CN112286913A - Method for establishing quality data warehouse based on cold rolling production process - Google Patents
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 80
- 238000005097 cold rolling Methods 0.000 title claims abstract description 34
- 238000000034 method Methods 0.000 title claims abstract description 27
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 12
- 239000010959 steel Substances 0.000 claims abstract description 12
- 238000007619 statistical method Methods 0.000 claims abstract description 6
- 238000001514 detection method Methods 0.000 claims description 8
- 239000002253 acid Substances 0.000 claims description 4
- 238000000137 annealing Methods 0.000 claims description 4
- 238000005246 galvanizing Methods 0.000 claims description 4
- 239000002994 raw material Substances 0.000 claims description 4
- 238000005096 rolling process Methods 0.000 claims description 4
- 239000010960 cold rolled steel Substances 0.000 abstract description 5
- 238000012544 monitoring process Methods 0.000 abstract description 5
- 238000004458 analytical method Methods 0.000 abstract description 4
- 230000009286 beneficial effect Effects 0.000 abstract description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000010354 integration Effects 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
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- 238000005516 engineering process Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000012797 qualification Methods 0.000 description 2
- 238000007405 data analysis Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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Abstract
The invention relates to a method for establishing a quality data warehouse based on a cold rolling production process, belonging to the field of quality analysis of cold rolled steel coils. The technical scheme of the invention is as follows: respectively collecting real-time data of a primary PLC, secondary single-value data and production and sales data of a tertiary MES of each cold rolling production line from different databases into a postgreSQL database integrated by a big data platform (mpp); dividing the acquired data into single value data and continuous value data according to a production line, and classifying and integrating the single value data and the continuous value data; and carrying out statistical analysis on the steel coil data integrated in series in the big data platform so as to guide the cold rolling production. The invention has the beneficial effects that: the data of parameters of all important monitoring points of the whole cold rolling production line, data contents such as order contracts, customer requirements, metallurgical specification requirements and the like can be clearly mastered, and therefore process quality production of the cold rolling production line can be guided according to the whole data information.
Description
Technical Field
The invention relates to a method for establishing a quality data warehouse based on a cold rolling production process, belonging to the technical field of cold rolled steel coil production.
Background
With the development of big data related technologies, data analysis, data processing and data fusion technologies are gradually applied in various fields. In most of these fields, data collected by a plurality of data sources needs to be fused and then subjected to subsequent analysis.
Most of mass fine-grained data generated in the production process of the cold-rolled steel coil are deposited on the site, and related data are not integrated and utilized from the whole situation and are in the local and short-term analysis and application stages. How to reasonably fuse the real-time data of the primary PLC, the secondary single-value data and the production and marketing data of the tertiary MES, perform classified statistical analysis on the data, and better guide the production process is a big problem faced by iron and steel enterprises in recent years.
Disclosure of Invention
The invention aims to provide a method for establishing a quality data warehouse based on a cold rolling production process, which integrates production data in different databases on different systems, facilitates technicians to integrally know parameters of each monitoring point of a complete cold rolling production line, and can guide cold rolling production in real time according to metallurgical specification values, so that the production is online and real-time in quality management, an operation department and a maintenance department can be assisted to quickly master stability key points of the process, and further, the defects on the process are improved; the integration of the first-level PLC real-time data, the second-level system data and the third-level MES production and sales data is realized, the guidance of strictly finishing the product manufacture according to the order contract and the customer requirements is presented integrally, and the order qualification rate is further improved; let quality department improve the judgement precision of steel product quality, effectively prevent the non-defective products outflow for product quality accords with market demand, promotes the whole competitiveness of company, has solved the above-mentioned problem that exists among the background art effectively.
The technical scheme of the invention is as follows: a method for establishing a quality data warehouse based on a cold rolling production process comprises the following steps:
step 1: respectively collecting real-time data of a primary PLC, secondary single-value data and production and sales data of a tertiary MES of each cold rolling production line from different databases into a postgreSQL database integrated by a big data platform (mpp);
step 2: dividing the acquired data into single value data and continuous value data according to a production line, and classifying and integrating the single value data and the continuous value data;
and step 3: according to the number of the cold rolled coil, the acid rolling, continuous annealing and galvanizing production lines are connected in series, and data of production lines under the same steel coil are analyzed;
and 4, step 4: and carrying out statistical analysis on the steel coil data integrated in series in the big data platform so as to guide the cold rolling production.
In the step 1, data is diversified, format standards are not uniform, the data comes from different databases of different systems, and multiple data sources of the data are cleaned, calculated, collected and stored in a postgreSQL database integrated with a big data platform (mpp).
In the step 2, the single-value data source has three parts: the two-level single value data, the three-level MES production and sales data and the one-level PLC real-time data; integrating contract order information, tolerance upper and lower limit data and raw material information into single value data according to the production and marketing data provided by the three-level MES according to the coil number of the cold-rolled finished product; the real-time data acquisition of the first-level PLC is a continuity detection point, the average value, the maximum value and the minimum value are calculated according to the requirement and the cold rolling coil number, and then the continuity detection point is fused with the production and sales data of the third-level MES according to the coil number; the single-value data from the second level is fused with the production and sales data of the third-level MES according to the finished product volume number, and then integrated into complete single-value data;
the continuous value data is derived from real-time data of a field first-level PLC, the partial data needs to be integrated with standard value data in a third-level MES according to a finished product cold-rolled coil number, and then the upper limit and the lower limit specified in the metallurgical specification can be reflected when each parameter curve is drawn, so that the method is a basis for measuring whether each important parameter meets the requirement in the cold rolling process, and the production process of each parameter can be intuitively and clearly mastered.
The invention has the beneficial effects that: production data in different databases on different systems are fused together, so that technicians can conveniently know parameters of each monitoring point of a complete cold rolling production line integrally and can guide cold rolling production in real time according to metallurgical specification values, online real-time quality management of the production can assist operating departments and maintenance departments to quickly master stability points of a manufacturing process, and further, defects in the manufacturing process are improved; the integration of the first-level PLC real-time data, the second-level system data and the third-level MES production and sales data is realized, the guidance of strictly finishing the product manufacture according to the order contract and the customer requirements is presented integrally, and the order qualification rate is further improved; the quality department can improve the judgment precision of the steel quality, effectively prevent the outflow of defective products, ensure that the product quality meets the market demand and improve the overall competitiveness of companies.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer and more fully describe the technical solutions of the embodiments of the present invention, it is obvious that the described embodiments are a small part of the embodiments of the present invention, not all embodiments, and all other embodiments obtained by a person of ordinary skill in the art without creative efforts based on the embodiments of the present invention belong to the protection scope of the present invention.
A method for establishing a quality data warehouse based on a cold rolling production process comprises the following steps:
step 1: respectively collecting real-time data of a primary PLC, secondary single-value data and production and sales data of a tertiary MES of each cold rolling production line from different databases into a postgreSQL database integrated by a big data platform (mpp);
step 2: dividing the acquired data into single value data and continuous value data according to a production line, and classifying and integrating the single value data and the continuous value data;
and step 3: according to the number of the cold rolled coil, the production lines of acid rolling, continuous annealing, galvanizing and the like are connected in series, integrated and analyzed, and data of the production lines under the same steel coil are analyzed;
and 4, step 4: and carrying out statistical analysis on the steel coil data integrated in series in the big data platform so as to guide the cold rolling production.
In the step 1, data is diversified, format standards are not uniform, the data comes from different databases of different systems, and multiple data sources of the data are cleaned, calculated, collected and stored in a postgreSQL database integrated with a big data platform (mpp).
In the step 2, the main sources of the single-value data comprise three parts: the two-level single value data, the three-level MES production and sales data and the real-time data of the first-level PLC, wherein most of the single value data are provided by the three-level MES production and sales data, and the contract order information, the metallurgical specification data such as tolerance upper and lower limits and the like, the raw material information and the like are integrated into the single value data according to the cold rolled finished product coil number; the real-time data acquisition of the first-level PLC is a continuity detection point, and the average value, the maximum value and the minimum value are calculated according to the cold-rolled coil number according to the requirement, so that the continuity detection point is fused with the production and sales data of the third-level MES according to the coil number; the rest part of the single-value data is derived from the second-level single-value data, and the second-level single-value data is fused with the production and sales data of the third-level MES according to the finished product volume number, so that the two-level single-value data is integrated into complete single-value data;
the continuous value data mainly comes from real-time data of a field first-level PLC, the partial data needs to be integrated with standard value data in a third-level MES according to a finished product cold rolling coil number, and then the upper limit and the lower limit specified in the metallurgical specification can be reflected when each parameter curve is drawn, so that the method is a basis for judging whether each important parameter meets the requirement in the cold rolling process, and the production process of each parameter can be intuitively and clearly mastered.
In practical application, the implementation range of the invention is mainly used in cold rolling production lines in iron and steel enterprises to serve cold rolling production maintenance personnel, technical personnel, quality management department personnel and the like. The method is convenient for field production personnel to adjust the feeding amount, chemical components and the like in real time according to the data of the monitoring points, is beneficial for relevant technical personnel to carry out statistics and analysis on the influence of the parameters of the monitoring points on the quality of the steel coil, and quickly helps quality management personnel to judge whether the product meets order contracts, customer requirements and the like.
In the step 1, real-time data of a first-level PLC, second-level single-value data and third-level MES production and sales data of each production line of a cold rolling plant are collected from different system databases through an ETL (extract transform and load) collection tool into a postgreSQL database integrated with a big data platform MPP. The database has the advantages of unifying data sources, supporting massive parallel operation of batch data and being high in instantaneity.
And 2, dividing the acquired data into single-value and continuous-value data according to a production line, and classifying and integrating the single-value and continuous-value data.
The specific classification and integration method is as follows:
the main sources of single-value data are three parts: the system comprises two-level single value data, three-level MES production and sales data and one-level PLC real-time data. Most of the single value data is provided by the production and sales data of the three-level MES, and the contract order information, the metallurgical specification data such as the upper and lower tolerance limits and the like, the raw material information and the like are integrated into the single value data according to the coil number of the cold-rolled finished product; the real-time data acquisition of the first-level PLC is a continuity detection point, and the average value, the maximum value, the minimum value and the like are calculated according to the cold-rolled coil number according to the requirement, so that the continuity detection point is fused with the production and sales data of the third-level MES according to the coil number; and the remaining single-value data comes from a second-level system, and the single-value data in the second-level system is fused with the production and sales data of the third-level MES according to the finished product volume number, so that the single-value data is integrated into complete single-value data.
The continuous value data mainly comes from real-time data of a field first-level PLC, the partial data needs to be integrated with standard value data in a third-level MES according to a finished product cold-rolled coil number, and then the upper limit and the lower limit specified in the metallurgical specification can be reflected when each parameter curve is drawn, so that the method is a basis for measuring whether each important parameter meets the requirement in the cold rolling process, and the production process of each parameter can be intuitively and clearly mastered.
And 3, connecting the production lines of acid rolling, continuous annealing, galvanizing and the like in series according to the number of the cold rolled coil, and analyzing data of each production line in the same furnace.
And 4, performing statistical analysis on the data of the cold-rolled steel coil integrated in the big data platform, and further guiding the production of the cold-rolled steel coil according to the metallurgical specification standard and the contract requirement.
Claims (3)
1. A method for establishing a quality data warehouse based on a cold rolling production process is characterized by comprising the following steps:
step 1: respectively collecting real-time data of a primary PLC, secondary single-value data and production and sales data of a tertiary MES of each cold rolling production line from different databases into a postgreSQL database integrated by a big data platform (mpp);
step 2: dividing the acquired data into single value data and continuous value data according to a production line, and classifying and integrating the single value data and the continuous value data;
and step 3: according to the number of the cold rolled coil, the acid rolling, continuous annealing and galvanizing production lines are connected in series, and data of production lines under the same steel coil are analyzed;
and 4, step 4: and carrying out statistical analysis on the steel coil data integrated in series in the big data platform so as to guide the cold rolling production.
2. The method for establishing a cold rolling process based quality data warehouse according to claim 1, wherein the method comprises the following steps: in the step 1, data of multiple data sources are cleaned, calculated, collected and stored in a postgreSQL database integrated with a big data platform (mpp).
3. The method for establishing a cold rolling process based quality data warehouse according to claim 1, wherein the method comprises the following steps: in the step 2, the single-value data source has three parts: the second-level single-value data, the third-level MES production and sales data and the first-level PLC real-time data are provided, and the third-level MES production and sales data integrates contract order information, tolerance upper and lower limit data and raw material information into the single-value data according to the coil number of the cold-rolled finished product; the real-time data acquisition of the first-level PLC is a continuity detection point, the average value, the maximum value and the minimum value are calculated according to the requirement and the cold rolling coil number, and then the continuity detection point is fused with the production and sales data of the third-level MES according to the coil number; the single-value data from the second level is fused with the production and sales data of the third-level MES according to the finished product volume number, and then integrated into complete single-value data;
the continuous value data is derived from real-time data of a field first-level PLC, the partial data needs to be integrated with standard value data in a third-level MES according to a finished product cold-rolled coil number, and then the upper limit and the lower limit specified in the metallurgical specification can be reflected when each parameter curve is drawn, so that the method is a basis for measuring whether each important parameter meets the requirement in the cold rolling process, and the production process of each parameter can be intuitively and clearly mastered.
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101403920A (en) * | 2008-10-31 | 2009-04-08 | 东北大学 | Productivity load equalization method for cold rolling final finishing units of steel enterprise |
| CN101751017A (en) * | 2008-12-10 | 2010-06-23 | 上海宝钢工业检测公司 | Integrated software interface for production data and process data of cold-rolling continuous annealing unit |
| CN104084426A (en) * | 2014-07-02 | 2014-10-08 | 济钢集团有限公司 | Cold rolled product plate type control system based on hot rolling process control |
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- 2020-09-04 CN CN202010922180.4A patent/CN112286913A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101403920A (en) * | 2008-10-31 | 2009-04-08 | 东北大学 | Productivity load equalization method for cold rolling final finishing units of steel enterprise |
| CN101751017A (en) * | 2008-12-10 | 2010-06-23 | 上海宝钢工业检测公司 | Integrated software interface for production data and process data of cold-rolling continuous annealing unit |
| CN104084426A (en) * | 2014-07-02 | 2014-10-08 | 济钢集团有限公司 | Cold rolled product plate type control system based on hot rolling process control |
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