Implementation of a fuzzy logic based system for the generation of a risk indicator in a DC electric arc furnace
Erives Sánchez, Omar
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The main objective of this research was to find a very robust EAF arc coverage indicator that may alert the furnace operator in advance of reaching any risky operating condition and build a reliable prototype that will prove its accuracy under real field conditions. The steps to accomplish this objective were: -Develop a mathematical tool, using fuzzy logic to design algorithms that could at least give outputs that were in line with the predictions of arc coverage done by the best furnace operator. This point is covered in chapter 3 of the dissertation. -Study the correlation between vibration and arc coverage, then research for an adequate technique to measure vibration under very hard environment conditions. Develop mathematical tools to process vibration signals and correlate them with measured water panel temperature. In chapter 4 is detailed the information regarding this point. -Study how to anticipate any risky operation situation and alert the furnace operator to take immediate actions, like graphite and oxygen injection or power control to avoid furnace damage. Combine different variables that today are measured at any EAF, like water panels temperature and its rate of change in time with vibration and sound, to have a more robust EAF “risk indicator”. Chapter 5 covers this point with detail. -Build a system that can run all these algorithms in real time under a steel shop environment condition. Make the final tuning of the entire system under real working conditions in a steel shop with a DC EAF and probe its reliability and accuracy along several weeks of field work. This point is described in chapter 6. In light of all the above-mentioned activities and the field experimental results obtained, it is clear that the objectives of the research proposal were fully accomplished and the developed “EAF risk indicator” is a novel contribution to improve safety in the steel industry and at the same time increase productivity and reduce maintenance costs.
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