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,该文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,该系统可实现冶炼全流程数据透明存储与可视化监测。依托回溯模型,质量异常溯源周期由数天压缩至实时级别,有效提升产品质量稳定性与批次一致性。此研究为硅基合金冶炼行业数字化转型提供了可行的技术参考。

     

    Abstract: Aiming at the black-box operation problem in ferrosilicon smelting, as well as the difficulty in improving the qualification rate of high-grade products caused by manual experience reliance and insufficient quantitative analysis in traditional quality control, this paper proposes a full smelting process data governance and precise quality composition traceability solution. Firstly, a full smelting process data acquisition system based on end-edge-cloud collaborative architecture is constructed, which realizes the spatio-temporal alignment and fusion of multi-source heterogeneous data including high-frequency electrical parameters and low-frequency assay data under high-temperature and strongly coupled conditions. Secondly, mathematical traceability models covering raw materials, electrical parameters and quality indicators are established based on material conservation and statistical process control principles, converting empirical smelting into accurate data mapping. Finally, an intelligent system consisting of four core modules, namely data management, quality analysis, traceability query and system management, is designed and developed. Engineering applications verify that the system supports transparent data storage and visual monitoring throughout the full smelting process. The traceability model shortens the quality anomaly tracing cycle from several days to real time, and improves product quality stability and batch consistency. This study provides a practical technical reference for the digital transformation of the silicon-based alloy smelting.

     

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