Development Of The Monitoring System For Brick-Firing Tunnel Kiln And Research On The Optimal Operation Guide For The Roasting Process

The sintered porous brick is one of the major building material products, which has been widely used in masonry engineering and produced mainly through the tunnel kiln sintering process. There are hundreds of fired brick production enterprises in Guangxi. Most of them are facing the problems of low cultural quality of the employees, low automation level, extensive production management, poor stability of the product quality, high energy consumption and low production efficiency. Therefore, Research of the monitoring system for brick-firing tunnel kiln and then exploring the optimization problem of brick tunnel kiln production process having important significance to industrial upgrading and energy saving in brick industry.Based on the analysis of the research and application in tunnel kiln technology, considering with the characteristics and process requirements of the brick industry in Guangxi, a monitoring system for brick-firing tunnel kiln has been exploited through investigating the facing problems and needs of the brick production enterprises. The system consist of3layers, they are monitoring host and the monitoring software, field testing transmission equipment and data communication network. The monitoring system includes these function modules:process monitoring, report and query, alarm, optimal operation guide, offline parameter input and the case base management. The real-time value of the temperature, current and other parameters can be displayed in the form of dynamic diagram on the monitor. Alarm signal would be sent automatically in abnormal conditions, so as to facilitate the operator to grasp the production status. Process parameters have been stored in the host with the form of database, preparing for the analysis of production in a period.Because of the characteristics of large time delay, nonlinear, strong coupling and time-varying, it is hard to establish the precise mechanism model and optimize it by traditional method. For this reason, an optimal operation guide method for roasting process based CBR has been proposed in this paper. According to the analysis made by technology experts and the person in charge of production, the original case base has been built based the process data collected by the monitoring system under various conditions. The optimal operation guide method based CBR compare the working conditions with all the cases periodically, and find out the historical cases within acceptable similarity, then obtain the case solution of present conditions by case reuse algorithm. Revised case solution will be applied to operator as optimal operation guide value and stored to case base for retrieved next time so as to updating the case database. The CBR method solves new problems using historical cases without modeling of the controlled process, and update the case base dynamically. Actual running results shows, the optimal operation guide method based CBR has good practical guiding significance.The system has been in stable running at a medium-sized fired brick enterprise in GuangXi since December2011, with its indices fitting the requirement of the production process and achieving the goal.