打壳过程；通电结束后，电磁阀关闭，气缸带动锤头向上运行，锤头返回到打壳前位置。打壳过程是由槽控系统对电磁阀通电时间长短决定的，但锤头长短区别很大，新更换的锤头很长，在电解质中浸泡的长度就长，造成锤头损耗加快，影响铝液的质量，同时也缩短了锤头的使用周期，增加了锤头的更换量和更换锤头的工作量；在电解质浸泡时间长也是打壳锤头“粘包”严重的重要原因，锤头“粘包”导致火眼增大，下料口过大，散热增多，电解槽能耗增大；锤头“粘包”严重时造成锤头不能返回到打壳前位置，造成锤头长时间在电解质中浸泡或造成气缸行程变小，对壳面打击力变小，不能顺利打开壳面造成下料不畅，从而引发阳极效应；需要人工巡视检查火眼和锤头状态，处理卡堵和锤头“粘包”，增大了工人劳动强度，甚至影响正常的电解生产。In aluminum electrolysis production, shelling and cutting is an important process, which has a great impact on the stable production of aluminum electrolysis. The existing shelling process is controlled by the tank control system. When shelling is required, the tank control system energizes the solenoid valve for a period of time, and controls the cylinder to drive the hammer to move downward to realize the shelling process; after the power is finished, the solenoid valve is closed. , the cylinder drives the hammer head to run upwards, and the hammer head returns to the position before shelling. The shelling process is determined by the length of time that the tank control system energizes the solenoid valve, but the length of the hammer head is very different. The newly replaced hammer head is very long, and the length of soaking in the electrolyte will be longer, resulting in faster wear of the hammer head and affecting the aluminum alloy. At the same time, it also shortens the service life of the hammer head, increases the replacement amount of the hammer head and the workload of replacing the hammer head; the long soaking time in the electrolyte is also an important reason for the serious "sticking" of the shelling hammer head. The "sticky bag" causes the fire hole to increase, the discharge port is too large, the heat dissipation increases, and the energy consumption of the electrolytic cell increases; when the "sticky bag" of the hammer head is serious, the hammer head cannot return to the position before shelling, resulting in the hammer head being in the shell for a long time. Soaking in the electrolyte may cause the stroke of the cylinder to become smaller, and the impact force on the shell surface will become smaller, and the shell surface cannot be opened smoothly, resulting in poor feeding, which will cause the anode effect; manual inspection is required to check the state of the fire hole and hammer head, and deal with jamming and hammer head The "sticky package" increases the labor intensity of workers and even affects the normal electrolysis production.
发明内容Contents of the invention
本发明为了解决现有技术中的不足之处，提供一种简便、自动化程度高、安全可靠的一种铝电解槽智能打壳系统和方法。In order to solve the deficiencies in the prior art, the present invention provides a simple, highly automated, safe and reliable aluminum electrolytic cell intelligent shelling system and method.
为解决上述技术问题，本发明采用如下技术方案：一种铝电解槽智能打壳系统，系统由打壳气缸、打壳杆、打壳锤头、拉绳位移传感器、电磁阀、控制装置构成，打壳气缸连接打壳杆一端，打壳杆另一端连接打壳锤头，拉绳位移传感器的拉绳固定在打壳杆与打壳锤头连接端的打壳杆上；电磁阀控制打壳气缸动作、打壳气缸通过打壳杆带动拉绳位移传感器运动，从而准确检测打壳气缸的运动距离。In order to solve the above technical problems, the present invention adopts the following technical solutions: an intelligent shelling system for aluminum electrolytic cells, the system is composed of shelling cylinder, shelling rod, shelling hammer, pull rope displacement sensor, solenoid valve, and control device. The shelling cylinder is connected to one end of the shelling rod, and the other end of the shelling rod is connected to the shelling hammer, and the pull rope of the pull rope displacement sensor is fixed on the shelling rod at the connection end of the shelling rod and the shelling hammer; the solenoid valve controls the shelling cylinder The action and the shelling cylinder drive the movement of the rope displacement sensor through the shelling rod, so as to accurately detect the movement distance of the shelling cylinder.
控制装置负责信号采集和处理，并对执行机构电磁阀发出控制信号；控制装置是可编程序装置，包括但不限于工业计算机、PLC、工业控制板卡和控制模块；控制装置可以独立工作，也可以组网工作，每一台铝电解槽配备一套控制装置。The control device is responsible for signal acquisition and processing, and sends control signals to the solenoid valve of the actuator; the control device is a programmable device, including but not limited to industrial computers, PLCs, industrial control boards and control modules; the control device can work independently, also It can work in a network, and each aluminum electrolytic cell is equipped with a set of control devices.
控制装置可独立于槽控系统，也可以与槽控系统进行数据通讯或组网；独立于槽控系统时，控制装置通过槽控系统输出的继电器动作信号控制电解槽的打壳和下料电磁阀；与槽控系统进行数据通讯或组网时，控制装置可以为槽控系统提供控制分析数据。The control device can be independent from the tank control system, and can also carry out data communication or networking with the tank control system; when it is independent from the tank control system, the control device controls the shelling and feeding electromagnetic of the electrolytic tank through the relay action signal output by the tank control system Valve; when performing data communication or networking with the tank control system, the control device can provide control and analysis data for the tank control system.
当铝电解槽智能打壳系统出现任何问题时，铝电解槽智能打壳系统主动退出控制，不影响原槽控系统的任何控制功能。When any problem occurs in the intelligent shelling system of the aluminum electrolytic cell, the intelligent shelling system of the aluminum electrolytic cell will automatically exit the control without affecting any control function of the original tank control system.
铝电解槽智能打壳系统的实现方法包括以下步骤：The realization method of the aluminum electrolytic cell intelligent shelling system includes the following steps:
（1）、根据电解槽特性由人工设定打壳杆运行L1为打开壳面的判据；(1) According to the characteristics of the electrolytic cell, the operation L1 of the shelling rod is manually set as the criterion for opening the shell surface;
（2）、由于气缸在电磁阀动作后仍会惯性下冲运行一段距离，根据气缸的特性由人工设定打壳杆运行L2为电磁阀动作的判据；(2) Since the cylinder will still inertially run down for a certain distance after the action of the solenoid valve, according to the characteristics of the cylinder, manually set the operating L2 of the shelling rod as the criterion for the action of the solenoid valve;
（3）、打壳杆实际运行的距离为L；(3) The actual running distance of the shelling rod is L;
（4）、当L>L2时，控制装置发出电磁阀动作的控制信号，连接杆惯性下冲运行，当运行到最大距离时，如果L>L1，则判断为顺利打通壳面，打壳控制结束，等待下一次打壳指令；如果L<=L1时，判断为未顺利打开壳面；将L1设定为电磁阀动作的判据，不提前使电磁阀动作，控制装置按设定的时间周期重复打壳，直至连接杆距离L>L1，恢复L2为电磁阀动作判据，进入正常打壳程序，当重复N次仍未打开壳面时，控制装置发出报警并暂停氧化铝加料，等待人工处理；系统以L1为电磁阀动作的判据打壳，不再重复打壳，直至壳面打开后恢复L2为电磁阀动作判据时，取消报警信号，恢复氧化铝下料，进入正常周期。(4) When L>L2, the control device sends a control signal for the action of the solenoid valve, and the connecting rod moves downward with inertia. When it runs to the maximum distance, if L>L1, it is judged that the shell surface is successfully opened and the shell is controlled. End, wait for the next shelling command; if L<=L1, it is judged that the shell surface has not been opened smoothly; set L1 as the criterion for the action of the solenoid valve, do not make the solenoid valve act in advance, and the control device will follow the set time Periodically repeat shelling until the connecting rod distance L>L1, restore L2 as the solenoid valve action criterion, and enter the normal shelling program. When the shell surface is not opened after repeating N times, the control device sends out an alarm and suspends the alumina feeding, and waits for Manual processing; the system uses L1 as the criterion for the action of the solenoid valve to shell, and does not repeat shelling until the shell surface is opened, and when L2 is restored as the criterion for the action of the solenoid valve, the alarm signal is canceled, the alumina blanking is resumed, and the normal cycle is entered .
（5）、根据每一次打壳和不打壳时L的变化值，判断打壳锤头和打壳气缸的工作状态，是否完全复位。(5) According to the change value of L during each shelling and non-shelling, judge whether the working status of the shelling hammer and the shelling cylinder is completely reset.
L1、L2为常数，不需要经常设定或修改，只在系统该开始调试时或换锤头时或锤头尺寸发生较大变化时进行设定或修改。L1 and L2 are constants and do not need to be set or modified frequently. They are only set or modified when the system should start debugging or when the hammer head is changed or when the size of the hammer head changes greatly.
附图说明Description of drawings
图1是本发明的系统原理图。Fig. 1 is a schematic diagram of the system of the present invention.
具体实施方式detailed description
本发明的一种铝电解槽智能打壳系统，系统由打壳气缸、打壳杆、打壳锤头、拉绳位移传感器、电磁阀、控制装置构成，图1是本发明系统原理图，打壳气缸连接打壳杆一端，打壳杆另一端连接打壳锤头，拉绳位移传感器的拉绳固定在打壳杆与打壳锤头连接端的打壳杆上；电磁阀控制打壳气缸动作、打壳气缸通过打壳杆带动拉绳位移传感器运动，从而准确检测打壳气缸的运动距离。An intelligent shelling system for an aluminum electrolytic cell of the present invention, the system is composed of a shelling cylinder, a shelling rod, a shelling hammer, a rope displacement sensor, a solenoid valve, and a control device. Figure 1 is a schematic diagram of the system of the present invention. The shelling cylinder is connected to one end of the shelling rod, and the other end of the shelling rod is connected to the shelling hammer, and the pull rope of the pull rope displacement sensor is fixed on the shelling rod at the connection end of the shelling rod and the shelling hammer; the solenoid valve controls the action of the shelling cylinder 1. The shelling cylinder drives the rope displacement sensor to move through the shelling rod, so as to accurately detect the movement distance of the shelling cylinder.
控制装置负责信号采集和处理，并对执行机构电磁阀发出控制信号；控制装置是可编程序装置，包括但不限于工业计算机、PLC、工业控制板卡和控制模块；控制装置可以独立工作，也可以组网工作，每一台铝电解槽配备一套控制装置。The control device is responsible for signal acquisition and processing, and sends control signals to the solenoid valve of the actuator; the control device is a programmable device, including but not limited to industrial computers, PLCs, industrial control boards and control modules; the control device can work independently, also It can work in a network, and each aluminum electrolytic cell is equipped with a set of control devices.
控制装置可独立于槽控系统，也可以与槽控系统进行数据通讯或组网；独立于槽控系统时，控制装置通过槽控系统输出的继电器动作信号控制电解槽的打壳和下料电磁阀；与槽控系统进行数据通讯或组网时，控制装置可以为槽控系统提供控制分析数据。The control device can be independent from the tank control system, and can also carry out data communication or networking with the tank control system; when it is independent from the tank control system, the control device controls the shelling and feeding electromagnetic of the electrolytic tank through the relay action signal output by the tank control system Valve; when performing data communication or networking with the tank control system, the control device can provide control and analysis data for the tank control system.
当铝电解槽智能打壳系统出现任何问题时，铝电解槽智能打壳系统主动退出控制，不影响原槽控系统的任何控制功能。When any problem occurs in the intelligent shelling system of the aluminum electrolytic cell, the intelligent shelling system of the aluminum electrolytic cell will automatically exit the control without affecting any control function of the original tank control system.
铝电解槽智能打壳系统的实现方法包括以下步骤：The realization method of the aluminum electrolytic cell intelligent shelling system includes the following steps:
（1）、根据电解槽特性由人工设定打壳杆运行L1为打开壳面的判据；(1) According to the characteristics of the electrolytic cell, the operation L1 of the shelling rod is manually set as the criterion for opening the shell surface;
（2）、由于气缸在电磁阀动作后仍会惯性下冲运行一段距离，根据气缸的特性由人工设定打壳杆运行L2为电磁阀动作的判据；(2) Since the cylinder will still inertially run down for a certain distance after the action of the solenoid valve, according to the characteristics of the cylinder, manually set the operating L2 of the shelling rod as the criterion for the action of the solenoid valve;
（3）、打壳杆实际运行的距离为L；(3) The actual running distance of the shelling rod is L;
（4）、当L>L2时，控制装置发出电磁阀动作的控制信号，连接杆惯性下冲运行，当运行到最大距离时，如果L>L1，则判断为顺利打通壳面，打壳控制结束，等待下一次打壳指令；如果L<=L1时，判断为未顺利打开壳面；将L1设定为电磁阀动作的判据，不提前使电磁阀动作，控制装置按设定的时间周期重复打壳，直至连接杆距离L>L1，恢复L2为电磁阀动作判据，进入正常打壳程序，当重复N次仍未打开壳面时，控制装置发出报警并暂停氧化铝加料，等待人工处理；系统以L1为电磁阀动作的判据打壳，不再重复打壳，直至壳面打开后恢复L2为电磁阀动作判据时，取消报警信号，恢复氧化铝下料，进入正常周期。(4) When L>L2, the control device sends a control signal for the action of the solenoid valve, and the connecting rod moves downward with inertia. When it runs to the maximum distance, if L>L1, it is judged that the shell surface is successfully opened and the shell is controlled. End, wait for the next shelling command; if L<=L1, it is judged that the shell surface has not been opened smoothly; set L1 as the criterion for the action of the solenoid valve, do not make the solenoid valve act in advance, and the control device will follow the set time Periodically repeat shelling until the connecting rod distance L>L1, restore L2 as the solenoid valve action criterion, and enter the normal shelling program. When the shell surface is not opened after repeating N times, the control device sends out an alarm and suspends the alumina feeding, and waits for Manual processing; the system uses L1 as the criterion for the action of the solenoid valve to shell, and does not repeat shelling until the shell surface is opened, and when L2 is restored as the criterion for the action of the solenoid valve, the alarm signal is canceled, the alumina blanking is resumed, and the normal cycle is entered .
（5）、根据每一次打壳和不打壳时L的变化值，判断打壳锤头和打壳气缸的工作状态，是否完全复位。(5) According to the change value of L during each shelling and non-shelling, judge whether the working status of the shelling hammer and the shelling cylinder is completely reset.
L1、L2为常数，不需要经常设定或修改，只在系统该开始调试时或换锤头时或锤头尺寸发生较大变化时进行设定或修改。L1 and L2 are constants and do not need to be set or modified frequently. They are only set or modified when the system should start debugging or when the hammer head is changed or when the size of the hammer head changes greatly.
控制系统的控制器选用SIMATIC S7-200PLC，组建 PLC网络，网络独立于现有槽控系统，上位机选用戴尔Precision T5810 系列Xeon，管理网络和系统数据，修改系统参数。The controller of the control system uses SIMATIC S7-200PLC to build a PLC network. The network is independent of the existing slot control system. The host computer uses Dell Precision T5810 series Xeon to manage network and system data and modify system parameters.
以上实施例仅用以说明而非限制本发明的技术方案，尽管参照上述实施例对本发明进行了详细说明，本领域的普通技术人员应当理解：依然可以对本发明进行修改或者等同替换，而不脱离本发明的精神和范围的任何修改或局部替换，其均应涵盖在本发明的权利要求范围当中。The above embodiments are only used to illustrate and not limit the technical solutions of the present invention. Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that the present invention can still be modified or equivalently replaced without departing from it. Any modifications or partial replacements within the spirit and scope of the present invention shall fall within the scope of the claims of the present invention.
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| CN201610359602.5ACN105862080A (en) | 2016-05-27 | 2016-05-27 | Intelligent crust breaking system and method for aluminum reduction cells |
| Application Number | Priority Date | Filing Date | Title |
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| CN201610359602.5ACN105862080A (en) | 2016-05-27 | 2016-05-27 | Intelligent crust breaking system and method for aluminum reduction cells |
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| CN105862080Atrue CN105862080A (en) | 2016-08-17 |
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| CN201610359602.5APendingCN105862080A (en) | 2016-05-27 | 2016-05-27 | Intelligent crust breaking system and method for aluminum reduction cells |
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| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| RJ01 | Rejection of invention patent application after publication | ||
| RJ01 | Rejection of invention patent application after publication | Application publication date:20160817 |