CN116294004B - 应用于锂电池生产线的集中除尘*** - Google Patents
应用于锂电池生产线的集中除尘*** Download PDFInfo
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Abstract
本发明公开了一种应用于锂电池生产线的集中除尘***,包括进口与锂电池生产线车间内部连通的前端粉尘收集模块、中间除尘过滤模块、出口与锂电池生产线车间内部连通的末端车间回风模块、辅助压缩气路模块和电控模块,前端粉尘收集模块的出口通过风机与中间除尘过滤模块的进口连通,中间除尘过滤模块的出口与末端车间回风模块的进口连通,辅助压缩气路模块的出口分别与气动阀门和除尘喷吹管的进气口连接,电控模块通过信号线路连接其它模块的各种传感器。本发明通过将处理后的洁净空气回到车间,减少***动力设备的容量和除湿机的数量,通过增设风速仪,利用风速与风机频率做正向PID调节,保证主管道风速在设定值的极小范围波动。
Description
技术领域
本发明涉及锂电池生产线除尘技术领域,尤其涉及一种应用于锂电池生产线的集中除尘***。
背景技术
全球新能源汽车产业迅猛发展,带动动力电池产业体系的壮大。锂电池生产工艺复杂,流程较多。集中除尘涉及合浆、涂布、辊压分切、卷绕、组装焊接、注液和化成等工艺流程,其每个工序的粉尘组分和粉尘量都不同,且具有易燃易爆的性质,需在集中除尘工艺中加入阻火、抗静电和防爆等要求。
锂电池是全球实现清洁能源的重要布局,锂电池生产车间封闭,整个生产流程需要严格控制温度、露点和洁净度(粉尘颗粒数)等关键性指标,其对作业环境要求极高。加之“双碳”政策,实现能源管控的目的,旨在开发一种应用于锂电池集中除尘的***,用以实现除尘后的洁净气体回风到洁净车间,减少除湿机的配置数量以及动力设备的容量。
发明内容
本发明旨在至少在一定程度上解决相关技术中的技术问题之一。为此,本发明的一个目的在于提出一种应用于锂电池生产线的集中除尘***,处理后的洁净空气回到车间,减少***动力设备的容量和除湿机的数量。
根据本发明提出的一种应用于锂电池生产线的集中除尘***,包括进口与锂电池生产线车间内部连通的前端粉尘收集模块、中间除尘过滤模块、出口与锂电池生产线车间内部连通的末端车间回风模块、辅助压缩气路模块和电控模块,所述前端粉尘收集模块的出口通过风机与所述中间除尘过滤模块的进口连通,所述中间除尘过滤模块的出口与所述末端车间回风模块的进口连通,所述辅助压缩气路模块的出口分别与气动阀门和除尘喷吹管的进气口连接,所述电控模块通过信号线路连接其它模块的各种传感器,通过控制线路连接其它模块的各个控制阀及部件。
优选地,所述前端粉尘收集模块沿进口往出口方向依次安装有阻火导流器、风速仪、压力传感器、温度传感器、防火阀、隔离阀、隔爆阀和温度传感器,所述前端粉尘收集模块进口处安装有手动调节阀门,所述手动调节阀门设置在锂电池生产线车间内部。
优选地,所述阻火导流器与风速仪之间外接有消防管道模块,所述消防管道模块出口端与前端粉尘收集模块连接处靠近所述阻火导流器位置处安装有红外火焰探测器,所述消防管道模块进口端连接有氮气存储罐,所述消防管道模块进口端往出口端方向上依次安装有手动球阀、压力变送器和电磁开关阀。
优选地,所述末端车间回风模块沿进口往出口方向依次安装有防火阀、回风阀、露点仪、粉尘浓度计和温度传感器。
优选地,所述前端粉尘收集模块的出口与风机连接处安装有外排阀。
优选地,包括用于提供冷却降温功能的循环冷却管模块,所述循环冷却管模块输入口连接有冷却水箱,所述循环冷却管模块输出口连接有冷却器。
优选地,包括报警提示模块,所述中间除尘过滤模块内部设置有除尘器,所述除尘器滤筒部安装有压差变送器,所述除尘器灰桶部安装有料位计,所述除尘器本体内部安装有烟感传感器和温度传感器,所述风机内部安装有温度传感器,所述报警提示模块的开启信号为:压差变送器检测的压差大于预设值或料位计到达触发值或烟感传感器检测到烟雾或除尘器本体内部检测的温度大于预设值或风机内部检测的温度大于预设值。
优选地,所述除尘器本体通过气体管道外接有灭火器,所述灭火器与所述除尘器本体连通的管道处安装有所述烟感传感器检测到烟雾开启的电磁阀。
优选地,所述防火阀外侧安装有泄露罩。
优选地,应用于锂电池生产线的集中除尘***的控制方法如下:
S10:开机控制方法;
S11,自检程序开启:***启动后,电控模块自检整机传感器无断线和超量程报警、消防***无异常;
S12,阀门按要求打开与关闭:防火阀打开且开到位,外排阀关闭且关到位,隔离阀打开且开到位,回风阀打开且开到位;
S13,风机工作:风机散热风扇启动,3S后风机启动,风机频率依据风速仪做PID调节,调节公式为N=7926.9ln(2826×D×D×V)-16304,其中N代表风机变频频率,D代表管道直径,V代表气体流速;
S14,中间除尘过滤模块工作:卸料器启动,电控模块控制脉冲阀依据除尘器差压和设定喷吹时间进行喷吹动作;
S15:除尘后的气体通过末端车间回风模块回到生产车间,开机完成;
S20:关机控制方法;
S21,风机停止工作:风机停机,散热风扇停机,待风机完全停止后执行步骤S22;
S22,阀门按要求打开与关闭:外排阀打开且开到位、隔离阀关闭且关到位、回风阀关闭且关到位;
S23,中间除尘过滤模块清灰:电控模块控制除尘器反吹,由第一个脉冲阀喷吹到最后一个脉冲阀喷吹完成为一个大循环;
S24,反吹结束,停止反吹,停机完成。
优选地,步骤S11中自检程序检测数据设定值为:
风速仪正常工作风速为0-25m/s,与风机做PID调节将风速稳定在20m/s;抽风管道压力正常值为7000pa,压力值低于-5000pa报警;抽风管道入口烟气正常温度范围为0-40℃,温度高于50℃报警;除尘器入口烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器内部烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器出口烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器差压变送器正常压强范围值为0-600pa,压强达到750pa报警;高效过滤器差压变送器正常压强范围值为0-800pa,压强大于1000pa报警;风机轴头或绕组正常温度范围为0-80℃,温度大于100℃报警;露点仪数值正常数值显示范围为大于-80且小于+20,显示为-80或+20报警;粉尘浓度仪正常数值显示范围为0-10mg/m3,显示数值大于10mg/m3报警,回风管道正常温度范围为0-40℃,温度高于50℃报警;压缩气体输出管道压力正常值为0.3MPa-0.8MPa,压力小于0.2MPa报警;消防管道处压力变送器压力正常值为0.4MPa-1.0MPa,压力小于0.3MPa报警。
本发明中的有益效果是:
(1)通过将各个车间存在工序电芯设备的单体除尘***,进行统一处理,并将车间粉尘收集处理后的洁净空气送回到车间,做到集中控制处理。由于锂电池生产线对生产环境的要求非常严格,若重新引入外界空气,需要提升***动力设备和除湿机的处理能力。因此采用集中处理后的洁净空气重新送回到车间,在保证车间的洁净度的同时减少了***动力设备的装机容量和除湿机的负荷能耗;
(2)通过增设风速仪,利用风速与风机频率做正向PID调节,即风速低于设定值时风机频率增加,反之则减小,保证主管道风速在设定值的极小范围波动,保证主管道风速要求,降低了除尘***主风机的用电能耗;
(3)通过对***内部异常值进行监控,利用报警提示模块进行报警显示,使得电芯设备按照高标准要求运行,保证***能够安全稳定运行;
(4)电控模块模块内部包括成套电气控制盘柜和物联网专用模块,增加物联网功能模块且开发了对应的APP和数据后台记录存储功能,极大地提高了***操作的便捷性和安全性,有效地减少了设备人员的巡检工作时长和频次。
附图说明
在附图中:
图1为本发明提出的一种应用于锂电池生产线的集中除尘***框图;
图2为本发明提出的一种应用于锂电池生产线的集中除尘***的结构框图;
图3为本发明提出的防火阀处的结构示意图;
图4为本发明提出的蜂窝泄露罩的结构示意图;
图5为本发明提出的开机控制方法的流程框图;
图6为本发明提出的关机控制方法的流程框图;
图7为本发明提出的***运行程序数值范围标定表。
具体实施方式
参照图1-3,一种应用于锂电池生产线的集中除尘***,包括进口与锂电池生产线车间内部连通的前端粉尘收集模块、中间除尘过滤模块、出口与锂电池生产线车间内部连通的末端车间回风模块、辅助压缩气路模块和电控模块,所述前端粉尘收集模块的出口通过风机与所述中间除尘过滤模块的进口连通,所述中间除尘过滤模块的出口与所述末端车间回风模块的进口连通,所述辅助压缩气路模块的出口分别与气动阀门和除尘喷吹管的进气口连接,所述电控模块通过信号线路连接其它模块的各种传感器,通过控制线路连接其它模块的各个控制阀及部件;所述前端粉尘收集模块沿进口往出口方向依次安装有阻火导流器、风速仪、压力传感器、温度传感器、防火阀、隔离阀、隔爆阀和温度传感器,所述前端粉尘收集模块进口处安装有手动调节阀门,所述手动调节阀门设置在锂电池生产线车间内部;所述阻火导流器与风速仪之间外接有消防管道模块,所述消防管道模块出口端与前端粉尘收集模块连接处靠近所述阻火导流器位置处安装有红外火焰探测器,所述消防管道模块进口端连接有氮气存储罐,所述消防管道模块进口端往出口端方向上依次安装有手动球阀、压力变送器和电磁开关阀;所述末端车间回风模块沿进口往出口方向依次安装有防火阀、回风阀、露点仪、粉尘浓度计和温度传感器;所述前端粉尘收集模块的出口与风机连接处安装有外排阀;包括用于提供冷却降温功能的循环冷却管模块,所述循环冷却管模块输入口连接有冷却水箱,所述循环冷却管模块输出口连接有冷却器;包括报警提示模块,所述中间除尘过滤模块内部设置有除尘器,所述除尘器滤筒部安装有压差变送器,所述除尘器灰桶部安装有料位计,所述除尘器本体内部安装有烟感传感器和温度传感器,所述风机内部安装有温度传感器,所述报警提示模块的开启信号为:压差变送器检测的压差大于预设值或料位计到达触发值或烟感传感器检测到烟雾或除尘器本体内部检测的温度大于预设值或风机内部检测的温度大于预设值;所述除尘器本体通过气体管道外接有灭火器,所述灭火器与所述除尘器本体连通的管道处安装有所述烟感传感器检测到烟雾开启的电磁阀;所述防火阀外侧安装有泄露罩;所述前端粉尘收集模块进口处安装有可手动调节开度的手动调节阀,所述电控***包括成套电气控制盘柜和物联网专用模块,成套电气控制盘柜和物联网专用模块通过交换机连接,将信息上传至网络平台进行监控。
参照图5-6,应用于锂电池生产线的集中除尘***的控制方法如下:
S10:开机控制方法;
S11,自检程序开启:***启动后,电控模块自检整机传感器无断线和超量程报警、消防***无异常;
S12,阀门按要求打开与关闭:防火阀打开且开到位,外排阀关闭且关到位,隔离阀打开且开到位,回风阀打开且开到位;
S13,风机工作:风机散热风扇启动,3S后风机启动,风机频率依据风速仪做PID调节,调节公式为N=7926.9ln(2826×D×D×V)-16304,其中N代表风机变频频率,范围为0-50HZ,D代表管道直径,V代表气体流速;
S14,中间除尘过滤模块工作:卸料器启动,电控模块控制脉冲阀依据除尘器差压和设定喷吹时间进行喷吹动作;
S15:除尘后的气体通过末端车间回风模块回到生产车间,开机完成;
S20:关机控制方法;
S21,风机停止工作:风机停机,散热风扇停机,待风机完全停止后执行步骤S22;
S22,阀门按要求打开与关闭:外排阀打开且开到位、隔离阀关闭且关到位、回风阀关闭且关到位;
S23,中间除尘过滤模块清灰:电控模块控制除尘器反吹,由第一个脉冲阀喷吹到最后一个脉冲阀喷吹完成为一个大循环;
S24,反吹结束,停止反吹,停机完成。
步骤S11中自检程序检测数据设定值为:
参照图7,风速仪正常工作风速为0-25m/s,与风机做PID调节将风速稳定在20m/s;抽风管道压力正常值为7000pa,压力值低于-5000pa报警;抽风管道入口烟气正常温度范围为0-40℃,温度高于50℃报警;除尘器入口烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器内部烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器出口烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器差压变送器正常压强范围值为0-600pa,压强达到750pa报警;高效过滤器差压变送器正常压强范围值为0-800pa,压强大于1000pa报警;风机轴头或绕组正常温度范围为0-80℃,温度大于100℃报警;露点仪数值正常数值显示范围为大于-80且小于+20,显示为-80或+20报警;粉尘浓度仪正常数值显示范围为0-10mg/m3,显示数值大于10mg/m3报警,回风管道正常温度范围为0-40℃,温度高于50℃报警;压缩气体输出管道压力正常值为0.3MPa-0.8MPa,压力小于0.2MPa报警;消防管道处压力变送器压力正常值为0.4MPa-1.0MPa,压力小于0.3MPa报警。
在水平风管每间隔6m处,以及风管转向大于45°的部位,设置清灰口,风管非清理状态时清灰口应封闭,其设计强度大于风管的设计强度。在风管弯管夹角大于45°的部位,设置监视粉尘在管道内流动的观察窗,其设计强度大于风管的设计强度;
所有的主/支管道均采用不锈钢满焊的形式,避免漏风至管道内造成洁净车间露点不达标的几率;
基于节能的目的,集中除尘后的洁净空气回风至洁净车间,需满足锂电池的生产工艺参数要求,其具体工况参数为温度25±3℃、露点-40±3℃、洁净度352颗粒数/L;
监测主/支管道风速,风速小于设定值时,除尘设备报警,具体流程为主管道加装风速仪,电控模块增加主管道风速设定值。风速与风机频率做正向PID调节(即风速低于设定值时风机频率增加,反之则减小),保证主管道风速在设定值的极小范围波动。当整机除尘器在自动启动且稳态运行时风速出现的过小且大于5S的时间,报警提示模块报警提示风速过低;
监测除尘器滤筒压差,达到反吹设定值后开始进行在线反吹;达到压差极限值后,除尘设备报警,具体流程为电控模块增加在线反吹压力设定值,达到设定值通入压缩空气对滤筒进行喷吹,待低于反吹压力设定值后延迟120S后停止喷吹。触摸屏增加滤筒压差报警设定值,当滤筒压差大于该设定值后,报警提示模块画面报警提示;
除尘器本体增加三处温度测点(进口、出口、除尘器本体中心位置),用以监测除尘器滤筒温度。电控模块增加上述三处的温度报警设定值,当三处有一处温度大于温度报警设定值时,报警提示模块报警提示除尘器温度异常,且打开外排阀同时关闭回风阀,最后主风机减速停机;
高效过滤器增加压差报警,用以监视高效过滤器是否堵塞情况。电控模块增加高效压差报警值,当达到压差报警值时,报警提示模块报警提示高效过滤器堵塞;
除尘器灰桶增加料位计,当灰内料位信号触发时,触摸屏显示报警提示灰桶已满;
除尘器本体增加烟感传感器,连锁二氧化碳或七氟丙烷灭火器。当烟感触发报警后,灭火器电磁阀动作对除尘器进行降温灭火处理,同时电控模块画面报警显示消防已触发且关闭进出口隔离阀、进出口防火阀、回风阀、打开外排阀、风机停机,最后整机停机;
风机增加轴温和绕组温度测点,用以监视主风机温度情况,防止堵转或阻力过大导致风机电机高温从而损坏电机。电控模块画面增加主风机温度保护设定值,当风机实际温度过高时,报警提示模块画面报警提示风机高温,且停止风机。
本发明涉及的关键性阀门及设备需满足以下技术方案:
除尘器:
除尘器,要求除尘器主体设备不漏风,漏风率为0;
除尘器核心部件滤筒为三角形或圆形,过滤精度满足粉尘粒径0.5μm,大于等于99.99%的过滤效率且滤筒需满足抗静电和阻燃的功能,其运行阻力小于750pa;
中间除尘过滤模块:
中间除尘过滤模块,要求高效过滤器耐压15000pa,泄露率为0,高效芯压紧方式采用可调式弹簧压紧;
高效过滤器,要求高效芯为并联布置方式,每组高效芯5通道,可处理3400m3/h的风量,过滤精度满足粉尘粒径0.3μm,大于等于99.999%的过滤效率,其初始阻力小于250pa;
如图4所示:风机,要求温升小于等于5℃,风机轴跟叶轮处的泄露率为0,风机出风口流速控制在20-40m/s,风机进出口需加***器,控制噪音值小于等于90分贝,高压风机轴与叶轮处安装有蜂窝泄露罩,漏风率的计算公式为:其中G回表示回风露点下含水量,G车表示车间露点下含水量,G空饱和空气含水量,RH表示相对湿度;
循环冷却管模块:
循环冷却管模块,要求温降5℃的容量,材质采用不锈钢,换热方式为逆流;
其它设备:
隔爆阀为单向性,为机械阀,具有防爆功能,泄露率为0;
防火阀,电动和手动一体化功能,实现电动和手动复位。由于防火阀本身具有2%的泄露率,在其阀杆处加装可视化泄露罩;
电控模块
电缆要求阻燃功能,实现***自动和手动运行,成套***利用PLC与HMI人机界面实现了设备的手/自动操作运行,设备内部程序采用PID稳态调节,保证了前端管道风速要求的前提下有效地降低了设备的运行能耗。同时电控***配备了远程物联网模块,实现了设备实时有效的监视报警功能和能耗查询功能,提高了设备运行的稳定性和安全性,降低了设备巡检的频次,极其有效地节约了人力成本。
Claims (3)
1.一种应用于锂电池生产线的集中除尘***,其特征在于:包括进口与锂电池生产线车间内部连通的前端粉尘收集模块、中间除尘过滤模块、出口与锂电池生产线车间内部连通的末端车间回风模块、辅助压缩气路模块和电控模块,所述前端粉尘收集模块的出口通过风机与所述中间除尘过滤模块的进口连通,所述中间除尘过滤模块的出口与所述末端车间回风模块的进口连通,所述辅助压缩气路模块的出口分别与气动阀门和除尘喷吹管的进气口连接,所述电控模块通过信号线路连接前端粉尘收集模块、中间除尘过滤模块、末端车间回风模块和辅助压缩气路模块;
所述前端粉尘收集模块的出口与风机连接处安装有外排阀;
所述前端粉尘收集模块沿进口往出口方向依次安装有阻火导流器、风速仪、压力传感器、温度传感器、防火阀、隔离阀、隔爆阀和温度传感器,所述前端粉尘收集模块进口处安装有手动调节阀门,所述手动调节阀门设置在锂电池生产线车间内部;
所述阻火导流器与风速仪之间外接有消防管道模块,所述消防管道模块出口端与前端粉尘收集模块连接处靠近所述阻火导流器位置处安装有红外火焰探测器,所述消防管道模块进口端连接有氮气存储罐,所述消防管道模块进口端往出口端方向上依次安装有手动球阀、压力变送器和电磁开关阀;
所述末端车间回风模块沿进口往出口方向依次安装有防火阀、回风阀、露点仪、粉尘浓度计和温度传感器;
包括用于提供冷却降温功能的循环冷却管模块,所述循环冷却管模块输入口连接有冷却水箱,所述循环冷却管模块输出口连接有冷却器;
包括报警提示模块,所述中间除尘过滤模块内部设置有除尘器,所述除尘器滤筒部安装有压差变送器,所述除尘器灰桶部安装有料位计,所述除尘器本体内部安装有烟感传感器和温度传感器,所述风机内部安装有温度传感器,所述报警提示模块的开启信号为:压差变送器检测的压差大于预设值、料位计到达触发值、烟感传感器检测到烟雾或除尘器本体内部检测的温度大于预设值和风机内部检测的温度大于预设值其中任意一种或多种状况的发生;
所述除尘器本体通过气体管道外接有灭火器,所述灭火器与所述除尘器本体连通的管道处安装有所述烟感传感器检测到烟雾开启的电磁阀;
所述电控模块通过通过信号线路阻火导流器、风速仪、压力传感器、温度传感器、防火阀、隔离阀、隔爆阀、红外火焰探测器、压力变送器、电磁开关阀、回风阀、露点仪、粉尘浓度计、冷却器、压差变送器、料位计、烟感传感器、电磁阀和外排阀;
应用于锂电池生产线的集中除尘***的控制方法,所述方法步骤如下:
S10:开机控制方法;
S11,自检程序开启:***启动后,电控模块自检整机传感器无断线和超量程报警、消防***无异常;
S12,阀门按要求打开与关闭:防火阀打开且开到位,外排阀关闭且关到位,隔离阀打开且开到位,回风阀打开且开到位;
S13,风机工作:风机散热风扇启动,3S后风机启动,风机频率依据风速仪做PID调节,调节公式为N=7926.9ln(2826×D×D×V)-16304,其中N代表风机变频频率,D代表管道直径,V代表气体流速;
S14,中间除尘过滤模块工作:卸料器启动,电控模块控制脉冲阀依据除尘器差压和设定喷吹时间进行喷吹动作;
S15:除尘后的气体通过末端车间回风模块回到生产车间,开机完成;
S20:关机控制方法;
S21,风机停止工作:风机停机,散热风扇停机,待风机完全停止后执行步骤S22;
S22,阀门按要求打开与关闭:外排阀打开且开到位、隔离阀关闭且关到位、回风阀关闭且关到位;
S23,中间除尘过滤模块清灰:电控模块控制除尘器反吹,由第一个脉冲阀喷吹到最后一个脉冲阀喷吹完成为一个大循环;
S24,反吹结束,停止反吹,停机完成。
2.根据权利要求1所述的一种应用于锂电池生产线的集中除尘***,其特征在于:所述防火阀外侧安装有泄露罩。
3.根据权利要求1所述的一种应用于锂电池生产线的集中除尘***,其特征在于,步骤S11中自检程序检测数据设定值为:
风速仪正常工作风速为0-25m/s,与风机做PID调节将风速稳定在20m/s;抽风管道压力正常值为7000pa,压力值低于-5000pa报警;抽风管道入口烟气正常温度范围为0-40℃,温度高于50℃报警;除尘器入口烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器内部烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器出口烟气正常温度范围为0-45℃,温度大于50℃报警;除尘器差压变送器正常压强范围值为0-600pa,压强达到750pa报警;高效过滤器差压变送器正常压强范围值为0-800pa,压强大于1000pa报警;风机轴头或绕组正常温度范围为0-80℃,温度大于100℃报警;露点仪数值正常数值显示范围为大于-80且小于+20,显示为-80或+20报警;粉尘浓度仪正常数值显示范围为0-10mg/m3,显示数值大于10mg/m3报警,回风管道正常温度范围为0-40℃,温度高于50℃报警;压缩气体输出管道压力正常值为0.3MPa-0.8MPa,压力小于0.2MPa报警;消防管道处压力变送器压力正常值为0.4MPa-1.0MPa,压力小于0.3MPa报警。
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