硅基合金冶炼全流程数据治理与质量成分精准回溯系统的设计与实现

Design and Implementation of a Comprehensive Data Governance Framework and Precise Quality Composition Analysis. Backtracking System for the Smelting of Silicon-based Alloys

  • 摘要: 针对硅铁合金冶炼过程存在的“黑箱”操作难题,以及传统质量控制依赖人工经验、缺乏量化分析手段导致高端牌号合格率提升困难的现状,提出了一套全流程数据治理与质量成分精准回溯解决方案。首先,构建了基于“端-边-云”协同架构的冶炼全流程数据采集体系,解决了高温强耦合环境下多源异构数据(高频电气参数与低频化验数据)的时空对齐与融合难题。其次,基于物料守恒与统计过程控制原理,建立了“原料-电气-质量”的数学回溯模型,将模糊的经验炼铁转化为精确的数据映射。最后,设计并开发了包含数据管理、质量分析、回溯查询及系统管理四大核心模块的智能化系统。工程应用显示,此系统可初步进行冶炼全流程数据透明化存储,能可视化监控,回溯模型把质量异常归因周期可从数天缩短到实时,对产品质量的稳定性与批次一致性有部分提高。本研究给硅基合金冶炼的数字化转型给出了一种参考技术范式。

     

    Abstract: To tackle the “black box” operational challenges in silicon iron alloy smelting process and the hard to improve the qualification rate of high-end grades because traditional quality control relies on manual experience, which lacks quantitative analysis methods, a full-process data governance and precise quality composition back-tracking solution is proposed. Firstly, a full-process data collection system for smelting, based on the “edge-cloud” collaborative architecture, is constructed. This system solves the spatiotemporal alignment and fusion difficulties in high-temperature, strongly coupled environments. Secondly, according to the principles of material balance and statistical process control, a mathematical back-tracking model for the “raw material-electrical-quality” is established, enabling the transformation of vague experience-based ironmaking into precise data mapping. Finally, a system with four core modules—data management, quality analysis, back-tracking query, and system management—is designed and developed. Engineering applications indicate that the system can effectively perform transparent storage and visual monitoring of full-process smelting data. With the precise back-tracking model, the quality anomaly attribution cycle is reduced from a few days to real-time, which makes product quality stability and batch consistency significantly improve. This research offers an effective technical approach for the digital transformation of silicon-based alloy smelting.

     

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