CN115261932A - Early warning method and system for electrolytic cell fault - Google Patents
Early warning method and system for electrolytic cell fault Download PDFInfo
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Abstract
The invention relates to the field of fault detection, in particular to an early warning method for electrolytic bath faults, which comprises the following steps: acquiring detection information of a detection device on the liquid level of electrolyte in an electrolytic cell; analyzing the detection information according to a preset liquid level, verifying the normal information of the electrolytic cell in a first analysis result, and correcting the preset liquid level to obtain a target liquid level when the verification result is wrong; judging the detection information according to the target liquid level; and generating warning information according to the judgment result and carrying out early warning. The normal information of the electrolytic cell in the first analysis result is verified, the preset liquid level is corrected when the verification result is wrong, the detection information is judged according to the corrected target liquid level, the judgment result is more accurate, the early warning of the electrolytic cell is more accurate and timely, the electrolytic cell is prevented from being broken down in time, and the early warning efficiency of the electrolytic cell is improved.
Description
Technical Field
The invention relates to the field of fault detection, in particular to an early warning method and system for electrolytic cell faults.
Background
The electrolytic bath is widely applied to production processes of acid pickling phosphorization, electrolysis, copper plating, nickel plating, zinc plating, palladium plating, gold plating and the like in industries such as metallurgy, electroplating, chemical engineering and the like, the electrolytic bath has higher requirements in the electrolysis process, and if the electrolytic bath fails and is not found in time, the electrolytic bath has great influence on the electrolysis, so that the fault early warning is timely carried out on the electrolytic bath, and the method has great significance.
Patent document with application number 201710706326. X discloses a warning method for electrolytic cell pole plate faults, which comprises the following steps: s1, acquiring an infrared thermal image and position information of a polar plate of an electrolytic cell, and extracting temperature information of a pixel area corresponding to the polar plate; s2, calculating a confidence interval of the temperature of the pole plate according to the temperature information, and confirming that the temperature of the pole plate is in the confidence interval; s3, constructing a gray prediction model for predicting the temperature of the polar plate based on the historical temperature data sequence of the polar plate; and S4, carrying out fuzzy analysis on the temperature variation and the variation rate of the polar plate based on the grey prediction model and by combining the position information, and realizing detection and early warning on faults of the polar plate.
In the prior art, temperature information is acquired through infrared thermal images, fault detection and early warning are carried out on an electrolytic cell pole plate according to the temperature information, but the infrared thermal images are acquired through continuous movement of an infrared camera above the electrolytic cell, and the infrared thermal images are inaccurate due to complex operation of the infrared camera and if problems occur, so that the fault early warning efficiency of the electrolytic cell is not high.
Disclosure of Invention
Therefore, the invention provides an early warning method and system for the fault of an electrolytic cell, which can solve the problem of low early warning efficiency for the fault of the electrolytic cell.
In order to achieve the above objects, one aspect of the present invention provides a method for early warning of a failure of an electrolytic cell, the method comprising:
acquiring detection information of a detection device on the liquid level of electrolyte in an electrolytic cell;
analyzing the detection information according to a preset liquid level, verifying the normal information of the electrolytic cell in a first analysis result, and correcting the preset liquid level to obtain a target liquid level when the verification result is wrong;
judging the detection information according to the target liquid level;
and generating warning information according to the judgment result and carrying out early warning.
Further, when the detection information is analyzed, the detection information comprises liquid levels h of a plurality of electrolytic tanks, the liquid level h of any electrolytic tank is compared with a first preset liquid level h1 and a second preset liquid level h2 to obtain a first analysis result, wherein h1 is more than h2,
if h is more than h1, judging that the electrolytic cell is in fault;
if h2 is not less than h and not more than h1, judging that the electrolytic cell is normal;
if h is more than 0 and less than h2, the fault of the electrolytic cell is judged.
Further, when the first analysis result is that the electrolytic cell is normal, verifying the normal information of the electrolytic cell to obtain a liquid level within a preset time T, establishing a two-dimensional coordinate system, wherein an X axis of the two-dimensional coordinate system is detection time, a Y axis of the two-dimensional coordinate system is liquid level h, drawing a curve according to the liquid levels, calculating a linear slope k of two liquid levels at any time point and a previous adjacent time point according to the curve, when k is less than 0, indicating that the electrolytic cell is in electrolysis, when k is greater than 0, indicating that the electrolytic cell is in electrolyte supplement, comparing the slope k with a first preset slope k1 and a second preset slope k2 to obtain a verification result, wherein the first preset slope k1 is the normal descending rate of the liquid level of the electrolyte in the electrolytic cell, the second preset slope k2 is the normal ascending rate of the liquid level of the electrolyte during the electrolysis and the electrolyte supplement, wherein k1 is less than 0, and k2 is greater than 0,
when k is less than 0, if k = k1, verifying that the first analysis result of the normal electrolytic cell is correct;
if k1 is more than k and less than 0, the liquid level descending rate of the electrolyte is less than the normal descending rate, and the normal first analysis result of the electrolytic cell is verified as an error;
if k is less than k1, indicating that the liquid level descending rate of the electrolyte is greater than the normal descending rate, verifying the normal first analysis result of the electrolytic cell as an error;
when k is larger than 0, if k = k2, verifying that the first analysis result of the normal electrolytic cell is correct;
if k is more than 0 and less than k2, the liquid level rising rate of the electrolyte is smaller than the normal rising rate, and the normal first analysis result of the electrolytic cell is verified as an error;
and if k is larger than k2, the electrolyte liquid level rising rate is larger than the normal rising rate, and the normal first analysis result of the electrolytic cell is verified as an error.
Further, when the verification result is an error, correcting the first preset liquid level H1 and the second preset liquid level H2, when k is less than 0, if k1 is less than k and less than 0, selecting a first preset liquid level H1 according to a first correction coefficient α 1 to obtain a first target liquid level H1, and if k is less than k1, and correcting the second preset liquid level H2 according to a second correction coefficient α 2 to obtain a second target liquid level H2, wherein H1= H1 × α 1, H2= H2 × α 2, H1 is greater than H2, the first correction coefficient α 1= (H1-H)/H, and the second correction coefficient α 2= (H2 + H)/H;
when k is greater than 0, if k is greater than 0 and less than k2, the second preset liquid level H2 is corrected according to a third correction coefficient alpha 3 to obtain a third target liquid level H3, and if k is greater than k2, the first preset liquid level H1 is corrected according to a fourth correction coefficient alpha 4 to obtain a fourth target liquid level H4, wherein H3= H2 × alpha 3, H4= H1 × alpha 4, H3 is less than H4, the third correction coefficient alpha 3= (H-H2)/H, and the fourth correction coefficient = (H1 + H)/H.
And further, judging the detection information according to the target liquid level to obtain a judgment result, wherein the judgment result comprises fault information and fault electrolytic tank position information, generating warning information from the fault information and the fault electrolytic tank position information, and performing early warning on a management end according to the warning information, wherein the early warning is in a voice or text form.
The invention provides an early warning method for failure of an electrolytic cell, which further comprises the following steps: acquiring position information of the plurality of electrolytic cells, and performing region division on the plurality of electrolytic cells according to the position information;
and acquiring warning information, analyzing the warning information, and correcting the detection interval time according to a second analysis result.
Further, when the plurality of electrolytic tanks are divided into areas according to the position information, the electrolytic tanks with the preset number M0 are divided into the same area, the areas are labeled, and the position information of each electrolytic tank in the areas is associated with the area label;
when the warning information is analyzed, acquiring a corresponding area label according to the position information of the fault electrolytic tank in the warning information, acquiring the number M of the fault electrolytic tanks with the same area label, calculating according to the number M and the preset number M0 of the electrolytic tanks in the area to obtain a fault rate P, comparing the fault rate P with a first preset fault rate P1 and a second preset fault rate P2 to acquire a second analysis result,
if P > P1, judging the importance level of the region as I level;
if P2 is not less than P and not more than P1, judging the importance level of the region as level II;
if P is more than 0 and less than P2, judging the importance level of the region as III level;
the failure rate P = M/M0, P1 is larger than P2, and the important level is I level larger than II level larger than III level.
Further, when the detection interval time is corrected according to the second analysis result, when the importance level of the area is I level, the detection interval time t of the electrolytic cell by the detection device in the area is corrected, and the detection interval time is corrected according to a fifth correction coefficient alpha 5 to obtain a detection interval time t ', wherein t' = t multiplied by alpha 5, and 0.8 < alpha 5 < 1;
and when the importance level of the area is level III, correcting the detection interval time t of the detection device in the area to the electrolytic tank, and correcting the detection interval time according to a sixth correction coefficient alpha 6 to obtain a detection interval time t '', wherein t '' = t multiplied by alpha 6,1 < alpha 6 < 1.2.
In another aspect of the invention, there is provided a warning system for failure of an electrolytic cell, the system comprising:
the acquisition module is used for acquiring the detection information of the detection device on the liquid level of the electrolyte in the electrolytic cell;
the first processing module is used for processing the detection information and comprises an analysis unit, a verification unit and a correction unit, wherein the analysis unit is used for analyzing the detection information according to a preset liquid level, the verification unit is used for verifying the normal information of the electrolytic cell in a first analysis result, and the correction unit is used for correcting the preset liquid level to obtain a target liquid level when the verification result is wrong;
the judging module is used for judging the detection information according to the target liquid level;
the early warning module is used for carrying out early warning according to the judgment result and comprises a generating unit and a warning unit, the generating unit is used for generating warning information according to the judgment result, and the warning unit is used for sending the warning information to the management end.
The invention provides a pre-warning system for failure of an electrolytic cell, which further comprises:
the dividing module is used for acquiring the position information of the electrolytic tank and dividing the electrolytic tank into areas according to the position information of the electrolytic tank;
and the second processing module is used for acquiring the warning information, analyzing the warning information and correcting the detection interval time according to a second analysis result.
Compared with the prior art, the method has the advantages that the analysis is carried out according to the detection information of the electrolytic cell, the normal information of the electrolytic cell in the first analysis result is verified, the analysis accuracy is improved, the preset liquid level is corrected when the verification result is wrong, the detection information is judged according to the corrected target liquid level, the judgment result is more accurate, the early warning of the electrolytic cell is more accurate and timely, the fault of the electrolytic cell is prevented timely, and the early warning efficiency of the electrolytic cell is improved.
Especially, through the liquid level that will detect with predetermineeing the liquid level and carry out the comparison, and then the state of preliminary judgement electrolysis trough, when the liquid level surpassed the highest liquid level of predetermineeing or be less than the minimum liquid level of predetermineeing, judge the electrolysis trough trouble, through predetermineeing the state of liquid level preliminary judgement electrolysis trough, and then in time prevent that the electrolysis trough from breaking down, improve electrolysis trough early warning efficiency.
Particularly, when the first analysis result is that the electrolytic cell is normal, the liquid level obtained within the preset time T is drawn into a curve graph, the slope of a liquid level straight line at any time point and the previous adjacent time is calculated, namely the liquid level change condition within the adjacent time, whether the analysis of the normal information of the electrolytic cell in the first analysis result for judging the electrolytic cell to be normal for the first time is correct is verified according to the preset slope, the correctness of the analysis of the normal information of the electrolytic cell in the first analysis result for judging the electrolytic cell to be normal for the first time is verified for the second time through the slope, so that the first analysis result of the electrolytic cell is more accurate, the electrolytic cell is prevented from being broken down in time, and the early warning efficiency of the electrolytic cell is improved.
Particularly, when the verification result is wrong, the first preset liquid level h1 and the second preset liquid level h2 are corrected, different correction coefficients are selected according to different conditions to correct, the target liquid level is obtained, and then the detection information can be analyzed according to the target liquid level when analyzed, so that the analysis result is more accurate, the electrolytic cell is prevented from being broken down in time, and the early warning efficiency of the electrolytic cell is improved.
Particularly, the detection information is judged according to the corrected target liquid level, and the judgment result is more accurate due to the fact that the judgment condition is corrected, so that the electrolytic cell is prevented from being broken down in time, and the early warning efficiency of the electrolytic cell is improved.
Particularly, the electrolytic cells in the important area are divided into one area, meanwhile, each area is labeled, the position information of each electrolytic cell in each area is associated with the area label, each electrolytic cell can be monitored in real time, the monitoring of the electrolytic cells is more accurate through the area division, the electrolytic cells in the area can be analyzed according to the electrolytic cells in the area when the electrolytic cells have problems, the detection mode is adjusted according to the fault condition of the electrolytic cells in the area, the early warning efficiency of the electrolytic cells is improved, the warning information is acquired to carry out overall analysis on the area where the electrolytic cells have the faults after early warning is carried out according to the judgment result, the fault rate P of the electrolytic cells in the area is calculated according to the fault rate M and the preset number M0 of the electrolytic cells in the area, the important level of the area, namely the important level of detection, the area is subjected to important detection according to the important level of the area, the analysis and early warning are carried out according to the detection information, the faults of the electrolytic cells in the important area are prevented in time, and the early warning efficiency of the electrolytic cells in the area is improved.
Particularly, when the important level of the area is obtained, the detection interval time t is corrected according to the important level of the area and the corresponding correction coefficient, namely when the detection important level of the area is high, the detection interval time is shortened according to the correction coefficient, when the detection important level of the area is low, the detection interval time is increased according to the correction coefficient, the detection is carried out through the corrected detection interval time, the detection is carried out on the important detection area for multiple times, the analysis and early warning are carried out according to the detection information in time, the electrolytic cell in the important area is prevented from being out of order in time, and the early warning efficiency of the electrolytic cell is improved.
Especially, the analysis unit analyzes the detection information, the verification unit verifies the normal information of the electrolytic cell, the analysis accuracy is improved, the correction unit corrects the preset liquid level according to the fact that the verification result is wrong, then the judgment module judges the detection information according to the corrected target liquid level, the judgment result is more accurate, the electrolytic cell is warned more accurately and timely, the electrolytic cell is prevented from being out of order timely, and the electrolytic cell warning efficiency is improved.
Particularly, a preset number of electrolytic cells are divided into one area through the dividing module, meanwhile, each area is labeled, the electrolytic cell position information in each area is associated with the area label, each electrolytic cell can be monitored in real time, monitoring of the electrolytic cells is more accurate through area division, after early warning is carried out according to a judgment result, the second processing module obtains the warning information to carry out overall analysis on the area where the failed electrolytic cell is located, the important grade of the area is judged, namely the important grade of detection, then the area is subjected to key detection according to the important grade of the area, analysis and early warning are carried out in time according to the detection information, the electrolytic cells in the important area are prevented from failing in time, and the early warning efficiency of the electrolytic cells is improved.
Drawings
FIG. 1 is a schematic flow chart of a method for early warning of failure of an electrolytic cell according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a pre-warning system for failure of an electrolytic cell according to an embodiment of the present invention;
fig. 3 is a schematic structural diagram of a first processing module according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of an early warning module according to an embodiment of the present invention.
Detailed Description
In order that the objects and advantages of the invention will be more clearly understood, the invention is further described below with reference to examples; it should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only for explaining the technical principle of the present invention, and do not limit the scope of the present invention.
It should be noted that in the description of the present invention, the terms of direction or positional relationship indicated by the terms "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, which are only for convenience of description, and do not indicate or imply that the device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.
Furthermore, it should be noted that, in the description of the present invention, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
Referring to fig. 1, the method for early warning of an electrolyzer fault according to an embodiment of the present invention includes:
step S110, acquiring detection information of the detection device on the liquid level of the electrolyte in the electrolytic cell;
step S120, analyzing the detection information according to a preset liquid level, verifying the normal information of the electrolytic cell in the first analysis result, and correcting the preset liquid level to obtain a target liquid level when the verification result is wrong;
step S130, judging the detection information according to the target liquid level;
and step S140, generating warning information according to the judgment result and carrying out early warning.
Specifically, the electrolytic cell array is uniformly distributed by a plurality of electrolytic cells, the detection device is a device arranged on any electrolytic cell and can be an electrolyte liquid level detection device, the detection device detects in the working process of the electrolytic cell, and the detection interval time during detection is consistent.
Specifically, the embodiment of the invention analyzes the electrolytic cell detection information, verifies the normal information of the electrolytic cell in the first analysis result, improves the accuracy of analysis, corrects the preset liquid level when the verification result is wrong, and judges the detection information according to the corrected target liquid level, so that the judgment result is more accurate, the early warning of the electrolytic cell is more accurate and timely, the fault of the electrolytic cell is prevented timely, and the early warning efficiency of the electrolytic cell is improved.
Specifically, when the detection information is analyzed, the detection information comprises liquid levels h of a plurality of electrolytic tanks, the liquid level h of any electrolytic tank is compared with a first preset liquid level h1 and a second preset liquid level h2 to obtain a first analysis result, wherein h1 is more than h2,
if h is more than h1, judging that the electrolytic cell has faults;
if h is more than or equal to h2 and less than or equal to h1, judging that the electrolytic cell is normal;
if h is more than 0 and less than h2, the fault of the electrolytic cell is judged.
Specifically, the embodiment of the invention compares the detected liquid level with the preset liquid level to preliminarily judge the state of the electrolytic cell, judges the fault of the electrolytic cell when the liquid level exceeds the preset highest liquid level or is lower than the preset lowest liquid level, preliminarily judges the state of the electrolytic cell through the preset liquid level to further timely prevent the electrolytic cell from being in fault and improve the early warning efficiency of the electrolytic cell.
Specifically, when the first analysis result is that the electrolytic cell is normal, the normal information of the electrolytic cell is verified, the liquid level within the preset time T is obtained, a two-dimensional coordinate system is established, the X axis of the two-dimensional coordinate system is detection time, the Y axis of the two-dimensional coordinate system is liquid level h, a curve graph is drawn according to the liquid levels, the linear slopes k of two liquid levels at any time point and the previous adjacent time point are calculated according to the curve graph, when k is less than 0, the electrolytic cell is in electrolysis, when k is greater than 0, the electrolytic cell is in electrolyte supplementation, the slope k is compared with a first preset slope k1 and a second preset slope k2 to obtain a verification result, the first preset slope k1 is the normal descending rate of the liquid level of the electrolyte in the electrolytic cell, the second preset slope k2 is the normal ascending rate of the liquid level of the electrolyte in the electrolytic cell during electrolysis and electrolyte supplementation, wherein k1 is less than 0, and k2 is greater than 0,
when k is less than 0, if k = k1, verifying that the first analysis result of the normal electrolytic cell is correct;
if k1 is more than k and less than 0, the liquid level descending rate of the electrolyte is less than the normal descending rate, and the normal first analysis result of the electrolytic cell is verified as an error;
if k is less than k1, the liquid level descending rate of the electrolyte is greater than the normal descending rate, and the normal first analysis result of the electrolytic cell is verified as an error;
when k is larger than 0, if k = k2, verifying that the first analysis result of the normal electrolytic cell is correct;
if k is more than 0 and less than k2, the liquid level rising rate of the electrolyte is smaller than the normal rising rate, and the normal first analysis result of the electrolytic cell is verified as an error;
and if k is larger than k2, the electrolyte liquid level rising rate is larger than the normal rising rate, and the normal first analysis result of the electrolytic cell is verified as an error.
Specifically, electrolyte can constantly reduce among the electrolysis trough electrolysis process, and the liquid level descends, and when the liquid level that reduces reachd certain liquid level and can supply electrolyte to the electrolysis trough automatically, electrolyte is constantly increasing, and the liquid level risees, and wherein the interval time of two adjacent time points of Y axle is detection interval time.
Specifically, in the embodiment of the invention, when the first analysis result is that the electrolytic cell is normal, the liquid level obtained within the preset time T is drawn into a curve graph, the slope of a liquid level straight line at any time point and the previous adjacent time is calculated, namely, the liquid level change condition within the adjacent time is calculated, whether the analysis of the normal information of the electrolytic cell in the first analysis result for firstly judging the normal state of the electrolytic cell is correct is verified according to the preset slope, and the correctness of the analysis of the normal information of the electrolytic cell in the first analysis result for firstly judging the normal state of the electrolytic cell is verified for the second time through the slope, so that the first analysis result of the electrolytic cell is more accurate, the fault of the electrolytic cell is prevented in time, and the early warning efficiency of the electrolytic cell is improved.
Specifically, when the verification result is an error, correcting a first preset liquid level H1 and a second preset liquid level H2, when k is less than 0, if k1 is less than k and less than 0, selecting a first preset liquid level H1 according to a first correction coefficient α 1 to obtain a first target liquid level H1, and if k is less than k1, and correcting a second preset liquid level H2 according to a second correction coefficient α 2 to obtain a second target liquid level H2, wherein H1= H1 × α 1, H2= H2 × α 2, H1 is greater than H2, the first correction coefficient α 1= (H1-H)/H, and the second correction coefficient α 2= (H2 + H)/H;
when k is greater than 0, if k is greater than 0 and less than k2, the second preset liquid level H2 is corrected according to a third correction coefficient alpha 3 to obtain a third target liquid level H3, and if k is greater than k2, the first preset liquid level H1 is corrected according to a fourth correction coefficient alpha 4 to obtain a fourth target liquid level H4, wherein H3= H2 × alpha 3, H4= H1 × alpha 4, H3 is less than H4, the third correction coefficient alpha 3= (H-H2)/H, and the fourth correction coefficient = (H1 + H)/H.
Specifically, h is the liquid level of the electrolytic cell at a later time point of the straight line corresponding to the slope k.
Specifically, according to the embodiment of the invention, when the verification result is wrong, the first preset liquid level h1 and the second preset liquid level h2 are corrected, different correction coefficients are selected according to different conditions for correction, so that the target liquid level is obtained, and further, when the detection information is analyzed, the analysis result can be analyzed according to the target liquid level, so that the analysis result is more accurate, the electrolytic cell is prevented from being in fault in time, and the early warning efficiency of the electrolytic cell is improved.
Specifically, the detection information is judged according to the target liquid level to obtain a judgment result, the judgment result comprises fault information and fault electrolytic tank position information, the fault information and the fault electrolytic tank position information are used for generating warning information, and early warning is carried out on a management terminal according to the warning information, wherein the early warning is in a voice or text mode.
Specifically, the fault information is the fault reason of the fault electrolytic cell, the target liquid levels are a first target liquid level H1 and a second target liquid level H2 or a third target liquid level H3 and a fourth target liquid level H4,
specifically, the detection information is judged according to the corrected target liquid level, and the judgment result is more accurate due to the fact that the judgment condition is corrected, so that the electrolytic cell is prevented from being broken down in time, and early warning efficiency of the electrolytic cell is improved.
Referring to fig. 1, the method for early warning of failure of an electrolytic cell according to an embodiment of the present invention further includes:
s150, acquiring the position information of the plurality of electrolytic cells, and performing area division on the plurality of electrolytic cells according to the position information;
when the electrolysis baths are divided into areas according to the electrolysis bath position information, the electrolysis baths with the preset number M0 are divided into the same area, the areas are labeled, and the position information of each electrolysis bath in the areas is associated with the area labels.
Specifically, the electrolytic cells in adjacent positions are divided into a region, the region is determined according to the number of the electrolytic cells, and the electrolytic cells are divided into a plurality of regions, wherein the number of the electrolytic cells in each region is constant.
Specifically, the embodiment of the invention divides a preset number of electrolytic cells into one area, marks each area, and associates the position information of the electrolytic cells in each area with the area marks, so that each electrolytic cell can be monitored in real time, the monitoring of the electrolytic cells is more accurate through the area division, the electrolytic cells in the area can be analyzed according to the electrolytic cells when the electrolytic cells have problems, and the detection mode is adjusted according to the failure condition of the electrolytic cells in the area, so that the early warning efficiency of the electrolytic cells is improved.
Referring to fig. 1, the method for early warning of an electrolyzer fault according to an embodiment of the present invention further includes:
step S160, acquiring warning information, analyzing the warning information, and correcting the detection interval time according to a second analysis result;
when the warning information is analyzed, acquiring a corresponding area label according to the position information of the fault electrolytic tank in the warning information, acquiring the number M of the fault electrolytic tanks with the same area label, calculating according to the number M and the preset number M0 of the electrolytic tanks in the area to obtain a fault rate P, comparing the fault rate P with a first preset fault rate P1 and a second preset fault rate P2 to acquire a second analysis result,
if P > P1, judging the importance level of the area as I level;
if P2 is not less than P and not more than P1, judging the importance level of the region as level II;
if P is more than 0 and less than P2, judging the importance level of the region as III level;
the failure rate P = M/M0, P1 > P2, and the important level is I level > II level > III level.
Specifically, after early warning is carried out according to the judgment result, the warning information is obtained to carry out overall analysis on the area where the electrolytic cell is in failure, the failure rate P of the electrolytic cell in the area is calculated according to the failure number M and the preset number M0 of the electrolytic cell in the area, the important grade of the area, namely the detected important grade, is judged according to the preset failure rate P0, the area is subjected to key detection according to the important grade of the area, analysis and early warning are carried out according to the detection information in time, the electrolytic cell in the important area is prevented from being in failure in time, and the early warning efficiency of the electrolytic cell is improved.
Specifically, when the detection interval time is corrected according to the second analysis result, when the importance level of the area is I level, the detection interval time t of the electrolytic cell by the detection device in the area is corrected, and the detection interval time is corrected according to a fifth correction coefficient alpha 5, so that the detection interval time t 'is obtained, wherein t' = t multiplied by alpha 5, and 0.8 < alpha 5 < 1;
and when the importance level of the area is level III, correcting the detection interval time t of the detection device in the area to the electrolytic tank, and correcting the detection interval time according to a sixth correction coefficient alpha 6 to obtain a detection interval time t '', wherein t '' = t multiplied by alpha 6,1 < alpha 6 < 1.2.
Specifically, the level of the electrolyte in the electrolytic cell is detected based on the detection interval t' or the detection interval t ″ after the region, the third correction coefficient α 3 is a shortening of the detection interval, and the fourth correction coefficient α 4 is an increasing of the detection interval.
Specifically, the embodiment of the invention obtains the importance level of the area, corrects the detection interval time t according to the importance level of the area and the corresponding correction coefficient, namely shortens the detection interval time according to the correction coefficient when the detection importance level of the area is high, increases the detection interval time according to the correction coefficient when the detection importance level of the area is low, detects the area by the corrected detection interval, detects the important detection area for multiple times, analyzes and gives an early warning according to the detection information in time, prevents the electrolytic cell in the important area from being failed in time, and improves the early warning efficiency of the electrolytic cell.
Referring to fig. 2 to 4, an early warning system for an electrolyzer fault according to an embodiment of the present invention includes:
an obtaining module 210, configured to obtain detection information of a detection apparatus on a liquid level of an electrolyte in an electrolytic cell;
the first processing module 220 is configured to process the detection information, and includes an analysis unit 221, a verification unit 222, and a correction unit 223, where the analysis unit is configured to analyze the detection information according to a preset liquid level, the verification unit is configured to verify the normal information of the electrolytic cell in the first analysis result, and the correction unit is configured to correct the preset liquid level to obtain a target liquid level when the verification result is an error;
the judging module 230 is configured to judge the detection information according to the target liquid level;
and the early warning module 240 is used for giving an early warning according to the judgment result, and comprises a generation unit 241 and a warning unit 242, wherein the generation unit is used for generating warning information according to the judgment result, and the warning unit is used for sending the warning information to the management terminal.
Specifically, the detection information is analyzed by the analysis unit in the first processing module, the verification unit verifies the normal information of the electrolytic cell, the analysis accuracy is improved, the correction unit corrects the preset liquid level according to the fact that the verification result is wrong, then the judgment module judges the detection information according to the corrected target liquid level, the judgment result is more accurate, the early warning of the electrolytic cell is more accurate and timely, the electrolytic cell is prevented from being out of order in time, and the early warning efficiency of the electrolytic cell is improved.
Referring to fig. 2, the early warning system for an electrolyzer fault according to an embodiment of the present invention further includes:
the dividing module 250 is used for acquiring the position information of the electrolytic tank and dividing the electrolytic tank into areas according to the position information of the electrolytic tank;
when the electrolysis baths are divided into areas according to the electrolysis bath position information, the electrolysis baths with the preset number M0 are divided into the same area, the areas are labeled, and the electrolysis bath position information in the areas is associated with the area labels.
Specifically, according to the embodiment of the invention, a preset number of electrolytic tanks are divided into one area through the dividing module, meanwhile, each area is labeled, and the position information of the electrolytic tanks in each area is associated with the area label, so that each electrolytic tank can be monitored in real time.
Referring to fig. 2, the early warning system for an electrolyzer fault according to an embodiment of the present invention further includes: the second processing module 260 is configured to obtain the warning information, analyze the warning information, and correct the detection interval time according to a second analysis result;
when the warning information is analyzed, the corresponding area label is obtained according to the position information of the fault electrolytic tank in the warning information, the number M of the fault electrolytic tanks with the same area label is obtained, the fault rate P is obtained by calculating according to the fault number M and the preset number M0 of the electrolytic tanks in the area, the fault rate P is compared with a first preset fault rate P1 and a second preset fault rate P2,
if P > P1, judging the importance level of the area as I level;
if P2 is more than or equal to P1, judging the importance level of the region as level II;
if P is more than 0 and less than P2, judging the importance level of the region to be III level;
the failure rate P = M/M0, P1 > P2, and the important level is I level > II level > III level.
Specifically, after early warning is performed according to the judgment result, the second processing module obtains the warning information to perform overall analysis on the area where the electrolytic cell is in the fault, the fault rate P of the electrolytic cell in the area is calculated according to the fault number M and the preset number M0 of the electrolytic cell in the area, the important level of the area, namely the important level of detection, is judged according to the preset fault rate P0, the area is subjected to important detection according to the important level of the area, analysis and early warning are performed according to the detection information in time, the electrolytic cell in the important area is prevented from being in fault in time, and the early warning efficiency of the electrolytic cell is improved.
So far, the technical solutions of the present invention have been described in connection with the preferred embodiments shown in the drawings, but it is easily understood by those skilled in the art that the scope of the present invention is obviously not limited to these specific embodiments. Equivalent changes or substitutions of related technical features can be made by those skilled in the art without departing from the principle of the invention, and the technical scheme after the changes or substitutions can fall into the protection scope of the invention.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention; various modifications and alterations to this invention will become apparent to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A method for early warning of a failure of an electrolytic cell, comprising:
acquiring detection information of a detection device on the liquid level of electrolyte in an electrolytic cell;
analyzing the detection information according to a preset liquid level, verifying the normal information of the electrolytic cell in a first analysis result, and correcting the preset liquid level to obtain a target liquid level when the verification result is wrong;
judging the detection information according to the target liquid level;
and generating warning information according to the judgment result and carrying out early warning.
2. The pre-warning method for electrolytic cell faults as claimed in claim 1, wherein in analyzing the detection information, the detection information comprises liquid levels h of a plurality of electrolytic cells, the liquid level h of any electrolytic cell is compared with a first preset liquid level h1 and a second preset liquid level h2 to obtain a first analysis result, wherein h1 > h2,
if h is more than h1, judging that the electrolytic cell has faults;
if h is more than or equal to h2 and less than or equal to h1, judging that the electrolytic cell is normal;
if h is more than 0 and less than h2, the fault of the electrolytic cell is judged.
3. The method as claimed in claim 2, wherein when the first analysis result is that the electrolytic cell is normal, the normal information of the electrolytic cell is verified, the liquid level within the preset time T is obtained, a two-dimensional coordinate system is established, the X axis of the two-dimensional coordinate system is the detection time, the Y axis is the liquid level h, a graph is drawn according to the liquid levels, the linear slope k of the two liquid levels at any time point and the previous adjacent time point is calculated according to the graph, when k is less than 0, the electrolytic cell is in electrolysis, when k is greater than 0, the electrolytic cell is in electrolyte supplement, the slope k is compared with a first preset slope k1 and a second preset slope k2, the verification result is obtained, the first preset slope k1 is the normal descending rate of the liquid level of the electrolytic cell, the second preset slope k2 is the normal ascending rate of the liquid level of the electrolytic cell during the electrolysis and the electrolyte supplement, wherein k1 is less than 0, and k2 is greater than 0,
when k is less than 0, if k = k1, verifying that the first analysis result of the normal electrolytic cell is correct;
if k1 is more than k and less than 0, the liquid level descending rate of the electrolyte is less than the normal descending rate, and the normal first analysis result of the electrolytic cell is verified as an error;
if k is less than k1, the liquid level descending rate of the electrolyte is greater than the normal descending rate, and the normal first analysis result of the electrolytic cell is verified as an error;
when k is larger than 0, if k = k2, verifying that the first analysis result of the normal electrolytic cell is correct;
if k is more than 0 and less than k2, the liquid level rising rate of the electrolyte is smaller than the normal rising rate, and the normal first analysis result of the electrolytic cell is verified as an error;
and if k is larger than k2, the electrolyte liquid level rising rate is larger than the normal rising rate, and the normal first analysis result of the electrolytic cell is verified as an error.
4. The pre-warning method for the failure of the electrolytic cell as claimed in claim 3, wherein when the verification result is false, the first preset liquid level H1 and the second preset liquid level H2 are corrected, when k is less than 0, if k1 is less than k and less than 0, the first preset liquid level H1 is selected according to a first correction coefficient α 1 to obtain a first target liquid level H1, and if k is less than k1, the second preset liquid level H2 is selected according to a second correction coefficient α 2 to obtain a second target liquid level H2, wherein H1= H1 × α 1, H2= H2 × α 2, H1 > H2, the first correction coefficient α 1= (H1-H)/H, and the second correction coefficient α 2= (H2 + H)/H;
when k is greater than 0, if k is greater than 0 and less than k2, the second preset liquid level H2 is corrected according to a third correction coefficient alpha 3 to obtain a third target liquid level H3, and if k is greater than k2, the first preset liquid level H1 is corrected according to a fourth correction coefficient alpha 4 to obtain a fourth target liquid level H4, wherein H3= H2 × alpha 3, H4= H1 × alpha 4, H3 is less than H4, the third correction coefficient alpha 3= (H-H2)/H, and the fourth correction coefficient = (H1 + H)/H.
5. The early warning method for the electrolytic cell fault as claimed in claim 4, wherein the detection information is judged according to the target liquid level to obtain a judgment result, the judgment result comprises fault information and fault electrolytic cell position information, the fault information and the fault electrolytic cell position information are used for generating warning information, and early warning is performed on a management terminal according to the warning information, wherein the early warning form is a voice or text form.
6. The early warning method for electrolytic cell failure according to claim 5, further comprising:
acquiring position information of the plurality of electrolytic cells, and performing region division on the plurality of electrolytic cells according to the position information;
and acquiring warning information, analyzing the warning information, and correcting the detection interval time according to a second analysis result.
7. The early warning method for the electrolytic cell fault as claimed in claim 6, wherein when the plurality of electrolytic cells are divided into the same area according to the position information, a preset number M0 of electrolytic cells are divided into the same area, the areas are labeled, and the position information of each electrolytic cell in the area is associated with the area label;
when the warning information is analyzed, acquiring a corresponding area label according to the position information of the fault electrolytic tank in the warning information, acquiring the number M of the fault electrolytic tanks with the same area label, calculating according to the number M and the preset number M0 of the electrolytic tanks in the area to obtain a fault rate P, comparing the fault rate P with a first preset fault rate P1 and a second preset fault rate P2 to acquire a second analysis result,
if P > P1, judging the importance level of the area as I level;
if P2 is not less than P and not more than P1, judging the importance level of the region as level II;
if P is more than 0 and less than P2, judging the importance level of the region to be III level;
the failure rate P = M/M0, P1 > P2, and the important level is I level > II level > III level.
8. The warning method for electrolytic cell failure according to claim 7, wherein when the detection interval time is corrected based on the second analysis result, when the importance level of the area is class I, the detection interval time t of the electrolytic cell by the detection device in the area is corrected, and the detection interval time is corrected based on a fifth correction coefficient α 5 to obtain a detection interval time t ', wherein t' = t × α 5,0.8 < α 5 < 1;
and when the importance level of the area is level III, correcting the detection interval time t of the electrolytic cell by the detection device in the area, and correcting the detection interval time according to a sixth correction coefficient alpha 6 to obtain a detection interval time t '', wherein t '' = t multiplied by alpha 6,1 < alpha 6 < 1.2.
9. An early warning system for electrolytic cell failure applying the early warning method for electrolytic cell failure according to any one of claims 1 to 8, comprising:
the acquisition module is used for acquiring the detection information of the detection device on the liquid level of the electrolyte in the electrolytic cell;
the first processing module is used for processing the detection information and comprises an analysis unit, a verification unit and a correction unit, wherein the analysis unit is used for analyzing the detection information according to a preset liquid level, the verification unit is used for verifying the normal information of the electrolytic cell in a first analysis result, and the correction unit is used for correcting the preset liquid level to obtain a target liquid level when the verification result is wrong;
the judgment module is used for judging the detection information according to the target liquid level;
the early warning module is used for carrying out early warning according to the judgment result and comprises a generation unit
And the generating unit is used for generating warning information according to the judgment result, and the warning unit is used for sending the warning information to the management terminal.
10. The early warning system for electrolyzer failure of claim 9, further comprising:
the dividing module is used for acquiring the position information of the electrolytic tank and dividing the area of the electrolytic tank according to the position information of the electrolytic tank;
and the second processing module is used for acquiring the warning information, analyzing the warning information and correcting the detection interval time according to a second analysis result.
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| CN117737815A (en) * | 2024-02-21 | 2024-03-22 | 山东裕能电力器材有限公司 | Intelligent operation quality early warning system suitable for electroplating bath impurity removal device |
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