Disclosure of Invention
The invention solves the technical problem of overcoming the defects of the prior art and provides an intelligent control system for aluminum electrolysis pole-changing operation, which is comprehensive in automation, informatization and high in efficiency.
The purpose of the invention is realized by the following technical scheme:
an intelligent control system for aluminum electrolysis pole-changing operation comprises an application layer, an intermediate layer and an execution layer which are sequentially in signal connection, wherein the application layer is used for receiving control parameters input by a user and downloading the control parameters to the intermediate layer, the intermediate layer issues the control parameters received from the application layer to the execution layer and uploads data collected by the execution layer to the application layer, the intermediate layer is a communication scheduling system, the intermediate layer generates an optimal strategy of pole-changing operation flow through information interaction of the application layer and the execution layer, and the execution layer controls pole-changing operation according to the optimal strategy issued by the intermediate layer;
the execution layer comprises a machine set module and a vision measurement module which are in signal connection with each other, the vision measurement module is used for scanning and photographing the anode to be replaced and feeding the scanning result back to the machine set module, and the machine set module adjusts the position, the lifting height and the rotation angle of the cart trolley according to the scanning feedback result of the vision measurement module to complete the pole changing operation.
Further, the application layer has two port input and output modes of a client and an APP.
Further, the application layer adopts a four-layer framework of a springboot frame, and comprises a web layer, a service layer, a Dao layer and a data storage layer, and the data storage layer uses a MySql database.
Furthermore, the application layer comprises a display module and a transmission terminal module which are in signal connection, the display module comprises a home page display module and a big data display module, the home page display module is used for displaying the current working process, and the big data display module is used for acquiring the position index information of the crown block, determining the state of the crown block, monitoring the lifting position information of the big trolley and the change of the current process in real time; the transmission terminal module is used for storing and interacting the operation flow data.
And furthermore, the home page display module stores the specified coordinate point information according to an instruction input by an operator, and updates the specified coordinate data stored by the acquisition and transmission terminal module so as to control and monitor the pole changing operation flow.
And further, the big data display module forms a 3D animation effect according to the current motion track of the crown block and the current situation point position value of the crown block.
Still further, big data display module still can carry out whole storage through gathering the overhead traveling crane index data, through big data analysis, realizes intelligent control system's operation and maintenance management.
Furthermore, the application layer further comprises a service monitoring module, wherein the service monitoring module comprises a camera and carries out safety monitoring on the process service operated by the crown block through the camera.
And the service monitoring module is in signal connection with the safety management module, and transmits the video signals acquired by the camera to a central control room of the intelligent control system through the Ethernet, so that video display is carried out in the central control room.
Further, the vision measuring module comprises a vision scanning device, and the vision scanning device is used for determining the actual position and the offset angle of the clamping hole of the anode guide rod.
Compared with the prior art, the invention has the following beneficial effects:
according to the method and the device, the pole changing target is rapidly determined through mutual information interaction of the application layer, the middle layer and the execution layer, an optimal pole changing strategy is generated by combining with actual conditions of a production library area, and pole changing operation is automatically completed. Only manual parameter input or monitoring and the like are needed in the pole changing overall process, the operation is simple, the pole changing operation efficiency is high, the manual labor intensity is reduced, the safety of production operation is improved, the production cost of enterprises is reduced, and the pole changing process is controlled accurately.
Detailed Description
The present invention will be further described with reference to the following detailed description, wherein the drawings are provided for illustrative purposes only and are not intended to be limiting; to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
Example 1
An intelligent control system for aluminum electrolysis pole-changing operation comprises an application layer, a middle layer and an execution layer which are sequentially in signal connection, wherein the application layer is used for receiving control parameters input by a user and downloading the control parameters to the middle layer, the application layer specifically adopts a four-layer framework of a springboot frame and comprises a presentation layer (web layer), a service logic layer (service layer), a data access layer (Dao layer) and a data storage layer, the data storage layer uses a MySql database, the web layer is responsible for front-end display and processing of user requests, the service layer realizes core service logic and transaction control, the Dao layer is mainly responsible for database access to complete a persistence function, and the data storage layer mainly stores service resources and data; the intermediate layer is mainly used for communication between the application layer and the execution layer, control parameters received from the application layer are issued to the execution layer, data collected by the execution layer are uploaded to the application layer, the intermediate layer is specifically a communication scheduling system, communication is established through TCP, HTTP and OPC, pole-changing operation flow optimal strategies are generated through data information interaction of the application layer and the execution layer, and the execution layer controls pole-changing operation according to the optimal strategies issued by the intermediate layer.
The execution layer comprises a unit module and a vision measurement module which are in signal connection with each other, the vision measurement module is used for scanning and photographing the anode to be replaced and feeding a scanning result back to the unit module, and accurate position information is provided for the unit module when the unit module finishes a pole changing operation procedure. The vision measuring module comprises a vision scanning device, the vision scanning device mainly scans and determines the actual position and the offset angle of the clamping hole of the anode guide rod, and the unit module adjusts the position, the lifting height and the rotation angle of the cart trolley according to the scanning feedback result of the vision measuring module to complete the pole changing operation.
For the staff controls and monitors intelligent control system immediately, the application layer has two kinds of port input/output modes of customer end and APP end, and the customer end is applicable to PC computer and PAD panel computer, and the APP end is applicable to the smart mobile phone.
The application layer comprises a display module and a transmission terminal module which are in signal connection, the display module comprises a home page display module and a big data display module, the home page display module is used for displaying the current work flow, an operator can realize management control on the current flow, an operator inputs an instruction, appointed coordinate point position information is stored, and appointed coordinate data stored by the transmission terminal module is updated and collected so as to control and monitor the pole changing work flow. The big data display module is used for acquiring the point position index information of the crown block in real time, determining the state of the crown block, monitoring the lifting position information of the big trolley and the current flow change, and specifically, a 3D animation effect can be formed according to the current motion track of the crown block and the point position value of the crown block under the current condition; the transmission terminal module is used for storing and interacting operation flow data and is divided into two parts: firstly, data related to a control system adopts an OPC-DA communication protocol, and an OPC server is used for processing data, such as: KEPSERVER, establishing communication with the unit module PLC, communicating with the PLC in real time, interacting data related to the operation flow, and controlling and monitoring the operation flow in the local area network; and secondly, configuring data related to equipment and process states into an internet of things gateway in advance through edge equipment such as the internet of things gateway, configuring a physical address of data needing to be acquired on the PLC into the internet of things gateway, and sending the data to a remote cloud server by the internet of things gateway through a 4G network by adopting an MQTT protocol, so that the running condition of an operation site can be remotely monitored, and the data required by 3D animation display comes from the internet of things gateway.
Big data display module still can carry out whole storage through gathering overhead traveling crane index data, through big data analysis, arranges some common problems that equipment appears, realizes equipment (being overhead traveling crane) predictive maintenance function under big data analysis, provides corresponding intelligent solution for faulty equipment, realizes intelligent control system's operation and maintenance management, greatly reduce cost, raises the efficiency.
The application layer also comprises a service monitoring module and a safety management module, wherein the service monitoring module comprises a camera and carries out safety monitoring on the whole process of the process service such as pole changing of the overhead traveling crane running through the camera, the equipment is ensured to efficiently execute the process task on the premise of safety, the service monitoring module sends a video signal acquired by the camera to a central control room of the intelligent control system through Ethernet, video display is carried out in the central control room, the service monitoring module is in signal connection with the safety management module, the safety management module comprises the camera and/or a laser scanning sensor and the like, the camera or the laser scanning sensor is mainly used for detecting the state of a working area, monitoring the working state of the equipment, whether the working area has mistaken intrusion of irrelevant personnel or not and the like, and the data of the service monitoring module is combined, if a scene of safety standard, operation or equipment working fault occurs, the safety management module records corresponding logs in time and sends out safety alarm or emergency stop according to the safety level.
The intermediate layer issues the pole-changing operation flow optimal strategy to the execution layer, and the unit module executes the strategy after receiving the strategy on the premise of ensuring the safety, wherein the pole-changing strategy specifically comprises the following steps: the communication dispatching system determines a pole-changing target according to a first-in first-out principle (the first-in first-out takes the actual working time as a standard), determines a coordinate point and sends the coordinate point to the middle layer, and after the middle layer receives a target point, the middle layer combines the actual reservoir area condition (avoids obstacles in a path matrix) to make action strategies for the big car and the small car and the hoisting mechanism, such as executing the big car, hoisting linkage operation or serial operation. And when the equipment reaches the designated position, starting the visual scanning equipment, scanning and photographing the anode to be replaced, determining the actual position and the offset angle of the clamping hole of the anode guide rod to be replaced, and finely adjusting the position of the big and small vehicle, the lifting height and the angle of the slewing mechanism according to the visual scanning feedback result to ensure that the anode clamp can accurately clamp the clamping hole of the anode guide rod.
Fig. 2 shows a schematic hardware layout of the intelligent control system, in the figure, an industrial control machine and a server are application layers, a switch is a middle layer, a vision measurement module and an aluminum electrolysis multifunctional unit (PLC) are execution layers, and the switch realizes information interaction between an operation area and an office area through wireless communication.
The pole changing operation procedures required by the unit module mainly comprise: the method comprises the following steps of cart walking, trolley walking, tool rotation, crust breaking, residual anode twisting, height measurement, residual anode placing, slag salvaging, slag unloading, new anode grabbing and new anode loading. The following describes the control process of the intelligent control system to the whole flow of the primary pole changing operation, as follows:
the method comprises the steps of beginning pole changing → determining a working mode of a crown block → determining and executing a position of a large car → determining and executing a position of a trolley → determining and executing a position of a rotary tool → withdrawing a single-point crust breaking end tilt cylinder → determining and executing a position of a rotary tool → descending a cylinder → descending a visual descending → a trolley, turning a tool in place → ascending a visual ascending → stretching a crust breaking tilt cylinder → judging a pressure of a crust breaking tilt cylinder in place → executing a single-point crust breaking → retracting a tool → determining and executing a position of a tool → descending a clamp cylinder → descending a visual descending → a trolley, turning a tool in place → retracting a visual descending → opening a clamp, descending a clamp cylinder → descending a head cylinder → descending a torsion executing x seconds → retracting a head cylinder → automatically lifting → moving a large car → moving a trolley to an aluminum end → measuring a residual pole height → a large car, turning a tool in place → descending a clamp cylinder → opening a clamp → ascending a clamp cylinder, retracting the clamp to close → turning tool position → cylinder lowering preset height → grab bucket opening → cylinder lowering → horizontal grabbing → cylinder raising preset position → cylinder raising → cart movement to aluminum out end → cart turning adjustment (to slag box) → grab bucket retracting, closing → turning tool position → clamp cylinder fast lowering → visual lowering → clamp retracting → clamp opening → cylinder slow lowering → clamp closing → cylinder raising → new anode height measurement → cart, the method comprises the steps of turning a tool in place → descending a preset height of a clamp oil cylinder → descending a preset height of a visual component → an installation path → an automatic hanging machine → descending of a clamp oil cylinder (h1) → segmental descending of a screw head oil cylinder (h2) → torque execution → retracting of the screw head oil cylinder → opening of a clamp → retracting of a clamp lifting oil cylinder, closing of a clamp → turning of a material nozzle → moving of a big car in place → descending of the material nozzle at a preset position → opening of the material nozzle for x seconds → lifting of the material nozzle for completing pole changing. In the section, "x", "h 1" and "h 2" in "twisting execution for x seconds", "lowering of clamp cylinder (h 1)" "lowering of screw head cylinder in stages (h 2)" refer to a certain numerical value, and do not form the structural relationship of the control system of the application.
It should be understood that the above examples are only for clearly illustrating the technical solutions of the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.