In order to achieve automatic diagnosis of burning-plate fault on the cathode bar and real-time monitoring of current distribution in the process of copper electrolysis

based on the principle of infrared imaging

an infrared camera was used to shoot the image of copper electrolytic tank

and the gray value on the cathode bar in the processed image was extracted. A mathematical model between gray value and cathode bar temperature was developed on the basis of field tests

and the surface temperature of the cathode bar could be calculated. A partial least squares (PLS) method was used to develop a mathematical model between surface temperature and current value of the cathode bar. The square of current value after integration was found to be in quasi-linear relationship with surface temperature of the cathode bar

the coordinates of cathode bar and ambient temperature. Contrast between the current on the cathode bar derived from the model and the current measurement on the field showed that the current on the cathode bar could be accurately determined with this method

which realized real-time monitoring of current value in the copper electrolysis process. In addition

the cathode bar with burning-plate fault could be accurately and automatically diagnosed

and this fault could be predicted by monitoring the current value on the cathode bar

achieving automatic diagnosis of the fault in the copper electrolysis process

thereby reducing burning-plate fault on the cathode bar and resulting in good economic benefits.