CN102059256B - Equipment operating and process quality state monitoring system for high-speed rolling mill - Google Patents
Equipment operating and process quality state monitoring system for high-speed rolling mill Download PDFInfo
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- CN102059256B CN102059256B CN201010569445A CN201010569445A CN102059256B CN 102059256 B CN102059256 B CN 102059256B CN 201010569445 A CN201010569445 A CN 201010569445A CN 201010569445 A CN201010569445 A CN 201010569445A CN 102059256 B CN102059256 B CN 102059256B
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Abstract
The invention discloses an equipment operating and process quality state monitoring system for a high-speed rolling mill, belonging to the technical field of high-speed wire rolling. Hardware comprises sensors for electric quantity, rotation speed and the like, a 4017+ intelligent data acquisition module, an RS485-RS232 communication conversion module and an industrial control computer. A rolling current signal, a rolling rotation speed signal and other signals are measured by the sensors, then subjected to A/D (Analog to Digital) conversion by the data acquisition module and then stored into the industrial control computer through the RS485-RS232 communication conversion module, the acquired data are issued to a network by utilizing an OPC (OLE (Object Linking and Embedding) for Process Control) protocol, and a user extracts the recorded information from an IE browser or a client side through the network for observing and analyzing. Software comprises an OPC communication module, an operation state real-time monitoring module, an alarm information recording and analyzing module, a trend information analyzing and processing module, a historical recall functional module and an industrial signal logic analysis module. The equipment operating and process quality state monitoring system has the advantages of improving the reliability for equipment operation, prolonging the service life and effectively lowering the cost.
Description
Technical field
The invention belongs to the high-speed wire rolling technical field, a kind of equipment operation and technology amount condition monitoring system that is used for high-speed wire mill particularly is provided.
Background technology
High-speed rod-rolling mill is typically increasingly automated, mechanization equipment, in case catastrophic failure takes place, will bring serious threat to ordinary production, loses huge.Because the influence of functions of the equipments, precision and reliability, the output and the precision of wire product also are affected, and index such as output, lumber recovery is unstable during machine; Equipment fault influences rhythm of production conversely, and for guaranteeing to accomplish the output task, the unavoidable excess load production that stage occurs constitutes bigger influence again to equipment state, function and precision, so forms vicious circle.Person more very, unbalanced production also can cause energy resource consumption increase, technology cost to raise, and equipment state, performance accuracy usually influence product quality in the production process, and be not accurate like Laying head, finishing mill speeds match relation, influences product quality.
Because high speed wire rolling enterprise lacks effective production status monitoring and scientific management means mostly; To the relation between relation, billet heating temperature and the required power of the ability of heating furnace heating steel billet and mill production and Laying head speed and finishing mill speed understanding and assurance deficiency with the aspects such as relation of different size, kind product; The means that can not use quantification are to producing and equipment enforcement fine-grained management; The organization of production model specification is science, reasonable not to the utmost; Be unfavorable for economy, High-efficient Production, cause the unreasonable increase of production cost, reduced product competitiveness.
Function, precision, equipment operational reliability have confidential relation as each links such as the manufacturing of the state of equipment and equipment, use, maintenance, operation, production status.In production practices, these relations all show with the form of information, and information is the media of state and management; Go deep into excavation, research state information; Carry out corresponding management, under the overall background of equipment control and quality integrated management, through technology and management means obtaining, handle, judging and utilizing to equipment and technique information; The quantitative relationship of apparatus for establishing state and product yield, quality; Hold equipment state trend, equipment is taked appropriate Maintenance and Repair, improve the control level of equipment state; Apparatus for establishing function, accuracy quantification standard; Equipment deficiency and mass defect are carried out early warning, tracking; Raising is to the response speed of equipment deficiency and mass defect, strengthens the retrospective to equipment, quality problems, make equipment control, quality management update, perfect; Thereby reach the purpose of functions of the equipments, precision and reliability management, finally realize the target of equipment control, production management, quality management.
At present, China's wire production industry gets into Rapid development stage, and technological level, developmental research, product structure, product quality etc. are drawn close to the International Development level gradually.Yet quantitative statistics of high speed wire rolling production process technology and wire rod installation level are incompatible, are the problems that current wire rod industry development must be paid attention to, and a lot of steel mills lack effective production process technology amount monitoring management means.
Summary of the invention
The present invention is a kind of equipment operation and technology amount condition monitoring system that is used for high-speed wire mill; This system to the roughing mill of high-speed rod-rolling mill, in advance finish rolling, finishing mill, add technology amount parameters such as the rolling electric current that send roller and Laying head and mill speed and monitor in real time; And the survey data are analyzed and calculate, display device running status in real time, record analysis warning message; The draw craft parameter variation tendency provides history to recollect function.Foundation is based on rolling electric current and mill speed information production procedure parameter model of cognition; Identify specification, kind, the production number of Rolling Production; Production process parameters such as the shutdown man-hour of each class, stand-by time realize the best of breed and the balanced production of kind, specification, instruct Manufacturing Worker's normalizing operation and adjustment; Improve the quality of weaving silk, make enterprise be in the optimal economic production status.
The present invention includes hardware and software, hardware comprises current transformer and speed probe, ADAM4017+ data acquisition module, ADAM4520 communication modular converter, industrial control computer; Wherein adopt the RVVP shielded cable to be connected between sensor and the ADAM4017+ data acquisition module; Sensor measurement goes out rolling electric current and rolling tach signal; And be input to the AD port of ADAM4017+ data acquisition module with the analog signal form of ± 10V or 4～20mA; General 8 tunnel analog signals that connect of ADAM module, the analog-signal transitions of sensor being exported through AD conversion chip in the ADAM4017+ module is a data signal.Utilize STP-120 Ω multiple twin shield type cable to be connected between ADAM4017+ data acquisition module and the ADAM4520 communication modular converter, an ADAM4520 module can connect a plurality of ADAM4017+ modules.The data signal that the ADAM4017+ data collecting module collected arrives is sent to the ADAM4520 module via 458 PORT COMs of ADAM4017+ module.ADAM4520 internal agreement conversion chip is the RS232 agreement with the RS485 protocol conversion.Utilize serial interface cable to be connected between ADAM4520 module and the industrial control computer, computer reads the data signal that the ADAM4520 module sends according to the RS232 protocol rule, realizes the distributed capture of rolling electric current and rolling tach signal.And then by industrial control computer with the storage of gathering to real-time data base, and utilize the intranet of OPC service distribution data to enterprise, the user observes and analyzes at IE browser or client extraction recorded information through network.
Software carries out the application layer system development, and software comprises that OPC communication module, running state real-time monitoring module, warning message record and analysis module, tendency information analysis and processing module, history recollects functional module, industrial signal logic analysis module.
(1) OPC (OLE for Process Control) communication module
Adopt the distributed capture system that module constitutes by the 4017+ number; Data centralization is to gathering industrial computer; The service end of OPC agreement is published to network with these data-signals; The data of OPC service end can be regarded as the shared information source on the network, and the OPC client of moving on any network can obtain the signal data that collects in real time.
(2) running state real-time monitoring module
The monitoring running state module shows in real time each item monitoring index of four lines, comprises all current signals, speed and temperature information etc., and the data that exceed standard are carried out alarm and record, utilize the status information of page-turning function switching displayed four lines.
(3) warning message record and analysis module
Warning message contains " Realtime Alerts " " historical warning " " historical query " three parts; The state in alarm message reminding site; Alert data is carrying out warning processing or artificial affirmation back elimination alarm, utilizes the warning message of the page turning selection different work line on the interface.
(4) tendency information analysis and processing module,
Tendency information contains the waveform trend of live signal, when measuring point is too much, need carry out selectivity and show, the user stores or calls in according to the trend configuration of oneself definition, and trend analysis is supported full screen to show and dynamically added deletion observation trend point.
(5) history is recollected module
When rolling operation occurs when unusual; Preserve and write down the historical data in this section period; Coming out to carry out comprehensive analysis and judgement in the unusual data extract that takes place in a period of time of front and back with unusual each relevant technological parameter, analyze the unusual reason that takes place, promptly history is recollected module.
(6) industrial signal logic analysis module
The high speed wire rolling running status technology amount signal of gathering can only reflect the rolling technology and the state of equipment; Can not directly be used for production management; And concerning the information that can be combined into production status between these signals; Industry signal logic analysis module utilizes the logical relation of electric current, rotating speed, temperature, electric weight, and the binding time mark is judged and production process parameters such as Rolling Production specification, kind, production number are derived in calculating.
The present invention can effectively monitor and manage the technology amount parameter of high-speed wire rolling production process; Several data analysis and Presentation Function are provided; But tap/dip deep into is realized the balanced production of enterprise based on the production process parameters information of electric current and rotating speed, makes enterprise be in the optimal economic production status.
The invention has the advantages that; Through being master's comprehensive monitoring with current signal and tach signal; High-speed wire rolling production technology amount is carried out on-line monitoring, increase technology component analysis and management tool, improve the reliability of equipment operation, the target that increases the service life, effectively reduces cost.
Description of drawings
Fig. 1 is a high-speed wire rolling production process technology amount system flow chart of the present invention.
Fig. 2 is a high-speed wire rolling production technology amount system hardware pie graph of the present invention.
Fig. 3 is a high-speed wire rolling production technology amount systems soft ware functional block of the present invention.
The specific embodiment
Below in conjunction with accompanying drawing the present invention is described further:
As shown in Figure 1, the present invention includes hardware and software.Hardware comprises electric current and speed probe, 4017+ intelligent object, ADAM4520 isolating converter, OPC standard interface, industrial control computer.
Measuring through the 4017+ intelligent object of said electric current and tach signal accomplished; Said 4017+ module is connected with 8 input signal ends; Be Vin0～Vin7, two data output signal ends, what this port was exported is one group of 8 current value that measuring point collects; Vs is a power port; Said ADAM-4520 converter need not carry out any modification to the PC hardware and software, can realize that on-the-spot DCS system industrial bus combines with the effective of traditional serial communication, and said OPC is the standard interface that is used for the industrial equipment server; Described software section adopts configuration software to carry out the application layer system development, divides and modular design to the kind of the technology amount parameter of monitoring target, has Monitoring Data real-time storage function, and is as shown in Figure 2.
The software section of high-speed wire rolling production process technology amount of the present invention system is developed based on the B/S architectural framework; At server end configuration opc server; Client uses browser just can directly observe technology amount on-line monitoring system, and can carry out associative operation.
High-speed wire rolling production process technology amount of the present invention system can realize the automatic monitoring of high speed wire rolling production technology amount parameter; Also can under manual intervention, carry out several data analysis and processing; Comprising electric current; Speed and temperature process amount etc., system have figure demonstration, data, result's printing and automatic failure alarm, functions such as remote access.The analytic function of system mainly comprises: the running state real-time monitoring module, and warning message record and analysis module, tendency information analysis and processing module, history is recollected module, and is as shown in Figure 3.
(1) running state real-time monitoring module
The monitoring running state module shows in real time each item monitoring index of four lines, comprises all current signals, speed and temperature information etc., and the data that exceed standard are carried out alarm and record, utilize the status information of page-turning function switching displayed four lines.
(2) warning message record and analysis module
Warning message contains " Realtime Alerts " " historical warning " " historical query " three parts, and the state in alarm message reminding site, alert data can be confirmed just can not point out, and utilizes the warning message of the page turning selection different work line on the interface.
(3) tendency information analysis and processing module,
Tendency information contains the waveform trend of live signal, when measuring point is too much, need carry out selectivity and show, the user stores or calls in according to the trend configuration of oneself definition, and trend analysis is supported full screen to show and dynamically added deletion observation trend point.
(4) history is recollected module
When rolling operation occurs when unusual; Preserve and write down the historical data in this section period; Coming out to carry out comprehensive analysis and judgement in the unusual data extract that takes place in a period of time of front and back with unusual each relevant technological parameter, analyze the unusual reason that takes place, promptly history is recollected module.
Rolling electric current and rolling rotating speed are the major parameters of reflection production status, analyze rotating speed and change in current, obtain multiple high speed wire rolling production process parameters, the judgment device running status:
(1) line balancing analysis
Detect the production process running status in real time, compare, in time adjust the technological parameter of production process, obtain best production status with the historical data that is accumulated in the system; Monitor the ratio and the variation thereof of finishing mill and Laying head speed in real time, adjust and improve the operational factor of equipment such as finishing mill, Laying head, realize the optimum Match of finishing mill and Laying head running speed, overcome the random phenomenon of weaving silk, improve the quality of products.
(2) rolling statistical analysis
Analyze the high speed wire rolling electric current; Obtain production process parameters such as rolling radical, kind, specification, calculate production output automatically, solved the loaded down with trivial details problem that is prone to make mistakes of complicate statistics that relies on; For enterprise examines the level of production of each class platform is provided, also foundation is provided for its rationalization produces; If production line often went wrong in a period of time; Why not normal produce in the systems inspection of the present invention capable of using during this period of time; Be often to occur shutting down for a long time or often occur repeatedly shutting down in short-term; Whether the velocity variations in the production process is obvious, plays the effect of instructing production rationalization; Check the current waveform profile of finishing mill, the standard current value of current current amplitude and steel rolling is compared, in time adjust the steel rolling load, realize the most economical of steel rolling electricity consumption.
(3) data sheet analysis
Well-designed several data form can show and printout at any time in real time.Analyze the rolling radical that the finishing mill electric current obtains; Statistical informations such as output form rolling data sheet; System provides the selection look facility; Can inquire radical per hour rolling in some day rapidly through " the previous day " and " one day after " button, total radical that total output that per tour is rolling and every day are rolling and output etc.; The finish rolling average speed of record per tour, shutdown number of times, downtime, standby times in the operating rate form, statistical informations such as stand-by time; The transient data of each monitoring target of record in the real time information table is like the information such as electric current, speed and temperature of Laying head, pinch roll, pre-finishing mill, finishing mill.
High-speed wire rolling production process technology amount system is from raising equipment prevision maintainability; Through being master's comprehensive monitoring with current signal and tach signal; Tandem mill technology amount production process to the steel rolling unit is carried out on-line monitoring; Increase technology component analysis and management tool, improve equipment operation reliability, increase the service life, effectively reduce.
Claims (7)
1. an equipment operation and a technology amount condition monitoring system that is used for high-speed wire mill is characterized in that, hardware comprises current transformer and speed probe, ADAM4017+ data acquisition module, ADAM4520 communication modular converter, industrial control computer; Wherein adopt the RVVP shielded cable to be connected between sensor and the ADAM4017+ data acquisition module; Sensor measurement goes out rolling electric current and rolling tach signal; And be input to the AD port of ADAM4017+ data acquisition module with the analog signal form of ± 10V or 4～20mA; An ADAM module connects 8 tunnel analog signals, and the analog-signal transitions of sensor being exported through AD conversion chip in the ADAM4017+ data acquisition module is a data signal; Utilize STP-120 Ω multiple twin shield type cable to be connected between ADAM4017+ data acquisition module and the ADAM4520 communication modular converter, an ADAM4520 communication modular converter connects a plurality of ADAM4017+ data acquisition modules; The data signal that the ADAM4017+ data collecting module collected arrives is sent to ADAM4520 communication modular converter via 458 PORT COMs of ADAM4017+ data acquisition module; ADAM4520 communication modular converter internal agreement conversion chip is the RS232 agreement with the RS485 protocol conversion; Utilize serial interface cable to be connected between ADAM4520 communication modular converter and the industrial control computer; Computer reads the data signal that ADAM4520 communication modular converter sends according to the RS232 protocol rule, realizes the distributed capture of rolling electric current and rolling tach signal; And then by industrial control computer with the storage of gathering to real-time data base, and utilize the intranet of OPC service distribution data to enterprise, the user observes and analyzes at IE browser or client extraction recorded information through network; Software comprises that OPC communication module, running state real-time monitoring module, warning message record and analysis module, tendency information analysis and processing module, history recollects functional module, industrial signal logic analysis module.
2. system according to claim 1; It is characterized in that; The distributed capture system of described OPC communication module for constituting by ADAM 4017+ data acquisition module, data centralization is to industrial control computer, and the service end of OPC agreement is published to network with these data-signals; The data of OPC service end can be regarded as the shared information source on the network, and the OPC client of moving on any network can both obtain the signal data that collects in real time.
3. system according to claim 1; It is characterized in that; Described running state real-time monitoring module shows each item monitoring index of four lines in real time, and the data that exceed standard are carried out alarm and record, utilizes the status information of page-turning function switching displayed four lines; Monitoring index comprises all current signals, speed and temperature information.
4. system according to claim 1; It is characterized in that; Warning message record and analysis module: warning message contains " Realtime Alerts " " historical warning " " historical query " three parts; The state in alarm message reminding site, alert data is carrying out warning processing or artificial affirmation back elimination alarm, utilizes the warning message of the page turning selection different work line on the interface.
5. system according to claim 1; It is characterized in that; Tendency information is analyzed and processing module: tendency information contains the waveform trend of live signal; When measuring point is too much, need carry out selectivity and show, the user stores or calls in according to the trend configuration of oneself definition, and trend analysis is supported full screen to show and dynamically added deletion observation trend point.
6. system according to claim 1; It is characterized in that; History is recollected functional module: when rolling operation occurs when unusual; Preserve and write down the historical data in this section period,, analyze the reason that takes place unusually coming out to carry out comprehensive analysis and judgement with relevant unusually each technological parameter data extract in a period of time before and after unusual the generation.
7. system according to claim 1 is characterized in that, utilizes the logical relation of electric current, rotating speed, temperature, electric weight, and the binding time factor is judged and Rolling Production specification, kind, production number production process parameters are derived in calculating.
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| CN201010569445A CN102059256B (en) | 2010-11-26 | 2010-11-26 | Equipment operating and process quality state monitoring system for high-speed rolling mill |
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Address after: 100041 Shijingshan Road, Shijingshan District, Shijingshan District, Beijing Patentee after: Shougang Group Co. Ltd. Address before: 100041 Shijingshan Road, Shijingshan District, Shijingshan District, Beijing Patentee before: Capital Iron & Steel General Company |
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