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山西铝业巧用 DP 通讯技术，为生产装上 “智慧大脑”

2025-09-17 16:52:11 来源：北方有色网责任编辑：王欣悦

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近日，山西铝业成功攻克一项关键技术难题，通过运用先进的DP通讯技术，将烧结车间的5台隔膜泵关键运行参数顺利接入DCS控制系统。这一创新举措，犹如为生产流程装上了“智慧大脑”，实现了设备状态的远程实时监控，大大提升了设备故障排查效率，为企业生产提质增效注入了强大的技术动能。

此前，烧结车间的隔膜泵运行状况监测面临诸多挑战。推进液压力、空气压力报警等关键参数，只能在现场控制柜的本地界面查看。一旦设备运行出现异常，检修人员不得不紧急奔赴现场，逐个核对参数。由于参数波动迅速且相互关联复杂，现场逐一核查不仅耗时费力，还极易出现遗漏，大大延长了故障响应时间。在紧急故障处置时，这种方式还增加了误判风险，严重影响了生产的连续性和效率，成为制约企业发展的一大痛点。

为了突破这一瓶颈，山西铝业电仪检修车间迅速组建了一支技术精湛的团队。他们深入研究、多轮论证，经过严谨的方案设计与技术评估，最终选定DP通讯技术作为解决问题的“金钥匙”。通过在PLC控制系统与DCS系统之间搭建数据传输桥梁，部署专用通讯模块，并编写高度适配的数据交互程序，团队成功将隔膜泵的12项核心运行参数进行标准化处理，实现了向DCS中央控制系统的实时稳定传输，彻底打通了设备数据“远程可视化”的关键链路。

如今，操作人员只需坐在DCS监控室，便能通过监控画面直观地掌握隔膜泵各项运行参数的动态变化。当设备出现压力异常等故障时，DCS系统会立即自动触发报警，并精准定位故障点。检修人员借助远程数据分析，即可快速判断故障原因，无需再像以往那样反复前往现场排查。这一变革成效显著，平均故障处理时间从原先的40分钟大幅缩短至15分钟以内，生产连续性得到了有力保障。

此次技术攻关，不仅实现了隔膜泵设备状态的远程实时监控，更构建起了一套“实时监测-自动报警-精准处置”的设备运维闭环管理体系，为生产提质增效提供了坚实的技术支撑。

展望未来，山西铝业将继续聚焦现场生产中的难点、痛点问题，充分发挥自身专业技术优势，持续深化设备智能化升级改造。通过不断优化运维流程与效率，以技术创新为驱动，推动生产效能迈向更高台阶，在行业中树立起智能化转型的新标杆。

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