阅读说明：本技术 铜电积车间极板电路故障实时监测预警方法 (Real-time monitoring and early warning method for fault of polar plate circuit in copper electrodeposition workshop ) 是由 杜素忠 张冬松 梁新星 贺小齐 张宇鹏 周飞舟 李新宇 于 2019-11-15 设计创作，主要内容包括：本发明公开了一种铜电积车间极板电路故障实时监测预警系统,包括具有红外热成像功能的球型视频监控摄像机、数据传输链路、局域网系统、服务器、计算机显示和操作设备,多台摄像机、服务器以及计算机显示和操作设备通过数据传输链路接入局域网系统,服务器上安装有视频监控和分析单元；通过温度监测,判断极板是否出现电路故障。即：设定槽面正常温度下限为T<Sub>l</Sub>,上限为T<Sub>h</Sub>,实时温度为T<Sub>0</Sub>。当T<Sub>0</Sub>>T<Sub>h</Sub>时,认为出现“短路”故障,当T<Sub>0</Sub><T<Sub>l</Sub>时,认为出现“断路”故障。本发明原理清晰,实现效果好,结构稳定,适合大规模工业化生产应用。(The invention discloses a real-time monitoring and early warning system for a circuit fault of a polar plate in a copper electro-deposition workshop, which comprises a spherical video monitoring camera with an infrared thermal imaging function, a data transmission link, a local area network system, a server and computer display and operation equipment, wherein the plurality of cameras, the server and the computer display and operation equipment are connected into the local area network system through the data transmission link, and a video monitoring and analysis unit is installed on the server; and judging whether the polar plate has circuit faults or not through temperature monitoring. Namely: setting the lower limit of the normal temperature of the groove surface to be T l Upper limit of T h Real time temperature of T 0 . When T is 0 >T h When a "short circuit" fault occurs, T is considered to be 0 <T l When it is time, an "open circuit" fault is considered to have occurred. The invention has clear principle, good realization effect and stable structure, and is suitable for large-scale industrial production and application.)

1. A real-time monitoring and early warning system for a circuit fault of a polar plate in a copper electro-deposition workshop is characterized by comprising a spherical video monitoring camera with an infrared thermal imaging function, a data transmission link, a local area network system, a server and computer display and operation equipment, wherein the plurality of cameras, the server and the computer display and operation equipment are connected into the local area network system through the data transmission link, and a video monitoring and analyzing unit is installed on the server; the number of the cameras is M, M>1, each camera is fixedly installed above the copper electrodeposition tank in an even sequencing mode, and a lower limit T of normal temperature for triggering early warning is set in each camera_lUpper limit of normal temperature T_hThe infrared thermal imaging lens of the camera irradiates the copper electrodeposition tank surface for measuring the temperature and measuring the real-time temperature T₀Video camera contrast T_l、T_hAnd T₀Relation, determine if there is T₀>T_hOr T₀<T_lAnd will T₀>T_hOr T₀<T_lEarly warning position information and real-time temperature T₀Lower limit of temperature T_lUpper temperature limit T_hTransmitting the video data to a video monitoring and analyzing unit; the video monitoring and analyzing unit processes and stores data, triggers circuit fault early warning and pushes early warning information to computer display and operation equipment; and the site worker receives the early warning information, rechecks the fault condition of the polar plate circuit in the specified area according to the early warning information and solves the fault condition.

2. The real-time monitoring and early warning system for the plate circuit fault of the copper electro-deposition workshop according to claim 1, further comprising: and the magnetic disk array is accessed to the local area network system through a data transmission link, and video information acquired by irradiating the copper electrodeposition tank surface by an infrared thermal imaging lens of the camera is stored in the magnetic disk array.

3. The real-time monitoring and early warning system for the plate circuit fault of the copper electrodeposition workshop as claimed in claim 2, wherein the temperature lower limit T of each camera is one of a plurality of camera types_lAnd an upper temperature limit T_hThe same or different.

4. The real-time monitoring and early warning system for the plate circuit fault of the copper electrodeposition workshop as claimed in claim 3, wherein N is set for the mth camera among M cameras_mPresetting point positions, and setting an automatic cruise path according to the presetting point positions; in the nth preset point monitoring range of the mth camera, a surface temperature measurement mode is adopted, and P is set_mnA temperature monitoring zone.

5. The real-time monitoring and early warning system for the plate circuit fault of the copper electrodeposition workshop as claimed in claim 4, wherein when the camera completely and vertically irradiates the copper electrodeposition bath, the distance between the infrared thermal imaging lens and the nearest monitoring position is D_sRequiring the nearest effective visual range L of the infrared thermal imaging of the camera_s<D_s。

6. The real-time monitoring and early warning system for the plate circuit fault of the copper electro-deposition workshop as claimed in claim 4, wherein when the camera rotates along the cruising path, the distance between the infrared thermal imaging lens and the farthest monitoring position is D_lRequires the farthest effective visual range L of the infrared thermal imaging of the camera_l>D_l。

7. The real-time monitoring and early warning system for the plate circuit fault of the copper electro-deposition workshop as claimed in claim 5 or 6, wherein the pth camera_mnThe surface temperature measurement size is not less than the minimum size of the target object which can be monitored by the camera; setting cameraThe total allowable temperature measurement areas of the camera are Q, the allowable temperature measurement areas of single irradiation temperature measurement are C, and then Q is obtained>N_m×P_mnAnd C is>P_mn。

8. The real-time monitoring and early warning system for the plate circuit fault of the copper electro-deposition workshop as claimed in claim 7, wherein the video monitoring and analyzing unit is used for M cameras and M x N cameras_mEach preset point location, MXN_m×P_mnThe temperature monitoring areas are numbered, and the numbers correspond to the positions of the copper electrodeposition tank surfaces and are used for accurately identifying the early warning positions.

9. The system for real-time monitoring and early warning of the plate circuit fault in the copper electro-deposition workshop according to claim 8, wherein the video monitoring and analyzing unit displays the information which is early-warned but not processed for a long time until an operator confirms that the processing is finished.

10. A real-time monitoring and early warning method for a circuit fault of a polar plate of a copper electrodeposition workshop is characterized by comprising the following steps:

firstly, video monitoring and analyzing software is installed on a server;

step two, the camera irradiates and measures the temperature of a certain area of the groove surface of the copper electrodeposition workshop to obtain the real-time temperature T of the irradiated area₀(ii) a Meanwhile, video information is stored in the disk array;

step three, in the camera, T is compared_l、T_hAnd T₀Relation, determine if there is T₀>T_hOr T₀<T_lThe case (1);

step four, the camera sends T₀>T_hOr T₀<T_lEarly warning position information and real-time temperature T₀Lower limit of temperature T_lUpper temperature limit T_hTransmitting the video data to a video monitoring and analyzing unit;

the video monitoring and analyzing unit processes data, triggers circuit fault early warning and pushes early warning information to computer display and operation equipment; meanwhile, the video monitoring and analyzing unit stores the current early warning information;

sixthly, the site worker receives the early warning information, rechecks the fault condition of the polar plate circuit in the specified area according to the early warning information and solves the fault condition;

and seventhly, recording the fault checking and processing conditions in the video monitoring and analyzing unit by a worker, and checking historical video information and early warning information.

Technical Field

The invention belongs to the technical field of wet metallurgy, and relates to a real-time monitoring and early warning method for a fault of a polar plate circuit in a copper electrodeposition workshop, which realizes real-time monitoring and early warning for the faults of short circuit and open circuit of the polar plate current loop in the copper electrodeposition workshop.

Background

In the hydrometallurgy copper electrodeposition process, the anode plate and the cathode plate are lapped with a conductive plate on the surface of the electrodeposition tank through the conductive cross beam to form a current loop, and qualified cathode copper products are produced through the electrodeposition effect. Because the actual production in-process receives the operation of going in and out the groove, the polar plate interval is adjusted unreasonablely, electrically conductive crossbeam and current conducting plate contact failure, the insulator drops or after long-term the use situation influence such as polar plate bending deformation, the current loop "short circuit" appears easily or (and) "open circuit" trouble (be short for circuit trouble) to cause many-sided loss: firstly, the quality of cathode copper products is damaged, some products cannot form qualified products, and some products cannot be sold at expected price; secondly, the current efficiency is reduced, and the production cost is improved; and thirdly, the cathode plate and the anode plate are corroded by the acidic solution in the electrodeposition tank, the plate burning is caused when the short circuit is serious, and the service lives of the cathode plate and the anode plate are shortened. In the industrial production, along with the increase of the number of the electrodeposition tanks, the anode plates and the cathode plates, the production period is increased, equipment is aged, the frequency of circuit faults is higher and higher, the timeliness of discovery and disposal cannot be guaranteed, and the loss is larger. For example, the traditional detection method mainly measures the surface temperature of the electrodeposition tank by a temperature measuring instrument held by a person, and manually judges whether a current loop has a fault; although the method is simple, the requirement of personnel is large, the fault is not found timely, and the missing rate and the misjudgment rate are high.

In recent years, other related reports also exist in the nonferrous smelting industry. Such as:

in the article of 'application of infrared thermal imaging technology in copper electrolysis current distribution measurement' (infrared application, 2015,37(11): 981-.

Houyu et al disclose a device for monitoring short circuit fault of a pyrometallurgical aluminum electrolysis cell in research on application of infrared thermal imaging temperature monitoring technology to an aluminum electrolysis cell (metallurgy automation, 2015(39),62), and disclose a device for monitoring short circuit fault of a pyrometallurgical copper electrolysis cell in research on copper electrolysis cell short circuit fault diagnosis and current distribution modeling method (Beijing: northern industry university, 2016). The basic principle of the two devices is as follows: the glass fiber reinforced plastic track is arranged above the electrolytic bath, the monitoring trolley is arranged on the track, the infrared camera is arranged on the trolley, the travelling action of the trolley is controlled by the programmable logic controller, and the surface of the bath surface is photographed; and carrying out gray level analysis on the obtained picture, and judging whether the polar plate has short circuit or not. On the first hand, no description is given to specific implementation methods and flows in both reports; in the second aspect, the devices are limited by rails, trolleys, infrared cameras, network transmission and the like, and are not high in stability and applicability. For example, when the workshop span is large, the track installation and the trolley control cannot be realized; the trolley movement is restricted by hoisting equipment such as a travelling crane.

Therefore, under the condition of large-scale industrial production, the invention provides a method for discovering, analyzing, judging and early warning the fault of the plate circuit in the copper electrodeposition workshop in real time, and has important effects on optimizing the production organization of the copper electrodeposition workshop, improving the quality of copper products and reducing the production cost. The existing devices, methods and research results can not meet the application requirements of industrial production.

Disclosure of Invention

Objects of the invention

The purpose of the invention is: by adopting an information technology means, the method for monitoring and early warning the fault of the polar plate circuit in the copper electrodeposition workshop in real time is provided, the fault position of the polar plate circuit in the copper electrodeposition workshop can be quickly positioned under the condition of large-scale industrial production, and the requirement of real-time online analysis and early warning is met.

(II) technical scheme

In order to solve the technical problem, the invention provides a real-time monitoring and early warning system for a circuit fault of a polar plate in a copper electro-deposition workshop, which comprises a spherical video monitoring camera with an infrared thermal imaging function, a data transmission link, a local area network system, a server and computer display and operation equipment, wherein the plurality of cameras, the server and the computer display and operation equipment are accessed into the local area network system through the data transmission link, and a video monitoring and analysis unit is installed on the server; the number of the cameras is M, M>1, each camera is fixedly installed above the copper electrodeposition tank in an even sequencing mode, and a lower limit T of normal temperature for triggering early warning is set in each camera_lUpper limit of normal temperature T_hThe infrared thermal imaging lens of the camera irradiates the copper electrodeposition tank surface for measuring the temperature and measuring the real-time temperature T₀Video camera contrast T_l、T_hAnd T₀Relation, determine if there is T₀>T_hOr T₀<T_lAnd will T₀>T_hOr T₀<T_lEarly warning position information and real-time temperature T₀Lower limit of temperature T_lUpper temperature limit T_hTransmitting the video data to a video monitoring and analyzing unit; the video monitoring and analyzing unit processes and stores data, triggers circuit fault early warning and pushes early warning information to computer display and operation equipment; and the site worker receives the early warning information, rechecks the fault condition of the polar plate circuit in the specified area according to the early warning information and solves the fault condition.

Wherein, still include: and the magnetic disk array is accessed to the local area network system through a data transmission link, and video information acquired by irradiating the copper electrodeposition tank surface by an infrared thermal imaging lens of the camera is stored in the magnetic disk array.

Wherein, a plurality of cameras are used, and the lower temperature limit T of each camera_lAnd an upper temperature limit T_hThe same or different.

Wherein, of the M cameras, the mth camera sets N_mPresetting point positions, and setting an automatic cruise path according to the presetting point positions; in the nth preset point monitoring range of the mth camera, a surface temperature measurement mode is adopted, and P is set_mnA temperature monitoring area。

Wherein, when the camera completely and vertically irradiates the copper electrodeposition bath surface, the distance between the infrared thermal imaging lens and the nearest monitoring position is D_sRequiring the nearest effective visual range L of the infrared thermal imaging of the camera_s<D_s。

When the camera rotates along the cruising path, the distance between the infrared thermal imaging lens and the farthest monitoring position is D_lRequires the farthest effective visual range L of the infrared thermal imaging of the camera_l>D_l。

Wherein the camera is of the P-th order_mnThe surface temperature measurement size is not less than the minimum size of the target object which can be monitored by the camera; q temperature measurement areas which are allowed to be set by the cameras are set, and C temperature measurement areas which are allowed to be set by single irradiation temperature measurement are set, so that Q temperature measurement areas are set>N_m×P_mnAnd C is>P_mn。

Wherein the video monitoring and analyzing unit is used for M cameras and M multiplied by N_mEach preset point location, MXN_m×P_mnThe temperature monitoring areas are numbered, and the numbers correspond to the positions of the copper electrodeposition tank surfaces and are used for accurately identifying the early warning positions.

And the video monitoring and analyzing unit displays the information which is early warned but not processed for a long time until the operator confirms that the processing is finished.

The invention also provides a real-time monitoring and early warning method for the circuit fault of the copper electrodeposition workshop polar plate, which comprises the following steps:

firstly, video monitoring and analyzing software is installed on a server;

step two, the camera irradiates and measures the temperature of a certain area of the groove surface of the copper electrodeposition workshop to obtain the real-time temperature T of the irradiated area₀(ii) a Meanwhile, video information is stored in the disk array;

step three, in the camera, T is compared_l、T_hAnd T₀Relation, determine if there is T₀>T_hOr T₀<T_lThe case (1);

step four, the camera sends T₀>T_hOr T₀<T_lEarly warning position information and real-time temperature T₀Lower limit of temperature T_lUpper temperature limit T_hTransmitting the video data to a video monitoring and analyzing unit;

the video monitoring and analyzing unit processes data, triggers circuit fault early warning and pushes early warning information to computer display and operation equipment; meanwhile, the video monitoring and analyzing unit stores the current early warning information;

sixthly, the site worker receives the early warning information, rechecks the fault condition of the polar plate circuit in the specified area according to the early warning information and solves the fault condition;

and seventhly, recording the fault checking and processing conditions in the video monitoring and analyzing unit by a worker, and checking historical video information and early warning information.

(III) advantageous effects

The real-time monitoring and early warning method for the circuit fault of the polar plate in the copper electrodeposition workshop, which is provided by the technical scheme, assists in carrying out production organization in the copper electrodeposition production workshop, and can achieve the following effects:

(1) the principle is clear, the realization effect is good, the structure is stable, and the method is suitable for large-scale industrial production and application.

(2) The number of operators for measuring the temperature of the groove surface of the copper electrodeposition workshop is reduced, and particularly, the number of the operators in a large-scale production environment is reduced. By way of example, a single copper electrodeposition plant can reduce approximately 2 slot level patrols and operators.

(3) The timeliness of the fault discovery of the short circuit and the open circuit of the current loop is improved. By way of example, a single plant may find a circuit fault monitoring within 5 minutes.

(4) Improve the quality of cathode copper products. Calculated by way of example, a single copper electrowinning plant increased at least 70 tons of acceptable cathode copper throughout the year.

(5) After circuit faults are avoided in time, the current efficiency is increased, the time of corroding the negative plate and the positive plate is shortened, the service life is prolonged, and the production cost is reduced.

Drawings

FIG. 1 is a schematic diagram of the equipment and equipment connections required by the present invention.

Fig. 2 is a basic flow chart of the monitoring and early warning method of the present invention.

Fig. 3 is a schematic view of the installation position of the camera of the present invention.

FIG. 4 is a schematic view of a temperature measurement arrangement according to the present invention.

Detailed Description

In order to make the objects, contents, and advantages of the present invention clearer, the following detailed description of the embodiments of the present invention will be made in conjunction with the accompanying drawings and examples.

The idea of the invention is as follows: and (3) taking the temperature of a certain area of the groove surface of the copper electrodeposition workshop as a circuit fault output index, and judging whether the circuit fault occurs on the polar plate or not through temperature monitoring. Namely: setting the lower limit of the normal temperature of the groove surface to be T_lUpper limit of T_hReal time temperature of T₀. When T is₀>T_hWhen a "short circuit" fault occurs, T is considered to be₀<T_lWhen it is time, an "open circuit" fault is considered to have occurred.

The equipment and system used in the invention are as follows: the system comprises a spherical video monitoring camera (camera for short) with an infrared thermal imaging function, a data transmission link, a local area network system, a server, a disk array and computer display and operation equipment, wherein a video monitoring and analysis unit is integrated on the server.

The method comprises the following specific steps:

firstly, a plurality of cameras, a server, a disk array, a computer and other display and operation equipment are all accessed to a local area network system through a data transmission link, and video monitoring and analysis software is installed on the server

Step two, the camera irradiates and measures the temperature of a certain area of the groove surface of the copper electrodeposition workshop to obtain the real-time temperature T of the irradiated area₀(ii) a Meanwhile, video information is stored in the disk array;

step three, in the camera, T is compared_l、T_hAnd T₀Relation, determine if there is T₀>T_hOr T₀<T_lThe case (1);

step four, the camera sends T₀>T_hOr T₀<T_lEarly warning position information and real-time temperature T₀Lower limit of temperature T_lUpper temperature limit T_hTransmitting the video data to a video monitoring and analyzing unit;

the video monitoring and analyzing unit processes data, triggers circuit fault early warning and pushes early warning information to computer display and operation equipment; meanwhile, the video monitoring and analyzing unit stores the current early warning information

Sixthly, the site worker receives the early warning information, rechecks the fault condition of the polar plate circuit in the specified area according to the early warning information and solves the fault condition;

and seventhly, recording the fault checking and processing conditions in the video monitoring and analyzing unit by a worker, and checking historical video information and early warning information.

The key points of the invention are as follows: camera mounting and arrangement

Firstly, mounting M cameras in total, wherein M is greater than 1; each camera is fixedly arranged above the copper electrodeposition tank in a uniform sequencing mode, and the infrared thermal imaging lens can irradiate the surface of the copper electrodeposition tank to measure the temperature;

secondly, setting the lower limit of normal temperature for triggering early warning for each camera as T_lAnd an upper normal temperature limit of T_h. Each camera T_lAnd T_hMay be the same or different;

third, setting N for mth camera_mPresetting point positions, and setting an automatic cruise path according to the presetting point positions;

fourthly, setting P in the nth preset point monitoring range of the mth camera in a surface temperature measurement mode_mnA temperature monitoring area;

the key point of the invention is two: video monitoring and analysis unit functionality

Function one, M cameras, MXN_mEach preset point location, MXN_m×P_mnNumbering the temperature monitoring areas, wherein the numbering corresponds to the surface position of the copper electrodeposition tank and is used for accurately identifying the early warning position;

receiving and displaying video monitoring image information returned by the camera;

function III, receiving and displaying early warning position information and real-time temperature T fed back by camera₀Lower limit of temperature T_lUpper temperature limit T_hGenerating circuit fault early warning and storing early warning information for a long time;

fourthly, an operator logs in the video monitoring and analyzing unit, looks up early warning detailed information and video information, and records circuit fault rechecking and processing conditions;

fifthly, displaying the information which is early-warned but not processed for a long time until the operator confirms that the processing is finished;

the key points of the invention are as follows: camera selection

The video monitoring camera with the first condition and the infrared thermal imaging function can set the lower limit T of the normal temperature for triggering early warning_lAnd an upper limit of normal temperature T_h；

The second condition is that the spherical video monitoring camera can be provided with a plurality of preset point positions and cruise paths;

and thirdly, when the camera completely and vertically irradiates the copper electrodeposition tank surface, the distance between the infrared thermal imaging lens and the nearest monitoring position is D_sRequiring the nearest effective visual range L of the infrared thermal imaging of the camera_s<D_s；

Fourthly, when the camera rotates according to the cruise path, the distance between the infrared thermal imaging lens and the farthest monitoring position is D_lRequires the farthest effective visual range L of the infrared thermal imaging of the camera_l>D_l；

Fifthly, the temperature measuring range is irradiated by the camera once and does not exceed the allowable range of the horizontal field angle of the camera;

setting a condition six, a preset point position of the camera and a cruise path, and simultaneously meeting the common constraints of a condition three, a condition four and a condition five;

condition seven, Camera No. P_mnThe surface temperature measurement size cannot be smaller than the minimum size of a target object which can be monitored by a camera;

setting Q temperature measurement areas which are allowed to be set by the cameras in total under the condition of eight, and setting the temperature measurement areas which are allowed to be set by single irradiation temperature measurementC, then Q>N_m×P_mnAnd C is>P_mn。