CN108073778B - Automatic cutting method and system for improving yield of FCL (fiber channel laser) unit - Google Patents
Automatic cutting method and system for improving yield of FCL (fiber channel laser) unit Download PDFInfo
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Abstract
The invention discloses an automatic cutting method and system for improving the yield of an FCL unit, wherein the method comprises the following steps: step one, setting a configuration rule and an optimization strategy, giving an optimized cutting scheme result, and outputting and integrating with an associated system and a device according to a specified interface through an output module; transmitting the basic data of the raw material coil material and the defect data of the raw material coil to a cutting scheme optimization strategy setting module, and requiring that the type, grade, size and position information of the raw material coil defect data are complete, processing the data and receiving manually input defect information; and step three, the optimization strategies, the rules and the like do not need to be maintained frequently, the configuration is needed only when the changes occur, and meanwhile, the system can provide default options and the like. The invention can improve the rate of finished products, reduce waste and economic loss, reduce the cost and increase the economic benefit.
Description
Technical Field
The invention relates to an FCL (hot drawing leveling unit of an oriented silicon steel product line of a steel enterprise), in particular to an automatic cutting method and an automatic cutting system for improving the yield of an FCL unit.
Background
The oriented silicon steel is an important magnetic material in the military industry and the electronic industry, is mainly used for high-frequency transformers, high-power magnetic amplifiers, pulse generators, general choke coils, inductors, storage and memory elements, switches and control elements, magnetic shields, transformation equipment working under vibration and radiation conditions and the like, and has wide market application. The oriented silicon steel has the characteristics of complex process, high production requirement, high manufacturing difficulty, low yield and the like, and is one of high-end products and important profitable products with high added value, export value and strategic significance in the steel industry at present. The market demands at home and abroad are continuous and stable, the prospect is good, and the method is also one of the hot spots of investment and extension of the current iron and steel enterprises.
In addition to the conventional pickling and cold rolling processes of hot rolled coil raw materials (normalization), the main processing processes in the production process flow of the oriented silicon steel are concentrated in the annealing and hot stretching flattening processes (including a small finishing process). The annealing mainly comprises decarburization annealing and high-temperature annealing, wherein the decarburization annealing is performed at 750-950 ℃ in a continuous furnace filled with N-H control gas, and the annealed steel strip is coated with magnesium oxide and dried; high-temperature annealing is carried out in a hood-type annealing furnace or a ring annealing furnace at 1200 ℃ for secondary recrystallization, steel purification to remove harmful impurities and internal stress elimination, thus forming a good magnesium silicate bottom layer. The hot-drawing and flattening process is to carry out insulating layer coating and hot-drawing flattening on the oriented silicon steel raw material after high-temperature annealing, and has the main tasks of: firstly, removing residual MgO and other dirt on the surface of the steel strip; secondly, coating an insulating layer, drying and sintering; thirdly, applying proper tension to the steel strip in a furnace filled with N2+ H2 protective gas at the furnace temperature of 700-900 ℃ to perform coating sintering and hot stretching leveling.
The hot-drawing and stretching flattening process belongs to a finished product process, and due to the reasons of complex process, excessive influence factors in the production process and the like, the oriented silicon steel product produced by the FCL unit has a large number of defects with different degrees, and most of the defects are almost difficult to avoid, and mainly comprise: edge defects, nicking, indentation, crease, elephant foot, edge wave, bell mouth, frost, bottom layer defect, parking spot, hole, magnesium oxide residue, transverse stripe, coating L stripe, bubble, watermark, annealing temperature inconsistency, surface inclusion, inner convex imprint, small white point, crystal exposure, roll mark and the like. Some of the defects are also classified into different classes. In this case, the FCL machine set is required to perform a cutting operation to separate and package the defects into small cut rolls, and finally, the sold products are formed.
And after the oriented silicon steel is produced in the FCL unit for the reasons, edge cutting and sub-packaging prejudgment are required to guide the edge cutting and sorting production of the finishing unit. The existing cutting scheme is mainly characterized in that a judging person in a quality inspection station judging and releasing operation area identifies and disposes strip steel (comprising a front surface and a back surface) which is hundreds of meters long in length in a manual mode, so that the cutting prejudging work is time-consuming and labor-consuming, the most reasonable cutting and the consistency, reliability and stability of a guarantee rule are difficult to realize in the continuous and quick production process, more importantly, the yield of oriented silicon steel products is directly influenced, the product selling price and enterprise profits are directly influenced, and the price difference between the finished products and the small-tail coil ton steel can reach about 1 time. More particularly, the yield of the FCL assembly is not completely targeted for maximizing the number of finished products, and for example, there may be a situation where the overall yield of one oriented silicon steel raw material coil using a small number of certified products + a plurality of small tail coil cutting schemes is less than the overall yield of a plurality of CGO certified products + a plurality of tail coil cutting schemes, so that it is difficult to maximize the overall benefit of the product in the existing manner and to automatically select a flexible and diverse cutting scheme under different production plan targets (for example, in the situations of periodically pursuing maximization of the number of finished products, maximization of the overall yield, minimization of the tail coil, etc.).
Therefore, in order to meet the market demand and the production requirement of the oriented silicon steel of the iron and steel enterprises, it is necessary to research and develop an automatic cutting scheme, a matching system and a matching device for improving the yield aiming at the FCL unit so as to meet the business demand of production and manufacturing.
Disclosure of Invention
The invention aims to provide an automatic cutting method and an automatic cutting system for improving the yield of an FCL unit, which can improve the yield, reduce waste and economic loss, reduce cost and increase economic benefits.
The invention solves the technical problems through the following technical scheme: an automatic cutting method for improving the yield of an FCL unit comprises the following steps:
step one, setting a configuration rule and an optimization strategy, giving an optimized cutting scheme result, and outputting and integrating with an associated system and a device according to a specified interface through an output module;
transmitting the basic data of the raw material coil material and the defect data of the raw material coil to a cutting scheme optimization strategy setting module, requiring that the type, grade, size and position information of the defect data of the raw material coil are complete, processing the data and receiving manually input defect information;
step three, optimizing strategies, rules and the like, which do not need to be maintained frequently, configuration is needed only when changes occur, and meanwhile, the system can provide default options;
step four, the optimization process of the cutting scheme requires certain calculation time, and the time length mainly depends on the scale and the type of the defect, the grade and the specification of the material;
step five, outputting the data of the cutting scheme on one hand, outputting all calculated schemes through configuration, and butting corresponding MES systems or PES systems; and on the other hand, a finishing and cutting instruction is directly generated, and the control device for finishing and cutting is butted.
The invention also provides an automatic cutting system for improving the yield of the FCL unit, which comprises a raw material roll basic data receiving module, a raw material roll defect data receiving module, a cutting scheme issuing and finishing cutting instruction generating module, a quality judgment rule module, a process disposal requirement rule module, a grade category judgment rule module, a cutting scheme optimizing module, a cutting scheme KPI calculating module and a cutting scheme optimizing strategy setting module, wherein:
the raw material roll basic data receiving module is used for receiving external raw material roll basic data to be cut, and belongs to an external input data interface module;
the raw material roll defect data receiving module is used for receiving the defect data of an external raw material roll to be cut;
the quality judgment rule module is used for configuring and maintaining quality judgment rules related to the cutting scheme, and mainly comprises neglect conditions, adoption conditions and defect influence area defining rules of various defect types and different grades under different material types, different brands and different specifications;
a process disposal requirement rule module for configuring and maintaining constraint rules of the cutting;
the grade type judgment rule module is used for configuring and maintaining the cut grade type judgment rules;
the cutting scheme optimization module is used for calculating and selecting an optimized cutting scheme according to a priority strategy;
the cutting scheme KPI calculation module is used for calculating KPI indexes of the cutting scheme, is a consideration basis for evaluating value targets of different angles of the cutting scheme, is not only a basis for calling dependence of the optimization module, but also is an index support of an optimization strategy;
the cutting scheme optimization strategy setting module is used for setting the optimization strategy of the cutting scheme, namely the optimization direction, and the optimization strategy is mainly set through the priority sequencing of different optimization targets;
the cutting scheme issuing and finishing cutting instruction generating module is defined in a main sub-table mode and mainly has the following two functions: firstly, outputting the generated cutting scheme according to a certain interface format, and writing the cutting scheme into a specified database or a CVS file under a specified FTP path; and secondly, generating a finishing and cutting instruction according to the optimal cutting scheme, and issuing the finishing and cutting instruction to a specified interface.
Preferably, the cutting scheme optimization module mainly implements cutting scheme calculation, KPI evaluation, and optimization selection according to a specified optimization strategy, and it respectively calls the relevant contents of the quality judgment rule module, the process treatment requirement rule module, the grade category judgment rule module, and the cutting scheme KPI calculation module.
Preferably, the calculation flow of the cutting scheme optimization module comprises the following steps:
step ten, merging the edge defects and the middle defects; merging the defects of the edge position and the median position which are connected or close to each other according to a quality judgment rule, and reducing the number of the defects and the cutting scale;
eleventh, cutting the key defects of the middle position into the pre-cut position; according to the process treatment requirement rule, precutting the heavy point defects under the condition that the heavy point defects contain necessary cutting positions to form precut subsection rolls, and then performing cyclic calculation on each precut subsection;
step twelve, whether the edge is cut twice or not; judging whether the merging defects of the inner edge positions of the precut sections are subjected to edge cutting treatment according to a process treatment requirement rule, if the edge positions are single defects or approximate single defects, turning to a thirteen step, otherwise, turning to a fourteen step;
thirteen, pre-cutting the sectional edge position for secondary cutting; the edge defects are cut off, so that the number of the defects and the cutting scale are further reduced;
fourteen, a cutting scheme calculation submodule: the sub-module calculates the scheme of how to cut specifically, and the following explains the details of the technical scheme in detail;
step fifteen, whether all calculation is finished is judged, if yes, the step sixteen is carried out, and if not, the step twelve is carried out;
and sixthly, ending.
Preferably, the step fourteen cut plan calculation sub-module includes the steps of:
twenty, generating cutting points, sorting in ascending order according to the coordinate position in the length direction (the sorting order does not influence the result), and forming a queue;
twenty one, taking the queue head element, and respectively making the value of the queue head element be 1 and 0 (indicating cutting or not cutting, the same applies below);
twenty-two, recursively searching each subsequent element of the queue, and respectively taking 1 and 0;
twenty-four steps, when recursion reaches the tail of the queue, initializing a newly-built blank cutting scheme, and filling cutting scheme data;
twenty five, copying a newly added cutting scheme according to different values in the recursive backtracking process, and recording the difference;
twenty-six, forming all cutting schemes meeting the rules in the process, gradually calling a quality judgment rule module and a process treatment requirement rule module, and filtering the cutting schemes not meeting the rules;
twenty-seventh, performing grade type judgment and KPI calculation on all cutting schemes meeting the rules, and selecting an optimized scheme according to an optimized strategy;
and twenty-eight steps are finished.
Preferably, the process treatment requirement rule module has a default process treatment rule as follows:
according to the first rule, the defects of 4 to 5 levels need to be separated and sorted according to the actual length, and the defects of 1 to 3 levels are not allowed to be additionally brought in;
according to the second rule, because the width specification is changed and needs to be split, the weight of a single coil is required to be more than or equal to 2 tons, and the split coil is not allowed to be split into 1-2 tons of small coils;
rule three, the width of the edge cut after pre-judgment must be ensured to be more than or equal to 900 mm;
the fourth rule is that the defects are edge defects of 4 grades and 5 grades, the width after edge cutting is judged in advance to be less than 900mm, and the edge cutting amount is judged in advance to be 10mm respectively for a single edge according to the cutting treatment;
the fifth rule is that the defects are 3-level edge defects, if the single-side edge cutting amount is less than or equal to 80mm, edge cutting is carried out according to the actual width of the defects; if the single-side trimming amount is larger than 80mm, the elephant foot and the horn mouth are cut cleanly according to trimming prejudgment;
the rule VI is that the scope of the elephant foot is 0-2000 m, the measured value is less than or equal to 70mm, and all the elephant feet are pre-judged according to 60mm or the measured value; the measured value is more than 70mm, the prediction is carried out according to the measured value of-10 mm, the range of the elephant foot is 2000-4000 meters, the measured value is less than or equal to 50mm, and the prediction is carried out according to the measured value of 35mm or the measured value; the measured value is larger than 50mm, and the prejudgment is carried out according to the measured value of-10 mm; the elephant foot ranges from 4000 meters to the tail, the measured value is less than or equal to 40mm, the elephant foot is pre-judged according to 20mm or the measured value, the measured value is more than 40mm, and the elephant foot is pre-judged according to the measured value of-20 mm.
The positive progress effects of the invention are as follows: the invention can realize automatic judgment of the cutting scheme, improve the rationality of the cutting scheme, improve the yield and the overall income, save labor, improve the efficiency, reduce waste and economic loss, reduce the cost and increase the economic benefit.
Drawings
FIG. 1 is a flow chart of the present invention.
Fig. 2 is a schematic structural diagram of the present invention.
FIG. 3 is a flow chart of the calculation of the cutting plan optimization module of the present invention.
Detailed Description
The following provides a detailed description of the preferred embodiments of the present invention with reference to the accompanying drawings.
As shown in fig. 1, the automatic cutting method for improving the yield of the FCL unit of the present invention includes the following steps:
step one, setting a configuration rule and an optimization strategy, giving an optimized cutting scheme result, and outputting and integrating with an associated system and a device according to a specified interface through an output module;
transmitting the basic data of the raw material roll material and the defect data of the raw material roll to a cutting scheme optimization strategy setting module, directly connecting equipment such as a meter detector, a hole detector and the like, processing the data and receiving manually input defect information, wherein the information is required to be complete in category, grade, size and position of the defect data of the raw material roll;
step three, the optimization strategies, rules and the like do not need to be maintained frequently, configuration is needed only when changes occur, and meanwhile, the system can provide default options;
step four, a certain calculation time is needed in the cutting scheme optimization process, the time length mainly depends on the scale and type of the defects, the material grade and the specification, the calculation time is generally 1-3 minutes from the condition of an application case, and the requirement of silicon steel continuous production is completely met (the application case refers to that the production speed is 40-60 minutes per coil);
step five, outputting the data of the cutting scheme on one hand, including available alternative schemes, or outputting all calculated schemes through configuration, and butting a corresponding MES (a set of production information management system facing a workshop execution layer of a manufacturing enterprise) system or a PES system; on the other hand, a finishing and cutting instruction can be directly generated, and a finishing and cutting control device is butted, the mode is optional, and customized expansion can be carried out according to different control manufacturers (application case refers to 1 recoiling unit +3 slitting units, Germany GEORG company).
As shown in fig. 2, the automatic cutting system for improving the yield of the FCL machine set of the present invention includes a raw material roll basic data receiving module, a raw material roll defect data receiving module, a cutting scheme issuing and finishing slitting instruction generating module, a quality determination rule module, a process treatment requirement rule module, a grade type determination rule module, a cutting scheme optimizing module, a cutting scheme KPI (Key Performance Indicator) calculating module, and a cutting scheme optimizing policy setting module, wherein the Key Performance Indicator is a target type quantitative management index for setting, sampling, calculating, and analyzing Key parameters of an input end and an output end of an organization internal process, and measuring the process Performance, and the cutting scheme optimizing policy setting module is configured to:
the raw material roll basic data receiving module is used for receiving external raw material roll basic data to be cut, such as material numbers, specification and size, grade steel types, various quality parameters and the like, and belongs to an external input data interface module;
the raw material roll defect data receiving module is used for receiving external defect data of the raw material roll to be cut, such as defect numbers, positions, categories, sizes and the like, and belongs to an external input data interface module;
the quality judgment rule module is used for configuring and maintaining quality judgment rules related to the cutting scheme, and mainly comprises neglect conditions, adoption conditions and defect influence area defining rules of various defect types and different grades under different material types, different brands and different specifications;
the process disposal requirement rule module is used for configuring and maintaining restrictive rules of cutting, such as conditional minimum trimming amount, minimum bundling weight, specific cutting requirements of cutting judgment trees and unconventional varieties and defects and the like;
the grade type judgment rule module is used for configuring and maintaining the cut grade type judgment rules, and if the single weight is less than 1 ton, the tail roll is small;
the cutting scheme optimization module is used for calculating and selecting an optimized cutting scheme according to a priority strategy;
the cutting scheme KPI calculation module is used for a KPI index calculation module of a cutting scheme, is a consideration basis for evaluating value targets of different angles of the cutting scheme, is not only a basis for calling dependence of an optimization module, but also an index support of an optimization strategy, and has main indexes such as each grade ratio, total amount of waste materials, total amount of finished products, achievement rate, yield, total income and the like;
the cutting scheme optimization strategy setting module is used for setting an optimization strategy of the cutting scheme, namely the optimization direction, main optimization targets such as yield maximization, waste minimization, total income maximization, tail roll minimization and the like, and the optimization strategy is mainly set through priority sequencing of different optimization targets;
the cutting scheme issuing and finishing cutting instruction generating module is defined in a main sub-table mode and mainly has the following two functions: firstly, outputting the generated cutting scheme (including alternative schemes) according to a certain interface format, and writing the cutting scheme into a designated database or a CVS (a C/S system, which is a common code version control software) File under a designated FTP (File Transfer Protocol) path; and secondly, generating a finishing and cutting instruction according to the optimal cutting scheme, and sending the finishing and cutting instruction to a specified interface (both a text format or a PLC process signal and the like).
The process treatment requirement rule module has the following default process treatment rules:
according to the first rule, the defects of 4 to 5 levels need to be separated and sorted according to the actual length, and the defects of 1 to 3 levels are not allowed to be additionally brought in;
according to the second rule, because the width specification is changed and needs to be split, the weight of a single coil is required to be more than or equal to 2 tons, and the split coil is not allowed to be split into 1-2 tons of small coils;
rule three, the width of the edge cut after pre-judgment must be ensured to be more than or equal to 900 mm;
the fourth rule is that the defects are edge defects of 4 grades and 5 grades, the width after edge cutting is judged in advance to be less than 900mm, and the edge cutting amount is judged in advance to be 10mm respectively for a single edge according to the cutting treatment;
the fifth rule is that the defects are 3-level edge defects, if the single-side edge cutting amount is less than or equal to 80mm, edge cutting is carried out according to the actual width of the defects; if the single-side trimming amount is larger than 80mm, the elephant foot and the horn mouth are cut cleanly according to trimming prejudgment;
the rule six is that the range of the elephant foot is 0-2000 m, the measured value is less than or equal to 70mm, and all the elephant feet are pre-judged according to 60mm or the measured value (which is used for a small elephant); the measured value is more than 70mm, the prediction is carried out according to the measured value of-10 mm, the range of the elephant foot is 2000-4000 meters, the measured value is less than or equal to 50mm, and the prediction is carried out according to the measured value of 35mm or the measured value; the measured value is larger than 50mm, and the prejudgment is carried out according to the measured value of-10 mm; the elephant foot ranges from 4000 meters to the tail, the measured value is less than or equal to 40mm, the elephant foot is pre-judged according to 20mm or the measured value, the measured value is more than 40mm, and the elephant foot is pre-judged according to the measured value of-20 mm.
Calculating whether the cutting schemes meet the restrictive process disposal requirements or not according to the process disposal requirement rules, and if the cutting schemes do not meet the process disposal requirements, indicating that the cutting schemes do not meet the process requirements; otherwise, performing an optimization comprehensive analysis link. The process disposal requirement rule module configures and maintains constraint rules of cutting, such as conditional minimum trimming amount, minimum bundling weight, specific cutting requirements of cutting judgment trees and unconventional varieties and defects, and the like.
The cutting scheme optimization module is a core module of the invention, mainly realizes cutting scheme calculation, KPI evaluation and optimization selection according to a specified optimization strategy, and respectively calls related contents of a quality judgment rule module, a process treatment requirement rule module, a grade category judgment rule module and a cutting scheme KPI calculation module.
As shown in fig. 3, the cutting plan optimization module includes the following calculation flow:
step ten, merging the edge defects and the middle defects; merging the defects of the edge position and the median position which are connected or close to each other according to a quality judgment rule, and reducing the number of the defects and the cutting scale;
eleventh, cutting the key defects of the middle position into the pre-cut position; according to the process treatment requirement rule, precutting the heavy point defects under the condition that the heavy point defects contain necessary cutting positions to form precut subsection rolls, and then performing cyclic calculation on each precut subsection;
step twelve, whether the edge is cut twice or not; judging whether the merging defects of the inner edge positions of the precut sections are subjected to edge cutting treatment according to a process treatment requirement rule, if the edge positions are single defects or approximate single defects, turning to a thirteen step, otherwise, turning to a fourteen step;
thirteen, pre-cutting the sectional edge position for secondary cutting; the edge defects are cut off, so that the number of the defects and the cutting scale are further reduced;
fourteen, a cutting scheme calculation submodule: the sub-module calculates the scheme of how to cut specifically, and the following explains the details of the technical scheme in detail;
step fifteen, whether all calculation is finished is judged, if yes, the step sixteen is carried out, and if not, the step twelve is carried out;
and sixthly, ending.
Through the above procedures, not only is the calculation scale reduced, but also the requirements of calculation accuracy and result optimization are ensured, but a larger calculation scale may still be faced in the cutting scheme calculation submodule. If the response speed requirement of the continuous operation of the oriented silicon steel hot-drawing balancing unit is difficult to meet according to a conventional serial computing mode, the characteristics of the continuous operation of the oriented silicon steel hot-drawing balancing unit can be known through deep research, the cutting schemes are independent from one another, and the condition of mutual influence does not exist, so that a foundation is provided for the introduction of parallel computing, and in addition, after the invalid cutting schemes caused by most quality and process requirements are eliminated through the process, the residual possible schemes have relatively pure computing environments, so that the time of overall computing can be greatly shortened by utilizing the parallel computing capability of the computing graphics card, meanwhile, the optimal solution can be obtained according to the set optimization strategy from the technical perspective, and meanwhile, an alternative optimization scheme (a plurality of solutions) can be obtained.
The step fourteen (cutting plan calculation sub-module) includes the steps of:
twenty, generating cutting points, sorting in ascending order according to the coordinate position in the length direction (the sorting order does not influence the result), and forming a queue;
twenty one, taking the queue head element, and respectively making the value of the queue head element be 1 and 0 (indicating cutting or not cutting, the same applies below);
twenty-two, recursively searching each subsequent element of the queue, and respectively taking 1 and 0;
twenty-four steps, when recursion reaches the tail of the queue, initializing a newly-built blank cutting scheme, and filling cutting scheme data;
twenty five, copying a newly added cutting scheme according to different values in the recursive backtracking process, and recording the difference;
twenty-six, forming all cutting schemes meeting the rules in the process, gradually calling a quality judgment rule module and a process treatment requirement rule module, and filtering the cutting schemes not meeting the rules;
twenty-seventh, performing grade type judgment and KPI calculation on all cutting schemes meeting the rules, and selecting an optimized scheme according to an optimized strategy;
and twenty-eight steps are finished.
The cutting scheme optimization strategy setting module represents the requirement of a user on the result optimization tendency, namely the definite optimization direction and the basis of the balance and the rejection of different schemes, the cutting scheme optimization strategy setting module is internally provided with the main optimization target of the cutting scheme, and is set by the priority sequence of different optimization targets, and the cutting scheme optimization strategy setting module comprises the following points: thirty, the total profit is maximized; thirty-one, maximizing total profit; thirty-two, the yield is maximized; thirty-three, the ratio of the genuine products is maximized; thirty-four, the CGO ratio is maximized; thirty-five, the total genuine ratio is maximized; thirty-six, tail roll ratio is minimized; thirty-seven, the small tail roll ratio is minimized; thirty-eight, cutting waste is minimized; thirty-nine, the scrap cosutting ratio is minimized; considering the requirements of production and manufacturing decisions on multiple cutting schemes, multiple sets of optimization strategies can be set, and the optimal strategies and alternative strategies are set in a differentiated mode and are respectively given out by the optimization modules.
The invention can realize automatic judgment of the cutting scheme, improve the rationality of the cutting scheme, improve the yield and the overall income, save labor, improve the efficiency, reduce waste and economic loss and reduce the cost. The invention completely aims at the production process and the flow of the oriented silicon steel hot-drawing leveling unit, has complete and effective technical scheme, simultaneously carries out systematic design abstraction and modularization treatment on parts such as quality judgment rules, process disposal rules, grade evaluation rules and the like, can be flexibly configured according to different steel enterprise conditions and process requirements, provides an extension mechanism, carries out optional design on the optimized evaluation target of the cutting scheme and is convenient to control according to different management strategies. Therefore, the invention has better feasibility, effectiveness and applicability to the oriented silicon steel production line in the domestic steel industry. The invention completely aims at the production process and the flow of the oriented silicon steel hot-drawing leveling unit, has complete and effective technical scheme, simultaneously carries out systematic design abstraction and modularization treatment on parts such as quality judgment rules, process disposal rules, grade evaluation rules and the like, can be flexibly configured according to different steel enterprise conditions and process requirements, provides an extension mechanism, carries out optional design on the optimized evaluation target of the cutting scheme and is convenient to control according to different management strategies. Therefore, the invention has better feasibility, effectiveness and applicability to the oriented silicon steel production line in the domestic steel industry. The matching system and the device have high integration level, are easy to deploy and use, and are particularly suitable for the requirements of the hot drawing leveling unit for continuous production in the hot drawing of the oriented silicon steel production line of the iron and steel enterprise.
The above embodiments are described in further detail to solve the technical problems, technical solutions and advantages of the present invention, and it should be understood that the above embodiments are only examples of the present invention and are not intended to limit the present invention, and any modifications, equivalent substitutions, improvements and the like made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (5)
1. The utility model provides an improve automatic cutout system of FCL unit yield which characterized in that, it includes:
the raw material roll basic data receiving module is used for receiving external raw material roll basic data to be cut, and belongs to an external input data interface module;
the raw material roll defect data receiving module is used for receiving the defect data of an external raw material roll to be cut;
the quality judgment rule module is used for configuring and maintaining quality judgment rules related to the cutting scheme, and mainly comprises neglect conditions, adoption conditions and defect influence area defining rules of various defect types and different grades under different material types, different brands and different specifications;
a process disposal requirement rule module for configuring and maintaining constraint rules of the cutting;
the grade type judgment rule module is used for configuring and maintaining the cut grade type judgment rules;
the cutting scheme optimization module is used for calculating and selecting an optimized cutting scheme according to a priority strategy;
the cutting scheme KPI calculation module is used for calculating KPI indexes of the cutting scheme, is a consideration basis for evaluating value targets of different angles of the cutting scheme, is not only a basis for calling dependence of the optimization module, but also is an index support of an optimization strategy;
the cutting scheme optimization strategy setting module is used for setting the optimization strategy of the cutting scheme, namely the optimization direction, and the optimization strategy is mainly set through the priority sequencing of different optimization targets;
the cutting scheme issuing and finishing cutting instruction generating module is defined in a main sub-table mode and mainly has the following two functions: firstly, outputting the generated cutting scheme according to a certain interface format, and writing the cutting scheme into a specified database or a CVS file under a specified FTP path; secondly, generating a finishing and cutting instruction according to the optimal cutting scheme, and issuing the finishing and cutting instruction to a designated interface;
the cutting scheme optimization module comprises the following calculation processes:
step ten, merging the edge defects and the middle defects; merging the defects of the edge position and the median position which are connected or close to each other according to a quality judgment rule, and reducing the number of the defects and the cutting scale;
eleventh, cutting the key defects of the middle position into the pre-cut position; according to the process treatment requirement rule, precutting the heavy point defects under the condition that the heavy point defects contain necessary cutting positions to form precut subsection rolls, and then performing cyclic calculation on each precut subsection;
step twelve, whether the edge is cut twice or not; judging whether the merging defects of the inner edge positions of the precut sections are subjected to edge cutting treatment according to a process treatment requirement rule, if the edge positions are single defects or approximate single defects, turning to a thirteen step, otherwise, turning to a fourteen step;
thirteen, pre-cutting the sectional edge position for secondary cutting; the edge defects are cut off, so that the number of the defects and the cutting scale are further reduced;
fourteen, a cutting scheme calculation submodule: the pre-cut and the secondary-cut pre-cut segments are distributed with defects of different positions and types;
step fifteen, whether all calculation is finished is judged, if yes, the step sixteen is carried out, and if not, the step twelve is carried out;
and sixthly, ending.
2. The automatic cutting system for improving the yield of the FCL plant according to claim 1, wherein the cutting plan optimization module is mainly used for implementing cutting plan calculation, KPI evaluation and optimization selection according to a specified optimization strategy, and it respectively calls the relevant contents of the quality judgment rule module, the process treatment requirement rule module, the grade category judgment rule module and the cutting plan KPI calculation module.
3. The automatic cutting system for improving the yield of an FCL assembly of claim 1, wherein said fourteen steps comprise the steps of:
twenty, generating cutting points, sequencing the cutting points in an ascending order according to the coordinate positions in the length direction, and forming a queue;
twenty one, taking the queue head element, and respectively making the value of the queue head element as 1 and 0;
twenty-two, recursively searching each subsequent element of the queue, and respectively taking 1 and 0;
twenty-four steps, when recursion reaches the tail of the queue, initializing a newly-built blank cutting scheme, and filling cutting scheme data;
twenty five, copying a newly added cutting scheme according to different values in the recursive backtracking process, and recording the difference;
twenty-six, forming all cutting schemes meeting the rules in the process, gradually calling a quality judgment rule module and a process treatment requirement rule module, and filtering the cutting schemes not meeting the rules;
twenty-seventh, performing grade type judgment and KPI calculation on all cutting schemes meeting the rules, and selecting an optimized scheme according to an optimized strategy;
and twenty-eight steps are finished.
4. The automatic cutting system for improving the yield of FCL assemblies of claim 1, wherein the process disposition requirement rule module has the following default process disposition rules:
according to the first rule, the defects of 4 to 5 levels need to be separated and sorted according to the actual length, and the defects of 1 to 3 levels are not allowed to be additionally brought in;
according to the second rule, because the width specification is changed and needs to be split, the weight of a single coil is required to be more than or equal to 2 tons, and the split coil is not allowed to be split into 1-2 tons of small coils;
rule three, the width of the edge cut after pre-judgment must be ensured to be more than or equal to 900 mm;
the fourth rule is that the defects are edge defects of 4 grades and 5 grades, the width after edge cutting is judged in advance to be less than 900mm, and the edge cutting amount is judged in advance to be 10mm respectively for a single edge according to the cutting treatment;
the fifth rule is that the defects are 3-level edge defects, if the single-side edge cutting amount is less than or equal to 80mm, edge cutting is carried out according to the actual width of the defects; if the single-side trimming amount is larger than 80mm, the elephant foot and the horn mouth are cut cleanly according to trimming prejudgment;
the rule VI is that the scope of the elephant foot is 0-2000 m, the measured value is less than or equal to 70mm, and all the elephant feet are pre-judged according to 60mm or the measured value; the measured value is more than 70mm, the prediction is carried out according to the measured value of-10 mm, the range of the elephant foot is 2000-4000 meters, the measured value is less than or equal to 50mm, and the prediction is carried out according to the measured value of 35mm or the measured value; the measured value is larger than 50mm, and the prejudgment is carried out according to the measured value of-10 mm; the elephant foot ranges from 4000 meters to the tail, the measured value is less than or equal to 40mm, the elephant foot is pre-judged according to 20mm or the measured value, the measured value is more than 40mm, and the elephant foot is pre-judged according to the measured value of-20 mm.
5. A method of using the automatic cutting system for improving the yield of FCL assemblies according to claim 1, comprising the steps of:
step one, setting a configuration rule and an optimization strategy, giving an optimized cutting scheme result, and outputting and integrating with an associated system and a device according to a specified interface through an output module;
transmitting the basic data of the raw material coil material and the defect data of the raw material coil to a cutting scheme optimization strategy setting module, requiring that the type, grade, size and position information of the defect data of the raw material coil are complete, processing the data and receiving manually input defect information;
step three, the optimization strategy and the rule do not need to be maintained frequently, the configuration is needed only when the optimization strategy and the rule change, and meanwhile, the system can provide default options;
step four, the optimization process of the cutting scheme requires certain calculation time, and the time length mainly depends on the scale and the type of the defect, the grade and the specification of the material;
step five, outputting the data of the cutting scheme on one hand, outputting all calculated schemes through configuration, and butting corresponding MES systems or PES systems; and on the other hand, a finishing and cutting instruction is directly generated, and the control device for finishing and cutting is butted.
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