Development Of Wireless Data Transmission Device For Smelting Process Of Fused Magnesium Furnace

The semi-physical simulation refers to the real-time simulation of accessing some physical objects in the simulation loop of the simulation experiment system.This paper,aiming at the application of electro-fused magnesia smelting under the harsh environment of ultra-high temperature and high dust,develops a wireless data transmission device that meets the requirements of real-time semi-physical simulation system for current control of fused magnesium furnace smelting process.The device can collect the production process data in real time in the smelting production site of the fused magnesium furnace with difficult wiring and environment,use the 4G transmission technology for remote cross-domain transmission.The research topic has important practical significance for the real-time simulation of industrial actual data and the development of wireless transmission technology for real-time data in industrial environments.The main works in the thesis are as follows:(1)This paper summarizes and analyses the characteristics of smelting process of electrolytic magnesium furnace and the requirement of real-time simulation of current control for industrial field data transmission,and summarizes the research and development progress of wireless transmission devices in the existing industrial environment.Based on the application background of a magnesia smelting plant,the overall architecture of wireless data transmission system for the current control real-time hardware-in-the-loop simulation system of the magnesia smelting process is designed.(2)Aiming at the limitation of hardware design in traditional top-down(or modular)design method,which lacks a clear understanding of software architecture and implementation mechanism,this paper adopts the method of hardware-software codesign to distribute the functions of hardware and software and map the system of wireless data transmission device in the smelting process of magnesium smelting furnace.In order to avoid a series of problems caused by repeated modifications in the later stage,the software and hardware resources should be fully considered in the function allocation,and the problems encountered in the system design and evaluation should be found and solved as soon as possible.The system mapping is based on the description of the realtime hardware-in-the-loop simulation system of current control in the smelting process of magnesium smelting furnace and the software and hardware tasks.As a result,the architecture of the real-time hardware-in-the-loop simulation system for current control in the smelting process of magnesium smelting furnace is finally determined by choosing the software and hardware modules of the system,realizing the corresponding interfaces and integrating them.The hardware-software co-design method in this paper is helpful to fully tap the functions of the current control real-time hardware-in-the-loop simulation system in the smelting process of magnesium smelting furnace,reduce the volume,reduce the cost and improve the overall efficiency.(3)A wireless data transmission device for the smelting process of magnesium smelting furnace was developed.According to the requirement of real-time simulation,reliable and remote data access of current control in the smelting process of magnesium smelting furnace,and based on the design of chapter 2,the wireless data transmission device with wireless acquisition and 4G transmission functions is synthetically realized in this paper.Hardware includes power integration board,protocol adapter board,wireless camera,raspberry pie,and 4G industrial router.The software includes data acquisition module,wireless transmission module,cloud storage module,abnormal data elimination module,cloud data offline verification module and data source customization module of hardware-in-the-loop simulation system.(4)Aiming at the real-time requirement of current control hardware-in-the-loop simulation in the melting process of magnesium smelting furnace for the accuracy of data acquisition time and real-time transmission,an end-to-end bidirectional time synchronization mechanism based on acquisition time window and an adaptive adjustment algorithm of transmission parameters are proposed,and the data time synchronization software and transmission parameters adaptive adjustment software are developed.In addition,cloud data validation software for offline verification of packet loss rate and error rate in remote transmission is developed.(5)The wireless data transmission device for the melting process of the magnesium smelting furnace is connected with the hardware-in-the-loop real-time simulation system for the current control of the magnesium smelting furnace built in the laboratory,and the transmission performance of the three-phase electrode current model is verified.By comparing the actual melting current with the current simulation value generated by the three-phase electrode current simulation model,it is verified that the parameters such as packet loss rate,error rate and jitter in the transmission process of the wireless data device developed can meet the needs of real-time simulation of the model.In addition,by monitoring the actual operation of the device,the transmission delay of the device can be effectively controlled within 500 ms,and the acquisition and wireless transmission of process data such as three-phase electrode current,three-phase electrode rotation frequency,three-phase electrode action and furnace rotation speed under charging/exhausting/melting conditions during the melting process of magnesium smelting furnace are realized.