CN104794224A - Automatic control system and method for nodular cast iron pipe production process - Google Patents
Automatic control system and method for nodular cast iron pipe production process Download PDFInfo
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Abstract
The invention provides a nodular cast iron pipe production process information tracking system. An automatic control system for a nodular cast iron pipe production process comprises an annealing furnace area, a zinc spraying area, a water pressure area, a cement smearing and lining area, a curing kiln area, a pitch spraying area, a curing oven area, a bulb tube RFID electronic tag, Ethernet interfaces and a server. The annealing furnace area, the zinc spraying area, the water pressure area, the cement smearing and lining area, the curing kiln area, the pitch spraying area and the curing oven area are connected with the server through the Ethernet interfaces. The bulb tube RFID electronic tag is installed on the inner surface of the straight tube portion of a bulb tube bell mouth. The seven areas are used for reading information of the bulb tube RFID electronic tag, and uploading the information to the server. The server is used for accessing the seven areas through the Ethernet, and reading the bulb tube production information stored in the seven areas. The real-time track record of the whole single-bulb tube process production information in nodular cast iron pipe producing is achieved, operating parameters of technology equipment is beneficial to being optimized, and the product quality is improved.
Description
Technical field
The invention belongs to metal casting technique field, particularly a kind of ductile iron pipe production run automatic control system and method.
Background technology
Tradition ductile iron pipe production technology is more complicated, device category is various, major equipment is provided by more than ten equipment suppliers usually, though each single devices is closely linked to by front and back operation, but all each actions of complete independently, have independently PLC and host computer thereof and bitcom separately, form is usually multifarious, different.
Do not have an equipment supplier can provide from the ductile iron pipe production equipment completely such as annealing furnace, spray zinc machine, water pressure engine, cement lining coating machine, spray pitch machine, curing oven in current worldwide, cannot provide a kind of online ductile iron pipe production information real-time tracking system and the method that contain armamentarium simultaneously yet.
Ductile iron pipe production line will realize the real-time follow-up record of each ductile iron pipe overall process actual motion position, each single devices original start information, actual production information on a production line very difficult.
At present both at home and abroad the production process information of ductile iron pipe normally " by batch " carry out, " by criticizing " sets in advance, the setting value of each single devices concrete technology parameter in actual production overall process, does not reach the degree of interior " each ductile iron pipe " the actual production serial number of real-time follow-up production overall process " each batch " and production information.Therefore often there is mixed number event in ductile iron pipe production run, is difficult to through artificial prevention.
This mode of production cannot meet the requirement that will have record and trackability to single ductile iron pipe production information, factory can not be met and improve ductile iron pipe quality to the actual needs often propping up the ductile iron pipe condition of production and will analyze, how on ductile iron pipe production line, realize the real-time follow-up to single arm production information, thus complete a great problem automatic control of parameters line being become to puzzlement ductile iron pipe production industry.
Summary of the invention
The object of this invention is to provide a kind of ductile iron pipe production run automatic control system, for solving the problems of the technologies described above, the present invention simultaneously also provides a kind of ductile iron pipe production run autocontrol method, for realizing the real-time follow-up Inspect and control to ductile iron pipe production overall process.
A kind of ductile iron pipe production run automatic control system, comprises annealing furnace district, Pen Xin district, hydraulic pressure district, cement coated lining district, health kiln district, spray pitch district, curing oven district, also comprises bulb RFID, Ethernet interface, server; Annealing furnace district, Pen Xin district, hydraulic pressure district, cement coated lining district, health kiln district, spray pitch district, curing oven district are connected with server respectively by Ethernet interface, described bulb RFID is arranged on bulb bellmouth straight tube place inside surface, for storing bulb information;
Bulb is placed in the straight length of bulb bellmouth side by RFID when annealing furnace district, Pen Xin district, hydraulic pressure district; Bulb is placed in the groove of bulb bellmouth by RFID when cement coated lining district, health kiln district; Bulb is placed in the straight length of bulb bellmouth side by RFID when spray pitch district, curing oven district.
Thermal insulation material is set up in described RFID inside, and for thermal insulation, outer setting magnetic material, for being adsorbed onto bulb.
Annealing furnace district, Pen Xin district, hydraulic pressure district, cement coated lining district, health kiln district, spray pitch district, curing oven district are respectively used to read bulb RFID information, and information are uploaded onto the server; Described server is used for by above-mentioned seven districts of ethernet access, and reads the parameters information stored in described seven districts;
Set up in described server and have Database Systems, data analysis control system, described Database Systems comprise bulb data module and bulb pointer module, the measured data that described bulb data module obtains in this stage for depositing bulb, described bulb pointer module real time record bulb is in production line actual motion position; Described data analysis control system is used for the parameters information stored in analytical database system, and controls above-mentioned seven districts according to analysis result.
Described ductile iron pipe production run automatic control system, also comprises jetting device for making number, for spray pipe number on bulb.
Described annealing furnace district comprises annealing furnace controller, annealing furnace reader; Pen Xin district comprises spray zinc controller, spray zinc reader; Hydraulic pressure district comprises hydraulic controller, hydraulic pressure reader; Cement coated lining district comprises cement coated lining controller, cement coated lining reader; Health kiln district comprises health kiln controller, health kiln reader; Spray pitch district comprises spray pitch controller, spray pitch reader; Curing oven district comprises curing oven controller, curing oven reader.
Described server comprises primary networking service device, backup network server.
Controller described in each district all adopts PLC to realize, and reader adopts RFID reader to realize.
A kind of ductile iron pipe production run autocontrol method, comprises the steps:
S1, when bulb enters annealing furnace district, Database Systems are numbered bulb automatically, and be stored in the pointer gauge of database as key word, and by read write line the pipe number write RFID generated, the parameters information in annealing furnace district is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and annealing furnace district compares analysis, if be consistent, enter Pen Xin district, if do not met, adjust the optimum configurations in annealing furnace district in real time, make it be consistent with preset standard parameter;
S2, bulb enter Pen Xin district, bulb is weighed, sprays zinc, Pen Xin district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and Pen Xin district compares analysis, if be consistent, enter hydraulic pressure district, if do not met, adjust the optimum configurations in Pen Xin district in real time, make it be consistent with preset standard parameter;
S3, bulb enter hydraulic pressure district, pressure testing detection is carried out to bulb, hydraulic pressure district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and hydraulic pressure district compares analysis, if be consistent, enter cement lining district, if do not met, adjust the optimum configurations in cement lining district in real time, make it be consistent with preset standard parameter;
S4, bulb enter cement coated lining district, bulb inwall serves as a contrast one deck cement, cement coated lining district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and cement lining district compares analysis, if be consistent, enter health kiln district, if do not met, adjust the optimum configurations in cement lining district in real time, make it be consistent with preset standard parameter;
S5, bulb enter health kiln district, after health 12-14h, chamfering is carried out to socket, health kiln district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and health kiln district compares analysis, if be consistent, enter curing oven district, if do not met, adjust the optimum configurations in health kiln district in real time, make it be consistent with preset standard parameter;
S6, bulb enter curing oven district, preheating is carried out to bulb, preheat temperature is no more than 80 DEG C, curing oven district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and curing oven district compares analysis, if be consistent, enter spray pitch district, if do not met, adjust the optimum configurations in curing oven district in real time, make it be consistent with preset standard parameter;
S7, bulb enter spray pitch district, bulb outer wall sprays one deck pitch, spray pitch district parameters information is uploaded to Database Systems simultaneously, data analysis control system compares analysis to the data uploaded and the preset standard parameter in spray pitch district, if be consistent, enter spray district, if do not met, the optimum configurations in the pitch district of adjustment spray in real time, makes it be consistent with preset standard parameter;
S8, jetting device for making number carry out spray number to bulb, and the packing of end product bulb is rolled off the production line.
The invention has the advantages that:
1, in can producing ductile iron pipe, single bulb overall process production information carries out real-time follow-up record;
2, meeting factory to improve ductile iron pipe quality will have the actual needs of track record and analysis to often propping up production tube production process information, being convenient to analyzing and processing quality objection, distinguishing responsibility;
3, be conducive to Optimization Technology equipment operational factor, improve the quality of products.
Below in conjunction with accompanying drawing, ductile iron pipe production run automatic control system of the present invention and method are described further.
Accompanying drawing explanation
Fig. 1 is ductile iron pipe production run automatic control system schematic diagram;
Fig. 2 is ductile iron pipe production run autocontrol method process chart.
Embodiment
Fig. 1 is ductile iron pipe production run automatic control system of the present invention, comprise annealing furnace district 001, Pen Xin district 002, hydraulic pressure district 003, cement coated lining district 004, health kiln district 005, spray pitch district 006, curing oven district 007, also comprise bulb RFID, Ethernet interface 010, server 009; Annealing furnace district 001, Pen Xin district 002, cement coated lining district 004, health kiln district 005, spray pitch district 006, curing oven district 007 are connected with server 009 respectively by Ethernet interface 010, described bulb RFID is arranged on bulb, for storing bulb information;
Bulb is placed in the straight length of bulb bellmouth side by RFID when annealing furnace district (001), Pen Xin district (002), hydraulic pressure district (003); Bulb is placed in the groove of bulb bellmouth by RFID when cement coated lining district (004), health kiln district (005); Bulb is placed in the straight length of bulb bellmouth side by RFID when spray pitch district (006), curing oven district (007).
Thermal insulation material is set up in described RFID inside, and for thermal insulation, outer setting magnetic material, for being adsorbed onto bulb.
Annealing furnace district 001, Pen Xin district 002, hydraulic pressure district 003, cement coated lining district 004, health kiln district 005, spray pitch district 006, curing oven district 007 are respectively used to read bulb RFID information, and information are uploaded onto the server 009; Described server 009 for passing through above-mentioned seven districts of ethernet access, and reads the parameters information stored in described seven districts;
Set up in described server 009 and have Database Systems, data analysis control system, described Database Systems comprise bulb data module and bulb pointer module, the measured data that described bulb data module obtains in this stage for depositing bulb, described bulb pointer module real time record bulb is in production line actual motion position; Described data analysis control system is used for the parameters information stored in analytical database system, and controls above-mentioned seven districts according to analysis result.
Described ductile iron pipe production run automatic control system, also comprises jetting device for making number 8, for spray pipe number on bulb.
Described annealing furnace district 001 comprises annealing furnace controller 1, annealing furnace reader 01; Pen Xin district 002 comprises spray zinc controller 2, spray zinc reader 02; Hydraulic pressure district 003 comprises hydraulic controller 3, hydraulic pressure reader 03; Cement coated lining district 004 comprises cement coated lining controller 4, cement coated lining reader 04; Health kiln district 005 comprises health kiln controller 5, health kiln reader 05; Spray pitch district 006 comprises spray pitch controller 6, spray pitch reader 06; Curing oven district 007 comprises curing oven controller 7, curing oven reader 07.
Described server 009 comprises primary networking service device 9, backup network server 09.
Controller described in each district all adopts PLC to realize, and reader adopts RFID reader to realize.
Hardware components of the present invention is made up of server and client computer (terminating machine, the i.e. controller in above-mentioned seven districts), and server ensures the integrality of data by disk array technology, and server working method is a-worker-a-backup; Client computer is arranged in each operation room and computer room and realizes human-computer interaction function, and this grid connects and adopts Y-connection, is connected on server by each region reader by Ethernet, and building database system in the server.
Single bulb is followed the tracks of to have been come by the RFID card reader in subregion and server in the position of each control partition, specifically, when a certain bulb enters certain region, the RFID card reader being arranged on this region can read the pipe information in the RFID on bulb, and upload onto the server, the PLC of server via Ethernet access one's respective area, its bulb of announcement enters one's respective area, and the production information that reading database needs.
Single arm tracking initiation point is positioned at annealing furnace outlet, when single arm enters this region, Database Systems are numbered single arm automatically, and be stored in the pointer gauge of database as key word, and by read write line the pipe number write RFID generated, RFID is placed on single arm (bulb) bellmouth straight tube place inside surface; The read write line readout tube that arranged by each region according to the position of bulb actual motion number and with the production information one_to_one corresponding generated in real time, autostore is carried out to bulb tracking data simultaneously, after the single arm tracking in one's respective area terminates, Track Date Central Table and tracking pointer gauge are automatically moved to next tracing area, carry out automatic mark finally by jetting device for making number to the pipe of each ball pipe on production line number.
Bulb is followed the tracks of and data management scope: from single arm goes out annealing furnace, to single arm goes out curing oven.The production line of bulb system enters to(for) each root is managed by bulb tables of data and bulb tracking pointer gauge.Pointer followed the tracks of by the corresponding bulb data record of each ball pipe and bulb.
After bulb to annealing furnace outlet, often prop up bulb and wear a RFID, by read write line for it arranges corresponding pipe number, and set up a bulb data record and bulb tracking pointer respectively in bulb tables of data and bulb tracking pointer gauge.When bulb moves on a production line, the read write line of corresponding region can read the RFID that bulb is worn, thus the tracking pointer of bulb moves in tracking pointer gauge, is used to refer to the position at the current place of bulb; Be provided with online jetting device for making number in curing oven exit, automatically can also spray each ball pipe pipe number with " uniqueness " by track record.
Bulb number definition: go out pipe serial number by annealing furnace and form, it can uniquely determine often to prop up bulb.
Bulb tables of data: deposit the measured data that bulb obtained in this stage.
Pointer gauge followed the tracks of by bulb: real time record bulb is in production line actual motion position.
As shown in Figure 2, be the process chart of a specific embodiment of the present invention, comprise production line zones of different production process information harvester.
Bulb in annealing furnace successively after bringing-up section, soaking zone, cooling section, cool after to 200 DEG C through forced cooling water, moved to before spray zinc machine without in drive track by the Flat Car for Transshipment; After bulb centering, weigh, then spray zinc to spray zinc machine, then manually cut ring, reconditioning bell and spigot to water pressure engine water pressure generation; The qualified bulb of pressure testing serves as a contrast one deck cement by liner machine on inwall, then delivers to health kiln by the Flat Car for Transshipment; After health 12-14h, carry out chamfering to socket, then send in curing oven and carry out preheating to bulb, preheat temperature is no more than 80 DEG C; Bulb after preheating sprays one deck pitch by spraying pitch machine on outer wall, then delivers to ink jet numbering machine and carries out spray number, and the packing of end product bulb is rolled off the production line.
A certain ball pipe pipe number on such as production line is A001 for " A001-5-10 " represents its heat (batch) number, 10th bulb of 5# hydro-extractor, the complete track record of this bulb should record following production process information: bulb warming temperature in the lehr and time, holding temperature and reality, chilling temperature and time; Guan Chong, spray zinc amount; Hydraulic test pressure size and dwell time; The cement consumption of cement lining, liner time; Health kiln temperature humidity, spray pitch amount etc.
As shown in the table, for realizing the tracing control of single bulb, production line has divided 8 equipment control partition, and concrete condition is as follows:
| Sequence number | Control partition | Concrete device name | The canonical parameter information of setting |
| 1 | Annealing furnace district | Annealing furnace | Annealing temperature curve |
| 2 | Pen Xin district | Spray zinc machine | Guan Chong, spray zinc amount |
| 3 | Hydraulic pressure district | Water pressure engine | Suppress pressure and dwell time |
| 4 | Cement lining district | Cement lining machine | Cement proportion and consumption |
| 5 | Health kiln district | Health kiln | Steam humiture curve |
| 6 | Curing oven district | Curing oven | Solidification temperature curve |
| 7 | Spray pitch district | Spray pitch machine | Spray pitch amount |
| 8 | Spray district | Jetting device for making number | Guan Hao |
In annealing temperature curve, bringing-up section standard temperature scope is 970 DEG C ~ 1100 DEG C; Soaking zone 960 DEG C ~ 1040 DEG C; Rapid cooling section 750 DEG C ~ 850 DEG C; 650 DEG C ~ 720 DEG C, slow cooling section;
The spray zinc amount >=200g/m2 in Pen Xin district, each caliber Guan Chongke of often kind of interface is with reference to GB;
Hydraulic pressure district suppress pressure also can with reference to GB and dwell time >=17s;
Thickness of inner lining 4 ~ the 6mm in cement lining district; Centrifugation time >=50s;
The vapor pressure in health kiln district: >=0.2MPa health temperature: 30 ~ 100 DEG C;
The solidification temperature in curing oven district 200 DEG C;
The spray pitch amount 100-200Kg/min in spray pitch district, spray pump working pressure 4MPa.
A kind of ductile iron pipe production run autocontrol method, comprises the steps:
S1, when bulb enters annealing furnace district, Database Systems are numbered bulb automatically, and be stored in the pointer gauge of database as key word, and by read write line the pipe number write RFID generated, the parameters information in annealing furnace district is uploaded to Database Systems simultaneously;
S2, bulb enter Pen Xin district, weigh, spray zinc to bulb, Pen Xin district parameters information are uploaded to Database Systems simultaneously;
S3, bulb enter hydraulic pressure district, carry out pressure testing detection to bulb, hydraulic pressure district parameters information are uploaded to Database Systems simultaneously;
S4, bulb enter cement coated lining district, and bulb inwall serves as a contrast one deck cement, cement coated lining district parameters information are uploaded to Database Systems simultaneously;
S5, bulb enter health kiln district, after health 12-14h, carry out chamfering to socket, health kiln district parameters information are uploaded to Database Systems simultaneously;
S6, bulb enter curing oven district, carry out preheating to bulb, and preheat temperature is no more than 80 DEG C, curing oven district parameters information are uploaded to Database Systems simultaneously;
S7, bulb enter spray pitch district, bulb outer wall sprays one deck pitch, spray pitch district parameters information is uploaded to Database Systems simultaneously;
S8, jetting device for making number carry out spray number to bulb, and the packing of end product bulb is rolled off the production line.
Above-described embodiment is only be described the preferred embodiment of the present invention; not scope of the present invention is limited; under not departing from the present invention and designing the prerequisite of spirit; the various distortion that those of ordinary skill in the art make technical scheme of the present invention and improvement, all should fall in protection domain that claims of the present invention determines.
Claims (8)
1. a ductile iron pipe production run automatic control system, comprise annealing furnace district (001), Pen Xin district (002), hydraulic pressure district (003), cement coated lining district (004), health kiln district (005), spray pitch district (006), curing oven district (007), it is characterized in that, also comprise bulb RFID, Ethernet interface (010), server (009); Annealing furnace district (001), Pen Xin district (002), cement coated lining district (004), health kiln district (005), spray pitch district (006), curing oven district (007) are connected with server (009) respectively by Ethernet interface (010), described bulb RFID is arranged on bulb, for storing bulb information;
Annealing furnace district (001), Pen Xin district (002), hydraulic pressure district (003), cement coated lining district (004), health kiln district (005), spray pitch district (006), curing oven district (007) are respectively used to read bulb RFID information, and information are uploaded onto the server (009); Described server (009) for accessing above-mentioned seven districts by Ethernet interface (010), and reads the parameters information stored in described seven districts;
Set up in described server (009) and have Database Systems, data analysis control system, described Database Systems comprise bulb data module and bulb pointer module, the measured data that described bulb data module obtains in this stage for depositing bulb, described bulb pointer module real time record bulb is in production line actual motion position; Described data analysis control system is used for the parameters information stored in analytical database system, and controls above-mentioned seven districts according to analysis result.
2. ductile iron pipe production run automatic control system according to claim 1, it is characterized in that, bulb is placed in the straight length of bulb bellmouth side by RFID when annealing furnace district (001), Pen Xin district (002), hydraulic pressure district (003); Bulb is placed in the groove of bulb bellmouth by RFID when cement coated lining district (004), health kiln district (005); Bulb is placed in the straight length of bulb bellmouth side by RFID when spray pitch district (006), curing oven district (007).
3. ductile iron pipe production run automatic control system according to claim 2, is characterized in that, thermal insulation material is set up in described RFID inside, and for thermal insulation, outer setting magnetic material, for being adsorbed onto bulb.
4. ductile iron pipe production run automatic control system according to claim 3, is characterized in that, also comprises jetting device for making number (8), for spray pipe number on bulb.
5. ductile iron pipe production run automatic control system according to claim 4, is characterized in that, described annealing furnace district (001) comprises annealing furnace controller (1), annealing furnace reader (01); Pen Xin district (002) comprises spray zinc controller (2), spray zinc reader (02); Hydraulic controller (3), hydraulic pressure reader (03) are drawn together by hydraulic pressure district bag (003); Cement coated lining district (004) comprises cement coated lining controller (4), cement coated lining reader (04); Health kiln district (005) comprises health kiln controller (5), health kiln reader (05); Spray pitch district (006) comprises spray pitch controller (6), spray pitch reader (06); Curing oven district (007) comprises curing oven controller (7), curing oven reader (07).
6. ductile iron pipe production run automatic control system according to claim 5, is characterized in that, described server (009) comprises primary networking service device (9), backup network server (09).
7. ductile iron pipe production run automatic control system according to claim 6, is characterized in that, controller described in each district all adopts PLC to realize, and reader adopts RFID reader to realize.
8. a ductile iron pipe production run autocontrol method, is characterized in that, comprises the steps:
S1, when bulb enters annealing furnace district, Database Systems are numbered bulb automatically, and be stored in the pointer gauge of database as key word, and by read write line the pipe number write RFID generated, the parameters information in annealing furnace district is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and annealing furnace district compares analysis, if be consistent, enter Pen Xin district, if do not met, adjust the optimum configurations in annealing furnace district in real time, make it be consistent with preset standard parameter;
S2, bulb enter Pen Xin district, bulb is weighed, sprays zinc, Pen Xin district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and Pen Xin district compares analysis, if be consistent, enter hydraulic pressure district, if do not met, adjust the optimum configurations in Pen Xin district in real time, make it be consistent with preset standard parameter;
S3, bulb enter hydraulic pressure district, pressure testing detection is carried out to bulb, hydraulic pressure district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and hydraulic pressure district compares analysis, if be consistent, enter cement lining district, if do not met, adjust the optimum configurations in cement lining district in real time, make it be consistent with preset standard parameter;
S4, bulb enter cement coated lining district, bulb inwall serves as a contrast one deck cement, cement coated lining district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and cement lining district compares analysis, if be consistent, enter health kiln district, if do not met, adjust the optimum configurations in cement lining district in real time, make it be consistent with preset standard parameter;
S5, bulb enter health kiln district, after health 12-14h, chamfering is carried out to socket, health kiln district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and health kiln district compares analysis, if be consistent, enter curing oven district, if do not met, adjust the optimum configurations in health kiln district in real time, make it be consistent with preset standard parameter;
S6, bulb enter curing oven district, preheating is carried out to bulb, preheat temperature is no more than 80 DEG C, curing oven district parameters information is uploaded to Database Systems simultaneously, the preset standard parameter of data analysis control system to the data uploaded and curing oven district compares analysis, if be consistent, enter spray pitch district, if do not met, adjust the optimum configurations in curing oven district in real time, make it be consistent with preset standard parameter;
S7, bulb enter spray pitch district, bulb outer wall sprays one deck pitch, spray pitch district parameters information is uploaded to Database Systems simultaneously, data analysis control system compares analysis to the data uploaded and the preset standard parameter in spray pitch district, if be consistent, enter spray district, if do not met, the optimum configurations in the pitch district of adjustment spray in real time, makes it be consistent with preset standard parameter;
S8, jetting device for making number carry out spray number to bulb, and the packing of end product bulb is rolled off the production line.
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| CN108537310B (en) * | 2018-04-26 | 2023-09-26 | 芜湖新兴铸管有限责任公司 | Cast iron pipe production system and pipe number marking and tracking management method thereof |
| CN109885000A (en) * | 2019-02-22 | 2019-06-14 | 新兴河北工程技术有限公司 | A kind of automatic access and exit control method of pipeline health furnace |
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Application publication date: 20150722 |