CN114578681B - LF electrode adjustment energy-saving control method based on sonar feedback - Google Patents
LF electrode adjustment energy-saving control method based on sonar feedback Download PDFInfo
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- CN114578681B CN114578681B CN202210169002.8A CN202210169002A CN114578681B CN 114578681 B CN114578681 B CN 114578681B CN 202210169002 A CN202210169002 A CN 202210169002A CN 114578681 B CN114578681 B CN 114578681B
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- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000012545 processing Methods 0.000 claims abstract description 19
- 238000002485 combustion reaction Methods 0.000 claims abstract description 14
- 238000010438 heat treatment Methods 0.000 claims abstract description 13
- 238000012360 testing method Methods 0.000 claims abstract description 7
- 238000004806 packaging method and process Methods 0.000 claims abstract description 4
- 238000007619 statistical method Methods 0.000 claims abstract description 4
- 238000007405 data analysis Methods 0.000 claims description 6
- 230000001105 regulatory effect Effects 0.000 claims description 6
- 238000012546 transfer Methods 0.000 claims description 6
- 238000001514 detection method Methods 0.000 claims description 4
- 230000002159 abnormal effect Effects 0.000 claims description 3
- 238000004088 simulation Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 230000005611 electricity Effects 0.000 description 6
- 238000013461 design Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000007670 refining Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000009628 steelmaking Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000035945 sensitivity Effects 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 238000011217 control strategy Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B11/00—Automatic controllers
- G05B11/01—Automatic controllers electric
- G05B11/36—Automatic controllers electric with provision for obtaining particular characteristics, e.g. proportional, integral, differential
- G05B11/42—Automatic controllers electric with provision for obtaining particular characteristics, e.g. proportional, integral, differential for obtaining a characteristic which is both proportional and time-dependent, e.g. P. I., P. I. D.
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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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Automation & Control Theory (AREA)
- Discharge Heating (AREA)
- Electrolytic Production Of Metals (AREA)
Abstract
The invention discloses an LF electrode regulation energy-saving control method based on sonar feedback, which comprises the following steps: step one, statistical analysis; step two, data acquisition; step three, signal processing; step four, serial pole control; step five, electrode adjustment; step six, calibrating and compensating; step seven, programming; step eight, testing and optimizing; step nine, packaging and publishing; according to the invention, sonar feedback is introduced on the basis of the traditional electrode regulator, so that automatic acquisition and processing of sonar signals are realized, the constant current type LF electrode regulator is modified, a current set point is dynamically set according to the sonar feedback, under the conditions of open arc combustion and embedded combustion, a current set point is reduced, electric quantity consumption is remarkably reduced, production cost is reduced, huge noise generated in the electrode heating process is reduced, meanwhile, the automation degree is improved, the full-automatic control of heating and slagging is realized at present, manual intervention is not needed, and the occurrence of misoperation is reduced.
Description
Technical Field
The invention relates to the technical field of LF refining furnaces, in particular to an LF electrode adjustment energy-saving control method based on sonar feedback.
Background
In the production process of the ladle refining furnace, molten steel is heated by electrode temperature rise, a large amount of energy is consumed, the traditional electrode regulation control is divided into constant impedance and constant current regulation, and two electrode control strategies have advantages and disadvantages respectively;
The constant impedance adjustment has the advantages of relatively saving energy and stable arcing, and the impedance set point of the constant impedance is a static impedance set point and is not an impedance optimal set point in a real sense, so that the optimal efficiency is difficult to realize, the sensitivity of the controller is low, and the maximum active power cannot be fully utilized;
The constant current regulator has the advantages of high sensitivity and quick temperature rise, the three-phase electrode regulator has no characteristic of automatic decoupling, namely mutual interference among three-phase electrode actions is large, the system is still greatly influenced by errors after entering a steady state, the system is easy to oscillate, and the energy-saving effect is poor;
The two electrode regulators emit huge noise in the open arc combustion or embedded combustion process caused by special process requirements or poor site slagging, so that a large amount of energy is wasted, and the constant current and constant impedance set points are static;
The research of the high-performance electrode automatic regulator has important significance for improving steelmaking quality, reducing electric energy consumption and reducing noise pollution.
Disclosure of Invention
The invention aims to provide an LF electrode regulation energy-saving control method based on sonar feedback, which aims to solve the problems in the background technology.
In order to achieve the above purpose, the present invention provides the following technical solutions: LF electrode regulation energy-saving control method based on sonar feedback comprises the following steps: step one, statistical analysis; step two, data acquisition; step three, signal processing; step four, serial pole control; step five, electrode adjustment; step six, calibrating and compensating; step seven, programming; step eight, testing and optimizing; step nine, packaging and publishing;
In the first step, firstly, on-site process parameters and equipment parameters are counted, data are analyzed, and the data are ready for use after the data analysis is completed;
in the second step, after the data analysis in the first step is completed, collecting noise sonar signals generated in the electrode heating process, sending the noise sonar signals into a programmable controller, setting a sonar collection threshold level, determining a feedback controller output dead zone, and completing the feedback controller output dead zone for later use;
In the third step, the control system is modeled, and a sonar signal processing digital controller is designed, and the pulse transfer function is as follows:
then, the noise sonar signal acquired in the second step is processed by a sonar signal processing digital controller, and the processing is finished for later use;
in the fourth step, the system adds the sonar signals processed in the third step to perform cascade control on the basis of the original PID control, and the transfer function is as follows:
In the fifth step, after the sonar signal cascade control is added in the system in the fourth step, the current controller is set to the maximum value only when the submerged arc is good and the secondary side current is balanced and the sonar feedback value is the lowest, the current set point is correspondingly and automatically reduced to save energy during embedded combustion and open arc combustion, and the current in the electrode is regulated and controlled;
in the sixth step, after the current of the electrode is regulated and controlled in the fifth step, the sonar signal is calibrated, judgment is performed after calibration is completed, sonar feedback is performed when distortion does not exist in the signal, compensation is performed on the sonar signal when distortion exists in the signal, and after compensation is completed, the lifting and the current of the electrode are controlled through the sonar feedback;
In the seventh step, the algorithm is programmed in the primary electrode adjusting PLC system by using programming software, and the program is downloaded and run;
In the eighth step, the program compiled in the seventh step is tested to eliminate abnormal conditions, then the program is debugged on site, the error cause is analyzed, and the program is optimized according to the analyzed cause;
and in the step nine, after the program optimization in the step eight is completed, program packaging and publishing are carried out, so that the electrode regulation energy-saving control program is obtained.
Preferably, in the first step, the in-situ process parameters include three secondary side currents and historical operation data of the proportional valve output.
Preferably, in the second step, a sonar detector is used to detect the sonar.
Preferably, in the third step, the sonar signal processing digital controller realizes minimum beat control under a unit step signal.
Preferably, in the sixth step, in order to ensure accurate sonar detection, the sonar analog signal is calibrated once a month.
Preferably, in the step eight, the method of program testing is as follows:
1) Carefully checking the program piece by piece, and correcting the writing errors;
2) Performing simulation test in a laboratory, simulating an input signal by using a toggle switch and a button, and displaying the on-off of an output quantity by using a light emitting diode;
3) According to the function chart, a switch and a button are utilized to simulate a feedback signal, and whether the test program meets the setting of the function chart or not is tested.
Compared with the prior art, the invention has the beneficial effects that:
1. According to the invention, sonar feedback is introduced on the basis of the traditional electrode regulator, so that the automatic acquisition and processing of the sonar signals are realized, the accuracy of electrode regulation is improved, and the sonar signals are subjected to periodic error calibration, thereby being beneficial to reducing errors;
2. according to the invention, the constant current type LF electrode regulator is modified, a current set point is dynamically set according to sonar feedback, and under the condition of open arc combustion and embedded combustion, a current set point is reduced, so that electrode consumption, electricity degree electricity charge and maximum required electricity charge are obviously reduced, and the production cost is reduced;
3. The invention reduces the huge noise generated in the electrode heating process, improves the working environment of operators, ensures the occupational health of operators, improves the degree of automation, realizes the full-automatic control of heating and slagging at present, does not need manual intervention, provides important guarantee for intelligent steelmaking, reduces manual gear setting and reduces the occurrence of misoperation.
Drawings
FIG. 1 is a diagram of a model structure of the present invention;
FIG. 2 is a flow chart of the technical scheme of the invention;
FIG. 3 is a system schematic block diagram of the present invention;
FIG. 4 is a graph of the heating current at the constant current set point of the original design of the present invention;
FIG. 5 is a graph of the heating current after application of the present patent;
FIG. 6 is a flow chart of the steps of the present invention;
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1-6, an embodiment of the present invention is provided: LF electrode regulation energy-saving control method based on sonar feedback comprises the following steps: step one, statistical analysis; step two, data acquisition; step three, signal processing; step four, serial pole control; step five, electrode adjustment; step six, calibrating and compensating; step seven, programming; step eight, testing and optimizing; step nine, packaging and publishing;
In the first step, firstly, on-site process parameters and equipment parameters are counted, data are analyzed, the on-site process parameters comprise three secondary side currents and historical operation data output by the proportional valve, and the data are ready for use after the data analysis is completed;
In the second step, after the data analysis in the first step is completed, collecting noise sonar signals generated in the electrode heating process, detecting the sonar by using a passive sonar detector, sending the detected sonar to a programmable controller, setting a sonar collection threshold level, determining a feedback controller output dead zone, and completing the detection for later use;
In the third step, the control system is modeled, and a sonar signal processing digital controller is designed, and the pulse transfer function is as follows:
then, the sonar signal processing digital controller is used for processing the noise sonar signal acquired in the second step, the sonar signal processing digital controller realizes minimum beat control under the unit step signal, and the processing is finished for later use;
in the fourth step, the system adds the sonar signals processed in the third step to perform cascade control on the basis of the original PID control, and the transfer function is as follows:
In the fifth step, after the sonar signal cascade control is added in the system in the fourth step, the current controller is set to the maximum value only when the submerged arc is good and the secondary side current is balanced and the sonar feedback value is the lowest, the current set point is correspondingly and automatically reduced to save energy during embedded combustion and open arc combustion, and the current in the electrode is regulated and controlled;
in the sixth step, after the current of the electrode is regulated and controlled in the fifth step, the sonar signal is calibrated, and in order to ensure accurate sonar detection, the sonar analog signal is calibrated once a month, judgment is performed after calibration is completed, when the signal is not distorted, sonar feedback is performed, when the signal is distorted, the sonar signal is compensated, and after compensation is completed, the lifting and the current of the electrode are controlled through the sonar feedback;
In the seventh step, the algorithm is programmed in the primary electrode adjusting PLC system by using programming software, and the program is downloaded and run;
In the eighth step, the program compiled in the seventh step is tested, and the program testing method is as follows:
1) Carefully checking the program piece by piece, and correcting the writing errors;
2) Performing simulation test in a laboratory, simulating an input signal by using a toggle switch and a button, and displaying the on-off of an output quantity by using a light emitting diode;
3) According to the function chart, a switch and a button are utilized to simulate a feedback signal, whether the test program meets the setting of the function chart or not is tested, abnormal conditions are eliminated, then the program is debugged on site, error reasons are analyzed, and program optimization is carried out according to the analyzed reasons;
and in the step nine, after the program optimization in the step eight is completed, program packaging and publishing are carried out, so that the electrode regulation energy-saving control program is obtained.
Compared with the original design, the invention has obvious advantages in the aspects of average current set value, current unbalance degree, heating efficiency and the like when applied to the No. 5 LF furnace in the refining operation area of the steel mill of the steel plate stock limited company in 12 months in 2020, and the specific data are shown in the following table:
| Application contrast | Average current set point | Degree of unbalance of current | Heating efficiency |
| Original design | 48KA | 5.82％ | 4.95℃/min |
| This patent | 45.24KA | 3.77％ | 5.24℃/min |
Based on the above, the invention has the advantages that the current regulation is more stable after the application of the patent, the overshoot of the system is smaller, the robustness is good, the original design constant given value 48KA is always unable to be matched with the actual value under the condition of poor submerged arc, the system is seriously overshoot, the three-phase electrode current balance is poor, a great amount of energy waste and noise pollution are caused, good application and popularization space are provided, the sonar feedback is introduced on the basis of the traditional electrode regulator, the current given value is dynamically set according to the sonar feedback, the current set point is reduced under the conditions of open arc combustion and embedded combustion, the electrode consumption, the electricity degree and the electricity charge are obviously reduced, the maximum electricity charge is required, the production cost is reduced, the huge noise generated in the electrode heating process is reduced, the working environment of operators is improved, the occupational health of operators is ensured, the automation degree is improved, the full-automatic control of heating and slag making is not required, the important guarantee is provided for intelligent steelmaking, and the error operation condition is reduced.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Claims (6)
1. LF electrode regulation energy-saving control method based on sonar feedback comprises the following steps: step one, statistical analysis; step two, data acquisition; step three, signal processing; step four, serial pole control; step five, electrode adjustment; step six, calibrating and compensating; step seven, programming; step eight, testing and optimizing; step nine, packaging and publishing; the method is characterized in that:
In the first step, firstly, on-site process parameters and equipment parameters are counted, data are analyzed, and the data are ready for use after the data analysis is completed;
in the second step, after the data analysis in the first step is completed, collecting noise sonar signals generated in the electrode heating process, sending the noise sonar signals into a programmable controller, setting a sonar collection threshold level, determining a feedback controller output dead zone, and completing the feedback controller output dead zone for later use;
In the third step, the control system is modeled, and a sonar signal processing digital controller is designed, and the pulse transfer function is as follows:
then, the noise sonar signal acquired in the second step is processed by a sonar signal processing digital controller, and the processing is finished for later use;
in the fourth step, the system adds the sonar signals processed in the third step to perform cascade control on the basis of the original PID control, and the transfer function is as follows:
In the fifth step, after the sonar signal cascade control is added in the system in the fourth step, the current controller is set to the maximum value only when the submerged arc is good and the secondary side current is balanced and the sonar feedback value is the lowest, the current set point is correspondingly and automatically reduced to save energy during embedded combustion and open arc combustion, and the current in the electrode is regulated and controlled;
in the sixth step, after the current of the electrode is regulated and controlled in the fifth step, the sonar signal is calibrated, judgment is performed after calibration is completed, sonar feedback is performed when distortion does not exist in the signal, compensation is performed on the sonar signal when distortion exists in the signal, and after compensation is completed, the lifting and the current of the electrode are controlled through the sonar feedback;
In the seventh step, the algorithm is programmed in the primary electrode adjusting PLC system by using programming software, and the program is downloaded and run;
In the eighth step, the program compiled in the seventh step is tested to eliminate abnormal conditions, then the program is debugged on site, the error cause is analyzed, and the program is optimized according to the analyzed cause;
and in the step nine, after the program optimization in the step eight is completed, program packaging and publishing are carried out, so that the electrode regulation energy-saving control program is obtained.
2. The sonar feedback-based LF electrode regulation energy-saving control method of claim 1, wherein the method comprises the following steps: in the first step, the on-site process parameters comprise three secondary side currents and historical operation data of the proportional valve output.
3. The sonar feedback-based LF electrode regulation energy-saving control method of claim 1, wherein the method comprises the following steps: in the second step, a passive sonar detector is used for detecting the sonar.
4. The sonar feedback-based LF electrode regulation energy-saving control method of claim 1, wherein the method comprises the following steps: in the third step, the sonar signal processing digital controller realizes minimum beat control under the unit step signal.
5. The sonar feedback-based LF electrode regulation energy-saving control method of claim 1, wherein the method comprises the following steps: in the sixth step, in order to ensure accurate sonar detection, the sonar analog signal is calibrated once a month.
6. The sonar feedback-based LF electrode regulation energy-saving control method of claim 1, wherein the method comprises the following steps: in the eighth step, the program testing method comprises the following steps:
1) Carefully checking the program piece by piece, and correcting the writing errors;
2) Performing simulation test in a laboratory, simulating an input signal by using a toggle switch and a button, and displaying the on-off of an output quantity by using a light emitting diode;
3) According to the function chart, a switch and a button are utilized to simulate a feedback signal, and whether the test program meets the setting of the function chart or not is tested.
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Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103024959A (en) * | 2012-12-03 | 2013-04-03 | 北京金自天正智能控制股份有限公司 | Intelligent electrode regulator and intelligent electrode control method |
| CN105404149A (en) * | 2015-11-27 | 2016-03-16 | 本钢板材股份有限公司 | Multi-model LF furnace electrode adjusting method based on steel type clearance slag thickness |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| KR100919422B1 (en) * | 2002-11-27 | 2009-09-29 | 주식회사 포스코 | Power control apparatus and method using arc tone during arc heating in ladle furnace |
| CN108265157A (en) * | 2018-01-26 | 2018-07-10 | 无锡东雄重型电炉有限公司 | Intelligent arc furnace steelmaking system |
| CN110017695B (en) * | 2019-04-17 | 2020-12-01 | 北京中联杰能科技有限公司 | Variable-resistance self-adaptive submerged arc control method and system for electrode of electric arc furnace or refining furnace |
| CN113281581B (en) * | 2021-04-14 | 2022-04-01 | 中国重型机械研究院股份公司 | Test method of LF furnace electrode test system |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103024959A (en) * | 2012-12-03 | 2013-04-03 | 北京金自天正智能控制股份有限公司 | Intelligent electrode regulator and intelligent electrode control method |
| CN105404149A (en) * | 2015-11-27 | 2016-03-16 | 本钢板材股份有限公司 | Multi-model LF furnace electrode adjusting method based on steel type clearance slag thickness |
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