铝电解槽槽壳温度在线检测及槽况诊断系统的研究与设计
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摘要
铝电解槽是炼铝的主要设备,但是由于铝电解过程一个多变量耦合、时变和大滞后的工业过程对象,其自身内部复杂的物理化学过程、各种外界条件和作业的干扰,形成了复杂多变的槽况特征,这给生产操作带来了很多难题。现在很多电解铝企业通过强化电流的方法来提高经济效益,但是随着电流的增大铝电解温度也相应的增大,进而槽壳的温度也变大。随着槽壳温度逐渐增大,槽帮结会变得越来越薄,直至铝液从电解槽漏出发生“漏槽”的危险,由于槽壳温度是槽帮结壳的外在表现,因此电解槽槽壳温度的实时在线检测显得很重要。同时,根据槽壳温度以及电解槽工艺参数等建立槽况诊断专家系统,对电解槽能量和物料平衡进行诊断,对电解槽冷热趋势进行预估。这对指导铝电解生产有很重要的现实意义。
以前电解槽槽壳温度的检测多采用人工的方法,这种方法根本适应不了铝电解企业自动化发展水平的需要。本文介绍了一种全新的铝电解槽槽壳温度在线检测系统的设计方法。该系统以C8051F020单片机为核心,采用在线式点式红外测温仪,通过采集控制器控制云台转动实现槽壳不同位置点的实时温度检测。系统通过CCD摄像头传回到主控制室的图象来判断测温仪是否对准被测点,从而达到准确测温的目的。同时,系统采用有线跟无线相结合的方式来实现现场和主控制室之间的通信。
系统首先介绍了铝电解槽槽壳温度检测的意义并介绍了国内外发展现状,接着介绍了红外测温技术的发展与应用。然后重点叙述了本系统的软硬件设计过程及其方法。接着根据槽壳温度值及电解槽工艺参数,用对象-属性-值三元组模式建立了数据库;根据各种病槽的发生原因、现象及处理方法,用产生式方法建立了规则库;在它们的基础上构建了专家系统,实现了电解槽冷热趋势的预估计。最后对本文的主要工作进行了总结,并对该系统的进一步发展提出了意见。
Aluminium Cell is the main equipment of electrolytic aluminium, which is an industry process object with many coupling variable、temporal charge and big lag. It forms complex and mutative cell case that its internal complicated chemistry and physics process and many external interrupt ,which brings many trouble to production manipulation. Now many corporation uses rasing current to increase benefit. As current rasing, the temperature of the cell shell rases, too. With the temperature rasing, the shell is more and more thin. When aluminium liquid pours from the shell, it's very dangerous. So it's very important to measure the temperature of the cell shell real-time and online.
Manpwer is used to measure the temperature before, which doesn't adapt to the automation development of the corporation at all. Anew method of the temperature measured is introdused by this article, which is gathered by C8051F020 MCU and Infrared Temperature Detector. Primary controlling room transmits command to the Pan-tilt and controls Pan-tilt running, which can measure different position temperature of the shell. Pan-tilt is fixed up in the trolly, which travels in the trolley track and is drived by stepper motor. Primary controlling room transmits command to the trolly and controls its advance. After some distance, the trolly stops and then Pan-tilt runs(up、down、left and right),which brings the Infrared Temperature Detector running. Furthermore,system can juge that Infrared Temperature Detector whether aim at the measured position by the image which is transmitted by CCD pick-up head. The communication between locale and primary controling room is realized by CAN bus.
This article first introduces the meaning of the temperature measured of Aluminium Cell shell and research actuality, next is the development and application of infrared measured temperature,and then describes the design method of software and hardware,last is sum-up and the research of diagnosis of cell status.According to monitored temperature of shell and aluminium cell technical parameter,the expert system database was built in the mode of object-property-value,and stored in tree structure.Based on the cause of its failure,phnonmenon and disposal of the diseased aluminium cell,rules for expert system was produced by the fuzzy producing method.Diagnosing of cell status was realized. Last brings forward idea of the next development of the system.
以前电解槽槽壳温度的检测多采用人工的方法,这种方法根本适应不了铝电解企业自动化发展水平的需要。本文介绍了一种全新的铝电解槽槽壳温度在线检测系统的设计方法。该系统以C8051F020单片机为核心,采用在线式点式红外测温仪,通过采集控制器控制云台转动实现槽壳不同位置点的实时温度检测。系统通过CCD摄像头传回到主控制室的图象来判断测温仪是否对准被测点,从而达到准确测温的目的。同时,系统采用有线跟无线相结合的方式来实现现场和主控制室之间的通信。
系统首先介绍了铝电解槽槽壳温度检测的意义并介绍了国内外发展现状,接着介绍了红外测温技术的发展与应用。然后重点叙述了本系统的软硬件设计过程及其方法。接着根据槽壳温度值及电解槽工艺参数,用对象-属性-值三元组模式建立了数据库;根据各种病槽的发生原因、现象及处理方法,用产生式方法建立了规则库;在它们的基础上构建了专家系统,实现了电解槽冷热趋势的预估计。最后对本文的主要工作进行了总结,并对该系统的进一步发展提出了意见。
Aluminium Cell is the main equipment of electrolytic aluminium, which is an industry process object with many coupling variable、temporal charge and big lag. It forms complex and mutative cell case that its internal complicated chemistry and physics process and many external interrupt ,which brings many trouble to production manipulation. Now many corporation uses rasing current to increase benefit. As current rasing, the temperature of the cell shell rases, too. With the temperature rasing, the shell is more and more thin. When aluminium liquid pours from the shell, it's very dangerous. So it's very important to measure the temperature of the cell shell real-time and online.
Manpwer is used to measure the temperature before, which doesn't adapt to the automation development of the corporation at all. Anew method of the temperature measured is introdused by this article, which is gathered by C8051F020 MCU and Infrared Temperature Detector. Primary controlling room transmits command to the Pan-tilt and controls Pan-tilt running, which can measure different position temperature of the shell. Pan-tilt is fixed up in the trolly, which travels in the trolley track and is drived by stepper motor. Primary controlling room transmits command to the trolly and controls its advance. After some distance, the trolly stops and then Pan-tilt runs(up、down、left and right),which brings the Infrared Temperature Detector running. Furthermore,system can juge that Infrared Temperature Detector whether aim at the measured position by the image which is transmitted by CCD pick-up head. The communication between locale and primary controling room is realized by CAN bus.
This article first introduces the meaning of the temperature measured of Aluminium Cell shell and research actuality, next is the development and application of infrared measured temperature,and then describes the design method of software and hardware,last is sum-up and the research of diagnosis of cell status.According to monitored temperature of shell and aluminium cell technical parameter,the expert system database was built in the mode of object-property-value,and stored in tree structure.Based on the cause of its failure,phnonmenon and disposal of the diseased aluminium cell,rules for expert system was produced by the fuzzy producing method.Diagnosing of cell status was realized. Last brings forward idea of the next development of the system.
引文
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