CN112269360A - Intelligent data analysis system based on alumina production - Google Patents
Intelligent data analysis system based on alumina production Download PDFInfo
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- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G05B19/4188—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by CIM planning or realisation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention discloses an intelligent data analysis system based on alumina production, which comprises an application system integration platform used in the alumina production process; the assay analysis system is used for counting, summarizing and contrastively analyzing various assay index parameters in the production link in the production process of the alumina; the metering management system is used for carrying out the processes of raw material purchase, finished product sale, material transfer and material allocation in a factory in the production process of the alumina; a quality inspection and management system for quality inspection and cheat prevention of raw materials entering a factory in the alumina production process; the production statistical system is used for collecting production operation results in time and carrying out clear-class statistical analysis on yield, consumption of various raw materials, quality indexes and technical indexes in the production process of the aluminum oxide. The invention improves the effective management of the raw materials in the production process of the aluminum oxide, fully-automatically shields the quality inspection process of the raw materials and improves the safety efficiency.
Description
Technical Field
The invention relates to the technical field of an alumina production management and control integrated system, in particular to an alumina production-based intelligent data analysis system.
Background
The process flow in the production process of the aluminum oxide is multiple and complex, the difficulty of statistics, management and prejudgment of data in the production process is too large, the effective management of the variety of raw materials entering a factory and the quantity of suppliers is great, and the more effective, accurate and confidential quality inspection of the raw materials entering the factory becomes a concern. The variety of the test samples is multiple, the number of the test indexes is large, the test tasks are effectively distributed, the work is more convenient, and the data is more accurate. The key point of alumina production is how to make production scheduling personnel analyze production data and production execution conditions more comprehensively, timely and accurately. Therefore, the technical process, the production process data and the production process execution condition are analyzed to establish a normative, real-time and intelligent alumina production management control model, an alumina production intelligent data analysis system is formed, and the method has important significance for improving the alumina production.
Disclosure of Invention
The invention aims to make up the defects of real-time performance, accuracy, convenience and complex analysis of data statistics in the production of aluminum oxide, and provides an intelligent data analysis system based on the production of aluminum oxide. Data are grabbed in the production process of the aluminum oxide, and the data are accurately analyzed and counted, so that the production of the aluminum oxide is integrated with data management and control, and the production and the data management and control are in a controllable range.
The technical scheme of the invention is as follows:
an intelligent data analysis system based on alumina production, comprising: the system integration platform is applied to the production process of the aluminum oxide; the assay analysis system is used for counting, summarizing and contrastively analyzing various assay index parameters in the production link in the production process of the alumina; the metering management system is used for carrying out the processes of raw material purchase, finished product sale, material transfer and material allocation in a factory in the production process of the alumina; a quality inspection and management system for quality inspection and cheat prevention of raw materials entering a factory in the alumina production process; the production statistical system is used for collecting production operation results in time and carrying out clear-class statistical analysis on yield, consumption of various raw materials, quality indexes and technical indexes in the production process of the aluminum oxide.
Compared with the prior art, the invention improves the effective management of the raw materials in the production process of the alumina, fully-automatically shields the quality inspection process of the raw materials, improves the safety efficiency, integrally controls the test indexes, and is beneficial to more efficient, accurate and convenient production scheduling management of production scheduling personnel.
Drawings
FIG. 1 shows the form of data transmission among the MES system network, the network interface machine, and the control system.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below.
The invention relates to an alumina production process and data management control system, which comprises: the system comprises an assay analysis system, a metering management system, a quality inspection and management system and a production statistical system. The following are detailed below:
an application system integration platform: the application system integration platform is responsible for collecting data, parameters, running states and running time of real-time running of the production engineering equipment. Such as the running time of raw material grinding in an alumina raw material workshop, ore discharge amount, the running state of a reclaimer 1#2#, the feeding amount of a digestion unit 1-4 group, starting gas, pre-desiliconization gas and the crude liquid level of refined liquid, the salt supply temperature, the salt return temperature and the salt tank temperature of a molten salt workshop, the liquid level of an AH slurry tank in a roasting workshop, AO bin positions and the like, raw material purchasing, finished product selling, material transportation in a factory, material allocation, direct-reading electronic balance of an assay center, a turbidity analyzer, a saturated magnetic analyzer, an automatic potentiometric titrator, conductivity meter and other confidential assay data provide data support for an assay analysis system, a metering management system, a quality inspection and management system and a production statistical system. The assay analysis system is responsible for accurately analyzing and counting all sample assay indexes in the alumina generation process; the metering management system is responsible for automatically acquiring weight-checking data, realizing query, statistics, summarization of the weight-checking metering data, compiling a metering report, realizing data sharing, solving the problems of authenticity, accuracy and instantaneity of the metering data and providing accurate basic data for other systems; the quality inspection and management system is responsible for integrating measurement and weighing system data and laboratory data, establishing a quality inspection system, sampling and grading inspection data of raw materials, finished products and the like, generating a quality inspection report sheet, and providing the quality inspection report after an auditor successfully audits the system to a marketing purchasing department, a scheduling and production operation post in time to serve as a basis for quality management and control; the production statistical system collects production operation results in time, compiles a production report and a comprehensive statistical report, provides a basis for enterprise operation, production decision and production scheduling, and enables enterprise decision makers to accurately master the production conditions of enterprises.
The application system integration platform network is connected with each control system through a network interface machine with protocol conversion and safety isolation, automatically collects production control process data information, acquires production process control and production management data in real time, and automatically stores the data in a real-time database and a relational database under the support of an interface protocol conversion program, a communication driving program, a data processing program and the like, so that accurate data resources are provided for real-time monitoring of the production process, production management application and optimized organization production.
The technical scheme of the I/O interface of the control system is as follows: the DCS and the PLC system of each control system support an OPC standard communication protocol (if the communication protocol is a non-OPC communication protocol, a buyer unit is required to coordinate a supply unit to provide the communication protocol and convert the communication protocol into the OPC communication protocol), and the data transmission form among the MES system network, the network interface machine and the control system is simply represented by the figure 1. And the OPCClient in the interface machine acquires real-time data from the OPCServer of the DCS or the PLC system and directly sends the real-time data to the real-time database.
An assay analysis system: the system comprises an input index module, an output index module, a sample management module, an assay data entry module, a report maintenance module and a curve analysis module. The module automatically generates a test report sheet for the sampling information according to the test items and test indexes customized by the production requirement, and automatically calculates the test data corresponding to the test object for the input and collected test results (directly connected with a test instrument interface). The automatic calculation function provided by the assay analysis system is used for improving the efficiency and accuracy of assay work, providing various inquiry and analysis functions and printing and outputting functions, operators and leaders at all posts can know the latest assay data at any time through corresponding authorities, and other systems can call the assay data to guide the production process. The test report can be flexibly used by various types of inquiry, such as inquiry according to sampling points, inquiry according to sampling time, inquiry according to groups, inquiry according to dates, inquiry according to weekly reports and monthly reports, and the like
Specifically, the method comprises the following steps: automatically collecting the automatically collected test data by a data collection program, and inputting part of the test data needing to be manually input into the system by filling in a test data input form; the system manager defines input indexes, output indexes and an analysis and calculation formula according to the enterprise standard, and the system operates according to the analysis and calculation formula defined by the buyer. The assay report forms are divided into a class report, a ten-day report, a month report, a year report and the like according to time periods; and dividing the report into a report form of each use department and a comprehensive statistical report form of a laboratory according to the use object. Analysis statistics of assay results: providing multiple analyses for assay quality, granularity can be sunk to the daily assay quality of a single assay technician, and providing highly customized analytical functionality
Measurement management system: the method comprises comprehensive query and data information tracing management, weighing measurement data gathering and statistics management and weighing single information management, and a statistical form can be generated according to weighing data; weighing and metering data summarizing and statistical management: the system collects and counts the weight measurement data according to class, day, month, year, etc., and respectively collects and counts goods according to goods category, name, unit, etc., and generates related report forms. Comprehensive query and data information tracing management: and carrying out random query display and monitoring management on the basic information, the list, various statistical reports and the like according to the management authority. The weight measurement information at any time (day, month and year) can be traced.
Specifically, the method comprises the following steps: the system is characterized in that an unattended metering equipment integration system is connected with data of all electronic weighing instruments, a C/S acquisition system is connected with weighing equipment, and a company material weighing platform is managed, so that the data acquisition of the weighing metering system covers all finished products; the method mainly aims at the metering management in the processes of raw material purchase, finished product sale, material transportation in a factory and material allocation, realizes the inquiry, statistics and summarization of weight checking metering data and the establishment of a metering report form by automatically acquiring weight checking data, realizes data sharing, solves the problems of authenticity, accuracy and real-time performance of the metering data, and provides accurate basic data
Quality inspection and management system: the system comprises a sampling registration module, a moisture detection module, an error data processing mechanism module and an arbitration sample transfer process management module. And (3) carrying out shielding and secret management on the processes of sampling, sample combination, sample preparation, moisture detection, component detection, system judgment and grade judgment, and carrying out sample preparation coding connected with a weighing metering system, wherein a weighing detection number is used as a primary coding of a sample according to the business mode of the original gold smelting company, and different types of samples are distinguished from the coding. The material sample without weighing is processed by manually compiling a primary code. The perfect secondary coding mechanism is as follows: after the sample preparation is generated, the secondary code is automatically generated, and the information of materials and suppliers cannot be leaked by the secondary code. A well-established sample distribution mechanism: the sample can be distributed to corresponding testing personnel through the system, so that the samples obtained by each testing personnel are isolated from each other, and multiple tests of the same sample can be distributed to different people for processing.
The system can automatically generate a test report sheet for the sampling information according to test items and test standards customized by production needs, the provided automatic quality judgment function is used for improving the working efficiency and accuracy of quality inspection, the provided multi-class inquiry and analysis functions and the function of printing output are provided, and the operators and leaders at all posts can know the latest quality data at any time through corresponding authorities. The quality report can be flexibly used by various types of queries, such as sampling time query, team query, date query, weekly report and monthly report query
The production statistical system comprises: the system comprises a multi-curve analysis module, a raw material in-plant multi-curve analysis module, a finished product delivery multi-curve analysis module, a production scheduling control module and an analysis comparison generation module. In order to solve various problems of production management of alumina enterprises, isolation of a large amount of data and the like, various models need to be established for process analysis and statistical analysis. A set of decision-making system for production management of alumina enterprises needs to be developed and can be deployed in industrial enterprises, and the system refers to the decision-making of production quality management work of production process organization, production technology preparation, production planning, raw material supply, production control and the like closely related to product production. The method aims to effectively combine various production factors, improve the labor productivity of enterprises and various economic and technical indexes according to an optimal mode, produce products meeting social needs and increase economic benefits.
Example 1:
the application system integration platform is responsible for collecting data, parameters, running states and running time of real-time running of the production engineering equipment. Such as the running time of a raw material mill in an alumina raw material workshop, the ore discharge amount, the running state of a reclaimer 1#2#, the feeding amount of a digestion unit 1-4 group, the starting gas, the pre-desiliconization gas and the crude liquid level of a refined solution, the salt supply temperature, the salt return temperature and the salt tank temperature of a molten salt workshop, the liquid level of an AH slurry tank in a roasting workshop, AO bin positions and the like, raw material purchase, finished product sale and material transportation in a factory, material allocation, a direct-reading electronic balance of an assay center, a turbidity analyzer, a saturated magnetic analyzer, an automatic potentiometric titrator, conductivity meter and other confidential assay data provide data support for an assay analysis system, a metering management system, a quality inspection and management system and a cockpit management system. The assay analysis system is responsible for accurately analyzing and counting all sample assay indexes in the alumina generation process; the metering management system is responsible for automatically acquiring weight-checking data, realizing query, statistics, summarization of the weight-checking metering data, compiling a metering report, realizing data sharing, solving the problems of authenticity, accuracy and instantaneity of the metering data and providing accurate basic data for other systems; the quality inspection and management system is responsible for integrating measurement and weighing system data and laboratory data, establishing a quality inspection system, sampling and grading inspection data of raw materials, finished products and the like, generating a quality inspection report sheet, and providing the quality inspection report after an auditor successfully audits the system to a marketing purchasing department, a scheduling and production operation post in time to serve as a basis for quality management and control; the cockpit management system is responsible for performing abstract analysis on main contents, and data mainly come from a quality inspection system, an assay analysis system and a metering management system; and the related data are subjected to budget estimation, and final data required by the cockpit are obtained through multi-level calculation.
The test analysis system is connected with the direct-reading electronic balance, the turbidity analyzer, the saturation magnetic analyzer, the automatic potentiometric titrator and other test instruments of the quality inspection test center through a computer network to automatically collect test data, establish a quality management system taking a test room and quality inspection as the center, and establish a perfect quality assurance system by adopting scientific laboratory management thought and advanced database technology.
And the intermediate test data after the auditor successfully audits through the system and the quality inspection report automatically generated by the quality inspection system are timely provided for the scheduling and production operation posts.
The system can automatically generate a test report sheet for the sampling information according to the test items and test indexes customized by the production requirement, and automatically calculate the test data corresponding to the test object for the input and collected test results (directly connected with a test instrument interface).
The system manager defines input indexes, output indexes and an analysis and calculation formula according to the enterprise standard, and the system operates according to the analysis and calculation formula defined by the buyer.
The metering management system is connected with data of all electronic weighing machines through an unattended metering equipment integration system, and the C/S acquisition system is connected with the weighing equipment to manage a company material weighing platform, so that the data acquisition of the weighing metering system covers all finished products.
The weight checking data is automatically collected, so that the query, statistics, summarization and establishment of a metering report of the weight checking metering data are realized.
When raw materials of the quality inspection and management system enter a factory and finished products leave the factory, a sampler samples, the sampler inputs sampling information, and sampling coding labels are printed through encryption. The printed information is sent to a central laboratory together with the sample for testing. The test information is recorded into the system by an analyst through test management, the sampling list is automatically associated to obtain a test result, the moisture sample is produced by a sample preparation person in the test list through division, the system is directly connected with a balance scale to automatically collect the weight, the sample is placed on the balance scale (2 electronic balances) to be weighed (the weight of a plate, the wet weight and the dry weight), and the water content of the sample is detected according to the (the wet weight-the dry weight)/(the wet weight-the weight of the plate) 100%. And other data needs to be directly input manually.
When the test data or the check weight data are wrong, a set of manually matched codes are needed to delete and regenerate the mechanism modified data, and the modified data is uploaded, stored and audited to check the paper photo, so that the requirement that the mistake is made can be met, the department can directly solve the problem, and the complex program is avoided.
The goods storehouse manager can rationally arrange the work of putting of storehouse sample according to the two-dimensional code information, makes things convenient for to seek in the future, transfers the sample.
The production statistical system generates scheduling on-duty records of each workshop from the test data, the weight checking data, the production data, the consumption data and the manual scheduling record information in the database, and generates daily reports, monthly reports and annual reports of all levels of production departments according to the on-duty records.
It should be emphasized that the examples described herein are illustrative and not restrictive, and thus the invention is not to be limited to the examples described in this detailed description, but rather to other embodiments that can be derived from the teachings of the invention by those skilled in the art.
Claims (6)
1. An intelligent data analysis system based on alumina production is characterized in that it includes: the system integration platform is applied to the production process of the aluminum oxide; the assay analysis system is used for counting, summarizing and contrastively analyzing various assay index parameters in the production link in the production process of the alumina; the metering management system is used for carrying out the processes of raw material purchase, finished product sale, material transfer and material allocation in a factory in the production process of the alumina; a quality inspection and management system for quality inspection and cheat prevention of raw materials entering a factory in the alumina production process; the production statistical system is used for collecting production operation results in time and carrying out clear-class statistical analysis on yield, consumption of various raw materials, quality indexes and technical indexes in the production process of the aluminum oxide.
2. The intelligent data analysis system based on alumina production according to claim 1, wherein: the system comprises an application system integration platform and a plurality of control systems, wherein the application system integration platform comprises a real-time database and an OPCClient, an application system integration platform network is connected with each control system through a network interface machine with protocol conversion and safety isolation, the data information of a production control process is automatically acquired, the production process control and production management data are acquired in real time, the data are automatically stored in the real-time database and a relational database under the support of an interface protocol conversion program, a communication driving program and a data processing program, and accurate data resources are provided for real-time monitoring of the production process, production management application and optimized organization production.
3. The intelligent data analysis system based on alumina production according to claim 1, wherein: the assay analysis system comprises an assay basic data maintenance module, an assay sample authority distribution module, an assay data entry module, an assay data auditing module and an assay index analysis module.
4. The intelligent data analysis system based on alumina production according to claim 1, wherein: the metering management system comprises a C/S weight checking data acquisition system, comprehensive query and data information tracing management, weight checking metering data summarizing and counting management and weighing list information management.
5. The intelligent data analysis system based on alumina production according to claim 1, wherein: the system for inspecting and managing the quality of raw materials entering a factory in the alumina production process comprises a sampling registration module, a moisture detection module, an error data processing mechanism module and an arbitration sample transfer flow management module.
6. The intelligent data analysis system based on alumina production according to claim 1, wherein: the production statistical system comprises basic data management, production consumption index statistical analysis and dynamic adjustment statistical calculation formulas.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011174496.6A CN112269360A (en) | 2020-10-28 | 2020-10-28 | Intelligent data analysis system based on alumina production |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116433108A (en) * | 2023-06-07 | 2023-07-14 | 张家港广大特材股份有限公司 | Raw material management method and system for smelting special steel |
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