CN110856859B - Hot continuous rolling back-up roll peeling on-line monitoring method - Google Patents
Hot continuous rolling back-up roll peeling on-line monitoring method Download PDFInfo
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- CN110856859B CN110856859B CN201810959794.2A CN201810959794A CN110856859B CN 110856859 B CN110856859 B CN 110856859B CN 201810959794 A CN201810959794 A CN 201810959794A CN 110856859 B CN110856859 B CN 110856859B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B38/00—Methods or devices for measuring, detecting or monitoring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product
Abstract
The invention relates to an online monitoring method for peeling of a hot continuous rolling support roller. The hot continuous rolling support roller peeling on-line monitoring method provided by the invention can be used for preventing and diagnosing the state of the support roller, preventing the support roller from being suddenly damaged or losing efficacy and realizing the stable production of hot rolled strip steel and the improvement of the control precision of product quality indexes.
Description
Technical Field
The invention relates to an online monitoring method for peeling of a hot continuous rolling support roller, belonging to the technical field of steel manufacturing.
Background
Roll peeling is a common production accident in the production process of hot continuous rolling strip steel. With the increasingly fierce market competition of hot rolled coils, products develop towards a high-strength thinning direction according to different purposes of downstream processes, the rolling pressure is increased, the rolling difficulty is improved, the contact stress borne by a roller during working is increased, and meanwhile, because tail flicking accidents are easy to happen when thin-specification products are rolled, the tail of strip steel is broken or torn and left in the rolling mill, partial fragments are often adhered to the surface of the roller, which is commonly called as a working roller for adhering to the meat, and stress concentration is caused. In this context, roll flaking will occur at a significantly higher frequency on-machine. As the prior roller has the characteristics of randomness, difficulty in prejudgment and the like in on-machine peeling, once the accident occurs, the processing difficulty is higher, the time is generally consumed for more than 2 hours, and the production efficiency and the effective operation rate of the hot continuous rolling line are seriously reduced.
The traditional roll equipment peeling monitoring is mainly carried out through manual visual inspection, a working roll and a supporting roll need to be respectively pulled out, and the roll surfaces of the rolls are inspected one by one through eye observation of people by using flashlight light, so that fault identification is realized. Since hot continuous rolling mills generally consist of 7 stands with four rolls, this method has the following disadvantages: (1) the roller peeling of a certain rolling mill cannot be accurately judged, and a large amount of roller extraction inspection is needed for removing, so that the production abnormal downtime is obviously increased; (2) the roll peeling failure monitoring method has the advantages that preventive monitoring cannot be carried out in advance, and only can be detected and found after the roll peeling failure, so that the roll failure and temporary halt are easily caused, and the accident is expanded.
Disclosure of Invention
The invention aims to solve the technical problems that: the method overcomes the defects of the technology and provides the hot continuous rolling support roller peeling on-line monitoring method which not only can accurately identify roller peeling, but also can prevent the roller peeling in advance.
In order to solve the technical problems, the technical scheme provided by the invention is as follows: an on-line monitoring method for peeling of a hot continuous rolling support roller comprises the following steps:
(1) enabling a supporting roller of the rolling mill to rotate at a constant speed, gradually reducing a roll gap of the rolling mill until the pressing force reaches a target range, continuously operating for a period of time, and recording a pressure curve in the period of time;
(2) analyzing and analyzing the pressure curve and analyzing a frequency spectrum, and if the pressure curve is a stable and smooth periodic curve, judging that the pressure curve is normal; if the pressure curve simultaneously satisfies the following conditions: 1. burrs with peak-valley difference values larger than or equal to a threshold value exist; 2. the fluctuation period of the burrs is matched with the period of one circle of rotation of the supporting roll; judging that the support roller of the rolling mill has a peeling phenomenon or a peeling risk;
(3) when it is determined that there is a peeling phenomenon or a peeling risk in the backup rolls of the rolling mill; and sending out fault alarm information.
The scheme is further improved in that: the linear speed of rotation of the support roller of the rolling mill in the step (1) is 0.5m/s to 1.5 m/s.
The scheme is further improved in that: the target range of the pressing force in the step (1) is 1000-1700 tons.
The scheme is further improved in that: the continuous operation period of the backup rolls of the rolling mill in the step (1) is 20 to 30 seconds.
The scheme is further improved in that: in the step (2), the threshold is 120 tons.
The scheme is further improved in that: and (4) after the step (3), removing the fault through data tracing, field fault troubleshooting and expert diagnosis.
The invention provides an on-line monitoring method for hot continuous rolling support roll peeling, which is characterized in that under the condition of a certain rotating speed of a rolling mill, a roll gap of the rolling mill is pressed to a certain pressure, the data of the pressing force in a period of time are continuously collected, the curve of the pressing force of the rolling mill in the period of time is analyzed, whether abnormal burrs exist in the pressing force of the rolling mill is judged, the fluctuation period of the abnormal burrs is monitored, and if the fluctuation period is consistent with the time of one circle of rotation of the support roll and the peak-valley difference of the abnormal burrs of the pressure curve exceeds a certain threshold value, a system automatically reports that the support roll peeling exists in the rolling mill or is about to. The method can prevent and diagnose the state of the supporting roller, prevent the supporting roller from being suddenly damaged or losing efficacy, and realize the stable production of the hot-rolled strip steel and the improvement of the control precision of the product quality index.
The method is characterized in that the method estimates the conservative condition that the on-machine peeling treatment time of each roller is 120 minutes, the normal rolling period of the hot continuous rolling strip steel is 3 minutes, and the unit weight of each roll of strip steel is 30 tons, if the real-time prejudgment can be realized, the productivity of more than 1200 tons can be increased by only avoiding 1 accident, the unnecessary energy consumption is reduced, and the loss caused by the complete scrapping of the rollers is added, so that the production cost is saved by at least more than 100 ten thousand yuan. The invention has positive practical significance at present when the steel industry generally pursues energy conservation, consumption reduction and fine production.
Drawings
Fig. 1 is a pressure curve when the backup roller is normal.
Fig. 2 is a graph of pressure at or near the point of release of the support roll.
Detailed Description
Examples
The method for monitoring the peeling of the hot continuous rolling supporting roller on line comprises the following steps:
(1) enabling a supporting roller of the rolling mill to rotate at a constant speed, gradually reducing a roll gap of the rolling mill until the pressing force reaches a target range, continuously operating for a period of time, and recording a pressure curve in the period of time;
(2) analyzing and analyzing the pressure curve and analyzing a frequency spectrum, if the pressure curve is a stable and smooth periodic curve, judging the pressure curve to be normal, and if the pressure curve is a normal pressure curve, judging the pressure curve to be normal as shown in figure 1; if the pressure curve simultaneously satisfies the following conditions: 1. burrs with peak-valley difference values larger than or equal to a threshold value exist, and the threshold value in the embodiment is 120 tons; 2. the fluctuation period of the burrs is matched with the period of one circle of rotation of the supporting roll; judging that the support roller of the rolling mill has a peeling phenomenon or a peeling risk, as shown in fig. 2, the peeling phenomenon or the peeling risk is an abnormal pressure curve, and the peak-to-valley difference value of burrs of the curve in the graph is about 290 tons;
(3) when the support roller of the rolling mill is judged to have the peeling phenomenon or the peeling risk; and sending out fault alarm information.
Wherein the linear speed of rotation of the supporting roller of the rolling mill in the step (1) is 0.5m/s to 1.5 m/s; the target range of the pressing force in the step (1) is 1000-1700 tons; the continuous operation period of the backup rolls of the rolling mill in the step (1) is 20 to 30 seconds.
In the step (2),
by using the method, a plurality of production lines can be monitored in a centralized manner through a computer, and the method specifically comprises the following steps: analyzing the data distributed in each branch factory data server to an application program server according to a channel by adopting a data analysis module; then, sending the state information to each branch factory computer terminal through a supporting roller peeling state monitoring and diagnosing module in the application server, and feeding back the information to the application program server through a data management module after each branch factory computer terminal gets rid of the fault according to the state information; and finally, the application program server regularly produces fault message information through the report reporting module and sends the fault message information to the head office management server.
More specifically, the encrypted file collected by the data server is analyzed through the data analysis and reading module, and accurate data information of the states of all equipment in the steel rolling process is obtained.
The production data of the steel rolling production line are independent encrypted files generated by a steel rolling control system, each file contains thousands of channel data, and the data size is large and the huge data are difficult to process by a conventional data analysis means. Therefore, the encrypted production data file can be automatically analyzed into a conventional txt data file through a data analysis module according to a specified channel, a sampling frequency and the like. Firstly, connecting to each branch plant data server through Ethernet, and obtaining txt data files related to the states of each device in the steel rolling process through path configuration, channel configuration, file scanning and file extraction, and then analyzing the data.
The data analysis is an online process, which is processed in real time along with the encrypted production data file continuously generated by a rolling line L1 (basic automation) control system, and can obtain various information such as time, rolling force, roll bending force, speed, steel coil number and the like according to the requirements of the rolling mill state monitoring. The key technology involved is to encrypt the analysis of the production data file, design a dynamic link library according to the construction mode of the production data file, and analyze the production data file into a state monitoring data file respectively according to the configuration conditions of a channel number, sampling frequency, sampling point number and the like. The capacity of a 10-minute production data file is about 150M, the daily data volume is up to 20G, the daily data volume of the rolling mill state monitoring data generated by the data analysis module only occupies a storage space less than 10M, the data storage capacity is greatly reduced, the time span of data storage is prolonged, and the follow-up rolling mill equipment fault information tracing is facilitated.
And obtaining the state information of the support roller peeling in the steel rolling process by adopting a state monitoring and fault diagnosis processing method mainly based on signal frequency domain comparison analysis.
The hot continuous rolling support roller peeling state monitoring and fault diagnosis module consists of three parts, namely a signal analysis and fault diagnosis module, a fault alarm module and a monitoring view module.
Firstly, extracting the state information of the supporting roller monitored by the monitoring method from analyzed data; then, by combining a frequency domain comparison analysis method, the state information is analyzed through a signal analysis and fault diagnosis module to diagnose whether the supporting roller peeling fault occurs or not; and then state information and fault alarm information are pushed to the computer terminal through the fault alarm module and the monitoring graph module.
In the signal analysis and fault diagnosis module, the forecasting principle of the support roller peeling is based on the rolling theory. Namely, when the surface of the supporting roll is locally peeled off in a small area, the roundness of the supporting roll is damaged, the strip steel is subjected to uneven plastic deformation along the rolling direction when being rolled by the roll, the roll is subjected to periodic bending deformation, the obvious periodic fluctuation of the rolling force is finally reflected, and corresponding frequency components appear in the acquired data signals. Based on the principle, the collected calibration rolling force data signals are subjected to fast Fourier transform and then subjected to frequency domain analysis, and compared with a large number of normal signals collected in the production process for analysis, so that whether the supporting roller has the stripping fault or not can be quickly diagnosed. Meanwhile, the fault signals are used as fault samples to be collected and stored, and a stripping fault sample library of the supporting roller is expanded, so that the fault diagnosis accuracy during comparative analysis is further improved.
The specific method of the signal frequency domain analysis comprises the steps of converting acquired time domain waveforms of the calibrated rolling force into a spectrogram through FFT (fast Fourier transform), and diagnosing and analyzing the peeling faults of the supporting roller by adopting the frequency spectrum characteristics of the signals, such as characteristic frequency, amplitude and the like. The fault signal has a fault characteristic frequency different from that of the normal signal, the amplitude of the frequency spectrum of the fault signal is also obviously higher than that of the normal signal, and whether the supporting roller peels off can be judged under the comparison and analysis.
And in the fault alarm module, the fault information judged by each support roller by the signal analysis and fault diagnosis module is extracted, and the fault alarm complete information is generated by comprehensive analysis and comprises fault time, the area of the production line to which the support roller belongs, the acquired index value, the steel coil number, the state and the like.
In the monitoring view module, complete fault alarm information generated by the fault alarm module is displayed on each branch computer terminal in a system state indicator lamp and data list form respectively.
And the computer terminal receives the support roller peeling fault alarm information and feeds back a processing result to the application program server through the data management module to form a closed loop processing mode of finding, eliminating and feeding back the support roller peeling fault.
The data management module consists of three parts, namely a channel management module, a standard management module and a fault feedback module.
And in the channel management module, data channels related to the peeling of the supporting roller of the rolling mill can be managed, wherein the data channels comprise channel numbers, channel names, equipment areas to which the channels belong and production line areas to which the channels belong.
In the standard management module, each data related to the peeling of the supporting roller can be set with upper and lower fault standard limits according to the process requirements, and the upper and lower standard limits can be configured and modified after the module is authorized.
In the fault feedback module, the operator manually enters basic information of fault removal, including fault removal time, fault removal method, fault influence factors and fault removal state.
After each branch computer terminal receives the fault alarm information, the fault elimination and feedback are completed next.
Firstly, finding whether the supporting roller has a fault or not through fault alarm information; then, after the support roll peeling fault is eliminated by adopting the modes of data tracing, field fault troubleshooting, expert diagnosis and the like, feeding back the solution of the support roll peeling to an application program server, and updating the confirmed support roll peeling information serving as new support roll peeling fault case sample data to a fault sample data set in an information comprehensive processing module; and finally, judging whether the standard value needs to be corrected or the channel needs to be increased or decreased according to the processing result, and feeding the result back to the application program server through the channel management module and the standard management module.
By adopting the scheme, a large number of encrypted production data files in the control system of the rolling line L1 can be analyzed, state data related to the peeling of the hot continuous rolling supporting roller can be extracted for deep analysis of the state of the hot continuous rolling supporting roller, the storage space of the data is greatly saved, the time span of data storage is improved, and the tracing of fault data and deep analysis based on the large data are facilitated; the state of the hot continuous rolling support roller can be monitored and diagnosed on line through the extraction and real-time analysis of the fault signal and the normal signal; the traceability of fault data and the high efficiency of fault removal can be effectively improved by a closed-loop processing mode of equipment fault discovery, removal and feedback; the report of the regular fault report is more beneficial to the overall control of the peeling state of the hot continuous rolling supporting roller by the previous stage. The method for monitoring the state of the hot continuous rolling supporting roller on line realizes the improvement of the control precision of the rolling state of the rolling mill and the surface quality index of the strip steel.
The embodiment has an early warning function and intelligence, can perform advanced processing on data on the basis of the existing steel rolling production line L1 control system, and simultaneously realizes a closed-loop processing mode of faults through man-machine interaction.
The present invention is not limited to the above-described embodiments. All technical solutions formed by equivalent substitutions fall within the protection scope of the claims of the present invention.
Claims (6)
1. The method for monitoring the peeling of the hot continuous rolling supporting roller on line is characterized by comprising the following steps of:
(1) enabling a supporting roller of the rolling mill to rotate at a constant speed, gradually reducing a roll gap of the rolling mill until the pressing force reaches a target range, continuously operating for a period of time, and recording a pressure curve in the period of time;
(2) analyzing and analyzing the pressure curve and analyzing a frequency spectrum, and if the pressure curve is a stable and smooth periodic curve, judging that the pressure curve is normal; if the pressure curve simultaneously satisfies the following conditions: 1. burrs with peak-valley difference values larger than or equal to a threshold value exist; 2. the fluctuation period of the burrs is matched with the period of one circle of rotation of the supporting roll; judging that the support roller of the rolling mill has a peeling phenomenon or a peeling risk;
(3) when it is determined that there is a peeling phenomenon or a peeling risk in the backup rolls of the rolling mill; and sending out fault alarm information.
2. The hot continuous rolling backup roll peeling on-line monitoring method according to claim 1, characterized in that: the linear speed of rotation of the support roller of the rolling mill in the step (1) is 0.5m/s to 1.5 m/s.
3. The hot continuous rolling backup roll peeling on-line monitoring method according to claim 1, characterized in that: the target range of the pressing force in the step (1) is 1000-1700 tons.
4. The hot continuous rolling backup roll peeling on-line monitoring method according to claim 1, characterized in that: the continuous operation period of the backup rolls of the rolling mill in the step (1) is 20 to 30 seconds.
5. The hot continuous rolling backup roll peeling on-line monitoring method according to claim 1, characterized in that: in the step (2), the threshold is 120 tons.
6. The hot continuous rolling backup roll peeling on-line monitoring method according to claim 1, characterized in that: and (4) after the step (3), removing the fault through data tracing, field fault troubleshooting and expert diagnosis.
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| JPS5935286B2 (en) * | 1975-02-19 | 1984-08-28 | 石川島播磨重工業株式会社 | Roll profile measuring device |
| DE102004051020A1 (en) * | 2004-10-20 | 2006-05-04 | Sms Demag Ag | Method, apparatus and circuit for detecting surface defects such as cracks, eruptions and the like on a roll of a rolling mill |
| CN102890475B (en) * | 2012-09-21 | 2015-08-19 | 江苏高精机电装备有限公司 | Large revolving body piece surface profile errors is measured and real-time compensation method |
| CN203197005U (en) * | 2013-04-25 | 2013-09-18 | 浙江瑞浦机械有限公司 | Online monitoring device for surface damage of working roll of continuous mill |
| CN107138541B (en) * | 2017-05-24 | 2019-03-05 | 山东钢铁集团日照有限公司 | A kind of cold roll operating condition inline diagnosis method |
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