Invention content
The object of the present invention is to provide a kind of single anode rod pawl capitiforms to become on-line detecting system, to solve using artificial
Hand inspection judge steel pawl whether can continue to the mode used measuring speed is slow, efficiency is low, error is big problem.
To achieve the above object, the present invention includes following technical scheme.
A kind of list anode rod pawl capitiform change on-line detecting system, which is characterized in that at detection subsystem and data
Subsystem is managed, the detection subsystem output connects the data process subsystem, and the detection subsystem realizes that pawl head is practical
The detection of diameter value and/or the detection of pawl head offset.The detection subsystem detects the actual diameter value of each pawl head, and will inspection
The data measured are exported to data process subsystem, and data process subsystem compares actual diameter value and carbon nest diameter, when having
When actual diameter value is more than carbon nest diameter, judges corresponding pawl head deformation, indicate that pawl head can not be placed in carbon block carbon nest;It is described
Detection subsystem detects offset of each pawl head along pawl head radial direction, and the data detected are exported to data process subsystem,
Data process subsystem compares offset and corresponding maximum allowable offset threshold value, permits when the amount of offsetting is more than corresponding maximum
Perhaps when offset threshold value, judgement has the offset of pawl head excessive, and being determined with pawl head can not be placed in carbon block carbon nest.
Detection subsystem detects the relevant information of each pawl head in real time, by judging the shape of pawl head to the processing of detection information
Become situation, and then judge whether had pawl head that can not be placed in carbon block carbon nest, i.e., whether pawl head being capable of normal use.So
The automatic detection that the deformation of single anode rod pawl head can be realized by the detecting system passes through the judgement processing to detection data
It realizes automatic detection, compared to artificial manual detection mode, a large amount of human resources need not be occupied, and obtaining testing number
According to later, testing result can be obtained immediately, so, measuring speed is fast, efficient, due to inartificial disturbing factor,
Therefore, detection error is small, can effectively improve production efficiency, improves accuracy of detection.Also, the detecting system can be electrolysed
It is detected at any time in aluminium production process, and staff is it is not necessary that aside, therefore, which can realize online inspection at any time
It surveys, additionally it is possible to avoid production pollution damage caused by health.
Further, the detection subsystem realizes the detection of the detection and pawl head offset of pawl head actual diameter value.
Further, pawl head includes deformation quantity and pawl head of the pawl head in pawl head orientation along the offset of pawl head radial direction
Deformation quantity on the direction perpendicular with pawl head orientation, the detection subsystem include first detection module and the second inspection
Survey module, the first detection module realize the pawl head actual diameter value detection and the pawl head in pawl head orientation
Deformation quantity detection, second detection module realizes shape of the pawl head on the direction perpendicular with pawl head orientation
The detection of variable.
Further, set pawl head number as N, the first detection module includes N number of distance measuring unit, each distance measuring unit with
Each pawl head corresponds, and distance measuring unit includes 2 distance measuring sensors, and i-th of pawl head corresponds to 2i-1 distance measuring sensor and the
2i distance measuring sensor, 2 distance measuring sensors of each distance measuring unit are used to be arranged in the both sides of corresponding pawl head, and each distance measuring unit
2 distance measuring sensors arranged in pawl head orientation, the actual diameter value φ of i-th of pawl headiCalculation formula be:
φi=Li-T2i-1-T2i
Wherein, LiFor the distance values between 2 distance measuring sensors of i-th of distance measuring unit, T2iIt is sensed for the 2i ranging
Device is at a distance from i-th of pawl head, T2i-1It is the 2i-1 distance measuring sensor at a distance from i-th of pawl head;
Offset Δ T of i-th of pawl head along pawl head orientationiCalculation formula be:
ΔTi=| T2i-T2i-1|
The corresponding maximum allowable offset threshold value Δ T of i-th of pawl headmaxiCalculation formula be:
Wherein, DiFor the corresponding carbon nest diameter of i-th of pawl head.
Further, second detection module includes two groups of correlation optoelectronic switches, first group of correlation optoelectronic switch
In light and second group of correlation optoelectronic switch in light ray parallel, the light edge in first group of correlation optoelectronic switch
Pawl head orientation extension, the light in first group of correlation optoelectronic switch and second group of correlation optoelectronic switch
In light between form a detection zone, each pawl head is sequentially arranged in the detection zone, when have pawl head with pawl head
When the offset in the perpendicular direction of orientation is more than corresponding maximum allowable offset threshold value, pawl head will exceed the inspection
Region is surveyed, has the light at least one set of correlation optoelectronic switch that will be blocked, by detecting whether light is blocked judgement
Whether there is offset of the pawl head on the direction perpendicular with pawl head orientation excessive.
Further, in the light in first group of correlation optoelectronic switch and second group of correlation optoelectronic switch
The distance between light be carbon nest diameter.
Further, distance measuring sensor is diffusing reflection laser range finder.
Specific implementation mode
List anode rod pawl head (i.e. single anode guide rod steel claw) deformation on-line detecting system provided in this embodiment includes two
It is most of, it is detection subsystem and data process subsystem, detection subsystem output connection data process subsystem, detection respectively
Subsystem is used to detect the related data information of single anode rod pawl head, the data that data process subsystem is used to obtain detection
Analyzing processing is carried out, to be detected to the deformation of single anode rod pawl head.Data process subsystem is data processing equipment, this
Embodiment provides a kind of realization method, and data process subsystem is made of PLC and host computer.
Single anode rod pawl head is there are two types of the detection of deformation, and one is the detection of pawl head actual diameter value, another kind is pawl
The detection (i.e. offset of the pawl head along pawl head radial direction) of head offset, therefore, by carrying out one of which detection process
The detection that single anode rod pawl capitiform becomes is realized, certainly, in order to realize the complete detection of single anode rod pawl head, the present embodiment
In, detection subsystem carries out the detection of the detection and pawl head offset of pawl head actual diameter value.
Detection subsystem detects the actual diameter value of each pawl head, and the data that detection obtains are exported and give data processing subsystem
System, data process subsystem compare actual diameter value and carbon nest diameter, when there is actual diameter value to be more than carbon nest diameter, judgement pair
The pawl head deformation answered, indicates that pawl head can not be placed in carbon block carbon nest, that is to say, that as long as detection has at least one pawl head to become
Shape can not be placed in carbon block carbon nest, mean that the list anode rod pawl head can not normal use again, need to be sent to maintenance area dimension
It repaiies.Detection subsystem detects offset of each pawl head along pawl head radial direction, and the data detected are exported and give data processing subsystem
System, data process subsystem compares offset and corresponding maximum allowable offset threshold value, when the amount of offsetting more than it is corresponding most
When big allowable offset threshold value, judgement has the offset of pawl head excessive, and being determined with pawl head can not be placed in carbon block carbon nest, that is,
It says, as long as detection has the offset of at least one pawl head to be more than corresponding maximum allowable offset threshold value, which can not set
Enter in carbon block carbon nest, mean that the list anode rod pawl head can not normal use again, need to be sent to maintenance area repair.I.e. by pair
The theoretical value of carbon block carbon nest and the maximum offset of permission carry out comparison and may determine that can pawl head be molded with carbon block.
The shape changing detection mode of single anode rod pawl head (i.e. single anode guide rod steel claw) is not unique, that is, detects subsystem
Specific implementation is not unique, can be detected using ultrasonic range finder, can also in the way of image procossing into
Row detection.But ultrasonic wave is larger by surrounding environment influence, general measure distance is shorter, and measurement accuracy is relatively low;At image
The cost of reason is higher, have it is more expensive compared with the usual price of the photographic device of high-protection level, and image procossing need more
Complicated hardware system and Processing Algorithm.Therefore, the present embodiment provides a kind of following specific detection mode.
As shown in Figure 1, each pawl head is arranged along pawl head orientation, then, for any one pawl head, the pawl head is along pawl
The radial offset of head includes two kinds, be deformation quantity (i.e. offset) of the pawl head in pawl head orientation and pawl head respectively with
Deformation quantity on the perpendicular direction of pawl head orientation.Correspondingly, detection subsystem includes two detection modules, is the respectively
One detection module and the second detection module, first detection module realize that the detection of pawl head actual diameter value and pawl head are arranged in pawl head
The detection of deformation quantity on direction, the second detection module realize deformation of the pawl head on the direction perpendicular with pawl head orientation
The detection of amount.
The pawl head number of single anode guide rod steel claw is set as N, then, first detection module includes just N number of distance measuring unit, i.e.,
Pawl head number is identical as the number of distance measuring unit, and each distance measuring unit is corresponded with each pawl head.For any one ranging
Unit, the distance measuring unit include 2 distance measuring sensors.So, if put in order there are one each pawl heads, each ranging list
Also there are one putting in order accordingly, corresponding two distance measuring sensors of each pawl head also have to put in order member accordingly.Specially:
1st pawl head corresponds to the 1st distance measuring sensor and the 2nd distance measuring sensor, the 2nd pawl head correspond to the 3rd distance measuring sensor and
4th distance measuring sensor, the 3rd pawl head correspond to the 5th distance measuring sensor and the 6th distance measuring sensor ... ..., i-th of pawl head
Corresponding 2i-1 distance measuring sensor and the 2i distance measuring sensor, wherein i=1,2 ... ..., N.For any one ranging
2 distance measuring sensors of unit, the distance measuring unit are arranged in the both sides of corresponding pawl head, and 2 surveys in all distance measuring units
It is arranged in pawl head orientation away from sensor, that is to say, that distance measuring sensor is arranged between pawl head both sides and pawl head, often
A distance measuring sensor for emitting light beam to different directions is respectively placed in a pawl head both sides, then, the arrangement side of each distance measuring sensor
Formula is with regard to as shown in Figure 2.In the present embodiment, distance measuring sensor is diffusing reflection laser range finder.
In addition, usually, pawl head is 360 ° omni-directional along the offset of pawl head radial direction, therefore, in addition to above-mentioned two side
To deformation except, other directions can be accomplished in the following manner it may also happen that the case where to other Direction distortions in pawl head
Deformation detection:Distance measuring unit includes more than two distance measuring sensor, these distance measuring sensors are circumferentially distributed along corresponding pawl head,
It is detected according to the testing principle of above-mentioned 2 distance measuring sensors, in this case, so that it may be occurred in all directions with detecting pawl head
The case where deformation, moreover, the number of distance measuring sensor is more, detection is more accurate.But due to the work of single anode guide rod steel claw
Property, the possibility occurred to the case where other Direction distortions is relatively low, and the present embodiment does not just consider further that these deformations.
Fig. 3 is the corresponding each detection data of each distance measuring sensor in Fig. 2, then, L1For 2 surveys of the 1st distance measuring unit
Away from the distance values between sensor, i.e. distance values between the 1st distance measuring sensor and the 2nd distance measuring sensor;L2It is the 3rd
Distance values between distance measuring sensor and the 4th distance measuring sensor;……;LiFor 2 distance measuring sensors of i-th of distance measuring unit
Between distance values, i.e. the distance values between 2i-1 distance measuring sensor and the 2i distance measuring sensor.T1For the 1st ranging
Sensor is at a distance from the 1st pawl head, T2It is the 2nd distance measuring sensor at a distance from the 1st pawl head;T3It is sensed for the 3rd ranging
Device is at a distance from the 2nd pawl head, T4It is the 4th distance measuring sensor at a distance from the 2nd pawl head;……;T2i-1It is surveyed for the 2i-1
Away from sensor at a distance from i-th of pawl head, T2iIt is the 2i distance measuring sensor at a distance from i-th of pawl head.D1For the 1st pawl head
Corresponding carbon nest diameter, D2For the corresponding carbon nest diameter ... ... of the 2nd pawl head, Di-1It is straight for the corresponding carbon nest of (i-1)-th pawl head
Diameter, DiFor the corresponding carbon nest diameter of i-th of pawl head (in general, each carbon nest diameter value is equal).φ1For the 1st pawl detected
The actual diameter value of head, φ2For the actual diameter value ... ... of the 2nd pawl head detected, φi-1For (i-1)-th detected
The actual diameter value of pawl head, φiFor the actual diameter value of i-th of the pawl head detected.
Wherein, Li、T2i-1、T2iFor the known quantity detected by distance measuring sensor, specially known analog amount signal, Di
For given value.
Each distance measuring sensor exports the data-signal detected in corresponding acquisition module in PLC13, by upper
Machine 14 writes software to handle measurement data.
Following calculating process and deterministic process are the processing procedures corresponding to the software program that host computer is write.
The actual diameter value φ of i-th of pawl headiCalculation formula be:
φi=Li-T2i-1-T2i
The pawl head diameter phi that will be measurediWith corresponding carbon nest diameter DiIt is compared, when the pawl head diameter phi measuredi> pairs
The carbon nest diameter D answerediWhen, showing that pawl head deforms, pawl head becomes also bigger than carbon nest diameter, then, which can not just be placed in pair
In the carbon block carbon nest answered, steel pawl cannot normal use, need to be sent to maintenance area repair.
Offset deformation of the pawl head in pawl head orientation, that is, the offset that curves inwardly, which will also result in pawl head, can not be placed in carbon block
In carbon nest.As soon as if by arrangement of all pawl heads in pawl head orientation as an integrated model, pawl head orientation
It is the axial direction of the integrated model.So, offset deformation of the pawl head in pawl head orientation can be understood as pawl head at this
Offset deformation in the axial direction of integrated model.
Offset Δ T of i-th of pawl head along pawl head orientationiCalculation formula be:
ΔTi=| T2i-T2i-1|
The corresponding maximum allowable offset threshold value Δ T of i-th of pawl headmaxi, i.e. i-th of pawl head can be placed in corresponding carbon block carbon
The calculation formula of maximum offset corresponding to nest is:
WhenWhen, indicate that i-th of pawl head cannot be placed in corresponding carbon block carbon nest, molding cannot
Success, steel pawl cannot normal use, need to be sent to maintenance area repair.
Second detection module includes two groups of correlation optoelectronic switches, and first group of correlation optoelectronic switch includes 9 He of transmitter
Receiver 10, second group of correlation optoelectronic switch include transmitter 11 and receiver 12.As shown in figure 4, transmitter (9,11) and
Two groups of correlation optoelectronic switches that receiver (10,12) is constituted are arranged in single anode guide rod steel claw both sides, the detection light beam sent out
It is parallel with multiple pawl heads, that is to say, that the light and second in first group of correlation optoelectronic switch between transmitter and receiver
The light ray parallel of group correlation optoelectronic switch, the direction of straight line is identical as pawl head orientation where light, also, the two light
Line extends each along pawl head orientation, a detection zone is formed between the two light, each pawl head is in the detection zone
It is sequentially arranged, then, it is corresponding maximum allowable when there is offset of the pawl head in the direction perpendicular with pawl head orientation to be more than
When offset threshold value, pawl head will exceed detection zone, have the light at least one set of correlation optoelectronic switch that will be blocked,
So, by detecting whether light is blocked the offset for judging whether there is pawl head on the direction perpendicular with pawl head orientation
It measures excessive.Further, due under normal conditions, the corresponding carbon nest diameter of each pawl head is equal, then, set first group of correlation
The distance between light in light and second group of correlation optoelectronic switch in optoelectronic switch is carbon nest diameter, it is also possible that
It says, the distance between this two groups of correlation optoelectronic switches are set as carbon nest diameter.Each pawl head is in first group of correlation optoelectronic switch
In light and second group of correlation optoelectronic switch in light between the space that is formed when setting gradually, between the two light
There are a center line, the center line and the two light ray parallels, and equal at a distance from the two light, the center edge of each pawl head
The center line to be sequentially arranged, then, for each pawl head when not shifting on the direction perpendicular with pawl head orientation, this two
Light in group correlation optoelectronic switch cannot be blocked, when having at least one pawl head perpendicular with pawl head orientation
When offset on direction is more than maximum allowable offset threshold value, pawl head will exceed carbon nest, i.e., will exceed detection zone, just
The light having at least one set of correlation optoelectronic switch is blocked, then, by detecting whether light is blocked and can sentence
Break and whether to have offset of the pawl head on the direction perpendicular with pawl head orientation excessive, offset is excessive just can not be with charcoal
Block is molded.Therefore, the signal of correlation optoelectronic switch output is I/O signals.
In foregoing description, the position relationship between detecting system and single anode guide rod steel claw determines the middle each group of detecting system
At the arrangement of part.
It is illustrated by taking single anode rod of four paws head as an example below.
Guide rod is made of aluminium bar and 4 pawl heads, then, N=4.It is 200mm to define four carbon nest diameters, i.e. Di(i=
1,2,3,4)=200mm, constant spacing value are 380mm, i.e. Li(i=1,2,3,4)=380mm.So:
1) assume to measure the 1st pawl head:T1=100, T2When=95, then pawl head diameter calculation obtains φ1=L1-T1-T2=
185mm.Understand φ1< D1, and so on, detect remaining three pawl heads.Work as φ1< D1, φ2< D2, φ3< D3, φ4< D4Together
When enter when meeting and 2) detect, otherwise show that deformation is serious, molding cannot succeed, and need to be sent to maintenance area repair.
2) to the 1st pawl head, the offset by pawl head along pawl head orientation is | T2i-T2i-1|, can be calculated | T2-T1|
=100-95=5mm, the maximum offset in an axial direction that can be successfully molded by pawl head areKnown toKnown toAnd so on, detect remaining three pawl heads.
When Simultaneously
When meeting, into 3) detecting, on the contrary to show that deformation is serious, molding cannot succeed, and need to be sent to maintenance area repair.
3) two groups of correlation optoelectronic switches are arranged in single anode rod pawl head both sides, the detection light beam sent out and multiple pawl heads
It is parallel.The distance between two groups of optoelectronic switches are set as the diameter 200mm of pawl head carbon nest.Multiple pawl heads are measured to arrange with pawl head
Whether the offset on the perpendicular direction in direction exceeds detection zone, can not be closed with carbon block if beyond detection zone
Mould.
4) condition meet simultaneously 1), 2), 3) when, then it represents that pawl head meets the requirements, and can mold success, carries out next step work
Sequence.
Therefore, 1, using laser range finder, optoelectronic switch, PLC and upper structure at detecting system have and preferably prolong
Malleability can configure into line sensor according to the quantity of single anode steel claw, have simple in structure, the convenient advantage of system building;2、
According to sensor detection data, equation φ is utilizedi> Di、And optoelectronic switch limit, it can determine whether out
Whether single anode steel claw, which can be placed in carbon block carbon nest, is completed molding work, and the computational methods are simple, and execution efficiency is high, by following
Ring judges, can quickly be detected, and can calculate which pawl head in single anode steel claw has deformation, facilitates amendment;
3, the advantages that system has simple in structure, is easily assembled to, and detection result is good, has liberated manpower, has greatly improved accuracy of detection
And detection efficiency.
Specific embodiment is presented above, but the present invention is not limited to described embodiment.The base of the present invention
This thinking is the specific detection mode of said detecting system, and do not lie in detection specific implementation means, that is, detect subsystem
The specific equipment composition of system.Without departing from the principles and spirit of the present invention to embodiment carry out variation, modification,
It replaces and modification is still fallen in protection scope of the present invention.