阅读说明：本技术 一种基于物联网技术的矿热炉电极升降自动控制方法 (Submerged arc furnace electrode lifting automatic control method based on Internet of things technology ) 是由 王莉 周潼 牛群峰 曹鹤铧 赵旭燕 吴书琪 于 2020-10-06 设计创作，主要内容包括：本发明公布了一种基于物联网技术的矿热炉电极升降自动控制方法。本发明使用研华ADAM系列智能控制器,通过ADAM系列采集模块,与各类检测设备相结合,采集矿热炉重要冶炼参数,传至上位机系统,并进一步上传至云平台进行重要参数的计算和优化。本发明根据上述矿热炉冶炼参数,结合恒阻抗控制策略和遗传算法优化PID算法,使用模拟量输出模块、比例阀、液压传动系统等对矿热炉电极升降进行自动控制。本发明将物联网技术充分应用于矿热炉电极升降控制中,并通过遗传算法优化常规的PID算法,提高了矿热炉电极控制的适应性和准确性,实现了各类监控功能,在后期维护、模块更换和用户交互等方面有突出优势,控制过程的直观性和灵活性较好。(The invention discloses an automatic submerged arc furnace electrode lifting control method based on an internet of things technology. According to the invention, a porphyry ADAM series intelligent controller is used, and an ADAM series acquisition module is combined with various detection devices to acquire important smelting parameters of the submerged arc furnace, transmit the important smelting parameters to an upper computer system and further upload the important smelting parameters to a cloud platform for calculation and optimization of the important parameters. According to the submerged arc furnace smelting parameters, the PID algorithm is optimized by combining a constant impedance control strategy and a genetic algorithm, and the electrode lifting of the submerged arc furnace is automatically controlled by using an analog output module, a proportional valve, a hydraulic transmission system and the like. The method fully applies the technology of the internet of things to the electrode lifting control of the submerged arc furnace, optimizes the conventional PID algorithm through the genetic algorithm, improves the adaptability and the accuracy of the electrode control of the submerged arc furnace, realizes various monitoring functions, has outstanding advantages in the aspects of later maintenance, module replacement, user interaction and the like, and has better intuitiveness and flexibility in the control process.)

1. An automatic submerged arc furnace electrode lifting control method based on the Internet of things technology is characterized by comprising the following specific steps:

(1): establishing a submerged arc furnace smelting parameter detection system, and detecting smelting parameters related to electrode lifting control; the system uses an ADAM series intelligent controller of the porphyry company, detects important smelting parameters of the submerged arc furnace by combining an ADAM series sampling module (an analog quantity input module, a counter module and the like) with equipment such as a Rogowski coil, an alternating voltage transmitter, a power factor transmitter, an encoder and the like, and controls the lifting of the electrode of the submerged arc furnace on the basis of the detection;

(2): configuring and programming an ADAM series intelligent controller to realize the acquisition of current signals corresponding to parameters such as copper tube current, secondary side voltage and the like and the output of electrode lifting control signals; the method is characterized in that 2 analog input modules, 1 counter module and 1 analog output module are arranged on a card slot of each controller (3 in total, and respectively correspond to three phases of the submerged arc furnace A, B, C), configuration of the controllers is realized under the environment of a virtual machine, and programming of current signal acquisition, actual value conversion, PID control based on a constant impedance strategy, determination and output of control signal size and the like is completed;

(3): calculating the impedance value of each phase of the submerged arc furnace according to the detected smelting parameters of the submerged arc furnace, and realizing automatic control of the electrode lifting of the submerged arc furnace based on the optimization of PID by a genetic algorithm by combining a WISE-PaaS cloud platform as the basis of a constant impedance control strategy; the specific calculation method of the resistance value of each phase of the submerged arc furnace is shown as the formula (1):

in the formula (1), U, I, cos phi respectively represents the secondary side current, the secondary side voltage and the power factor of a certain phase of the submerged arc furnace, and R and R respectively represent the operating resistance and the equipment resistance corresponding to the certain phase of the submerged arc furnace; considering that the value of the equipment resistor R is very small and can be ignored to a certain extent relative to the operation resistor R in practice, in order to improve the efficiency of the electrode lifting control of the submerged arc furnace, the impedance value of each phase of the submerged arc furnace can be approximately calculated by the formula (1);

(4): an upper computer system is established through WebAccess, and communication between the submerged arc furnace smelting parameter detection system and the upper computer system is realized; the method uses a Modbus/RTU communication protocol to realize data transmission between a controller and an upper computer system, and transmits submerged arc furnace smelting parameter data to the upper computer; in the method, considering the problems of high temperature, more harmful gas and the like existing in the surrounding environment of the submerged arc furnace, the distance between the detection system and the PC client side provided with the upper computer system is prolonged by combining the RS232, the serial port optical transceiver and the optical fiber, and the health safety of monitoring personnel is better guaranteed; the method comprises the steps of constructing an upper computer system through Internet configuration software WebAccess, obtaining specific numerical values of smelting parameters calculated in an ADAM series intelligent controller, and realizing the functions of a user login interface, real-time smelting parameter display, a three-phase electrode control interface of the submerged arc furnace, report inquiry and other upper computers;

(5): on the basis of an electrode lifting control upper computer system of the submerged arc furnace constructed by using WebAccess, the system is further developed by using the technology of Internet of things, so that the system is suitable for actual requirements of different users; the method establishes a mobile client of the submerged arc furnace electrode lifting control upper computer system by editing the Dashboard viewer in WebAccess and combining the functions of WebAccess related software, further expands the way for a user to check the smelting parameters and the variation trend of the submerged arc furnace, and has more specific knowledge on the actual operation and the electrode control state of the submerged arc furnace.

2. The method according to claim 1, characterized in that the specific method for configuring and programming the intelligent controller of ADAM series in step (2) is as follows:

in the virtual machine development environment, firstly, a shared folder between the virtual machine and the host is established, and the transmission of files such as running programs and the like between the virtual machine and the host is realized; on the basis, the method transmits debugging and running programs to the controller through FTP software and a network cable (two ends are respectively connected with the controller and a LAN port of a PC); the method checks signals measured by various modules such as an analog input module, a counter module and the like through PuTTY software and judges whether a controller is in a normal working state.

3. The method according to claim 1, characterized in that the automatic control method for the electrode lifting of the submerged arc furnace based on the PID optimization by the genetic algorithm in the step (3) comprises the following steps:

the method uses a constant impedance strategy in the electrode lifting control of the submerged arc furnace, and takes the impedance value of each phase as a control object of a PID algorithm; the method optimizes the conventional PID control through a genetic algorithm to realize PID control parameters (K) in consideration of the problems that the traditional PID algorithm is not ideal in control effect in the electrode lifting process of the submerged arc furnace, long in adjustment time, large in overshoot, low in control precision and the like_P、K_I、K_D) The optimization method comprises the following specific steps:

(1): firstly, setting a reference impedance value R in an upper computer constructed by using WebAccess according to the actual condition and manual experience of the submerged arc furnace, and transmitting the reference impedance value R to each corresponding controller;

(2): according to signals collected by each corresponding analog input module and counter module, calculating actual values of smelting parameters such as secondary side voltage, secondary side current, electrode moving distance and the like of the submerged arc furnace respectively; on the basis, calculating the actual impedance value of each phase of the submerged arc furnace;

(3): comparing the actual impedance value of each phase with a set value, and determining the specific lifting mode of the electrode according to the comparison result so that the actual impedance value approaches to the set value;

(4): in the process of comparing the actual impedance value with the set value and carrying out electrode lifting operation, the genetic algorithm is used for optimizing PID to realize automatic control; calculating a deviation e between a set value and a system output value in a controller, and further calculating a control quantity m through an equation (2) on the basis of the deviation e;

in the formula (2), m (t) represents a controlled variable, m₀Indicates the initial value of the output, K_PDenotes the proportionality coefficient, K_IRepresents an integral coefficient, whereinT_ITo integrate the time constant, K_DRepresents a differential coefficient, where K_D＝K_P×T_D，T_DIs a differential time constant;

(5): optimizing PID control parameters through a genetic algorithm on the basis of using a PID control electrode to lift; considering that the system requires to rapidly reach stable and actual dynamic performance, the integral of time and an absolute value of error is taken as an optimization target of the genetic algorithm, and a penalty function is further combined to obtain a target function calculation method of the genetic algorithm, which is shown in a formula (3);

in the formula (3), f represents an objective function value, e (t) represents a system error, k₁、k₂Represents a weight value, and k₂Is far greater than k₁H (t) ═ g (t) -g (t-1), where g (t) represents the output of the controlled object, and when h (t) < 0, i.e., g (t) < g (t-1), the overshoot is taken into account in the calculation of the objective function; the method is an objective function meter shown in formula (3)On the basis of the calculation method, taking the reciprocal of the objective function value as the individual fitness value;

when the objective function value is smaller, the system reaches a stable speed faster, the oscillation of the system is smaller, the adaptability value is larger, and the PID control parameter corresponding to the individual can be considered to have better performance;

(6): through a connection port between WebAccess and a WISE-PaaS cloud platform, combining WebAccess/SCADA and Datahub, realizing data exchange between an upper computer constructed by using WebAccess and the WISE-PaaS cloud platform, and uploading smelting parameters and related control data of each phase of the submerged arc furnace to the WISE-PaaS cloud platform in real time; according to the real-time data, compiling and establishing a genetic algorithm model in a WISE-PaaS cloud platform through an AIFS module to optimize PID parameters;

(7): in a genetic algorithm model established by a cloud platform, determining a PID parameter K according to the actual operation condition of the submerged arc furnace_P、K_I、K_DSetting genetic algorithm parameters such as initial population size, maximum evolution algebra and the like; on the basis, combining a random function to generate an initial population, and coding all individuals in the initial population; according to the fitness calculation method shown in the step (5), the fitness of each individual in the initial population is calculated by combining the submerged arc furnace smelting data uploaded to the WISE-PaaS cloud platform in real time, the selection probability and the accumulation probability of the population are calculated, and the best individual of the current generation is stored by using the best storage strategy; performing genetic operation according to the selection probability and the accumulation probability of the population to generate a new generation of population; calculating the fitness of each individual in the new generation population according to the method, replacing the individual with the lowest fitness in the new generation population with the optimal individual stored before, and then performing genetic operation; by analogy, when the maximum evolution algebra is reached or the stop condition is met, outputting an optimization result, and transmitting PID parameters corresponding to the optimal individuals in the whole optimization process to the WebAccess upper computer;

(8): through communication between the WebAccess host computer and the ADAM series intelligent controller, a PID parameter optimization result is further transmitted to the controller, and the original PID parameter is adjusted; on the basis, a control signal is determined by combining the PID control method shown in the formula (2), a corresponding voltage signal is output by using an analog output module arranged in a controller card slot, an execution mechanism consisting of a proportional valve, a hydraulic transmission system and the like is controlled, the opening degree of the proportional valve and the oil inlet and outlet speed of the hydraulic transmission system are changed, and finally, the automatic adjustment of the lifting of the three-phase electrode of the submerged arc furnace is realized;

(9): according to the control method, when the actual impedance values of the three phases of the submerged arc furnace are close to the set values, the three-phase balance of the submerged arc furnace can be realized.

4. The method according to claim 1, characterized in that the specific method for controlling the upper computer of the electrode lifting control of the submerged arc furnace is established in the step (4) through WebAccess software:

the method comprises the steps that firstly, engineering nodes and corresponding monitoring nodes are established in WebAccess software, three communication ports are established, wherein the three-phase electrodes of the submerged arc furnace correspond to one controller respectively and are accessed to an upper computer system through serial port optical terminals, one controller corresponds to each communication port, and communication protocols are Modbus/RTU; establishing an analog quantity point under each device, acquiring data uploaded by the controller, establishing a calculation point and a constant point according to the analog quantity point, and calculating smelting parameters and control data of other submerged arc furnaces; in the MQTT Connection Setting function of WebAccess, WISE-PaaS Connection Setting is carried out according to node information established in WISE-PaaS, an analog quantity point, a calculation point and a constant point which need to be transmitted to a cloud end are selected, and data exchange between a WebAccess host computer and a WISE-PaaS cloud platform is finally realized through Setting of a script program of the cloud end and combination of WebAccess/SCADA and Datahub; a visual submerged arc furnace parameter display and control interface is established through a drawing tool in WebAccess software, and functions of a user login interface, real-time smelting parameter display, a submerged arc furnace three-phase electrode control interface, report inquiry and the like are realized in an upper computer system by combining a WebAccess functional module.

Technical Field

The invention relates to a method in the field of submerged arc furnace electrode control research, in particular to an automatic submerged arc furnace electrode lifting control method based on the Internet of things technology.

Technical Field

The submerged arc furnace is an important smelting device for producing ferro-alloys such as ferromanganese, ferrosilicon and the like, and the ferro-alloys produced by the device occupy a large proportion of the total production. The production level of ferroalloy is related to the further development of important industrial departments such as national defense industry, mechanical manufacturing industry, aerospace industry and the like. The ore-smelting furnace mainly uses carbon as a reducing agent, mixed raw materials are added from a furnace mouth, a three-phase electrode is buried in furnace burden, and electric energy is continuously converted into heat energy, so that ores are melted, and metal smelting is realized. The rapid and effective control of the three-phase electrode lifting of the submerged arc furnace is one of the key links of the submerged arc furnace production, and the control effect directly influences the quality of the ferroalloy product. At present, many smelting enterprises adopt a manual regulation method based on primary side current balance to carry out three-phase electrode lifting control, and the method has the defects of long regulation time, more energy consumption, low precision and the like. According to the method, the technology of Internet of things such as an ADAM series intelligent controller, an ADAM series acquisition module, WebAccess and a WISE-PaaS cloud platform is fully applied to electrode control of the submerged arc furnace, a PID algorithm is optimized by combining a constant impedance control strategy and a genetic algorithm, and the automatic control method for electrode lifting of the submerged arc furnace is designed, so that the method has practical significance for improving the automation level of electrode control of the submerged arc furnace, increasing the safety of a production process, realizing energy conservation and consumption reduction and the like.

PID control, namely proportional-integral-derivative control, has the advantages of good adaptability, high reliability, good robustness and the like, and is widely applied to various control scenes such as machinery, chemical engineering, metallurgy and the like. However, in the actual use process, the PID control has the problems that parameter (proportional coefficient, integral coefficient, differential coefficient) setting is difficult, overshoot is likely to occur, oscillation is likely to occur, and the like. The invention optimizes PID parameters through a genetic algorithm, and further improves the response speed and accuracy of the control system.

Genetic Algorithm (Genetic Algorithm) is a global optimization method that mimics the mechanism of biological evolution by referencing evolutionary theory and Genetic mechanism. The genetic algorithm encodes the optimized variables, combines random functions to generate an initial population, and then realizes the continuous evolution of the population by taking fitness as a standard through genetic operations such as selection, crossing, variation and the like until a termination condition is reached. In the invention, the limitations of ADAM series intelligent controllers on the memory size and the operational performance are considered, and a genetic algorithm optimization model is established on a WISE-PaaS cloud platform through an AIFS module to realize the optimization of PID parameters.

The Rohua WebAccess software is an Internet configuration software based on B/S architecture. The software is developed completely based on a browser and has better compatibility with various controllers and acquisition modules which are researched and researched. Compared with other configuration software, WebAccess has outstanding advantages in the aspects of remote maintenance, camera access, remote monitoring, collaborative development and the like. Meanwhile, a connection port exists between the WebAccess software and the WISE-PaaS cloud platform, and after the WebAccess and the WISE-PaaS cloud platform are configured by combining WebAccess/SCADA and Datahub, data exchange between the WebAccess and the WISE-PaaS cloud platform can be realized, so that the function of WebAccess is further expanded by utilizing the computing capability of the WISE-PaaS cloud platform and various modules (Dashboard, APM, AIFS and the like).

The rogowski coil (rogowski coil) is an alternating current sensor designed according to ampere loop law and electromagnetic induction law, and has the advantages of good linearity, high precision, no saturation phenomenon and the like. When the current to be measured passes through the center of the Rogowski coil, an induced voltage signal is generated on the coil due to the change of magnetic flux, an integrator is needed to perform integral reduction and conversion processing on the signal, and then signal acquisition is performed. The method measures the current of each copper pipe on the low-voltage side of the transformer of the submerged arc furnace through the Rogowski coil and the integrator, and further calculates to obtain the secondary side current of the submerged arc furnace, which is used as the basis of constant impedance control.

Disclosure of Invention

The invention aims to provide an automatic submerged arc furnace electrode lifting control method based on the Internet of things technology. The invention fully applies the technology of Internet of things to the electrode lifting control of the submerged arc furnace, firstly uses an ADAM series intelligent controller and an ADAM series acquisition module to be combined with a Rogowski coil, an encoder, an alternating voltage transmitter and other equipment to acquire important smelting parameters such as secondary side current, secondary side voltage, electrode moving distance and the like, uploads the parameters to an upper computer (which has the functions of a user login interface, real-time smelting parameter display, a submerged arc furnace three-phase electrode control interface and the like and can be checked in a mobile terminal) constructed by WebAccess, realizes data exchange between the upper computer and a cloud platform through a connection port and relevant settings between the WebAccess and a WISE-PaaS cloud platform, optimizes a PID algorithm by combining a constant impedance control strategy and a genetic algorithm, runs a PID control algorithm in the ADAM series intelligent controller, wherein the PID parameter is optimized and set in the cloud platform by using a constructed genetic algorithm model, and the lifting of the electrode of the submerged arc furnace is automatically controlled by using an analog output module, a proportional valve, a hydraulic transmission system and the like.

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

an automatic submerged arc furnace electrode lifting control method based on the Internet of things technology comprises the following specific steps:

(1): and establishing a submerged arc furnace smelting parameter detection system, and detecting smelting parameters related to electrode lifting control. The system uses an ADAM series intelligent controller of the Jones company, detects important smelting parameters of the submerged arc furnace by combining an ADAM series sampling module (an analog input module, a counter module and the like) with equipment such as a Rogowski coil, an alternating voltage transmitter, a power factor transmitter, an encoder and the like, and controls the lifting of the electrode of the submerged arc furnace on the basis of the detection.

(2): and configuring and programming the ADAM series intelligent controller to acquire current signals corresponding to parameters such as copper tube current, secondary side current and secondary side voltage and output electrode lifting control signals. According to the method, 2 analog input modules, 1 counter module and 1 analog output module are installed on a card slot of each ADAM series intelligent controller (3 in total, and the card slots respectively correspond to A, B, C three phases of a submerged arc furnace), configuration of the ADAM series intelligent controller is achieved under the environment of a virtual machine, and programming of current signal acquisition, actual value conversion, PID control based on a constant impedance strategy, control signal size determination and output and the like is completed.

(3): and calculating the impedance value of each phase of the submerged arc furnace according to the detected smelting parameters of the submerged arc furnace, and realizing automatic control of the electrode lifting of the submerged arc furnace based on optimization of PID (proportion integration differentiation) by a genetic algorithm by combining a WISE-PaaS cloud platform as the basis of a constant impedance control strategy. The specific calculation method of the resistance value of each phase of the submerged arc furnace is shown as the formula (1):

in the formula (1), U, I, cos phi respectively represents the secondary side current, the secondary side voltage and the power factor of a certain phase of the submerged arc furnace, and R and R respectively represent the operation resistance and the equipment resistance corresponding to the certain phase of the submerged arc furnace. Considering that the value of the equipment resistance R is small and can be ignored to a certain extent relative to the operating resistance R in practice, in order to improve the efficiency of the electrode lifting control of the submerged arc furnace, the impedance value of each phase of the submerged arc furnace can be approximately calculated by the formula (1).

(4): and constructing an upper computer system through WebAccess, and realizing communication between the submerged arc furnace smelting parameter detection system and the upper computer system. The method uses a Modbus/RTU communication protocol to realize data transmission between the controller and an upper computer system, and transmits the smelting parameter data of the submerged arc furnace to the upper computer. In the method, considering the problems of high temperature, more harmful gas and the like existing in the surrounding environment of the submerged arc furnace, the distance between the detection system and the PC client side provided with the upper computer system is prolonged by combining the RS232, the serial port optical transceiver and the optical fiber, and the health safety of monitoring personnel is better guaranteed. The method constructs an upper computer system through Internet configuration software WebAccess, obtains specific numerical values of smelting parameters calculated in an ADAM series intelligent controller, and realizes the functions of a user login interface, real-time smelting parameter display, a three-phase electrode control interface of the submerged arc furnace, report inquiry and other upper computers.

(5): on the basis of an electrode lifting control upper computer system of the submerged arc furnace constructed by using WebAccess, the system is further developed by using the technology of Internet of things, and the system is suitable for actual requirements of different users. The method establishes a mobile client of the submerged arc furnace electrode lifting control upper computer system by editing the Dashboard viewer in WebAccess and combining the functions of WebAccess related software, further expands the way for a user to check the smelting parameters and the variation trend of the submerged arc furnace, and has more specific knowledge on the actual operation and the electrode control state of the submerged arc furnace.

In the invention, the specific method for configuring and programming the ADAM series intelligent controller in the step (2) is realized by the following steps:

in the virtual machine development environment, the method firstly establishes a shared folder between the virtual machine and the host machine, and realizes the transmission of files such as running programs and the like between the virtual machine and the host machine. On the basis, the method transmits debugging and operating programs to the controller through FTP software and a network cable (two ends are respectively connected with the controller and a LAN port of the PC). The method checks signals measured by various modules such as an analog input module, a counter module and the like through PuTTY software and judges whether a controller is in a normal working state.

In the invention, the automatic control method for the electrode lifting of the submerged arc furnace based on the genetic algorithm optimization PID in the step (3) is realized by the following steps:

the method uses a constant impedance strategy in the electrode lifting control of the submerged arc furnace, and takes the impedance value of each phase as a control object of a PID algorithm. The method optimizes the conventional PID control through a genetic algorithm to realize PID control parameters (K) in consideration of the problems that the traditional PID algorithm is not ideal in control effect in the electrode lifting process of the submerged arc furnace, long in adjustment time, large in overshoot, low in control precision and the like_P、K_I、K_D) The optimization method comprises the following specific steps:

1): firstly, setting a reference impedance value R in an upper computer constructed by using WebAccess according to the actual condition and the manual experience of the submerged arc furnace, and transmitting the reference impedance value R to each corresponding controller.

2): and respectively calculating actual values of smelting parameters such as secondary side voltage, secondary side current, electrode moving distance and the like of the submerged arc furnace according to signals collected by the corresponding analog quantity input module and the counter module. On the basis, the actual impedance value of each phase of the submerged arc furnace is calculated.

3): and comparing the actual impedance value of each phase with a set value, and determining the specific lifting mode of the electrode according to the comparison result so that the actual impedance value approaches to the set value.

4): and in the process of comparing the actual impedance value with the set value and carrying out electrode lifting operation, optimizing PID by using a genetic algorithm to realize automatic control. The deviation e between the set value and the system output value is calculated in the ADAM-series intelligent controller, and on the basis of this, the control amount m is further calculated by the equation (2).

In the formula (2), m (t) represents a controlled variable, m₀Indicates the initial value of the output, K_PDenotes the proportionality coefficient, K_IRepresents an integral coefficient, whereinT_ITo integrate the time constant, K_DRepresents a differential coefficient, where K_D＝K_P×T_D，T_DIs the differential time constant.

5): and optimizing PID control parameters through a genetic algorithm on the basis of using PID to control the electrode to ascend and descend. Considering that the system requires to rapidly reach stable and actual dynamic performance, the integral of the time and the absolute value of the error is taken as the optimization target of the genetic algorithm, and a penalty function is further combined, so that the target function calculation method of the genetic algorithm can be obtained, and is shown in the formula (3).

In the formula (3), f represents an objective function value, e (t) represents a system error, k₁、k₂Represents a weight value, and k₂Is far greater than k₁And h (t) ═ g (t) — g (t-1), where g (t) represents the output of the controlled object, and when h (t) < 0, i.e., g (t) < g (t-1), the overshoot amount is taken into account in the calculation of the objective function. The method is as shown in formula (3)On the basis of the target function calculation method, the reciprocal of the target function value is taken as the individual fitness value.

When the objective function value is smaller, the system reaches a stable speed faster, the oscillation of the system is smaller, the adaptability value is larger, and the PID control parameter corresponding to the individual can be considered to have better performance.

6): through a connection port between the WebAccess and the WISE-PaaS cloud platform and combination of the WebAccess/SCADA and the Datahub, data exchange between an upper computer constructed by the WebAccess and the WISE-PaaS cloud platform is realized, and smelting parameters and related control data of each phase of the submerged arc furnace are uploaded to the WISE-PaaS cloud platform in real time. And according to the real-time data, compiling and establishing a genetic algorithm model in the WISE-PaaS cloud platform through an AIFS module to optimize PID parameters.

7): in a genetic algorithm model established by a cloud platform, determining a PID parameter K according to the actual operation condition of the submerged arc furnace_P、K_I、K_DSetting the initial population size, the maximum evolution algebra and other genetic algorithm parameters. On the basis, combining a random function to generate an initial population, and coding all individuals in the initial population. According to the fitness calculation method shown in the step 5), the fitness of each individual in the initial population is calculated by combining the submerged arc furnace smelting data uploaded to the WISE-PaaS cloud platform in real time, the selection probability and the accumulation probability of the population are calculated, and the best individual of the current generation is stored by using the best storage strategy. And performing genetic operation according to the selection probability and the accumulation probability of the population to generate a new generation of population. According to the method, the fitness of each individual in the new generation population is calculated, the optimal individual stored before is used for replacing the individual with the lowest fitness in the new generation population, and then genetic operation is carried out. And analogizing in sequence, outputting an optimization result when the maximum evolution algebra is reached or the stop condition is met, and transmitting PID parameters corresponding to the optimal individuals in the whole optimization process to the WebAccess upper computer.

8): and further transmitting the PID parameter optimization result to the controller through communication between the WebAccess upper computer and the ADAM series intelligent controller, and adjusting the original PID parameters. On the basis, a control signal is determined by combining the PID control method shown in the formula (2), a corresponding voltage signal is output by using an analog output module installed in a controller card slot, an execution mechanism composed of a proportional valve, a hydraulic transmission system and the like is controlled, the opening degree of the proportional valve and the oil inlet and outlet speed of the hydraulic transmission system are changed, and finally, the automatic adjustment of the lifting of the three-phase electrode of the submerged arc furnace is realized.

9): according to the control method, when the actual impedance values of the three phases of the submerged arc furnace are close to the set values, the three-phase balance of the submerged arc furnace can be realized.

In the invention, the specific method for establishing the submerged arc furnace electrode lifting upper computer through WebAccess software in the step (4) is realized through the following steps:

the method comprises the steps of firstly establishing engineering nodes and corresponding monitoring nodes in WebAccess software, considering that three-phase electrodes of the submerged arc furnace respectively correspond to one controller and are respectively accessed to an upper computer system through a serial port optical transceiver, establishing three communication ports, wherein each communication port corresponds to one controller, and the communication protocols are Modbus/RTU. And establishing an analog quantity point under each device, acquiring data uploaded by the controller, establishing a calculation point and a constant point according to the analog quantity point, and calculating smelting parameters and control data of other submerged arc furnaces. In the MQTT Connection Setting function of WebAccess, WISE-PaaS Connection Setting is carried out according to node information established in WISE-PaaS, an analog quantity point, a calculation point and a constant point which need to be transmitted to a cloud end are selected, and data exchange between a WebAccess host computer and a WISE-PaaS cloud platform is finally realized through Setting of a script program of the cloud end and combination of WebAccess/SCADA and Datahub. A visual submerged arc furnace parameter display and control interface is established through a drawing tool in WebAccess software, and functions of a user login interface, real-time smelting parameter display, a submerged arc furnace three-phase electrode control interface, report inquiry and the like are realized in an upper computer system by combining a WebAccess functional module.

The invention has the beneficial effects that:

(1): the related technology of the Internet of things is fully applied to the electrode lifting control of the submerged arc furnace, the optimization of control parameters is realized by utilizing the computing capability and abundant functional modules of the cloud platform, the efficiency of parameter optimization is improved, and the operation pressure of the controller is reduced.

(2): conventional PID control is improved through a genetic algorithm, and then the genetic algorithm is combined with a constant impedance strategy to automatically control the electrode lifting of the submerged arc furnace, so that the control parameter (K) can be improved_P、K_I、K_D) The problems of long adjusting time, low control precision, large overshoot and the like caused by non-ideality can effectively improve the accuracy of electrode lifting control and the adaptability of the control method to different submerged arc furnace systems.

(3): an upper computer system for controlling the electrode lifting of the submerged arc furnace is constructed by using internet configuration software WebAccess, can be well compatible with an ADAM series intelligent controller and an ADAM series acquisition module, and realizes functions of a user login interface, real-time smelting parameter display, report inquiry and the like. Compared with the traditional configuration software, the upper computer system constructed by the invention has great advantages in the aspects of remote monitoring, collaborative development, maintenance development and the like.

(4): after WebAccess/SCADA and Datahub are combined and a cloud script program is set, the communication between an upper computer system and a WISE-PaaS cloud platform is realized, smelting and control data of the submerged arc furnace can be transmitted to the cloud platform in real time, and then an optimization and prediction model is further established through the computing capability and various functional modules of the cloud platform, so that the method has better expansibility and practicability.

(5): by editing a Dashboard reader in WebAccess, setting a local area network and combining the functions of software such as WebAccess client and the like, a mobile client of the submerged arc furnace electrode lifting control upper computer system is established, the way for a user to check smelting parameters of the submerged arc furnace is expanded, the user can know the running state and the control condition of the submerged arc furnace more specifically, and the actual requirements of the user are met more widely.

Drawings

FIG. 1 is a schematic diagram of the overall structure of an automatic control system for electrode lifting of a submerged arc furnace;

FIG. 2 is a control structure diagram of a genetic algorithm optimized PID;

FIG. 3 is a main flow chart for realizing automatic control of electrode lifting of the submerged arc furnace;

FIG. 4 is a flow chart for configuring and programming an ADAM family intelligent controller;

FIG. 5 is a flow chart of a genetic algorithm optimizing PID;

FIG. 6 is a flow chart of establishing the submerged arc furnace electrode lifting control upper computer through WebAccess software.

Detailed Description

The invention will now be described in detail with reference to specific embodiments thereof, with reference to the accompanying drawings.

Example 1: the invention relates to an automatic submerged arc furnace electrode lifting control method based on the Internet of things technology, wherein the overall structure of a corresponding automatic submerged arc furnace electrode lifting control system is shown in figure 1 and comprises a submerged arc furnace parameter detection system, an upper computer system, a cloud platform optimization system, an execution mechanism, a mobile client and the like. The invention combines a constant impedance control strategy and a genetic algorithm optimization PID algorithm to realize the automatic regulation of the electrode lifting of the submerged arc furnace, and the main control structure is shown in figure 2.

In the embodiment, an ADAM-5630 controller is selected as an ADAM series intelligent controller, an ADAM-5017P is selected as an analog input module, an ADAM-5081 is selected as a counter module, and an ADAM-5024 is selected as an analog output module. The ADAM-5630 controller is an edge intelligent data acquisition controller produced by Mohua company, and has the advantages of high performance, flexible configuration, wide temperature range and the like. The ADAM-5630 controller carries a Linux open operating system, has more I/O card slots, can flexibly select various I/O modules or communication ports, and meets the actual requirements of different application environments. Therefore, in the embodiment, ADAM-5630 is selected as a controller for lifting the submerged arc furnace electrode, and modules such as ADAM-5017P, ADAM-5081 and ADAM-5024 are mounted to realize the acquisition of various sensor signals and the output of control signals.

The invention provides an automatic submerged arc furnace electrode lifting control method based on the technology of the Internet of things, which is carried out according to the following steps by combining the drawings of fig. 1, fig. 2, fig. 3, fig. 4, fig. 5 and fig. 6:

step 1: in the embodiment, firstly, a submerged arc furnace smelting parameter detection system is established, and the specific structure is shown in figure 1 (the submerged arc furnace three-phase structure is similar, and only the smelting parameter detection system of the A phase is shown in figure 1). The ADAM series intelligent controller in the submerged arc furnace smelting parameter detection system established in the embodiment is an ADAM-5630 controller, important smelting parameters (secondary side current, secondary side voltage, electrode moving distance and the like) of the submerged arc furnace are detected by combining a Rogowski coil, an alternating current voltage transmitter, a power factor transmitter, an encoder and the like through ADAM series sampling modules (every two corresponding analog input modules ADAM-5017P and one counter module ADAM-5081), and the electrode lifting control of the submerged arc furnace is performed on the basis of the smelting parameters.

In the embodiment, the current on each copper pipe on the low-voltage side of the transformer of the submerged arc furnace is detected through the Rogowski coil and the integrator and is output in a 4-20mA current form, 4-20mA current signals corresponding to each copper pipe are collected through the ADAM-5017P module and are converted into the actual current of each copper pipe in the ADAM-5630 controller, and the secondary side current of the submerged arc furnace is obtained through calculation. In the embodiment, the secondary side voltage and the power factor of the submerged arc furnace are respectively detected by an alternating current voltage transmitter and a power factor transmitter, and are transmitted to an ADAM-5017P module for collection by 4-20mA current signals and are converted into actual values in ADAM-5630. This example uses the encoder to detect hot stove electrode travel distance in ore deposit, and when hot stove electrode in ore deposit goes up and down, the encoder will produce pulse signal, gathers through ADAM-5081 to carry out hot stove electrode travel distance's in ore deposit calculation in ADAM-5630, realize the accurate measurement to hot stove electrode in ore deposit lift distance.

Step 2: in the embodiment, the ADAM-5630 controller is configured and programmed to realize the acquisition of current signals corresponding to smelting parameters such as copper tube current, secondary side voltage and the like and the output of electrode lifting control signals.

In the embodiment, 2 ADAM-5017P modules, 1 ADAM-5081 module and 1 ADAM-5024 module are installed on a card slot of each ADAM-5630 controller (3 ADAM-5630 controllers respectively corresponding to three phases of a submerged arc furnace A, B, C), and in the environment of a virtual machine VirtualBox, the configuration of ADAM-5630 is realized by using Linux C, and the programming of parts such as current signal acquisition, actual value conversion, PID control based on a constant impedance strategy, control signal size determination and output is completed.

And step 3: according to the submerged arc furnace smelting parameters detected in the steps, the impedance values of all phases of the submerged arc furnace are calculated and used as the basis of a constant impedance control strategy, and the automatic control of the lifting of the submerged arc furnace electrode based on the genetic algorithm optimization PID is realized by combining a WISE-PaaS cloud platform. The method for calculating the impedance value of each phase of the submerged arc furnace in the embodiment is shown as the formula (1):

in the formula (1), U, I, cos phi respectively represents the secondary side current, the secondary side voltage and the power factor of a certain phase of the submerged arc furnace, and R and R respectively represent the operation resistance and the equipment resistance corresponding to the certain phase of the submerged arc furnace. In the embodiment, the resistance values of all phases of the submerged arc furnace are approximately calculated by the formula (1) in consideration of the fact that the value of the equipment resistance R is very small and can be ignored to a certain extent relative to the operation resistance R in the actual smelting process.

And 4, step 4: in the embodiment, the upper computer system is constructed through WebAccess software, and communication between the submerged arc furnace smelting parameter detection system and the upper computer system is realized. In the embodiment, a Modbus/RTU communication protocol is used, and communication modes are compiled and set in an ADAM-5630 controller and a WebAccess respectively, so that data transmission between the ADAM-5630 controller and an upper computer system is realized, and smelting parameter data of the submerged arc furnace is transmitted to the upper computer.

In the embodiment, the problems of high temperature, more harmful gas and the like in the surrounding environment of the submerged arc furnace are considered, and the distance between the submerged arc furnace smelting parameter detection system and the PC client side provided with the upper computer system is prolonged in a mode of combining RS232, a serial port optical transceiver and an optical fiber. The main mode is that the RS232 port of the controller is connected with a serial port optical transmitter and receiver, and is transmitted to another serial port optical transmitter and receiver through a long-distance optical fiber, and then is accessed to a PC client end provided with an upper computer system through a serial port line.

In the embodiment, an upper computer system is constructed through WebAccess software, engineering nodes are established, communication ports are set, analog quantity points and calculation points are established, specific numerical values of smelting parameters such as copper pipe current, secondary side voltage, power factor and impedance value calculated in an ADAM-5630 controller are obtained, and functions such as user login interface, real-time smelting parameter display, three-phase electrode control interface of a submerged arc furnace, report query and the like are realized on the basis.

And 5: according to the embodiment, the system is developed more deeply by using the technology of the internet of things on the basis of the electrode lifting control upper computer system of the submerged arc furnace constructed by using WebAccess. The embodiment edits a Dashboard reader in WebAccess, sets a local area network, combines the functions of software such as WebAccess client and the like, establishes a mobile client of the submerged arc furnace electrode lifting control upper computer system, and further expands the way for a user to check smelting parameters (secondary side voltage, secondary side current, power factor, electrode moving distance and the like) and the variation trend of the submerged arc furnace.

In step 2, the present example configures and programs an ADAM-family intelligent controller (in the present example, ADAM-5630 controller), and the specific flow is as shown in fig. 4, and the following steps are performed:

step 2-1: in the example, an ADAM series module comprising two ADAM-5017P, one ADAM-5081 and one ADAM-5024 is arranged on a clamping groove of each ADAM-5630 controller (three in total and respectively corresponding to three-phase electrodes of the submerged arc furnace).

Step 2-2: in the embodiment, a shared folder between the VirtualBox and the host is established under the VirtualBox development environment of the virtual machine, so that the transmission of files such as running programs and the like between the virtual machine and the host is realized.

Step 2-3: according to actual requirements, the current signal acquisition, actual value conversion, PID control based on a constant impedance strategy, determination and output of control signal size, Modbus/RTU communication and other parts of programming are completed.

Step 2-4: in the embodiment, debugging and running programs are transmitted to the ADAM-5630 controller through FTP software (FileZillaportable software is used in the embodiment) and a network cable (LAN ports with two ends respectively connected with ADAM-5630 and a PC), and then the running programs are compiled.

Step 2-5: in the example, PuTTY software checks signals measured by modules such as ADAM-5017P, ADAM-5081 and the like to judge whether the ADAM-5630 controller is in a normal working state.

Step 2-6: if the system is in a normal working state, the operation is stopped, the ADAM-5630 controller is allowed to continue to operate, and otherwise, the ADAM-5630 controller is continuously configured and programmed.

In step 3, optimizing the PID based submerged arc furnace electrode lifting automatic control method based on the genetic algorithm, wherein the control structure of the PID optimized by the genetic algorithm is shown in fig. 2, the specific flow of the method is shown in fig. 5, and the method comprises the following steps:

step 3-1: according to the embodiment, firstly, a reference impedance value R is set in an electrode lifting control upper computer of the submerged arc furnace constructed by using WebAccess according to the actual condition and the manual experience of the submerged arc furnace, and is transmitted to the ADAM-5630 controllers corresponding to the submerged arc furnace.

Step 3-2: in the embodiment, actual values of smelting parameters such as secondary side voltage, secondary side current, electrode moving distance and the like of the submerged arc furnace are respectively calculated according to signals acquired by ADAM-5017P and ADAM-5081 corresponding to the submerged arc furnace. And calculating the actual impedance value of each phase according to the related data of the smelting parameters of the submerged arc furnace.

Step 3-3: in the embodiment, the actual impedance value of each phase is compared with a set value, and the lifting direction of the electrode of the submerged arc furnace is determined according to the conditions: when the actual impedance value is smaller than the set value, the electrode is subjected to ascending operation to increase the voltage and reduce the current so as to improve the impedance value, and when the actual impedance value is larger than the set value, the electrode is subjected to descending operation to reduce the voltage and increase the current so as to reduce the impedance value and finally enable the actual impedance value to approach the set value.

Step 3-4: in the process of comparing the actual impedance value with the set value and carrying out electrode lifting operation, the genetic algorithm is used for optimizing the conventional PID algorithm to realize automatic control. The deviation e between the set value and the system output value is calculated in the ADAM-5630 controller, and on the basis of this, the control amount m is further calculated by equation (2).

In the formula (2), m (t) represents a controlled variable, m₀Indicates the initial value of the output, K_PDenotes the proportionality coefficient, K_IRepresents an integral coefficient, whichInT_ITo integrate the time constant, K_DRepresents a differential coefficient, where K_D＝K_P×T_D，T_DIs the differential time constant.

Step 3-5: the example controls the PID parameter (K) through a genetic algorithm based on the control of the electrode lifting by using a PID algorithm_P、K_I、K_D) And (6) optimizing. In order to meet the requirement that the control system quickly reaches stability and improve the actual dynamic performance, in the embodiment, the integral of the time and the absolute value of the error is used as the optimization target of the genetic algorithm, and a penalty function is further combined to establish a target function calculation method of the genetic algorithm, as shown in the formula (3).

In the formula (3), f represents an objective function value, e (t) represents a system error, k₁、k₂Represents a weight value, and k₂Is far greater than k₁And h (t) ═ g (t) — g (t-1), where g (t) represents the output of the controlled object, and when h (t) < 0, i.e., g (t) < g (t-1), the overshoot amount is taken into account in the calculation of the objective function. In the embodiment, the fitness value is calculated on the basis of the calculation method of the objective function shown in the formula (3), and the specific calculation method is shown in the formula (4).

In the formula (4), S represents a fitness value of a certain individual in the genetic algorithm optimization process, and f represents an objective function value of the individual calculated by the formula (3).

Step 3-6: the embodiment realizes data exchange between the submerged arc furnace electrode lifting control upper computer constructed by using WebAccess and the WISE-PaaS cloud platform by combining a connection port between the WebAccess software and the WISE-PaaS cloud platform and WebAccess/SCADA and Datahub, and uploads smelting parameters and related control data of each phase of the submerged arc furnace to the WISE-PaaS cloud platform in real time. According to the real-time data of the submerged arc furnace, a genetic algorithm model is compiled and established in an AIFS module (AI Framework Service) in a WISE-PaaS cloud platform to carry out PID parameter optimization.

Step 3-7: in a genetic algorithm model established by a cloud platform, PID parameter optimization is carried out according to the following process according to the actual operation condition of the submerged arc furnace:

1. determining PID parameter K_P、K_I、K_DSetting the initial population size, the maximum evolution algebra and other genetic algorithm parameters. On the basis, combining a random function to generate an initial population, and coding all individuals in the initial population.

2. According to the fitness calculation methods shown in the formulas (3) and (4), the fitness of each individual in the initial population generated in the step 1 is calculated by combining submerged arc furnace smelting data uploaded to a WISE-PaaS cloud platform in real time, the selection probability and the accumulation probability of the population are calculated on the basis, and the optimal individual in the current population is stored by using an optimal storage strategy.

3. And carrying out genetic operations such as selection, crossing, mutation and the like according to the selection probability and the cumulative probability of the population to generate a new generation of population. According to the method, the fitness of each individual in the new generation population is calculated, the optimal individual stored before is used for replacing the individual with the lowest fitness in the new generation population, and then genetic operation is carried out.

4. Analogizing in turn, when the genetic algorithm optimization process reaches the maximum evolution algebra or meets the stop condition, outputting the optimization result, and outputting the PID parameter (K) corresponding to the optimal individual of the whole optimization process_P、K_I、K_D) And transmitting the data to a WebAccess upper computer. Step 3-8: the embodiment further transmits the PID parameter optimization result to the ADAM-5630 controller through the communication between the WebAccess upper computer and the ADAM-5630 controller, and adjusts the original PID parameters. On the basis, a control signal is determined by combining a PID control method shown in the formula (2) in the steps 3-4, a corresponding voltage signal is output by using an ADAM-5024 module installed in an ADAM-5630 clamping groove, and a proportional valve and hydraulic transmission are controlled to be used for controllingThe system and other actuating mechanisms change the opening of the proportional valve and the oil inlet and outlet speed of the hydraulic transmission system, so as to realize the automatic control of the electrode lifting of the submerged arc furnace.

Step 3-9: according to the control method, when the actual impedance values of the three phases of the submerged arc furnace approach the set values, the three-phase balance of the submerged arc furnace is realized in the example.

In step 4, the example establishes the submerged arc furnace electrode lifting control upper computer through WebAccess software, the specific flow is as shown in FIG. 6, and the method comprises the following steps:

step 4-1: in the embodiment, an engineering node and a corresponding monitoring node are firstly established in WebAccess software, three communication ports (the name of an interface selects SERIAL, and a corresponding port number is determined according to a connected COM port) are established by considering that three phase electrodes of the submerged arc furnace respectively correspond to an ADAM-5630 controller and respectively access an upper computer system established by using WebAccess through a SERIAL port optical transceiver, each communication port corresponds to an ADAM-5630 controller, and a communication protocol is set to Modbus/RTU.

Step 4-2: in the embodiment, an analog quantity point is established under each device (three device nodes of ADAM5630-1, ADAM5630-2 and ADAM5630-3 respectively), data uploaded by an ADAM-5630 controller are obtained, a calculation point and a constant point are established according to the analog quantity point, and the smelting parameters and the control data of other submerged arc furnaces are calculated.

Step 4-3: in the MQTT Connection Setting function of WebAccess software, WISE-PaaS Connection Setting is carried out according to node information established in WISE-PaaS, analog quantity points, calculation points and constant points which need to be uploaded to a WISE-PaaS cloud platform are selected, and finally data exchange between a WebAccess-based submerged arc furnace electrode lifting control upper computer and the WISE-PaaS cloud platform is achieved through Setting of a cloud script program and combination of WebAccess/SCADA and Datahub.

Step 4-4: in the embodiment, a visual submerged arc furnace parameter display and control interface is constructed through a drawing tool DrawDAQ in WebAccess software.

And 4-5: the embodiment combines modules of WebAccess such as real-time trend display, historical trend display, user permission and password setting, report forms and records, realizes functions of a user login interface, real-time smelting parameter display, a three-phase electrode control interface of the submerged arc furnace, report form query and the like in an upper computer system, and can continuously develop other functions such as operation logs, overrun alarm, alarm records and the like according to actual requirements of users.

The present invention is not limited to the above embodiments. All changes made according to the technical scheme of the invention, when the generated functional function does not exceed the scope of the technical scheme of the invention, belong to the protection scope of the invention.