CN102912275B - Automatic control system for coating thickness of hot galvanizing line - Google Patents
Automatic control system for coating thickness of hot galvanizing line Download PDFInfo
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- 239000011248 coating agent Substances 0.000 title claims abstract description 100
- 238000000576 coating method Methods 0.000 title claims abstract description 100
- 238000005246 galvanizing Methods 0.000 title claims abstract description 17
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- 238000004519 manufacturing process Methods 0.000 claims abstract description 15
- 238000005070 sampling Methods 0.000 claims abstract description 8
- 230000008901 benefit Effects 0.000 claims abstract description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 41
- 239000011701 zinc Substances 0.000 claims description 41
- 229910052725 zinc Inorganic materials 0.000 claims description 41
- 230000008859 change Effects 0.000 claims description 16
- 230000001276 controlling effect Effects 0.000 claims description 12
- 230000001105 regulatory effect Effects 0.000 claims description 11
- 239000002994 raw material Substances 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 7
- 239000010959 steel Substances 0.000 claims description 7
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- 230000007774 longterm Effects 0.000 claims description 2
- 230000000694 effects Effects 0.000 abstract description 11
- 230000008569 process Effects 0.000 abstract description 11
- 238000005097 cold rolling Methods 0.000 abstract 1
- 230000003247 decreasing effect Effects 0.000 abstract 1
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000004308 accommodation Effects 0.000 description 2
- 238000004422 calculation algorithm Methods 0.000 description 2
- 238000011217 control strategy Methods 0.000 description 2
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- 238000009628 steelmaking Methods 0.000 description 1
- 238000004260 weight control Methods 0.000 description 1
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Abstract
The invention provides a coating thickness control system of a cold-rolling hot-dip galvanizing line, which comprises an air knife, a thickness gauge, an industrial PC, a PLC controller and a coating thickness control program, wherein the control program runs in the industrial PC, the industrial PC is connected with the PLC by PROFIBUS DP field bus, the PLC collects the actual value of the coating thickness and the production process data and sends the actual value and the production process data to the industrial PC, the control program adopts a cascade control method, designs the secondary loop into a follow-up system by utilizing the conventional PID dense sampling advantage, the sampling period of the primary loop is 50-100 times of that of the secondary loop, calculates the set values of the air knife pressure, the space and the frame position in real time according to the actual value of the coating thickness and the production process data and sends the set values to a PLC controller to realize the adjustment of the air knife pressure, the space and the frame position, meanwhile, the manual/automatic mode undisturbed switching and the coating specification-variable switching control in the roll changing process are designed. The invention can quickly eliminate the thickness deviation of the coating and has good control effect in the processes of specification changing and speed increasing and decreasing. < | 1- >)
Description
Technical field
The invention belongs to steel making equipment technical field, be applicable to the zinc coat thickness control of galvanization production line.
Background technology
Heat zinc coating plate is widely used in building, household electrical appliances, automobile and other industries because of its good erosion resistance.In the last few years, along with heat zinc coating plate market competition is day by day fierce, the requirement of user to heat zinc coating plate quality was more and more higher.Thickness of coating and even property thereof evaluate an important indicator of galvanized sheet quality, the too thin erosion resistance affecting product of coating, and coating is too thick affects the waste that the spot weldability of product and tack cause zinc raw material simultaneously.At present, domestic most galvanization production line still adopts traditional control method to the control of thickness of coating, namely empirically carries out manual setting to set(ting)value by operator.Manual setting inevitably caused thin or super thick, finally caused the waste of galvanizing production Quality Down and zinc raw material.Therefore develop high performance zinc coating thickness automatic control system for improve the quality of products and economize in raw materials consume significant.
At present, each main hot dip galvanizing process producer of the world, on summary knowhow basis, has defined oneself Controlling System a set of.The hardware device that different manufacturers hot dip galvanizing coating Controlling System adopts is substantially identical, and topworks adopts air knife, and test set adopts cold state thickness gauge, but different on control strategy and Controlling model, and this also determines the control effects of system.
" the closed-loop control brief introduction of hot galvanizing line zinc coating thickness " (bang dragon, Sichuan is metallurgical, 200628 (6)), describe the zinc coat thickness control system of VAICLACIM company, system comprises set(ting)value model, feedforward close loop control circuit and feedback closed loop control loop.Set(ting)value model adopts FUZZY ALGORITHMS FOR CONTROL to set up, and describes the relation between thickness of coating and air pressure, air knife nozzle gap, travelling speed, and set(ting)value model calculates air pressure, air knife nozzle gap initial set value.Feed forward control release rate fluctuates the disturbance brought, and maintains thickness of coating constant during velocity variations, carrys out release rate change the thickness of coating caused and fluctuate by regulating air pressure.By the linear approximate relationship between thickness of coating and speed, air pressure, air knife nozzle gap, indirect calculation goes out air pressure and adds set(ting)value.Feedback closed loop control loop adopts air pressure, spacing combine regulation control mode, adopts air pressure preferential regulative mode, keeps that pressure set points is constant carries out spacing adjustment when pressure regulates and reaches amplitude limit.According to thickness of coating actual value, by the linear approximate relationship between thickness of coating and speed, air pressure, air knife nozzle gap, calculate the additional set(ting)value of air pressure and spacing.Control strategy, first calculates the initial set value of air pressure, air knife nozzle gap according to set(ting)value model; Feed forward control release rate fluctuates the thickness deviation caused, and calculates the additional set(ting)value of air pressure according to velocity variations; Feedback control for control objectives with single side surface average coating thickness and both side surface thickness of coating deviation, is regulated by pressure and eliminates average coating thickness deviation, is regulated eliminate both sides thickness of coating deviation by air knife nozzle opening degree.This system can realize closed-loop automatic control to thickness of coating, but in feedforward and feedback closed loop control loop, linearization process is carried out to controller gain, think that between thickness of coating and air knife nozzle gap, air pressure, travelling speed be linear relationship, and air pressure, be nonlinear relationship between spacing and thickness of coating, especially exist stronger non-linear between air knife nozzle gap and thickness of coating, therefore carry out linearization process and there is comparatively big error.
" simulation study of thickness of coating system DMC serials control " (Yao Gangxia, microcomputer information, 200723 (25)), describe Wuhan Iron and Steel Plant hot galvanizing line thickness of coating automatic control system, system adopts DMC predictive control algorithm, calculates air pressure set(ting)value according to thickness of coating and velocity variations.System robust sex chromosome mosaicism when adopting DMC predictive control to solve model mismatch, but article themselves recite only and regulates the Simulation results of carrying out zinc coat thickness control by pressure, it is inadequate for controlling thickness of coating by means of only adjustment air pressure in actual application.
" application of Baosteel continuous galvanizing line zinc layers weight control model " (Lin Lijun, bao steel technology, 2007 (4)), introduce the zinc coating thickness Controlling System of Baosteel hot galvanizing line, system comprises predictive model and feedback closed loop control loop.Predictive model calculates air pressure and air knife nozzle gap initial set value, and feedback control loop calculates air pressure and air knife nozzle gap adds set(ting)value.System can realize thickness of coating and automatically control, but predictive control loop and feedback control loop are all be based upon on model basis, and control performance too relies on model accuracy, controls poor effect when model mismatch.
At present, the zinc coat thickness control of most domestic galvanization production line is still completed by operative employee's manual setting, inevitably causes thickness of coating deviation excessive.Also the defect that regulating time is long and control effects is not good is there is in existing thickness of coating automatic control system.
Summary of the invention
The object of the present invention is to provide a kind of hot galvanizing line thickness of coating automatic control system, native system can eliminate thickness of coating deviation fast, especially become in specification and Up and down speeding and there is good control effects, thus reach the object improving lumber recovery and reduce zinc raw material consumption.
In order to realize foregoing invention object, the invention provides a kind of hot galvanizing line thickness of coating automatic control system, comprising following content:
1, system comprises air knife, thickness tester, Industrial PC Computer, PLC, zinc coat thickness control program.In zinc coat thickness control system, air knife is topworks, and thickness tester is feeler mechanism, and sequence of control operates in Industrial PC.Adopt PROFIBUSDP fieldbus to be connected between Industrial PC Computer with PLC, between thickness tester with PLC, adopt EPA to be connected.PLC gathers thickness of coating actual value and production process data is sent in Industrial PC Computer, thickness of coating automatic control program calculates air pressure, spacing, frame position set(ting)value be sent in PLC in real time according to thickness of coating actual value and production process data, realizes air pressure, spacing, frame position adjustment.
Zinc coat thickness control program adopts serials control, and subloop adopts regulatory PID control algorithm, utilizes Traditional PID intensive sampling advantage that subloop is designed to stochastic system.The master loop sampling period be the 50-100 in subloop sampling period doubly, by multi level control, freedom from jamming and the conflicting performance requriements of robustness these two are divided into different levels and process.The master loop of system is thickness of coating close loop control circuit, and the subloop of system is the pressure of airblade device, spacing, frame position close loop control circuit.Master loop calculates set-point data for subloop in real time, comprises air pressure, spacing, frame position set(ting)value.
2, master loop, feedforward closed-loop control, feedback closed loop presetting by air knife nozzle gap controls three parts and forms.
(1) air knife nozzle gap is presetting, according to production process rule of thumb data, sets up raw material belt steel thickness and the two-dimensional data table of relation between thickness of coating and air knife nozzle gap, selects air knife nozzle gap set(ting)value by look-up table.
(2) closed-loop control that feedovers calculates air pressure basis set(ting)value by feed forward control model.Method of least squares is adopted to return out description thickness of coating w and strip speed v, air pressure p, the mathematical model of the relation between the parameters such as air knife nozzle gap d according to production process data.Mode input is thickness of coating set(ting)value, speed actual value, air knife nozzle gap actual value, export as air pressure set(ting)value, when thickness of coating set(ting)value or strip speed or air knife nozzle gap change, system calculates air pressure set(ting)value according to feed forward models, realizes zinc coat thickness control by changing air pressure.
(3) feedback closed loop controls to adopt two-sided average coating thickness and deviation thickness of coating to jointly control mode.With two-sided average coating thickness for control objectives, regulated by air pressure and eliminate two-sided average coating thickness error.Thick in control objectives with deviation plating, by regulating air knife frame position, ensure that band steel is positioned at the central position of air knife, the thickness of coating deviation of cancellation band steel upper and lower surface.Feedback control adopts model-free adaptive controller for characteristics such as control object large time delay, non-linear, tight couplings, eliminates model mismatch error and system long-term accumulated error.
3, subloop comprises air pressure closed-loop control, air knife nozzle gap position-force control loop.Air pressure controls adoption rate integral controller, and air knife nozzle gap, air knife framework control adoption rate controller.
4, zinc coat thickness control manual/auto pattern switching undisturbed control method.During manual mode, master loop does not participate in controlling, and subloop air pressure, spaced position, frame position set(ting)value are by operative employee's manual setting.Current manual set(ting)value is followed in the presetting loop of air knife nozzle gap, feed forward control model calculates air pressure basis set(ting)value in real time, feedback control large deviations zinc coat thickness control loop stops calculating, and average coating thickness control loop set(ting)value is the difference of the basic set(ting)value that the manual set(ting)value of current air pressure and feed forward control model calculate.When by when being manually switched to automatic mode, air knife nozzle gap position remains unchanged, and deviation zinc coat thickness control loop starts to calculate, the initial set value that current air pressure set(ting)value exports as two-sided average coating thickness master loop.When automatic mode is switched to manual mode, the set(ting)value that before latching master loop, scan cycle exports is as the initial set value of subloop, and master loop controls excision.
5, reel change zinc coat thickness control method.In reel change, feed forward control model calculates all the time.If reel change thickness of coating specification is constant, when weld seam arrives air knife, current air knife nozzle gap set(ting)value and feedback controller output valve are latched, remove until weld seam latches through thickness tester.If reel change thickness of coating specification changes, first feedback controller is exported when weld seam arrives air knife and reset, then select air knife nozzle gap pre-set value to carry out air knife nozzle gap adjustment by tabling look-up, when weld seam enters thickness tester, feedback controller started to calculate air pressure and added set(ting)value.
Thickness of coating automatic control system puts into operation and eliminates some defects of manual operation existence, the thickness of coating of product can reach target value fast, regulate process is less than 2 minutes (Baosteel system is less than 3 minutes), thickness of coating deviation and homogeneity make moderate progress, also reduce zinc raw material consumption, different size plates thick reduction zinc raw material consumption 1 ~ 4g/m simultaneously
2.
Accompanying drawing explanation
Fig. 1 hot dip galvanizing coating gauge control schematic diagram;
Fig. 2 Controlling System pie graph;
The control effects curve of Fig. 3 feed forward control model release rate disturbance;
Fig. 4 two-sided average coating thickness control effects curve;
Fig. 5 two-sided deviation zinc coat thickness control effect curve.
Embodiment
Below in conjunction with accompanying drawing, the specific embodiment of the invention is further described:
Certain hot galvanizing line domestic, thickness tester distance air knife 150 meters, travelling speed 50-150 m/min.6 kinds of conventional plating think gauge 80,100,120,180,220,275g/m
2.
1, system configuration.
German FOEN company air knife, THERMO company of U.S. layer thickness meter, air knife controller is selected to select SIEMENS company S7-300PLC controller, Industrial PC Computer to select SIEMENS company IPC427C type built-in industrial PC.As shown in Figure 1, adopt PROFIBUSDP agreement to carry out data communication between PC and PLC, PC does slave station, and PLC does main website.PC side configuration CP5611 network interface card, PLC side configuration CP342-5 network interface card, is connected by PROFIBUSDP bus between network interface card.WINPE operating system is installed in PC, SIMATICNET6.2, LABVIEW8.6 develop software.The network configuration of PC side completes in SIMATICNET6.2 software, and PLC side network configuration completes in STEP75.3 develops software.In LABVIEW8.6 software, develop master loop sequence of control, in STEP75.3 software, develop subloop sequence of control.
2, as shown in Figure 2, system adopts serials control, and master loop sequence of control operates in PC, and subloop sequence of control operates in PLC.Controlling System master loop scanning period 1s, subloop scanning period 20ms.
3, master loop, feedforward closed-loop control, feedback closed loop presetting by air knife nozzle gap controls three parts and forms.
(1) the presetting form of air knife nozzle gap:
(2) feed forward control model.According to different thickness of coating specification, method of least squares is utilized to set up the mathematical model of object:
W(80)=-0.029P+2.795D+0.229V；
W(100)=-0.285P+5.567D+0.704V；
W(120)=-0.174P+5.672D+0.451V；
W(180)=-0.409P+7.587D+0.780V；
W(220)=-0.148P+5.485D+0.508V；
W(275)=-0.191P+3.181D+1.027V；
Wherein W-thickness of coating, P-air pressure, D-air knife nozzle gap, V travelling speed.
The control effects of feed forward control model release rate disturbance as shown in Figure 3, the pressure set points that feed forward control model calculates when velocity variations adjusts, the disturbance of release rate fluctuation to thickness of coating.
(3) feedback control loop comprises two-sided average coating thickness control loop and two-sided deviation zinc coat thickness control loop.Select universal model-free adaptive controller for the large time delay of process, non-linear, time-varying characteristics, controller carrys out the whole trend of analysis deviation by top n sampled value, observes the kinetic characteristic of process.Utilize nerual network technique by this observation, the historical data according to deviation directly calculates next step control action kou.
Two-sided average coating thickness control loop, when deviation is less than 3g/m
2time, finely tune, controller parameter Kc=0.5, Tc=30s, maximum 300s retardation time of process, minimum 80s.When the thick deviation of plating is greater than 3g/m
2be less than 30g/m
2time, the amplitude of accommodation is strengthened, and controller parameter selects Kc=0.55, Tc=45s.Two-sided average coating thickness control effects as shown in Figure 4, thickness of coating specification is 36g/m
2, carry out two-sided average coating thickness control by dynamic conditioning air pressure in steady state operation, two-sided average coating thickness deviation control is at 4g/m
2within.
Two-sided deviation zinc coat thickness control loop, when the thick deviation of plating is less than 2g/m
2time, finely tune, controller parameter Kc=0.1, Tc=8s, maximum 300s retardation time of process, minimum 80s.When the thick deviation of plating is greater than 3g/m
2be less than 30g/m
2time, the amplitude of accommodation is strengthened, and controller parameter selects Kc=0.25，Tc=45s。Two-sided deviation zinc coat thickness control effect as shown in Figure 5, thickness of coating specification is 36g/m
2, when relatively large deviation appears in two-sided thickness of coating, carry out two-sided deviation zinc coat thickness control, by two-sided thickness of coating deviation control at 4g/m by adjustment air knife frame position
2within.
4, subloop comprises air pressure, spacing, frame position closed-loop control, as shown in Figure 2.
(1) air pressure close loop control circuit.Loop comprises variable-frequency motor, pressure transmitter, PI controller.Driving air sword blower fan to regulate air pressure by variable-frequency motor, controlling air pressure by controlling variable-frequency motor rotating speed.
(2) air knife nozzle gap close loop control circuit.Loop comprises stepper-motor, position transducer, P controller.Air knife nozzle gap is regulated by stepper-motor on off control.
(3) air knife frame position close loop control circuit.Loop comprises common alternating current machine, position transducer, P controller.Air knife frame position is regulated by motor on off control.
5, the manual/auto pattern switching undisturbed of zinc coat thickness control.During manual mode, master loop does not participate in controlling, and subloop air pressure, spaced position, frame position set(ting)value are by operative employee's manual setting.Current manual set(ting)value is followed in the presetting loop of air knife nozzle gap, feed forward control model calculates air pressure basis set(ting)value in real time, feedback control large deviations zinc coat thickness control loop stops calculating, and average coating thickness control loop set(ting)value is the difference of the basic set(ting)value that the manual set(ting)value of current air pressure and feed forward control model calculate.When by when being manually switched to automatic mode, air knife nozzle gap position remains unchanged, and deviation zinc coat thickness control loop starts to calculate, the initial set value that current air pressure set(ting)value exports as two-sided average coating thickness master loop.When automatic mode is switched to manual mode, the set(ting)value that before latching master loop, scan cycle exports is as the initial set value of subloop, and master loop controls excision.
6, reel change zinc coat thickness control.In reel change, feed forward control model calculates all the time.If reel change thickness of coating specification is constant, when weld seam arrives air knife, current air knife nozzle gap set(ting)value and feedback controller output valve are latched, remove until weld seam latches through thickness tester.If reel change thickness of coating specification changes, first feedback controller is exported when weld seam arrives air knife and reset, then select air knife nozzle gap pre-set value to carry out air knife nozzle gap adjustment by tabling look-up, when weld seam enters thickness tester, feedback controller started to calculate air pressure and added set(ting)value.
Claims (3)
1. a hot galvanizing line thickness of coating automatic control system, it is characterized in that: comprise air knife, thickness tester, Industrial PC Computer, PLC, zinc coat thickness control program, sequence of control operates in Industrial PC, PROFIBUSDP fieldbus is adopted to be connected between Industrial PC Computer with PLC, PLC gathers thickness of coating actual value and production process data is sent in Industrial PC Computer, zinc coat thickness control program adopts cascade control method, utilize Traditional PID intensive sampling advantage that subloop is designed to stochastic system, the master loop sampling period be the 50-100 in subloop sampling period doubly, thickness of coating automatic control program calculates air pressure in real time according to thickness of coating actual value and production process data, spacing, frame position set(ting)value is also sent in PLC, realize air pressure, spacing, frame position adjusts, have also been devised manual/auto pattern undisturbed switching method and reel change zinc coat thickness control method simultaneously,
Master loop is presetting by air knife nozzle gap, feedforward closed-loop control, feedback closed loop control three parts and form, (1) air knife nozzle gap is presetting, according to production process rule of thumb data, set up raw material belt steel thickness and the two-dimensional data table of relation between thickness of coating and air knife nozzle gap, select air knife nozzle gap set(ting)value by look-up table, (2) closed-loop control that feedovers calculates air pressure basis set(ting)value by feed forward control model, method of least squares is adopted to return out description thickness of coating w and strip speed v according to production process data, air pressure p, the mathematical model of the relation between air knife nozzle gap d parameter, mode input is thickness of coating set(ting)value, speed actual value, air knife nozzle gap actual value, export as air pressure set(ting)value, when thickness of coating set(ting)value or strip speed or air knife nozzle gap change, system calculates air pressure set(ting)value according to feed forward models, zinc coat thickness control is realized by changing air pressure, (3) feedback closed loop controls to adopt two-sided average coating thickness and deviation thickness of coating to jointly control mode, with two-sided average coating thickness for control objectives, regulated by air pressure and eliminate two-sided average coating thickness error, thick in control objectives with deviation plating, by regulating air knife frame position, ensure that band steel is positioned at the central position of air knife, the thickness of coating deviation of cancellation band steel upper and lower surface, feedback control, for control object large time delay, non-linear, tight coupling characteristic employing model-free adaptive controller, eliminates model mismatch error and system long-term accumulated error,
Subloop comprises air pressure closed-loop control, air knife nozzle gap position, frame position close loop control circuit, and air pressure controls adoption rate integral controller, and air knife nozzle gap, air knife framework control adoption rate controller.
2. a kind of hot galvanizing line thickness of coating automatic control system according to claim 1, it is characterized in that: zinc coat thickness control manual/auto pattern switching undisturbed control method, during manual mode, master loop does not participate in controlling, and subloop air pressure, spaced position, frame position set(ting)value are by operative employee's manual setting; Current manual set(ting)value is followed in the presetting loop of air knife nozzle gap, feed forward control model calculates air pressure basis set(ting)value in real time, feedback control large deviations zinc coat thickness control loop stops calculating, and average coating thickness control loop set(ting)value is the difference of the basic set(ting)value that the manual set(ting)value of current air pressure and feed forward control model calculate; When by when being manually switched to automatic mode, air knife nozzle gap position remains unchanged, and deviation zinc coat thickness control loop starts to calculate, the initial set value that current air pressure set(ting)value exports as two-sided average coating thickness master loop; When automatic mode is switched to manual mode, the set(ting)value that before latching master loop, scan cycle exports is as the initial set value of subloop, and master loop controls excision.
3. a kind of hot galvanizing line thickness of coating automatic control system according to claim 1 and 2, it is characterized in that: reel change zinc coat thickness control method, in reel change, feed forward control model calculates all the time, if reel change thickness of coating specification is constant, when weld seam arrives air knife, current air knife nozzle gap set(ting)value and feedback controller output valve are latched, remove until weld seam latches through thickness tester; If reel change thickness of coating specification changes, first feedback controller is exported when weld seam arrives air knife and reset, then select air knife nozzle gap pre-set value to carry out air knife nozzle gap adjustment by tabling look-up, when weld seam enters thickness tester, feedback controller started to calculate air pressure and added set(ting)value.
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| JPS6353248A (en) * | 1986-08-22 | 1988-03-07 | Hitachi Ltd | Thickness control device for surface treatment |
| US5683514A (en) * | 1992-12-15 | 1997-11-04 | Weirton Steel Corporation | Coating control apparatus |
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| CN202226907U (en) * | 2011-08-03 | 2012-05-23 | 清远市东上钢业有限公司 | Precision automatic control device for hot galvanizing aluminum layer of cold rolled steel rolling plate |
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| JP4347867B2 (en) * | 2006-07-27 | 2009-10-21 | 株式会社日立製作所 | Plating adhesion amount control system and plating adhesion amount control method |
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| JPS6353248A (en) * | 1986-08-22 | 1988-03-07 | Hitachi Ltd | Thickness control device for surface treatment |
| US5683514A (en) * | 1992-12-15 | 1997-11-04 | Weirton Steel Corporation | Coating control apparatus |
| CN1174246A (en) * | 1996-07-04 | 1998-02-25 | 株式会社日立制作所 | Method and apparatus for controlling galvanization coating weight |
| CN202226907U (en) * | 2011-08-03 | 2012-05-23 | 清远市东上钢业有限公司 | Precision automatic control device for hot galvanizing aluminum layer of cold rolled steel rolling plate |
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