Summary of the invention
The measuring process that the objective of the invention is to overcome common tracking system is dangerous, measurement result inaccuracy, the single system's unsafe factor that causes of signal source, solve identification of signal source benchmark and switching problem; Solution causes tracking data error compensation, accurate processing signals source to overflow by the mechanical roller wearing and tearing, to the tracking data safe handling, is distributed to each user of continuous casting.
To achieve these goals, the invention provides a kind of conticaster casting stream tracking system, comprising:
The encoder group comprises that correspondence is installed on a plurality of encoders of a plurality of fan-shaped section drive motors rear axles, and each encoder rotates with the fan-shaped section drive motors of correspondence, and encoder whenever turns around and produces the pulse of fixed number;
The man-machine interface unit is used for determining the driven roller actual diameter according to the mechanical roller abrasion condition;
Programmable logic controller (PLC), be connected with encoder group and man-machine interface unit, the driven roller actual diameter that is used for determining in the pulse that produces according to each encoder and man-machine interface unit calculates strand and dummy bar in the physical location of fan-shaped section and the cast length of strand.
In one embodiment of the invention, described programmable logic controller (PLC) comprises:
The high-speed counting template is connected with each encoder, is used to receive the pulse that each encoder produces, and stored count is carried out in the pulse that each encoder produces respectively;
Correct identification of signal source and screening module, be connected with the high-speed counting template, be used for each encoder, the umber of pulse that it adds up is converted the high-speed counting template to speed, when the difference of the speed of arbitrary coder transitions and system's given speed is in specified scope, this encoder is defined as current correct signal source;
Follow the tracks of computing module, be connected with screening module and man-machine interface unit with the correct identification of signal source, be used for the correct identification of signal source and each definite current correct signal source of screening module, the driven roller actual diameter of the umber of pulse and the man-machine interface unit of its accumulative total being determined according to the high-speed counting template calculates strand and the physical location of dummy bar in fan-shaped section and the cast length of strand.
In an embodiment more of the present invention, described programmable logic controller (PLC) also comprises:
The signal source counting overflows processing module, be connected with high-speed counting template and tracking computing module, be used for when the high-speed counting template exceeds presetting pulse and counts the umber of pulse of encoder accumulative total, to add 1 corresponding to the overflow position of this encoder, this moment, the high-speed counting template was again to this encoder accumulative total pulse
Then, follow the tracks of computing module and also overflow overflow position calculating strand and dummy bar physical location in fan-shaped section and the cast length of strand of processing module this encoder according to the signal source counting.
In another embodiment of the present invention, described programmable logic controller (PLC) also comprises:
Follow the tracks of the classification processing module, be connected, be used for strand and the physical location of dummy bar and the cast length of strand of following the tracks of computing module calculating is carried out data transaction according to different production models with the tracking computing module;
Dispensing continuous casting user data module is connected with tracking classification processing module, is used for tracking classification processing module data converted is distributed to the continuous casting different user.
Compared with prior art, the advantage of conticaster casting stream tracking system of the present invention is:
1) by a plurality of encoders, supercomputing template, signal source counting overflow processing module, the correct identification of signal source with the screening module, follow the tracks of computing module and successfully measure base and the physical location of dummy bar in fan-shaped section and the cast length of strand;
2) a plurality of encoder correspondences place a plurality of fan-shaped section drive motors rear axles, measuring process safety;
3) adopt a plurality of encoders, with the rotation synchronously of corresponding fan-shaped section drive motors and produce count pulse respectively separately, detect strand or dummy bar stroke situation simultaneously, it is standby mutually that multiple spot detects, and detects safe and reliable than single-point;
4) adopt the signal source counting to overflow processing module, when counting down to of record high-speed counting template specified overflow value, overflow to handle and remove and overflow variable in advance, guaranteeing to overflow under the prerequisite of handling safety, the tracking range (through adjusting error) that error was produced less than a cycle of operation less than 2mm, and dried scratching overflowed in the vacation that effectively eliminating " zero wafts " causes, solve the overflow problem in accurate processing signals source, improved the reliability and the tracking accuracy (accumulative total of overflowing number of times also will be handled with zero clearing) in signal source;
5) correct identification of signal source and screening module have been adopted, from a plurality of encoders, identify reference signal source, overcome this fixed signal source signal distortion that causes owing to unpredictalbe reason when selecting the fixed signal source in the prior art as reference signal, cause and follow the tracks of failure, influence the ordinary production influence.
6) adopted the man-machine interface unit, can determine the driven roller actual diameter according to the mechanical roller abrasion condition, solved the tracking data error compensation problem that is caused by the mechanical roller wearing and tearing, measurement result is more accurate;
7) tracking classification processing module and dispensing continuous casting user data module have been adopted, follow the tracks of the classification processing module and can convert the cast length of the physical location of the strand that calculates and dummy bar and strand the data of user's needs to according to different production models, dispensing continuous casting user data module is distributed to the continuous casting different user with data converted.
By following description also in conjunction with the accompanying drawings, it is more clear that the present invention will become, and these accompanying drawings are used to explain embodiments of the invention.
The specific embodiment
With reference now to accompanying drawing, describe embodiments of the invention, the similar elements label is represented similar elements in the accompanying drawing.
Before setting forth conticaster casting stream tracking system of the present invention, the technology background to this system describes earlier.
Fan-shaped section is made up of a driven roller and a plurality of (general 6, each 3 of driven roller front and back) non-driving pressure roller.Fig. 1 has schematically showed the composition of fan-shaped section, and wherein filled circles is represented the driven roller of fan-shaped section, and open circles is represented the non-driving pressure roller of fan-shaped section.Driven roller is connected on the drive motors of outside by mechanical linkage.
Below conticaster casting stream tracking system of the present invention is described, as shown in Figure 2, described conticaster casting stream tracking system comprises:
Encoder group 001 comprises that correspondence is installed on a plurality of encoders 002 of a plurality of fan-shaped section drive motors rear axles, and each encoder 002 rotates with the fan-shaped section drive motors of correspondence, and encoder 002 whenever turns around and produces the pulse of fixed number;
Man-machine interface unit 100 is used for determining the driven roller actual diameter according to the mechanical roller abrasion condition, and the driven roller actual diameter of determining is sent to programmable logic controller (PLC) 200, mends the reward machine error to revise;
Programmable logic controller (PLC) 200, the driven roller actual diameters that are used for determining in the pulse that produces according to each encoder 002 and man-machine interface unit 100 calculate strand and dummy bar in the physical location of fan-shaped section and the cast length of strand.
Wherein, programmable logic controller (PLC) 200 comprises:
High-speed counting template 201 is connected with each encoder 002, is used to receive the pulse that each encoder 002 produces, and stored count is carried out in the pulse that each encoder 002 produces respectively;
Central processing unit 202, be connected with high-speed counting template 201 and man-machine interface unit 100 by the internal system bus, be used for calculating strand and dummy bar in the physical location of fan-shaped section and the cast length of strand according to the driven roller actual diameters that high-speed counting template 201 is determined the umber of pulse and the man-machine interface unit 100 of each encoder 002 accumulative total.
Wherein, central processing unit 202 comprises:
Correct identification of signal source and screening module 203, be connected with high-speed counting template 201, be used for each encoder 002, the umber of pulse that it adds up is converted high-speed counting template 201 to speed, when the difference of the speed of arbitrary encoder 002 conversion and system's given speed is in specified scope, this encoder is defined as current correct signal source;
The signal source counting overflows processing module 204, be connected with high-speed counting template 201, when being used for umber of pulse when 201 pairs one encoders of high-speed counting template 002 accumulative total and exceeding presetting pulse and count, to add 1 corresponding to the overflow position of this encoder 002, this moment, high-speed counting template 201 was again to this encoder 002 accumulative total pulse;
Follow the tracks of computing module 205, count with the correct identification of signal source and screening module 203, signal source and to overflow processing module 204 and man-machine interface unit 100 is connected, be used for each current correct signal source that correct identification of signal source and screening module 203 are determined, according to high-speed counting template 201 umber of pulse, the signal source counting of its accumulative total overflowed processing module 204 its overflow position and the driven roller actual diameters determined of man-machine interface unit 100 are calculated strand and the physical location of dummy bar in fan-shaped section and the cast length of strand;
Follow the tracks of classification processing module 206, be connected, be used for strand and the physical location of dummy bar and the cast length of strand of following the tracks of computing module 205 calculating is carried out data transaction according to different production models with tracking computing module 205;
Dispensing continuous casting user data module 207 is connected with tracking classification processing module 206, is used for tracking classification processing module 206 data converted are distributed to the continuous casting different user.
Fig. 3 has showed that conticaster shown in Figure 2 casting stream tracking system measures strand and the dummy bar physical location in fan-shaped section and the principle of the cast length of strand.As shown in Figure 3, the measuring process of described conticaster casting stream tracking system comprises:
When step S1, each encoder 002 rotate with the fan-shaped section drive motors of correspondence, produce pulse respectively;
Step S2, supercomputing template 201 adds up the umber of pulse of each encoder 002 respectively;
Step S3, to each encoder 002, the correct identification of signal source converts high-speed counting template 201 to speed to the umber of pulse that it adds up with screening module 203;
Step S4, whether the difference that the correct identification of signal source and screening module 203 are judged the speed of current encoder 002 conversion and system's given speed in prescribed limit, if not, continues next step, if, commentaries on classics step S6;
Step S5 is defined as current encoder with next encoder, changes step S4;
Step S6, the correct identification of signal source is defined as current correct signal source with screening module 203 with this encoder;
Step S7, the signal source counting overflows the umber of pulse of processing module 204 real time monitoring supercomputing templates 201 to each encoder 002 accumulative total, when the umber of pulse of 201 pairs one encoders of high-speed counting template 002 accumulative total exceeds presetting pulse and counts, to add 1 corresponding to the overflow position of this encoder 002, this moment, high-speed counting template 201 was again to this encoder 002 accumulative total pulse;
Step S8, follow the tracks of the diameter that computing module 205 receives the driven roller of man-machine interface unit 100 transmissions, to correct each the current correct signal source determined with screening module 203 of discerning of signal source, follow the tracks of computing module 205 and its umber of pulse that adds up, signal source counting are overflowed the overflow position of processing module 204 to it, and the diameter of the driven roller of man-machine interface unit 100 transmissions calculates strand and the physical location of dummy bar in fan-shaped section and the cast length of strand according to high-speed counting template 201;
Step S9, tracking classification processing module 206 will be followed the tracks of strand and the physical location of dummy bar and the cast length of strand of computing module 205 calculating and be carried out data transaction according to different production models;
Step S10, dispensing continuous casting user data module 207 will be followed the tracks of classification processing module 206 data converted and will be distributed to the continuous casting different user.
As from the foregoing, conticaster casting stream tracking system of the present invention has following advantage:
1) correctly identification is overflowed processing module 204 with screening module 203, signal source counting, tracking computing module 205 is successfully measured base and the physical location of dummy bar in fan-shaped section and the cast length of strand by a plurality of encoders 002, supercomputing template 201, signal source;
2) a plurality of encoder 002 correspondences place a plurality of fan-shaped section drive motors rear axles, measuring process safety;
3) adopt a plurality of encoders 002, with the rotation synchronously of corresponding fan-shaped section drive motors and produce count pulse respectively separately, detect strand or dummy bar stroke situation simultaneously, it is standby mutually that multiple spot detects, and detects safe and reliable than single-point;
4) adopt the signal source counting to overflow processing module 204, when the counting arrival presetting pulse of high-speed counting template 201 is counted, signal source counting overflows processing module 204 and overflows to handle and remove and overflow variable in advance, guaranteeing to overflow under the prerequisite of handling safety, the tracking range (through adjusting error) that error was produced less than a cycle of operation less than 2mm, and dried scratching overflowed in the vacation that effectively eliminating " zero wafts " causes, solve the overflow problem in accurate processing signals source, improved the reliability and the tracking accuracy (accumulative total of overflowing number of times also will be handled with zero clearing) in signal source;
5) correct identification of signal source and screening module 203 have been adopted, from a plurality of encoders 002, identify current correct signal source (reference signal source), overcome this fixed signal source signal distortion that causes owing to unpredictalbe reason when selecting the fixed signal source in the prior art as reference signal source, cause and follow the tracks of failure, influence ordinary production.
6) adopted man-machine interface unit 100, can revise the diameter of driven roller according to the mechanical roller abrasion condition, solved the tracking data error compensation problem that is caused by the mechanical roller wearing and tearing, measurement result is more accurate;
7) tracking classification processing module 206 and dispensing continuous casting user data module 207 have been adopted, follow the tracks of classification processing module 206 and can convert the cast length of the physical location of the strand that calculates and dummy bar and strand the data of user's needs to according to different production models, dispensing continuous casting user data module 207 is distributed to the continuous casting different user with data converted.
Wherein, the correct identification of signal source with the process that 203 identifications of screening module filter out current correct signal source is:
Step S101, to each encoder 002, the correct identification of signal source and screening module 203 are calculated the instantaneous velocity of corresponding fan-shaped section drive motors according to high-speed counting template 201 to its umber of pulse totally, and computing formula is:
(get unit interval V
n=Δ C
n/ Pm), and wherein, V
nBe the instantaneous velocity of the fan-shaped section drive motors corresponding, Δ C with n encoder 002
nFor to n encoder 002, the umber of pulse in the unit interval that umber of pulse of its accumulative total is obtained by high-speed counting template 201, Pm is the umber of pulse of encoder individual pen, wherein n is the numbering of encoder 002;
Step S102, signal source is correctly discerned and is screened the average speed that the instantaneous velocity of
module 203 according to each the fan-shaped section drive motors that calculates calculates each fan-shaped section drive motors, and computing formula is:
Wherein, V
n' be the average speed of the fan-shaped section drive motors corresponding with
n encoder 002, K
nBe the sampling number of the fan-shaped section corresponding, V with
n encoder 002
nThe instantaneous velocity of the fan-shaped section drive motors corresponding during for each sampling with
n encoder 002;
Step S103, correct identification of signal source and screening module 203 be average speed and system's whether overshoot scope of given speed of each fan-shaped section drive motors relatively, if not, be current correct signal source according to definite successively the fan-shaped section drive motors corresponding codes device of formation with not overshoot scope;
In addition, because difference (as the asynchronism(-nization) of starting shipment of each encoder 002, leak sign indicating number etc.), their count value is asynchronous, therefore before it is used as reference signal, state " synchronously " before at first will making itself and original signal normally is promptly the initial value of the normal value of original signal as this encoder.
Moreover when reference signal source switched, the umber of pulse in the current correct signal source that the correct identification of signal source and screening module 203 are deposited deposit unit was sent to the deposit unit in the current correct signal source of newly choosing, and scratches switching to realize not having.
Wherein, follow the tracks of computing module 205 calculate strands and dummy bar in fan-shaped section physical location and the process of the cast length of strand be specially:
Step S201, follow the tracks of computing module 205 and receive the driven roller actual diameter that man-machine interface unit 100 is determined according to the mechanical roller abrasion condition, calculate straightening roller machine error correction factor e according to the driven roller actual diameter, computing formula is: the e=driven roller actual diameter/straight warp of nameplate roller;
Step S202 follows the tracks of
computing module 205 and calculates overflow error, and computing formula is
Wherein τ is an overflow error, and Sm is the maximum cycle of
central processing unit 202, and Pn is the maximum impulse of
encoder 002, and D is the diameter of driven roller (as Fig. 1), and N is the maximum speed of fan-shaped section drive motors, and i is a speed reducing ratio, and 60000 is the dimension adaptation coefficients;
Step S203 follows the tracks of computing module 205 and calculates to overflow according to overflow error τ and mend reward E, and computing formula is: E=overflows number of times * τ/2, wherein overflows number of times and be the value that the signal source counting overflows the overflow position that processing module 204 determines;
Step S204, follow the tracks of computing module 205 according to straightening roller machine error correction factor e value, overflow and mend reward E value calculating tracking length function, computing formula is: T (l)=X
c* e+X
l+ E, wherein, T (l) is for following the tracks of length function, X
c(overflow value is with interior length for strand is followed the tracks of this register cell length that computing formula calculates, it is that correct current baseline encoded number of pulses and the computing of associated mechanical parameter of discerning current correct signal source (reference signal source) the corresponding codes device of determining with screening module 203 of signal source gets), e is a straightening roller machine error correction factor, X
lOverflow the tracking cumulative length that formula calculates for strand is all previous, computing formula is: X
l=overflowing number of times * one overflows maximum, overflow maximum and overflow processing module 204 by the signal source counting and determine), E appreciates for overflowing to mend;
Step S205 follows the tracks of computing module 205 and calculates strand and the physical location of dummy bar in fan-shaped section and the cast length of strand according to the tracking length function of calculating.
In addition, (operating personnel operate by the production operation case according to rhythm of production in the production model conversion, operation signal is received by system, finish associative mode conversion) time, follow the tracks of that computing module 205 will be followed the tracks of the encoded radio of computing deposit unit and output valve that signal source is counted the overflow register that overflows processing module 204 resets.During continuous casting was produced, different production models should have different tracking mutually.
Wherein, following the tracks of classification processing module 206 will follow the tracks of computing module 205 result calculated and carry out data transaction, dispensing continuous casting user data module 207 according to different production models and will follow the tracks of the process that processing module 206 data converted of classifying are distributed to the continuous casting different user and be specially:
Step S301 follows the tracks of classification processing module 206 sending dummy ingot, roll gap to measure, simulate the current operator scheme of selection in casting, casting, the clear pattern, determines the distance R u of dummy bar head from each section driven roller according to the current operator scheme of selecting
n, the dummy ingot tail is crossed or dummy bar head from the distance R d of each section driven roller
n
Step S302 follows the tracks of classification processing module 206 according to the distance R u of the dummy bar head of determining from each section driven roller
n, the dummy ingot tail is crossed or dummy bar head calculates from the distance R d of each section driven roller that the fan-shaped section driven roller lifts tracing function ST (r) and the fan-shaped section driven roller is depressed tracing function ST (d), and is as follows respectively:
N section fan-shaped section driven roller lifts the tracking expression formula:
ST(r)
n=C
n-DB-Ru
n(n=1、2、3、4、5......)
Wherein, ST (r)
nBe that n section driven roller lifts pursuit gain, C
nBe n section driven roller to crystallizer copper pipe distance suitable for reading, DB is actual pursuit gain (is the cast length of strand among the step S205, just the length of travel of dummy bar), Ru
nBe the distance of dummy bar head from each section driven roller;
N section fan-shaped section driven roller is depressed the tracking expression formula:
ST(d)
n=C
n-DB+Rd
n(n=3、4、5......)
Wherein, ST (d)
nBe that n section driven roller is depressed pursuit gain, C
nBe n section driven roller to crystallizer copper pipe distance suitable for reading, DB is actual pursuit gain (is the cast length of strand among the step S205, just the length of travel of dummy bar), Rd
nFor the dummy ingot tail cross or dummy bar head from the distance of each section driven roller;
Step S303, tracking classification processing module 206 lifts tracing function ST (r) according to the fan-shaped section driven roller and the fan-shaped section driven roller is depressed tracing function ST (d) calculating tracking data, obtain speed parameter, follow the tracks of length value, production model conversion or end mark (ST (r), ST (d) is each fan-shaped section driven roller lifted or depressed instruction under different production models a executive condition), dispensing continuous casting user data module 207 is with speed parameter, follow the tracks of length value, production model conversion or end mark are sent to each user, to respond different track demand incidents, as the casting streaming system, crystallizer is transferred wide, soft depressing, mold oscillation, secondary cooling water, cutting machine, secondary process control computer system etc.
Above invention has been described in conjunction with most preferred embodiment, but the present invention is not limited to the embodiment of above announcement, and should contain various modification, equivalent combinations of carrying out according to essence of the present invention.