Design And Development Of Hardware Of Embedded Control System For Fused Magnesia Furnace

Fused magnesia is an advanced refractory material with high melting point, strong oxidation and slag resistance which is widely used in metallurgy and aerospace industries. Problems are found in the production of fused magnesia, including high energy consumption and low grade. With requirements of higher efficiency of energy utilization and the product grade, the control algorithm in fused magnesia industry is increasingly complex. Since the traditional PLC controller is difficult to meet the requirements of the complex control algorithm, the design and development of embedded controller is necessary to solve the existing problems in fused magnesium furnace.Supported by national basic research program of China (973 Program, NO2009CB320601), this thesis considers the condition of current controller systems and demonstrates the feasibility of embedded controller in fused magnesia industry. In accordance with the requirements of the control algorithm, this thesis, based on the design of X86, presents the overall framework of hardware in embedded controller system for the first time. Under that framework, this thesis completed the design and development of the embedded controller, offered a platform to support the complex control algorithm and verified the results on industrial fields. The main works of this thesis are as follows:(1) This thesis analyzed the current situation and limitations of PLC control systems for fused magnesium furnace, introduced the trends of embedded industrial controllers, described the structure and smelting technology of fused magnesia, and analyzed the difficulties and methods in controlling, as well as the feasibility of embedded technology in fused magnesium industry.(2) Then, the thesis analyzed the needs of embedded controller in fused magnesium furnace, determined the functions of embedded controller and completed the overall framework’s design.(3) This thesis completed the development of embedded controller in fused magnesium furnace. According to the overall design, the thesis completed the selection of an embedded controller board and a data acquisition board. Matlab Simulink module is used to complete the programming of the data acquisition board drivers. The signal conditioning board is developed to solve the problems like the mismatching between signals in embedded controller and on the worksite, thus achieving transformation and isolation of signals’input and output. In addition, the mechanical design and implication is completed to solve thermal dissipation and dust prevention problems.(4) Finally, series of experiments are carried out to test the embedded controller in fused magnesium furnace, including fused magnesium furnace hardware-in-loop simulation system experiment and industrial worksites experiment. The results show that the controller is effective in the scene of the production process.