CN104777817A - Intelligent control system for thermal diffusion production process - Google Patents
Intelligent control system for thermal diffusion production process Download PDFInfo
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- CN104777817A CN104777817A CN201510188436.2A CN201510188436A CN104777817A CN 104777817 A CN104777817 A CN 104777817A CN 201510188436 A CN201510188436 A CN 201510188436A CN 104777817 A CN104777817 A CN 104777817A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 47
- 238000009792 diffusion process Methods 0.000 title abstract 7
- 238000005516 engineering process Methods 0.000 claims abstract description 32
- 238000012544 monitoring process Methods 0.000 claims description 24
- 239000002994 raw material Substances 0.000 claims description 13
- 238000004364 calculation method Methods 0.000 claims description 12
- 229910000831 Steel Inorganic materials 0.000 claims description 9
- 239000010959 steel Substances 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 7
- 229910052710 silicon Inorganic materials 0.000 claims description 7
- 239000010703 silicon Substances 0.000 claims description 7
- 238000004458 analytical method Methods 0.000 claims description 6
- 239000003086 colorant Substances 0.000 claims description 6
- 238000012545 processing Methods 0.000 claims description 6
- 238000003860 storage Methods 0.000 claims description 6
- 238000012546 transfer Methods 0.000 claims description 6
- 238000004861 thermometry Methods 0.000 claims description 5
- 230000008859 change Effects 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 230000002950 deficient Effects 0.000 claims description 3
- 239000000446 fuel Substances 0.000 claims description 3
- 230000009897 systematic effect Effects 0.000 claims description 3
- 239000003921 oil Substances 0.000 description 6
- 239000000498 cooling water Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000004891 communication Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000005098 hot rolling Methods 0.000 description 2
- 230000001939 inductive effect Effects 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000001133 acceleration Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000005021 gait Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000008676 import Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
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Abstract
The invention discloses an intelligent control system for a thermal diffusion production process. The system comprises a thermal diffusion production process data processor mounted in an upper computer, wherein the upper computer is correspondingly connected with a PLC lower computer; the thermal diffusion production process data processor calculates production process parameters according to production conditions and then sends the production process parameters to the PLC lower computer; the PLC lower computer is correspondingly connected with a thermal diffusion production control element. According to the intelligent control system for the thermal diffusion production process, quality accidents which are probably caused can be avoided, and the production level of a thermal diffusion process technology is improved.
Description
Technical field
The invention belongs to software control and administrative skill field, relate to a kind of heat and expand production technology intelligent control system.
Background technology
It is high added value metallurgic product that heat expands caliber seamless steel pipe, and along with the high speed development of national economy, it is increasing that heat expands the solid drawn tube market demand.Its main application is the industries such as boiler manfacturing, power plant construction, machining and building iron structure, oil and gas transmission, chemical industry and compressed natural gas, and the heavy caliber seamless steel pipe consumption that external diameter is greater than 400 millimeters accounts for the 4-5% of the apparent consumption total amount of weldless steel tube.Hot expansion equipment is Germany's invention fifties in last century, and the mid-80 imports China with the type of elbow push machine into by Japan.Obtained transformation to 97 years in China to improve and obtain intellecture property, and to name be the pusher pipe expanders of two stepped hydraulics, adopt hydraulic jack push pipe to add Medium frequency induction coil heats technology, all adopt manual operation, manual mode controls heating-up temperature and ejector sleeve speed.Heat expands and goes up detective less, domestic existing hundreds of bar production line than the simple backwardness of hot rolling technology, equipment investment.Study less because heat expands technology theory, hot expanding wall thick being difficult to controls, and as adopted estimation algorithm to calculate for finished product wall thickness, expanding exactly a time subtracts wall 0.2-1.5 millimeter in wall thickness ratio, comparatively large with actual deviation, there is heat and expand the technical barriers such as unstable product quality.Therefore, anxious the waiting of China's hot-expanding steel tube technology is improved with progressive.
At present, Germany have developed Carta process system, achieve technological parameter Automated Design and process in small-caliber seamless steel pipe hot rolling production process automatically to control, less wall thickness and diameter deviation can be realized, reduce material unaccounted-for (MUF), and have that automaticity is high, labour intensity is low and the advantage such as constant product quality.But also nobody did such trial in heat expansion technology Based Intelligent Control.
Summary of the invention
The technical matters that patent of the present invention solves realizes by the following technical solutions: patent of the present invention provides a kind of heat to expand production technology intelligent control system (HESPS), software is arranged in PC host computer, form both-way communication by network and programmable controller PLC to be connected, PLC forms input and output with elements such as frequency converter, electromagnetic relay, thermometry element, scrambler, limit switches again and is connected, and reaches the object of the hot expansion equipment of Based Intelligent Control.
The present invention is realized by following proposal:
A kind of heat expands production technology intelligent control system, this system comprises the heat be arranged in host computer and expands production technology data processor, described host computer is corresponding with PLC slave computer to be connected, described heat expands production technology data processor and calculates processing parameter according to working condition, then processing parameter is sent to described PLC slave computer, described PLC slave computer and heat expand that production control element is corresponding to be connected.
Described heat expands production technology data processor and comprises main interface module, in described main interface module, select other module to run, the basic condition load module that connect corresponding to main interface module, described basic condition load module is for inputting raw material, finished product name physical dimension, material, quantity and check criteria, the measured data load module that connect corresponding to main interface module, described measured data load module is used for the input of mother tube measured data to be saved in quality database, the tool management module that connect corresponding to main interface module, described tool management module is mainly used in input, preserve whole plug and coil geometries data to tool storage room, and the service time of the instrument of listing can be added up, reparation situation and production quantity, operator is helped to pass a judgement to instrument quality,
Described basic condition load module, measured data load module and tool management module are all corresponding with prediction of quality module to be connected, described prediction of quality module is used for calculating finished product physical dimension from raw material physical dimension, also transfer quality history data, and the physical dimension fluctuation range of finished product is extrapolated according to current raw material measured data prediction, compare with standard-required, if prediction of quality is defective, need to reselect raw material or instrument, transfer plug and loop data in tool storage room and carry out automatic analysis, select suitable instrument, determine suitable heating-up temperature and ejector sleeve speed, described prediction of quality module is corresponding with complicated calculations module to be connected, the various data that described complicated calculations module provides according to prediction of quality module, carry out complicated data computing, then the result of data computing is sent to prediction of quality module,
Described main interface module is also corresponding with equipment running monitoring module and performance graph monitoring modular to be connected, described equipment running monitoring module and performance graph monitoring modular are also all corresponding with PLC slave computer to be connected, equipment running monitoring module is run control equipment and is given PLC slave computer, the display of the working order of Supervision measuring point is sent to main interface module show, when ejector sleeve end-of-job or device fails, send acousto-optic hint signal, position of failure point and time all can by systematic conservation, the quantity of ejector sleeve also can be recorded, described performance graph monitoring modular and equipment running monitoring module are run simultaneously, receive the working order of the Supervision measuring point of PLC slave computer, and in main interface module in units of the time, plot with different colours, the curve representation temperature of different colours, speed, electric current, ejector sleeve power, power consumption, performance graph monitoring modular helps operator to carry out analysis judgement to curve.
Described finished product name physical dimension comprises external diameter, wall thickness, length, and mother tube measured data comprises external diameter, wall thickness, length.
The data computing of the complexity that described complicated calculations mould carries out comprises reducing district unit Force Calculation, the calculating of Zhou Jihua metallic high temperature resistance of deformation, wall thickness change rule iterative computation, finished product external diameter calculate, finished product external diameter, wall thickness deviation calculate, calculated ejector sleeve power by integrating meter, check to capacity of equipment to utilize historical data regression curve to predict.
The working order of described Supervision measuring point comprises motor operating state and revolution value, pressure fuel pump value, heating-up temperature value, ejector sleeve velocity amplitude, controllable silicon water-cooling system running status and water temperature value, coil water-cooling system running status and water temperature value, push pedal and steel pipe advanced positions.
Described heat expands production control element and comprises frequency converter, electromagnetic relay, thermometry element, scrambler, limit switch.
Beneficial effect of the present invention is:
1. the technical knowhow of production unit professional experiences for many years and specialty is contained in the present invention, the heat be arranged in host computer expands production technology data processor, form both-way communication by network and programmable controller PLC to be connected, PLC forms input and output with elements such as frequency converter, electromagnetic relay, thermometry element, scrambler, limit switches again and is connected, reach the object of the hot expansion equipment of Based Intelligent Control, this is one and brings better economy, reliability and the following combination ensured for heat expands workshop.
2. the present invention's heat expands production technology data processor by preanalysis, can carry out Quality estimation in advance, avoid contingent quality accident to the result that heat expands, and improves heat and expands technology production level.
Accompanying drawing explanation
Fig. 1 is that the present invention's heat expands production technology data processor architecture block diagram.
Embodiment
Below in conjunction with Fig. 1, the embodiment of optimization of the present invention is further illustrated:
A kind of heat expands production technology intelligent control system, this system comprises the heat be arranged in host computer and expands production technology data processor, described host computer is corresponding with PLC slave computer to be connected, described heat expands production technology data processor and calculates processing parameter according to working condition, then processing parameter is sent to described PLC slave computer, described PLC slave computer and heat expand that production control element is corresponding to be connected.
Heat expands production technology data processor by modular design, and each functional module all has oneself interface and content computing function, its interface can with customer interaction information.
Described heat expands production technology data processor and comprises main interface module, in described main interface module, select other module to run, the basic condition load module that connect corresponding to main interface module, described basic condition load module is for inputting raw material, finished product name physical dimension, material, quantity and check criteria, the measured data load module that connect corresponding to main interface module, described measured data load module is used for the input of mother tube measured data to be saved in quality database, the tool management module that connect corresponding to main interface module, described tool management module is mainly used in input, preserve whole plug and coil geometries data to tool storage room, and the service time of the instrument of listing can be added up, reparation situation and production quantity, operator is helped to pass a judgement to instrument quality,
Described basic condition load module, measured data load module and tool management module are all corresponding with prediction of quality module to be connected, described prediction of quality module is used for calculating finished product physical dimension from raw material physical dimension, also transfer quality history data, and the physical dimension fluctuation range of finished product is extrapolated according to current raw material measured data prediction, compare with standard-required, if prediction of quality is defective, need to reselect raw material or instrument, transfer plug and loop data in tool storage room and carry out automatic analysis, select suitable instrument, determine suitable heating-up temperature and ejector sleeve speed, described prediction of quality module is corresponding with complicated calculations module to be connected, the various data that described complicated calculations module provides according to prediction of quality module, carry out complicated data computing, then the result of data computing is sent to prediction of quality module,
Described main interface module is also corresponding with equipment running monitoring module and performance graph monitoring modular to be connected, described equipment running monitoring module and performance graph monitoring modular are also all corresponding with PLC slave computer to be connected, equipment running monitoring module is run control equipment and is given PLC slave computer, the display of the working order of Supervision measuring point is sent to main interface module show, when ejector sleeve end-of-job or device fails, send acousto-optic hint signal, position of failure point and time all can by systematic conservation, the quantity of ejector sleeve also can be recorded, described performance graph monitoring modular and equipment running monitoring module are run simultaneously, receive the working order of the Supervision measuring point of PLC slave computer, and in main interface module in units of the time, plot with different colours, the curve representation temperature of different colours, speed, electric current, ejector sleeve power, power consumption, performance graph monitoring modular helps operator to carry out analysis judgement to curve.
Described finished product name physical dimension comprises external diameter, wall thickness, length, and mother tube measured data comprises external diameter, wall thickness, length.
The data computing of the complexity that described complicated calculations mould carries out comprises reducing district unit Force Calculation, the calculating of Zhou Jihua metallic high temperature resistance of deformation, wall thickness change rule iterative computation, finished product external diameter calculate, finished product external diameter, wall thickness deviation calculate, calculated ejector sleeve power by integrating meter, check to capacity of equipment to utilize historical data regression curve to predict.
The working order of described Supervision measuring point comprises motor operating state and revolution value, pressure fuel pump value, heating-up temperature value, ejector sleeve velocity amplitude, controllable silicon water-cooling system running status and water temperature value, coil water-cooling system running status and water temperature value, push pedal and steel pipe advanced positions.
Described heat expands production control element and comprises frequency converter, electromagnetic relay, thermometry element, scrambler, limit switch.The effect of frequency converter is: the input end by pump speed scrambler and ejector sleeve acceleration module, numerical value being passed to PLC slave computer, control signal is sent by PLC slave computer output terminal, frequency converter is made to change frequency to oil pump group electric machine speed regulation, control oil cylinder gait of march and reach setting value, so the effect of frequency converter reaches by control oil pump motor rotations the object controlling ejector sleeve speed, also has energy-saving effect in addition.
When start native system time, first PLC slave computer controls the work of controllable silicon intermediate frequency cabinet, inductive coil energising to raw material steel pipe heating, by infrared measurement of temperature inductor by heating-up temperature Real-time Feedback to PLC slave computer and host computer; When temperature reaches setting value, PLC slave computer controls frequency converter and makes operation of oil pump, controlling solenoid directional control valve forward conduction again makes hydraulic cylinder advance, when arriving front limit switch, signal feedback is to PLC slave computer, first PLC slave computer stops hydraulic cylinder works by reversal valve, then by frequency converter, Oil pump electrical machinery reduction of speed is economized on electricity, control controllable silicon intermediate frequency cabinet voltage-reducing and electricity-saving, finally controlling solenoid directional control valve reverse-conducting makes hydraulic cylinder retreat, when arriving rear limit switch, signal feedback is to PLC slave computer, and PLC slave computer stops hydraulic cylinder works by reversal valve.When automatically judging that hydraulic jack needs again to advance by operating personnel or host computer, restart by aforementioned process.
Before controllable silicon intermediate frequency cabinet starts, first PLC slave computer starts controllable silicon cooling water circulating pump and inductive coil cooling water circulation pump startup, after work a period of time, temperature is passed to slave computer and host computer by cooling-water temperature sensor in real time, when water temperature reaches 40 degree, PLC slave computer controls fan starting to water for cooling.
Real time value is fed back to PLC slave computer and host computer by current detection module and voltage detection module, by software analysis power consumption, provides foundation, occur abnormal conditions energy and alarm for energy-saving and cost-reducing.
Although done comparatively detailed elaboration to technical scheme of the present invention and enumerated; be to be understood that; to those skilled in the art; amendment is made to above-described embodiment or adopts equivalent replacement scheme; this is apparent to those skilled in the art; these modifications or improvements without departing from theon the basis of the spirit of the present invention, all belong to the scope of protection of present invention.
Claims (6)
1. a heat expands production technology intelligent control system, it is characterized in that: this system comprises the heat be arranged in host computer and expands production technology data processor, described host computer is corresponding with PLC slave computer to be connected, described heat expands production technology data processor and calculates processing parameter according to working condition, then processing parameter is sent to described PLC slave computer, described PLC slave computer and heat expand that production control element is corresponding to be connected.
2. a kind of heat according to claim 1 expands production technology intelligent control system, it is characterized in that: described heat expands production technology data processor and comprises main interface module, in described main interface module, select other module to run, the basic condition load module that connect corresponding to main interface module, described basic condition load module is for inputting raw material, finished product name physical dimension, material, quantity and check criteria, the measured data load module that connect corresponding to main interface module, described measured data load module is used for the input of mother tube measured data to be saved in quality database, the tool management module that connect corresponding to main interface module, described tool management module is mainly used in input, preserve whole plug and coil geometries data to tool storage room, and the service time of the instrument of listing can be added up, reparation situation and production quantity, operator is helped to pass a judgement to instrument quality,
Described basic condition load module, measured data load module and tool management module are all corresponding with prediction of quality module to be connected, described prediction of quality module is used for calculating finished product physical dimension from raw material physical dimension, also transfer quality history data, and the physical dimension fluctuation range of finished product is extrapolated according to current raw material measured data prediction, compare with standard-required, if prediction of quality is defective, need to reselect raw material or instrument, transfer plug and loop data in tool storage room and carry out automatic analysis, select suitable instrument, determine suitable heating-up temperature and ejector sleeve speed, described prediction of quality module is corresponding with complicated calculations module to be connected, the various data that described complicated calculations module provides according to prediction of quality module, carry out complicated data computing, then the result of data computing is sent to prediction of quality module,
Described main interface module is also corresponding with equipment running monitoring module and performance graph monitoring modular to be connected, described equipment running monitoring module and performance graph monitoring modular are also all corresponding with PLC slave computer to be connected, equipment running monitoring module is run control equipment and is given PLC slave computer, the display of the working order of Supervision measuring point is sent to main interface module show, when ejector sleeve end-of-job or device fails, send acousto-optic hint signal, position of failure point and time all can by systematic conservation, the quantity of ejector sleeve also can be recorded, described performance graph monitoring modular and equipment running monitoring module are run simultaneously, receive the working order of the Supervision measuring point of PLC slave computer, and in main interface module in units of the time, plot with different colours, the curve representation temperature of different colours, speed, electric current, ejector sleeve power, power consumption, performance graph monitoring modular helps operator to carry out analysis judgement to curve.
3. a kind of heat according to claim 2 expands production technology intelligent control system, it is characterized in that: described finished product name physical dimension comprises external diameter, wall thickness, length, and mother tube measured data comprises external diameter, wall thickness, length.
4. a kind of heat according to claim 2 expands production technology intelligent control system, it is characterized in that: the data computing of the complexity that described complicated calculations mould carries out comprises reducing district unit Force Calculation, calculatings of Zhou Jihua metallic high temperature resistance of deformation, wall thickness change rule iterative computation, finished product external diameter calculate, utilize historical data regression curve to predict the calculating of finished product external diameter, wall thickness deviation, calculated ejector sleeve power by integrating meter, check to capacity of equipment.
5. a kind of heat according to claim 2 expands production technology intelligent control system, it is characterized in that: the working order of described Supervision measuring point comprises motor operating state and revolution value, pressure fuel pump value, heating-up temperature value, ejector sleeve velocity amplitude, controllable silicon water-cooling system running status and water temperature value, coil water-cooling system running status and water temperature value, push pedal and steel pipe advanced positions.
6. a kind of heat according to claim 1 expands production technology intelligent control system, it is characterized in that: described heat expands production control element and comprises frequency converter, electromagnetic relay, thermometry element, scrambler, limit switch.
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110147070A (en) * | 2019-04-30 | 2019-08-20 | 大连力达环境工程有限公司 | A kind of biological treatment system core process intelligent control method |
CN112346404A (en) * | 2020-11-13 | 2021-02-09 | 广东精迅里亚特种线材有限公司 | Automatic tracking and monitoring system for aluminum rod production process parameters |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN110147070A (en) * | 2019-04-30 | 2019-08-20 | 大连力达环境工程有限公司 | A kind of biological treatment system core process intelligent control method |
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