阅读说明：本技术 一种电解铝打壳控制柜、控制系统及方法 (Electrolytic aluminum crust breaking control cabinet, control system and method ) 是由 阮镇浩 兰奎海 于 2021-03-30 设计创作，主要内容包括：本发明提供了一种电解铝打壳控制柜、控制系统及方法,控制柜包括电源模块、控制模块和若干独立控制单元,所述控制模块用于接收槽控机的打壳信号,将所述打壳信号分配给对应的独立控制单元,并在打壳失败时,拦截槽控机的下料信号；每个所述独立控制单元用于控制一条打壳通道,并将打壳状态反馈给所述控制模块。本发明实时监测打壳成功的信号,在打壳失败时,能够拦截下料信号,阻止持续下料,避免下料口於料；同时在监测到打壳成功后,气缸电磁阀换向,使锤头离开铝水,避免长时间浸泡在高温铝水里出现的锤头融化、结包的现象。(The invention provides an electrolytic aluminum crust breaking control cabinet, a control system and a method, wherein the control cabinet comprises a power module, a control module and a plurality of independent control units, the control module is used for receiving crust breaking signals of a tank control machine, distributing the crust breaking signals to the corresponding independent control units, and intercepting blanking signals of the tank control machine when crust breaking fails; each independent control unit is used for controlling one crust breaking channel and feeding the crust breaking state back to the control module. The present invention monitors the successful crust breaking signal in real time, and can intercept the blanking signal to prevent the continuous blanking when the crust breaking fails, so as to avoid the blanking port from blanking; meanwhile, after the successful crust breaking is monitored, the electromagnetic valve of the cylinder is reversed, so that the hammer head is separated from molten aluminum, and the phenomena of hammer head melting and caking which occur when the hammer head is soaked in the high-temperature molten aluminum for a long time are avoided.)

1. An electrolytic aluminum crust breaking control cabinet comprises a power module and is characterized by further comprising a control module and a plurality of independent control units, wherein the control module is used for receiving crust breaking signals of a tank control machine, distributing the crust breaking signals to the corresponding independent control units and intercepting blanking signals of the tank control machine when crust breaking fails; each independent control unit is used for controlling one crust breaking channel and feeding the crust breaking state back to the control module.

2. The electrolytic aluminum crust breaking control cabinet according to claim 1, wherein the control module further comprises a monitoring unit for triggering the electromagnetic valve of the cylinder to reverse after a contact signal between the crust breaking hammer head and the molten aluminum is monitored.

3. An electrolytic aluminum crust breaking control cabinet according to claim 1, wherein the control cabinet further comprises a touch display module connected with the control module, and the touch display module is used for displaying the crust breaking state and acquiring a manual control instruction.

4. An electrolytic aluminum crust breaking control cabinet according to claim 1, wherein the control cabinet further comprises a wireless communication module connected with the control module, the wireless communication module is in wireless communication with an application program of a mobile terminal, and the application program is used for displaying the crust breaking state and acquiring a manual control instruction.

5. An electrolytic aluminum crust breaking control cabinet according to claim 1, wherein the control cabinet further comprises an alarm module connected with the control module, and the alarm module is used for giving an alarm prompt in one or more modes of sound and light, short messages or mobile terminal application programs when crust breaking fails.

6. An electrolytic aluminum crust breaking control system, comprising an electrolytic cell and a cell controller, wherein the electrolytic cell comprises a plurality of crust breaking cylinders and a feeder, and the electrolytic aluminum crust breaking control system is characterized by further comprising a control cabinet as claimed in any one of claims 1 to 5, and the control cabinet is respectively connected with the electrolytic cell and the cell controller.

7. An electrolytic aluminum crust breaking control method is characterized by comprising the following steps:

receiving crust breaking signals of the slot control machine and distributing the crust breaking signals to corresponding independent control units;

the independent control unit controls the current crust breaking cylinder to execute crust breaking operation and controls the pressure of the working cavity of the cylinder according to the crust breaking state;

and after monitoring that the crust breaking signal is broken through, controlling the electromagnetic valve of the air cylinder to change the direction, and controlling the blanking device to carry out blanking.

8. An electrolytic aluminum crust breaking control method as claimed in claim 7, wherein the independent control unit controls the current crust breaking cylinder to execute crust breaking operation, and the specific process of controlling the pressure of the working chamber of the cylinder according to the crust breaking state comprises the following steps:

and controlling the cylinder to start low-pressure crust breaking, continuously ventilating the working cavity of the cylinder if the opening signal is not monitored within a first time threshold value, controlling the cylinder to perform high-pressure crust breaking, and controlling the cylinder to forcibly perform high-pressure crust breaking if the opening signal is not monitored within a second time threshold value.

9. The electrolytic aluminum crust breaking control method as claimed in claim 8, wherein the controlling cylinder forced high-pressure crust breaking is specifically:

the crust breaking pressure of the working cavity of the cylinder is enhanced, or the cylinder is in a high-pressure state to repeatedly execute crust breaking operation.

10. An electrolytic aluminum crust breaking control method according to claim 8, wherein an alarm prompt is given if the opening signal is not monitored yet after the forced high-voltage crust breaking.

Technical Field

The invention relates to the technical field of electrolytic aluminum, in particular to an electrolytic aluminum crust breaking control cabinet, a control system and a control method.

Background

Along with the rapid development of electrolytic aluminum industry in China, more and more hydraulic and pneumatic elements are applied to electrolytic aluminum production equipment.

The traditional electrolytic aluminum crust breaking pneumatic control system has single function, the cell control machine energizes the electromagnetic valve of the crust breaking cylinder for 5-10 seconds to enable the crust breaking cylinder to act, the electromagnetic valve of the cylinder supplies a blanking signal to the electromagnetic valve of the blanking device after being powered off, and the former action is repeated after a plurality of seconds.

The distance of cavity and solenoid valve's pipeline about 10 meters before the cylinder, the cylinder need full stroke operation at the during operation, and the working chamber is inflated for a long time, even accomplish the crust breaking work back, installs the most still stay a period in the electrolytic aluminum water of tup at the cylinder front end, causes the phenomenon that the tup melts, the knot package to appear easily in high temperature aluminum water for a long time in the tup.

Disclosure of Invention

The invention provides an electrolytic aluminum crust breaking control cabinet, a control system and a control method, which are used for solving the problems that compressed air is wasted due to long inflation time of a working cavity of the existing control system, a hammer stays in aluminum water for a long time, and the hammer melts and is wrapped.

In order to achieve the purpose, the invention adopts the following technical scheme:

the invention provides an electrolytic aluminum crust breaking control cabinet, which comprises a power module, a control module and a plurality of independent control units, wherein the control module is used for receiving crust breaking signals of a tank control machine, distributing the crust breaking signals to the corresponding independent control units and intercepting blanking signals of the tank control machine when crust breaking fails; each independent control unit is used for controlling one crust breaking channel and feeding the crust breaking state back to the control module.

Furthermore, the control module also comprises a monitoring unit, and the monitoring unit triggers the electromagnetic valve of the cylinder to change the direction after monitoring a contact signal between the crust breaking hammer head and molten aluminum.

Furthermore, the control cabinet further comprises a touch display module connected with the control module, and the touch display module is used for displaying the crust breaking state and acquiring a manual control instruction.

Further, the control cabinet further comprises a wireless communication module connected with the control module, the wireless communication module is in wireless communication with an application program of the mobile terminal, and the application program is used for displaying the crust breaking state and acquiring a manual control instruction.

Furthermore, the control cabinet also comprises an alarm module connected with the control module, and the alarm module is used for giving an alarm prompt in one or more modes of sound and light, short messages or mobile terminal application programs when the crust breaking fails.

The invention provides an electrolytic aluminum crust breaking control system in a second aspect, which comprises an electrolytic cell and a cell control machine, wherein the electrolytic cell comprises a plurality of crust breaking cylinders and a blanking device, and the control system also comprises a control cabinet which is respectively connected with the electrolytic cell and the cell control machine.

The third aspect of the invention provides an electrolytic aluminum crust breaking control method, which comprises the following steps:

receiving crust breaking signals of the slot control machine and distributing the crust breaking signals to corresponding independent control units;

the independent control unit controls the current crust breaking cylinder to execute crust breaking operation and controls the pressure of the working cavity of the cylinder according to the crust breaking state;

and after the opening signal is monitored, controlling the electromagnetic valve of the air cylinder to change the direction, and controlling the blanking device to carry out blanking.

Further, the independent control unit controls the current crust breaking cylinder to execute crust breaking operation, and the specific process of controlling the pressure of the working cavity of the cylinder according to the crust breaking state comprises the following steps:

and controlling the cylinder to start low-pressure crust breaking, continuously ventilating the working cavity of the cylinder if the opening signal is not monitored within a first time threshold value, controlling the cylinder to perform high-pressure crust breaking, and controlling the cylinder to forcibly perform high-pressure crust breaking if the opening signal is not monitored within a second time threshold value.

Further, the control cylinder forced high-pressure crust breaking specifically comprises:

the crust breaking pressure of the working cavity of the cylinder is enhanced, or the cylinder is in a high-pressure state to repeatedly execute crust breaking operation.

Further, if the opening signal is not monitored yet after the high-voltage crust breaking is forced, an alarm is given.

The effect provided in the summary of the invention is only the effect of the embodiment, not all the effects of the invention, and one of the above technical solutions has the following advantages or beneficial effects:

1. the present invention monitors the successful crust breaking signal in real time, and can intercept the blanking signal when the crust breaking fails, so as to prevent the blanking port from blanking continuously; meanwhile, after the successful crust breaking is monitored, the electromagnetic valve of the cylinder is reversed, so that the hammer head is separated from molten aluminum, and the phenomena of hammer head melting and caking which occur when the hammer head is soaked in the high-temperature molten aluminum for a long time are avoided.

2. The invention comprises a plurality of independent control units, each control unit correspondingly controls one crust breaking channel, realizes the control of a single crust breaking cylinder and a feeder, is beneficial to the smooth operation of each crust breaking channel, and improves the working efficiency.

3. In the crust breaking process, based on the monitoring of the success or failure signal of crust breaking, low-pressure crust breaking, high-pressure crust breaking and forced high-pressure crust breaking are gradually adopted, the crust pressing time is adjusted, the cost is saved, the service lives of the cylinder and the hammer head are prolonged, and the air source is saved.

4. The control cabinet is connected in the conventional crust breaking system, is combined with the cell control machine, is used for realizing auxiliary crust breaking, and can temporarily replace the cell control machine to control the work of a crust breaking cylinder and a feeder when the cell control machine fails, so that the production capacity is improved.

Drawings

In order to more clearly illustrate the embodiments or technical solutions in the prior art of the present invention, the drawings used in the description of the embodiments or prior art will be briefly described below, and it is obvious for those skilled in the art that other drawings can be obtained based on these drawings without creative efforts.

FIG. 1 is a schematic diagram of a control cabinet according to the present invention;

FIG. 2 is a schematic diagram of the control system of the present invention;

FIG. 3 is a schematic flow diagram of the method of the present invention.

Detailed Description

In order to clearly explain the technical features of the present invention, the following detailed description of the present invention is provided with reference to the accompanying drawings. The following disclosure provides many different embodiments, or examples, for implementing different features of the invention. To simplify the disclosure of the present invention, the components and arrangements of specific examples are described below. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. It should be noted that the components illustrated in the figures are not necessarily drawn to scale. Descriptions of well-known components and processing techniques and procedures are omitted so as to not unnecessarily limit the invention.

As shown in figure 1, the electrolytic aluminum crust breaking control cabinet comprises a power supply module 1, a control module 2, a plurality of independent control units 3, a touch display module 4, a wireless communication module 5 and an alarm module 6. The control module 2 is used for receiving a crust breaking signal of the cell controller, distributing the crust breaking signal to the corresponding independent control unit 3, and intercepting a blanking signal of the cell controller when crust breaking fails; each independent control unit 3 is used for controlling one crust breaking channel and feeding back crust breaking states to the control module 2.

The power module 1 is used for supplying power to each module of the control cabinet, and providing 24V power and 5-12V power.

The touch display module 4 is connected with the control module 2, and the touch display module 4 is used for displaying the crust breaking state, acquiring a manual control instruction of an operator, sending the manual control instruction to the control module 2, and manually controlling the crust breaking process, wherein the function is usually used in special scenes such as system fault maintenance and trial operation.

The wireless communication module 5 is connected with the control module 2, the wireless communication module 5 is in wireless communication with an application program (APP) of the mobile terminal, and the application program is used for displaying the crust breaking state and acquiring a manual control instruction.

The alarm module 6 is connected with the control module 2, and the alarm module 2 is used for giving an alarm and prompting in one or more modes of sound and light, short messages or mobile terminal application programs when the crust breaking fails.

The control module 2 further comprises a monitoring unit 21 which triggers the cylinder electromagnetic valve to change direction after monitoring a contact signal between the crust breaking hammer and molten aluminum.

This monitoring unit accessible relay realizes, regard tup and aluminium water as the conductor, when tup and aluminium water contact, the relay coil switches on, makes the signal of telecommunication that the switch board sent form a return circuit, triggers the solenoid valve and forces the switching-over, makes the cylinder return initial position.

As shown in figure 2, the electrolytic aluminum crust breaking control system comprises an electrolytic cell, a cell control machine and the control cabinet, wherein the control cabinet is respectively connected with the electrolytic cell and the cell control machine.

The electrolytic bath is divided into 240KA, 660KA and the like. The largest electrolytic cell at present is a 660KA electrolytic cell, and consists of 7 cylinders, 7 alumina powder feeders, 1 fluoride salt feeder and 1 aluminum outlet cylinder. The 240KA electrolytic tank consists of 4 cylinders, 4 alumina powder feeders, 1 fluoride salt feeder and 1 aluminum outlet cylinder.

The control cabinet is built between the cell controller and the crust breaking cylinder and the blanking device, so that the crust breaking and blanking processes are more intelligent. Establishing data parameters of each crust breaking point according to the liquid level height of each electrolytic cell and the state of the hammerhead of each crust breaking point, and setting a normal crust breaking trend range; during production, whether the shell surface of each crust breaking point is unblocked or not is judged based on the collected real-time data parameters, so that whether each crust breaking point is blocked, clamped hammer head, secondary crust breaking or unblocked stop beating is determined, and the purposes of intelligently controlling crust breaking and blanking by the system are achieved. The device is suitable for high-dust, high-magnetic-field and high-temperature environments of an electrolysis workshop, meets the production process of an electrolysis bath, detects the variation trend of the cylinder pressing shell process, analyzes the state of the cylinder pressing shell, adjusts the single-point crust breaking time by using an independent control unit, solves the problem of hammer head sticking and reduces the labor intensity of workers; the shell pressing time is adjusted, and the service life of the hammer head is prolonged; saving gas source and prolonging the service life of the electrolytic bath.

As shown in FIG. 3, the electrolytic aluminum crust breaking control method of the invention comprises the following steps:

s1, receiving the crust breaking signal of the slot control machine and distributing the crust breaking signal to the corresponding independent control unit;

s2, the independent control unit controls the current crust breaking cylinder to execute crust breaking operation and controls the pressure of the working cavity of the cylinder according to the crust breaking state;

and S3, controlling the electromagnetic valve of the cylinder to change direction and controlling the blanking of the blanking device after the opening signal is monitored.

In step S2, the specific process of the independent control unit controlling the current crust breaking cylinder to execute crust breaking operation and controlling the pressure of the working chamber of the cylinder according to the crust breaking state is:

and controlling the cylinder to start low-pressure crust breaking, continuously ventilating the working cavity of the cylinder if the opening signal is not monitored within a first time threshold value, controlling the cylinder to perform high-pressure crust breaking, and controlling the cylinder to forcibly perform high-pressure crust breaking if the opening signal is not monitored within a second time threshold value.

The forced high-pressure crust breaking by the control cylinder is specifically as follows: the crust breaking pressure of the working cavity of the cylinder is enhanced, or the cylinder is in a high-pressure state to repeatedly execute crust breaking operation. And if the opening signal is not monitored yet after the high-voltage shell breaking is forced, alarming and prompting are carried out.

The electrolytic aluminum water shell surface is generally divided into: soft shell, hard shell and superhard shell,

softening a shell: treatment mode low-pressure crust breaking

And starting low-pressure crust breaking after the cylinder receives a crust breaking signal, breaking the aluminum water crust surface in about 2-3 seconds (the pressure value in the working cavity of the cylinder is about 2-2.5bar at the moment), contacting the aluminum water after the hammer breaks the crust, triggering the electromagnetic valve to forcibly reverse, returning the cylinder to the initial position, and completing the crust breaking step.

Hard shell: treatment mode high-pressure crust breaking

The air cylinder starts low-pressure crust breaking after receiving a crust breaking signal, the hammer head contacts a hard shell of molten aluminum in about 2-3 seconds, (the pressure value in the working cavity is about 2-2.5bar at the moment), after the hammer head contacts the hard shell of the molten aluminum, the air cylinder does not have one of three conditions for returning, the air cylinder is continuously ventilated in the working cavity, the pressure of the working cavity is continuously boosted until the pressure is equal to the air pressure of a main pipeline, finally, an electric signal sent by the control cabinet is in contact conduction with the electrolytic molten aluminum through the hammer head to form a loop, and then the electromagnetic valve is triggered to forcibly reverse, so that the purpose of high-pressure crust breaking is achieved.

③ superhard shell: forced high-pressure crust breaking requires manual treatment in special cases

The air cylinder starts low-pressure crust breaking after receiving a crust breaking signal, the hammer head contacts a hard shell of molten aluminum in about 2-3 seconds, (the pressure value in the working cavity is about 2-2.5bar at the moment), the air cylinder does not have one of three return conditions after the hammer head contacts the hard shell of the molten aluminum, the air cylinder is continuously ventilated in the working cavity of the air cylinder, the pressure of the working cavity is continuously boosted until the pressure of the working cavity is equal to the air pressure of the main pipeline, the air cylinder returns to the initial position until the air cylinder meets one of the three return conditions, and when the control cabinet receives the air cylinder according to the first return signal and does not receive the 3 rd return signal, generally the crust breaking is not passed, and the crust breaking operation is required to be.

When the crust breaking is forced, the working energization time of the cylinder is prolonged or the cylinder is repeatedly stamped in a high-pressure state frequently so as to achieve the goal of crust breaking. And when the crust breaking fails in special conditions, sound and light alarm is carried out, and appointed workers are informed to carry out on-site treatment in time through the mobile phone APP.

When the crust breaking is unsuccessful, the blanking signal of the cell controller is intercepted actively to prevent the blockage of the blanking port caused by the failure of crust breaking.

The three conditions for the above mentioned returns are: 1) the extension and retraction of the cylinder are controlled by the electrifying time of the electromagnetic valve; 2) the piston impacts a two-position three-way reversing valve arranged on the front cover to realize the automatic retraction of the cylinder; 3) the hammer head and the molten aluminum are used as conductors, when the hammer head is in contact with the molten aluminum, an electric signal sent by the control cabinet forms a loop, the electromagnetic valve is triggered to forcibly reverse, and the cylinder returns to the initial position. On the basis of the prior two return conditions, the return condition shown in the step 3) is added, the working stroke of the cylinder is shortened, and the compressed air quantity is saved; the depth of the hammer head inserted into the high-temperature electrolytic aluminum water is shortened, the stay time of the hammer head in the electrolytic aluminum water is shortened, the hammer head melting is reduced, and the hammer head caking phenomenon is reduced.

Although the embodiments of the present invention have been described with reference to the accompanying drawings, it is not intended to limit the scope of the present invention, and it should be understood by those skilled in the art that various modifications and variations can be made without inventive efforts by those skilled in the art based on the technical solution of the present invention.