CN109821900B - Online detection method for working abnormity of rolling mill transmission equipment - Google Patents
Online detection method for working abnormity of rolling mill transmission equipment Download PDFInfo
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- CN109821900B CN109821900B CN201910137632.5A CN201910137632A CN109821900B CN 109821900 B CN109821900 B CN 109821900B CN 201910137632 A CN201910137632 A CN 201910137632A CN 109821900 B CN109821900 B CN 109821900B
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Abstract
The invention relates to an online detection method for the working abnormity of rolling mill transmission equipment, belonging to the technical field of automatic control of metallurgical equipment. The technical scheme is as follows: the output torque of the frequency conversion cabinet is equal to the working torque of a load in a stable working state, the load torque is equal to the sum of the working torque of the rolling mill and the torque loss from the motor to the intermediate transmission link of the rolling mill, and when the rolling mill and the intermediate transmission link of the rolling mill are abnormal, the amplitude and the change rate of the output torque of the frequency conversion cabinet can be changed; the amplitude change and the change rate of the output torque of the frequency conversion cabinet are detected in real time through the programmable controller to judge whether the transmission equipment works abnormally; if the abnormal condition exists, alarm information is sent out through the HMI computer. The invention can detect the abnormality of the transmission equipment in time and give an alarm in the whole working period of the transmission equipment, thereby avoiding the enlargement of accidents.
Description
Technical Field
The invention relates to an online detection method for the working abnormity of rolling mill transmission equipment, belonging to the technical field of automatic control of metallurgical equipment.
Background
In the steel rolling production of the metallurgical industry, because the load of the transmission equipment of the rolling mill is large, the probability of equipment failure is high, and accidents such as pipe explosion of a frequency conversion cabinet and the like caused by poor performance of parts of a rolling mill bearing burning, gear punching of a speed reducer, roller breakage and a transmission control cabinet often occur; such accidents, once they occur, can result in significant equipment and production losses. If the transmission equipment can be timely found and timely checked and processed when abnormality happens, accidents can be eliminated in a bud state, and the serious loss caused by the accidents is reduced or avoided. At present, a fault detection method for steel rolling transmission equipment is to manually detect mechanical transmission equipment, but cannot realize real-time detection on the equipment; secondly, the abnormality of the equipment is detected through overcurrent alarm of the transmission equipment, but the abnormality of the equipment which does not reach the overcurrent alarm can not be detected; and thirdly, a vibration measuring sensor is adopted to detect vibration waves of the transmission machinery, and whether the mechanical equipment is abnormal or not is judged through analysis, and the method has poor application effect on the steel rolling equipment because the operation working condition of the steel rolling machinery is large in impact and vibration and the vibration waves are not real reflection of the working condition of the equipment.
Disclosure of Invention
The invention aims to provide an online detection method for the working abnormity of the transmission equipment of the rolling mill, which judges whether the transmission equipment of the rolling mill has abnormity by detecting the change rate and the change amplitude of the torque of the transmission equipment of the rolling mill in real time, and sends out an alarm in time if the transmission equipment of the rolling mill has abnormity, thereby avoiding the enlargement of accidents.
The technical scheme adopted by the invention is as follows:
an online detection method for the abnormal working of the transmission equipment of a rolling mill, the output torque of a frequency conversion cabinet is equal to the working torque of a load under the stable working state, the load torque is equal to the sum of the working torque of the rolling mill and the torque loss from a motor to the intermediate transmission link of the rolling mill, and when the rolling mill and the intermediate transmission link thereof are abnormal (such as the abnormal conditions of equipment components such as the damage of a bearing of the rolling mill, the gear beating of a transmission shaft of a speed reducer and the like), the amplitude and the change rate of the output torque of the frequency conversion cabinet can be; the amplitude change and the change rate of the output torque of the frequency conversion cabinet are detected in real time through the programmable controller to judge whether the rolling mill transmission equipment works abnormally; if the abnormal condition exists, alarm information is sent out through the HMI computer.
The running state of the transmission equipment of the rolling mill is divided into a no-load state and a load state, and the states are distinguished by acquiring the output quantity of the output torque of the frequency conversion cabinet and the characteristic value of the output torque of the frequency conversion cabinet converted from the two working states through a programmable controller; the state transition characteristic value is set as a torque value weighted by the no-load torque;
when the transmission equipment of the rolling mill is in an idle load state, the idle load torque of the transmission equipment is basically a constant value and is changed up and down in a small range, and when the change of the idle load torque greatly exceeds the fluctuation range, the control system sends out an alarm in time; the fault alarm threshold value is set after weighting the normal no-load torque according to the actual state of the load of the transmission equipment of the rolling mill.
The load torque of the rolling mill is generally stable in the rolling process of the rolled piece, when the transmission equipment of the rolling mill is abnormal, the change amplitude and the change rate of the load torque of the rolling mill are large, and when the values of the load torque and the change rate exceed the set threshold value, an alarm is given out.
When the rolling mill transmission equipment is in no-load and load conversion, the output torque of the rolling mill transmission equipment has a dynamic regulation process, the process can cause the torque to be distorted due to overshoot, the output torque needs to be sampled in a delayed mode when the two states are converted, and the delay time is determined according to the dynamic regulation performance of the actual rolling mill transmission equipment.
The invention monitors the torque change of the whole working cycle of the transmission equipment in the no-load state and the load state of the transmission equipment of the rolling mill in real time, and ensures that no dead angle exists in the monitoring of the transmission equipment.
The invention has the beneficial effects that: whether the rolling mill transmission equipment is abnormal is judged by detecting the change rate and the change amplitude of the output torque of the variable frequency cabinet of the rolling mill transmission equipment in real time, and if the change rate and the change amplitude are abnormal, an alarm is sent out in time. The invention is the innovation of the on-line diagnosis technology of the fault of the transmission equipment of the rolling mill, can detect the abnormity in time and give an alarm in the whole working period of the transmission equipment of the rolling mill, avoids the expansion of the accident, has simple and convenient detection method, high accuracy and obvious effect, and has extremely high popularization and application values.
Drawings
FIG. 1 is a schematic diagram of a system according to an embodiment of the present invention;
the figures are labeled as follows: the system comprises a programmable controller 1, a frequency conversion cabinet 2, an HMI computer 3, a motor 4, a speed reducer 5, a rolling mill 6, a transmission shaft 7, an electric reduction connecting shaft 8, a PROFIBUS network 9 and an Ethernet 10;
FIG. 2 is a typical torque curve diagram of the rolling mill transmission equipment according to the embodiment of the invention when the rolling mill transmission equipment works abnormally;
the figures are labeled as follows: t is t1For the rolling mill no-load starting point, t2The rolling mill no-load end starting point (also the starting point of the load state), t3End point, T, for the rolling mill load state0Torque value, T, for normal space-time load condition of rolling mill transmission equipment1Torque threshold, T, for abnormal space-time load conditions of rolling mill drive equipmentKIn order to distinguish the torque characteristic value of the rolling mill transmission equipment in the idle state and the load state (the actual torque is smaller than the value and is in the idle state, otherwise, the actual torque is in the load state), a, b and c are typical torque jumping points when the rolling mill transmission equipment works abnormally.
Detailed Description
The invention is further illustrated by the following examples in conjunction with the accompanying drawings.
An online detection method for the abnormal working of the transmission equipment of a rolling mill, the output torque of a frequency conversion cabinet is equal to the working torque of a load under the stable working state, the load torque is equal to the sum of the working torque of the rolling mill and the torque loss from a motor to the intermediate transmission link of the rolling mill, and when the rolling mill and the intermediate transmission link thereof are abnormal (such as the abnormal conditions of equipment components such as the damage of a bearing of the rolling mill, the gear beating of a transmission shaft of a speed reducer and the like), the amplitude and the change rate of the output torque of the frequency conversion cabinet can be; the amplitude change and the change rate of the output torque of the frequency conversion cabinet are detected in real time through the programmable controller to judge whether the rolling mill transmission equipment works abnormally; if the abnormal condition exists, alarm information is sent out through the HMI computer.
The running state of the transmission equipment of the rolling mill is divided into a no-load state and a load state, and the states are distinguished by acquiring the output quantity of the output torque of the frequency conversion cabinet and the characteristic value of the output torque of the frequency conversion cabinet converted from the two working states through a programmable controller; the state transition characteristic value is set as a torque value weighted by the no-load torque;
1. the rolling mill transmission equipment is in an idle state
For the rolling mill, the normal transmission torque of the no-load state of the rolling mill is changed up and down within a small range and is basically a constant value, when the actual torque greatly exceeds the fluctuation range, the abnormal condition of the transmission equipment of the rolling mill is indicated, and the control system sends out an alarm in time; the no-load state fault alarm threshold is set after weighting according to the normal no-load torque of the steel rolling equipment;
2. the transmission equipment of the rolling mill is in a production load state
The state is divided into three stages of gripping a rolled piece into a rolling mill, rolling the rolled piece and separating the tail of the rolled piece from the rolling mill;
A. rolling mill for gripping rolled piece
When a rolled piece bites into a rolling mill, because the load of a transmission device of the rolling mill is suddenly increased, a short-time adjusting process is carried out on impact load by a frequency conversion cabinet, and the problem of data distortion caused by torque overshoot exists in the adjusting process, sampling is delayed, and the delay time is related to the adjusting parameter of the frequency conversion cabinet and is generally millisecond level;
B. in the rolling process of rolled pieces
The torque of the rolling mill is generally stable and gentle in change in the rolling process of a rolled piece, when the transmission equipment of the rolling mill is abnormal, the torque index is generally reflected, the change amplitude and the change rate of the torque are obvious, and whether the transmission equipment of the rolling mill is abnormal or not can be detected by detecting the change conditions of the two indexes in real time; if the abnormal condition exists, an alarm is sent out;
C. rolled piece tail break-away mill process
When the tail of the rolled piece is separated from the rolling mill, the transmission torque is reduced to the sudden change of the no-load torque from the load torque, the frequency conversion cabinet also has an adjusting process, and the judgment method of the separation signal is the same as the biting signal of the rolling mill; namely: the signal that the rolled piece is separated from the rolling mill takes the torque load sampled in real time lower than the state transition torque characteristic value as a judgment condition; and the torque after the state conversion is delayed for sampling, and the delay time is set according to the dynamic adjustment parameters of the frequency conversion cabinet.
In an embodiment, referring to fig. 1, a hardware device according to the present invention includes: programmable controller 1, frequency conversion cabinet 2, motor 3, electricity subtract connecting axle 4, speed reducer 5, transmission shaft 6, rolling mill 7, HMI computer 8, PROFIBUS network 9, ethernet 10.
In the figure 1, a programmable controller 1 is connected with a frequency conversion cabinet 2 through a control network 9, the frequency conversion cabinet 2 provides a frequency conversion power supply for a motor 3, the motor 3 is connected with a speed reducer 5 through an electric reduction connecting shaft 4, the speed reducer 5 drives a rolling mill 7 to operate through a transmission shaft 6, and an HMI computer is connected with the programmable controller 1 through an Ethernet 10. The programmable controller collects and stores the torque value of the frequency conversion cabinet according to a certain sampling period (millisecond level) through a communication network, and is used for analyzing and judging the running condition of the transmission equipment of the rolling mill.
The output torque of the frequency conversion cabinet 2 is equal to the sum of the working torque of the rolling mill and the torque loss from the motor to the intermediate transmission link of the rolling mill in a stable working state, when the rolling mill and the intermediate transmission link thereof are abnormal, the output torque of the frequency conversion cabinet is changed due to abnormal conditions of mechanical components such as the damage of a bearing of the rolling mill, the gear beating of a transmission shaft of a speed reducer and the like, for example, the output torque of the frequency conversion cabinet is changed in a no-load state t of the1~t2Is in a normal state from t2~t3After the torque in the load stage jumps at the point a, the torque in the subsequent no-load stage becomes high, the torque in the subsequent load stage is also unstable, and the jumps are frequent, such as the point b and the point c.
The invention realizes the judgment of the abnormal work of the rolling mill transmission equipment in the idle load stage by using the following method. In the stage, the torque is small, and the change rate is small even if torque jumps, so that the torque is difficult to distinguish accurately. The threshold comparison method is simple and practical, and is based on the normal no-load torque value T as shown in FIG. 20Reasonably determining torque threshold T when transmission equipment of rolling mill is abnormal1For example, if the normal torque of the rolling mill transmission device during idling is within the range of 13% to 15% of the rated torque, the threshold value of the torque abnormality may be set to a torque greater than 20% of the rated torque. If the programmable controller detects that the actual output torque of the frequency conversion cabinet at the no-load stage is greater than T1And then sending out an abnormal alarm of the condition of the transmission equipment of the rolling mill.
The invention realizes the judgment of the working abnormity of the transmission equipment of the rolling mill in the loading stage by using the following method. The load torque at the stage is large, the change rate and the change amplitude of the load are obvious when the transmission equipment of the rolling mill is abnormal, and the change rate is the ratio of the change amplitude to the time period of the calculation interval, so that when the value of the time period is small, the change amplitude can represent the size of the change rate. And when the torque variation amplitude value in a certain time period exceeds a set threshold value, an abnormal operation alarm of the transmission equipment of the rolling mill is sent out.
Firstly, a time detection window is determined for a torque value in a rolling process, the size of the window is determined according to the dynamic performance and the torque sampling period of a transmission device of a rolling mill (for example, the torque sampling period is 50 milliseconds, and the dynamic adjustment time is 150 milliseconds, then the time detection window can adopt 400 milliseconds), the transmission torque in the window range is sampled and stored, and the following torque value sequence is established:
Buff=(t1, t2,..., tn)
except for t1And sequencing the rest sampling values in the sequence, removing a certain number of maximum values and minimum values in the sequence, summing the rest values, and averaging to remove the influence of pulsating torque and random torque in the load torque on a true torque value. Current sample value t1And then making a difference with the average value, comparing the difference with a set threshold value, and if the difference exceeds the threshold value, sending an alarm on an HMI computer picture. If the difference is less than 0 during alarming, the abnormal condition that the load of the rolling mill transmission equipment is suddenly increased, such as rolling mill roll breakage, transmission shaft gear beating and the like, is generated, if the value is more than 0 during alarming, the abnormal condition that the load of the rolling mill transmission equipment is suddenly increased, such as rolling mill bearing burning, motor grounding and the like, is generated, and corresponding alarm information can be set according to the characteristic expression when the rolling mill transmission equipment is abnormal.
The latest torque sample value will update t in the sequence1Value, original t1~ tn-1Sequentially replacing t in the original sequence2~tnAnd forming a new torque value sequence, thereby ensuring the real-time performance of the detection window. And the programmable controller carries out the analysis and judgment on the new torque value sequence again, so that the real-time detection on the working condition of the transmission equipment of the rolling mill is realized.
The judgment of the no-load and no-load states of the rolling mill transmission equipment is distinguished by the intermediate value of normal load and no-load torque (such as T in figure 2)k) E.g. normal idling torque of 15% rated torque, normal load is all at 40% rated torque, then TkA 25% rated torque may be selected as a criterion for distinguishing between the two.
During the no-load and load switching, because the rolling mill transmission equipment has a dynamic regulation process (the regulation time of the process is short, generally in millisecond level) when the load changes, the process can distort the torque due to the overshoot, so that the delay sampling is needed during the switching of the two states, and the delay time is determined according to the dynamic regulation performance of the actual rolling mill transmission equipment, such as 200 milliseconds.
Claims (2)
1. An online detection method for the abnormal working of the transmission equipment of the rolling mill is characterized in that: the output torque of the frequency conversion cabinet is equal to the working torque of a load in a stable working state, the load torque is equal to the sum of the working torque of the rolling mill and the torque loss from the motor to the intermediate transmission link of the rolling mill, and when the rolling mill and the intermediate transmission link of the rolling mill are abnormal, the amplitude and the change rate of the output torque of the frequency conversion cabinet can be changed; the amplitude change and the change rate of the output torque of the frequency conversion cabinet are detected in real time through the programmable controller to judge whether the rolling mill transmission equipment works abnormally; if the abnormal condition exists, sending alarm information through an HMI computer; the running state of the transmission equipment of the rolling mill is divided into an idle load state and a load state, and the states are distinguished by acquiring the output quantity of the output torque of the frequency conversion cabinet and the characteristic value of the output torque of the frequency conversion cabinet converted from the two working states through a programmable controller;
judging the working abnormity of the rolling mill transmission equipment at the load stage: when the torque variation amplitude value in a certain time period exceeds a set threshold value, an abnormal operation alarm of the transmission equipment of the rolling mill is sent out;
firstly, determining a time detection window for a torque value in a rolling process, wherein the size of the window is determined according to the dynamic performance and the torque sampling period of a rolling mill transmission device, sampling and storing the transmission torque within the window range, and establishing the following torque value sequence:
Buff=(t1, t2,..., tn)
except for t1In addition, the rest sampling values in the sequence are sorted and removed from the sequenceA certain number of maximum values and minimum values in the rows, and the rest values are summed and then averaged, so as to remove the influence of pulsating torque and random torque in the load torque on a torque true value; current sample value t1Making a difference with the average value, comparing the difference with a set threshold value, and if the difference exceeds the threshold value, sending an alarm on an HMI computer picture; if the difference is less than 0 during alarming, the device abnormity that the load of the transmission device of the rolling mill is suddenly reduced is shown, if the difference is more than 0 during alarming, the abnormal condition that the load of the transmission device of the rolling mill is suddenly increased is shown, and corresponding alarm information is set according to the characteristic expression when the transmission device of the rolling mill is abnormal;
the latest torque sample value will update t in the sequence1Value, original t1- tn-1Sequentially replacing t in the original sequence2-tnForming a new torque value sequence, and ensuring the real-time performance of a detection window; and the programmable controller carries out the analysis and judgment on the new torque value sequence again, so that the real-time detection on the working condition of the transmission equipment of the rolling mill is realized.
2. The online detection method for the abnormal operation of the transmission equipment of the rolling mill as claimed in claim 1, wherein: when the rolling mill transmission equipment is in no-load and load conversion, the output torque of the rolling mill transmission equipment has a dynamic regulation process, the process can distort the torque due to overshoot, and the output torque needs to be sampled in a delayed mode when the two states are converted.
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| CN113686569A (en) * | 2021-08-19 | 2021-11-23 | 深圳市汇川技术股份有限公司 | Transmission mechanism torque detection method, device, equipment and storage medium |
| CN116809652B (en) * | 2023-03-28 | 2024-04-26 | 材谷金带(佛山)金属复合材料有限公司 | Abnormality analysis method and system for hot rolling mill control system |
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