CN113537720A - Full-line automatic tracking method for wide and thick plates - Google Patents
Full-line automatic tracking method for wide and thick plates Download PDFInfo
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Abstract
The invention discloses a full-line automatic tracking method for wide and thick plates, which relates to the technical field of steel production and is mainly applied to intelligent production and management of a wide and thick plate heat treatment line.
Description
Technical Field
The invention relates to the technical field of steel production, in particular to a full-line automatic tracking method for wide and thick plates.
Background
With the increasingly fierce market competition of steel products, the number of steel application scenes is continuously increased. At present, the automatic material tracking range of a heat treatment line of a wide and thick plate factory is from a material loading roller way of a heat treatment furnace to a quenching machine, a steel plate is basically tracked by manpower after being discharged from the quenching machine, and an up-and-down transverse moving rack, a straightening machine (the function and the using effect of a secondary model of the straightening machine are poor), a cooling bed, a mark and a related roller way are operated until the product is put in storage. This method easily results in poor matching between production plan and actual performance, and low production efficiency, which is not satisfactory.
Disclosure of Invention
The present invention is directed to the above technical problems, and provides 1. a method for full-line automatic tracking of a wide and thick board, comprising
No. 5 heat treatment furnace, quenching machine area
1) Adding 1 set of plate number identification equipment at the inlet of the No. 5 heat treatment furnace, automatically reading the number of the steel plate and transmitting the number to a No. 5 heat treatment furnace secondary system, automatically issuing an operation instruction and a heat treatment process by the secondary system according to a production plan, and starting a roller way by the system and automatically feeding the steel plate into the furnace after the determination is finished;
2) the added steel plate has the function of comparing the actual in-furnace process with the technical requirement process, and the process does not conform to the requirements, and has a prompt and an error report;
3) automatically generating a heating trend curve of the steel plates of the heat treatment furnace, and inquiring and exporting the heating trend curve in an MES (manufacturing execution system) corresponding to each steel plate;
(II) straightener area
The straightening machine is additionally provided with 1 meter spraying machine on a front roller way, and the meter spraying machines are used for spraying and printing the quenched steel plate number and used for the data tracking of materials; meanwhile, 1 set of plate number identification equipment is additionally arranged and is used for automatically identifying the number of the steel plate by a system when the steel plate is on-line and back corrected;
(III) marking machine area
Adding 1 set of plate number identification equipment in front of an inlet roller way of the marking machine to automatically identify the number of the steel plate;
(IV) newly-added heat treatment line full-automatic material tracking system full line L2
1) The full line L2 is used for material tracking, and the material tracking starts from a roller way in front of a No. 5 heat treatment furnace and a No. 6 heat treatment furnace to cover a feeding roller way in front of the No. 5 heat treatment furnace to a centering position, behind a quenching machine, in a transverse moving, straightening, cooling bed and marking area;
2) a communication interface of a newly-added full line L2 and an MES, an interface of a full line L2 and a quenching machine L2, an interface of a full line L2 and a straightening machine L2, an interface of a full line L2 and a marking machine L2, an interface of a full line L2 and a newly-added 6# heat treatment furnace, and an interface of a newly-added marking machine L2;
3) the communication function of the newly added full line L2 and the newly added full line L1 system;
(V) transformation of heat treatment full-line basic automation control system full line L1
1) Adding 22 sets of hardware facilities and field sensing equipment of basic automation systems such as a laser range finder, a computer operation terminal, a switch and the like;
2) the original basic automation L1 system application software is modified, automatic and semi-automatic functions are added, and the interfaces of a network system matched with the original basic automation L1 system and other related systems, namely the full line L2, the newly-added 6# heat treatment furnace, the newly-added table spraying machine, the marking machine of the newly-added 6# heat treatment furnace project, the newly-added board number identification equipment and each equipment L1 are completed.
The technical scheme of the invention is further defined as follows:
the wide and thick plate full-line automatic tracking method comprises the following MES modification:
the steel plate operation instruction data throwing full line L2;
the steel plate flows to the planned throwing full line L2;
automatically receiving the actual performance data of the steel plate flow by the MES;
collecting and counting the actual flow direction performance of the steel plate;
the MES automatically receives the straightening actual results and the marking results;
and (6) reporting.
In the foregoing full-line automatic tracking method for a wide and thick board, the board number identification system is as follows:
shooting a steel plate running on a roller way through visual collection equipment, capturing a character area for content identification, identifying a plate number in a visual detection mode, and supporting the content identification of two writing modes, namely handwriting and jet printing;
and (4) checking the plate number: automatically retrieving the production plan according to the identification information, and performing secondary confirmation of the identification plate number through plan database information;
panel number grab show: besides displaying the detection result, the HMI also displays a panel number screenshot, and an operator can check the original panel number information through the screenshot to perform secondary confirmation;
fuzzy matching: when the writing quality of the plate numbers is poor and the plate numbers can only be partially identified due to smearing and scratches, fuzzy query is carried out through a production plan database, and information of several plate numbers with high matching degree is pushed and displayed for operators to select;
and (3) voice prompt: after the plate number identification process is executed, the system sends out a prompt tone to remind an operator to execute plate number confirmation operation.
The full-line automatic tracking method for the wide and thick plates comprises the following steps:
after the steel plate reaches the spray printing position and stops, a position detector of a full line L1 sends a steel plate in-place signal to a meter spraying machine, the meter spraying machine receives steel plate spray number information input by a full line L2/manual work, the meter spraying machine automatically enters a spray number process cycle, the meter spraying machine is started, a conveying roller way stops running, the meter spraying machine is interlocked with a roller way signal, after all characters are sprayed, the interlocking between the roller way and the meter spraying machine is released, the steel plate continues the next material flow direction through a straightening machine, and the meter spraying machine waits for the next steel plate to be sprayed with a number;
and (3) carrying out spray mark identification on the quenched steel plate after heat treatment, enabling the steel plate to correspond to the data before heat treatment one by one, identifying the temperature of the steel plate to be 0-100 ℃, and identifying the finished steel plate to be hung off line by a magnetic conveyor.
The full-line automatic tracking method for the wide and thick plates comprises the following steps of:
1) system function module
Managing a production plan: receiving a steel plate PDI, a production plan and production process information issued by an MES;
material on-line tracking: micro-tracking and positioning the steel plate within the production line area;
and (3) production actual performance management: recording actual results of all procedures of material feeding, charging, discharging, transverse moving and the like;
production trend management: acquiring and visually displaying large data such as a heat treatment furnace plate temperature change trend, a furnace temperature change trend, a pyrometer detection trend, a quenching machine flow trend and the like;
data report management: information data such as production information, process information and tracking support the export of reports, and meanwhile, the automatic generation and pushing of daily reports, class reports and monthly reports are supported;
HMI human machine operation screen: the method comprises the following steps of area positive line tracking, production planning, up-down display verification, communication state maintenance, production actual performance, trend data and other interfaces;
2) system architecture
The whole line L2 hardware system mainly comprises 1 Server, engineer station, 2 clients, namely, 1 configured in each of the straightening and marking operation room, and network equipment to form a Client/Server system structure, wherein the Server end adopts distributed deployment, and adopts independent service methods for issuing on-line tracking, data acquisition, model control and the like, and performs message interaction by adopting a data bus; the client adopts a lightweight design and supports simultaneous login and operation of multiple terminals;
3) service terminal
Core service: the system is responsible for business management of information such as production plans, material tracking, production actual results, production trends and the like, and an intermediate result adopts Redis as a cache medium to support two persistence modes of an internal memory and a hard disk;
the communication control module: responsible for communication management with MES, L1 and other L2 process control systems;
a trend data management module: providing furnace temperature, plate temperature and other energy consumption trend data access functions, wherein the storage mode adopts a time sequence database;
application service interface: the server is connected to an L2/L3 central switch through a twisted pair and is connected with an MES host through the central switch, the server is connected to an L1 network through an optical fiber so as to be communicated with an HMI server of basic automation, and a firewall is added between the entire line L2 and the MES for isolation.
The full-line automatic tracking method for the wide and thick plates comprises the following steps of:
1) the transformation range of the L1 system is from the furnace front input roller way of the No. 5 heat treatment furnace to the area of the heat treatment marking machine P11 roller way, and comprises an online roller way control device, a transverse moving device and a cooling bed;
2) area range: the automatic marking machine comprises a 5# heat treatment furnace input roller way, a transverse moving device output roller way, a straightening machine inlet roller way, a straightening machine outlet roller way, a cooling bed input roller way, a cooling bed body, a cooling bed output roller way, a finished product marking machine inlet roller way, a finished product marking machine rear roller way, a 6# heat treatment furnace input roller way, a 6# heat treatment furnace output roller way, a newly-added finished product marking machine rear extension roller way and a newly-added cooling bed output extension roller way;
3) tracking of steel plates on the area line:
the tracking area includes: all on-line roller ways, transverse moving devices and cooling beds in the heat treatment area;
the following functions are implemented by the tracking:
designing the whole heat treatment area as a continuous coordinate system;
the steel plate in the area has the tracking function in the X direction, namely the roller way direction, and the Y direction, namely the traversing device direction/cooling bed direction;
the tracking information of the steel plate comprises a head position (X, Y), a length, a width and a steel plate number;
the steel plate swings on the transverse moving feeding roller way;
the steel plate swings on a transverse blanking roller way;
the control of the roller path is prolonged after a finished product marking machine is newly added;
newly adding control of an output extension roller way of the cooling bed;
interlocking between the newly-added cooling bed output extension roller way and the newly-added marking machine of the No. 6 heat treatment furnace project; interlocking between the output roller way of the No. 6 heat treatment furnace and the transverse moving blanking device and the transverse moving blanking roller way;
the steel plate has the function of prolonging the swing of the roller way at the output of the cooling bed;
4) the L1 system completes the automatic logistics control of the steel plate according to the full-line L2 instruction, and the main functions are as follows:
the L1 receives a next plate area instruction issued by the full-line L2 system, and completes the automatic conveying function of the steel plate according to the instruction;
l1 receives a steel plate off-line instruction issued by a full-line L2 system, and finishes off-line of the steel plate according to the instruction;
l1 receives a steel plate on-line instruction issued by a full-line L2 system, and finishes the steel plate on-line according to the instruction;
5) the control system comprises the following components:
PLC switch board and HMI: the PLC system utilizes an original full-line L1-level system, adopts a TCP/IP Ethernet to complete data mutual transmission, signal communication and communication with a heat treatment rear control system, expands an existing remote slave station ET200MI/O module, is used for collecting signals of a newly added sensor on site, and adopts a PROFIBUS DP network to perform data exchange and communication with a controller;
the HMI system adopts a running version, 3 HMI operator stations are newly configured in an operating room, and the HMI system adopts programmable software WINCC V7.2;
the HMI operator station mainly implements the following functions:
reflecting the production line flow operation and control pictures;
the production line main picture reflects the working state of the main equipment;
reflecting logistics information and equipment state information;
displaying process data, displaying and correcting set values;
data input, data storage and invocation;
a device calibration function;
selecting class operation, including operation mode selection;
control operation, directly controlling the running and stopping of the equipment;
the maintenance operation is used for monitoring and maintaining the system;
displaying the state of the network system and diagnosing faults;
PLC module diagnosis information;
displaying an interlocking state;
displaying, recording and printing operation event information, various faults and alarm information;
PDA: upgrading original configuration data by using an original PDA hardware system for signal acquisition and data analysis of a heat treatment area;
the remote IO cabinet expands a remote IO module;
the in-place operation box IO cabinet in-place operation box remains unchanged.
The wide and thick plate full-line automatic tracking method comprises the following steps:
performing data docking with an L1 system and an L2 system of each device in the original production line to perfect tracking data feedback;
the large data acquisition capacity of each instrument is improved, the mass data acquisition capacity is provided, the data acquisition frequency of less than 50ms is supported, and the data is stored for a long time at a high compression ratio;
the multi-angle data analysis function is used for performing fault early warning, process curve analysis, capacity analysis, energy consumption analysis and the like on the acquired high-frequency data, and visually checking the acquired high-frequency data through a digital billboard;
the production process capability evaluation function is used for statistically evaluating key process parameters of each grade specification and ensuring the production quality;
the key process parameter abnormity counting function is used for counting whether key process parameters such as heating time, tapping temperature and anti-red temperature in a time range meet the upper and lower limits set by the process or not and counting the process overrun abnormity;
and the report export push function supports export operation of all display data reports, reserves interfaces and supports pushing to an ERP system and an MES system.
The invention has the beneficial effects that:
(1) the invention is mainly applied to the intelligent production and management of the wide and thick plate heat treatment line, and the information automatic control system transformation of all the on-line process processes from the beginning of steel loading of a heat treatment furnace to the time from the outlet of a quenching machine to the storage of a steel plate comprises the material automatic tracking, the set data issuing, the actual data acquisition, the automatic and semi-automatic control of the basic automation and the like of the material automatic tracking, the set data issuing, the actual data acquisition, the automatic and semi-automatic control and the like of the storage roller way of the quenching machine, and improves the model of the straightening machine, thereby improving the production data tracking and the flow control level of the wide and thick plate heat treatment area and meeting the requirement of the intelligent manufacturing management level promotion of the wide and thick plate;
(2) in order to realize the full-automatic material tracking of the heat treatment production line, the network and control equipment required by automation and informatization of the area are supplemented except for the addition of the table spraying machine and the plate number identification equipment, and software development is carried out on logistics control on the basis, so that the full-automatic material tracking control of the heat treatment production line is finally realized;
(3) the plate number recognition system is mainly used for on-line recognition of the moving steel plate on the roller way, can greatly reduce the workload of manual number copying and number searching, improves the operating efficiency of a production line, and avoids the phenomenon of wrong number;
(4) the data platform analysis system is responsible for integrating all the single equipment in the range of the furnace group to carry out centralized data acquisition, analysis and control, and realizes the automatic control of the whole production line on the basis of the automatic control of the original single equipment;
(5) after the invention is transformed, the automatic tracking identification is realized, and the indirect benefits are that the identification error is avoided, the risk of quality objection is reduced, and the credit degree to customers is improved.
Drawings
Fig. 1 shows a process of identifying a board number according to the present invention.
Detailed Description
The method for full-line automatic tracking of the wide and thick plate provided by the embodiment comprises the following steps
No. 5 heat treatment furnace, quenching machine area
1) The method comprises the following steps that 1 set of plate number identification equipment is additionally arranged at the inlet of a No. 5 heat treatment furnace, the number of a steel plate is automatically read and transmitted to a No. 5 heat treatment furnace secondary system, the secondary system automatically issues an operation instruction and a heat treatment process (heating temperature, heating rate, heat preservation time and the like) according to a production plan, and after the determination is made, the system starts a roller way and automatically enters the furnace;
2) the added steel plate has the function of comparing the actual in-furnace process with the technical requirement process, and the process does not conform to the requirements, and has a prompt and an error report;
3) automatically generating a heating trend curve of the steel plates of the heat treatment furnace, and inquiring and exporting the heating trend curve in an MES (manufacturing execution system) corresponding to each steel plate;
(II) straightener area
The straightening machine is additionally provided with 1 meter spraying machine on a front roller way, and the meter spraying machines are used for spraying and printing the quenched steel plate number and used for the data tracking of materials; meanwhile, 1 set of plate number identification equipment is additionally arranged, and is used for automatically identifying the number of the steel plate by a system when the steel plate is on-line and back-corrected, so that the damage of the equipment caused by the influence of the alignment parameter adjustment due to the manual verification error is avoided, and the steel plate alignment qualified rate is improved;
(III) marking machine area
The marking machine is additionally provided with 1 set of plate number recognition equipment before an inlet roller way, the steel plate number is automatically recognized, manual checking and issuing are not needed, the mark time of each steel plate is shortened to 2-3 minutes, preparation is made for improving the later-stage heat treatment capacity to 2.9 ten thousand tons of monthly insurance driving and protecting navigation, and the mark speed of finishing the transported residual materials, splitting and returning correction plates is also increased;
(IV) newly-added heat treatment line full-automatic material tracking system full line L2
1) The full line L2 is used for material tracking, and the material tracking starts from a roller way in front of a No. 5 heat treatment furnace and a No. 6 heat treatment furnace to cover a feeding roller way in front of the No. 5 heat treatment furnace to a centering position, behind a quenching machine, in a transverse moving, straightening, cooling bed and marking area;
2) a communication interface of a newly-added full line L2 and an MES, an interface of a full line L2 and a quenching machine L2, an interface of a full line L2 and a straightening machine L2, an interface of a full line L2 and a marking machine L2, an interface of a full line L2 and a newly-added 6# heat treatment furnace, and an interface of a newly-added marking machine L2;
3) the communication function of the newly added full line L2 and the newly added full line L1 system;
(V) transformation of heat treatment full-line basic automation control system full line L1
1) Adding 22 sets of hardware facilities and field sensing equipment of basic automation systems such as a laser range finder, a computer operation terminal, a switch and the like;
2) the original basic automation L1 system application software is modified, automatic and semi-automatic functions are added, and the interfaces of a network system matched with the original basic automation L1 system and other related systems, namely the full line L2, the newly-added 6# heat treatment furnace, the newly-added table spraying machine, the marking machine of the newly-added 6# heat treatment furnace project, the newly-added board number identification equipment and each equipment L1 are completed.
The MES was modified as follows:
the steel plate operation instruction data throwing full line L2;
the steel plate flows to the planned throwing full line L2;
automatically receiving the actual performance data of the steel plate flow by the MES;
collecting and counting the actual flow direction performance of the steel plate;
the MES automatically receives the straightening actual results and the marking results;
and (6) reporting.
The plate number identification system is as follows:
shooting a steel plate running on a roller way through visual collection equipment, capturing a character area for content identification, identifying a plate number in a visual detection mode, supporting the content identification of two writing modes of handwriting and jet printing, and identifying the flow as shown in figure 1;
and (4) checking the plate number: the production plan is automatically retrieved according to the identification information, secondary confirmation of the identification plate number is carried out through plan database information, and the detection accuracy is improved;
panel number grab show: besides the detection result, the HMI interface also displays a panel number screenshot, and an operator can check the original panel number information through the screenshot to perform secondary confirmation, so that the operation that the operator needs to check on site when the operator performs false identification is avoided;
fuzzy matching: when the writing quality of the plate numbers is poor and the plate numbers can only be partially identified due to smearing and scratches, fuzzy query is carried out through a production plan database, and information of several plate numbers with high matching degree is pushed and displayed for operators to select;
and (3) voice prompt: after the plate number identification process is executed, the system sends out a prompt tone to remind an operator to execute plate number confirmation operation.
The surface spraying system is as follows:
after the steel plate reaches the spray printing position and stops, a position detector of a full line L1 sends a steel plate in-place signal to a meter spraying machine, the meter spraying machine receives steel plate spray number information input by a full line L2/manual work, the meter spraying machine automatically enters a spray number process cycle, the meter spraying machine is started, a conveying roller way stops running, the meter spraying machine is interlocked with a roller way signal, after all characters are sprayed, the interlocking between the roller way and the meter spraying machine is released, the steel plate continues the next material flow direction through a straightening machine, and the meter spraying machine waits for the next steel plate to be sprayed with a number;
and (3) carrying out spray mark identification on the quenched steel plate after heat treatment, enabling the steel plate to correspond to the data before heat treatment one by one, identifying the temperature of the steel plate to be 0-100 ℃, and identifying the finished steel plate to be hung off line by a magnetic conveyor.
The full line L2 system is as follows:
1) system function module
Managing a production plan: receiving a steel plate PDI, a production plan and production process information issued by an MES;
material on-line tracking: micro-tracking and positioning the steel plate within the production line area;
and (3) production actual performance management: recording actual results of all procedures of material feeding, charging, discharging, transverse moving and the like;
production trend management: acquiring and visually displaying large data such as a heat treatment furnace plate temperature change trend, a furnace temperature change trend, a pyrometer detection trend, a quenching machine flow trend and the like;
data report management: information data such as production information, process information and tracking support the export of reports, and meanwhile, the automatic generation and pushing of daily reports, class reports and monthly reports are supported;
HMI human machine operation screen: the method comprises the following steps of area positive line tracking, production planning, up-down display verification, communication state maintenance, production actual performance, trend data and other interfaces;
2) system architecture
The whole line L2 hardware system mainly comprises 1 Server, engineer station, 2 clients, namely, 1 configured in each of the straightening and marking operation room, and network equipment to form a Client/Server system structure, wherein the Server end adopts distributed deployment, and adopts independent service methods for issuing on-line tracking, data acquisition, model control and the like, and performs message interaction by adopting a data bus; the client adopts a lightweight design and supports simultaneous login and operation of multiple terminals;
3) service terminal
Core service: the system is responsible for business management of information such as production plans, material tracking, production actual results, production trends and the like, and the intermediate result adopts Redis as a cache medium, supports two persistence modes of a memory and a hard disk and can be quickly recovered when a fault occurs;
the communication control module: responsible for communication management with MES, L1 and other L2 process control systems;
a trend data management module: the method has the advantages that a furnace temperature, a plate temperature and other energy consumption trend data access function is provided, a time sequence database is adopted in a storage mode, the query speed is guaranteed not to change along with the change of data magnitude, and high query efficiency is always kept;
application service interface: the server is accessed to an L2/L3 central switch through a twisted pair and connected with an MES host through the central switch, the server is accessed to an L1 network through an optical fiber so as to communicate with a basic automatic HMI server, a firewall is newly added between the full-line L2 and the MES for isolation, 360 industrial version antivirus software is configured on the full-line L2 server of the project, and 360 white lists are configured on other engineer stations and terminals.
The full line L1 system is as follows:
1) the transformation range of the L1 system is from the furnace front input roller way of the No. 5 heat treatment furnace to the area of the heat treatment marking machine P11 roller way, and comprises an online roller way control device, a transverse moving device and a cooling bed;
2) area range: the automatic marking machine comprises a 5# heat treatment furnace input roller way, a transverse moving device output roller way, a straightening machine inlet roller way, a straightening machine outlet roller way, a cooling bed input roller way, a cooling bed body, a cooling bed output roller way, a finished product marking machine inlet roller way, a finished product marking machine rear roller way, a 6# heat treatment furnace input roller way, a 6# heat treatment furnace output roller way, newly-added finished product marking machine rear extension roller ways P10 and P11, newly-added cooling bed output extension roller ways N13, N14 and N15;
3) tracking of steel plates on the area line:
the tracking area includes: all on-line roller ways, transverse moving devices and cooling beds in the heat treatment area;
the following functions are implemented by the tracking:
designing the whole heat treatment area as a continuous coordinate system;
the steel plate in the area has the tracking function in the X direction, namely the roller way direction, and the Y direction, namely the traversing device direction/cooling bed direction;
the tracking information of the steel plate comprises a head position (X, Y), a length, a width and a steel plate number;
the steel plate swings on the transverse moving feeding roller ways (N6 a, N7 a);
the steel plate swings in the transverse feeding roller ways (N6, N7);
the newly added finished product marking machine is controlled by a rear extension roller way (P10, P11);
newly adding a cooling bed output extension roller way (N13, N14 and N15) for control;
interlocking between the newly-added cooling bed output extension roller way and the newly-added marking machine of the No. 6 heat treatment furnace project; interlocking between the output roller way of the No. 6 heat treatment furnace and the transverse moving blanking device and the transverse moving blanking roller way;
the steel plate has the swinging function on the output extension roller ways (N13, N14 and N15) of the cooling bed;
4) the L1 system completes the automatic logistics control of the steel plate according to the full-line L2 instruction, and the main functions are as follows:
the L1 receives a Next Plate Zone instruction (Next Plate Zone) issued by the full-line L2 system, and completes the automatic conveying function of the steel Plate according to the instruction;
l1 receives a steel plate off-line instruction issued by a full-line L2 system, and finishes off-line of the steel plate according to the instruction;
l1 receives a steel plate on-line instruction issued by a full-line L2 system, and finishes the steel plate on-line according to the instruction;
5) the control system comprises the following components:
PLC switch board and HMI: the PLC system utilizes an original full-line L1-level system, adopts a TCP/IP Ethernet to complete data mutual transmission, signal communication and communication with a heat treatment rear control system, expands an existing remote slave station ET200MI/O module, is used for collecting signals of a newly added sensor on site, and adopts a PROFIBUS DP network to perform data exchange and communication with a controller;
the HMI system adopts a running version, 3 HMI operator stations are newly configured in an operating room, and the HMI system adopts programmable software WINCC V7.2;
the HMI operator station mainly implements the following functions:
reflecting the production line flow operation and control pictures;
the production line main picture reflects the working state of the main equipment;
reflecting logistics information and equipment state information;
displaying process data, displaying and correcting set values;
data input, data storage and invocation;
a device calibration function;
selecting class operation, including operation mode selection;
control operation, directly controlling the running and stopping of the equipment;
the maintenance operation is used for monitoring and maintaining the system;
displaying the state of the network system and diagnosing faults;
PLC module diagnosis information;
displaying an interlocking state;
displaying, recording and printing operation event information, various faults and alarm information;
PDA: upgrading original configuration data by using an original PDA hardware system for signal acquisition and data analysis of a heat treatment area;
the remote IO cabinet expands a remote IO module;
the in-place operation box IO cabinet in-place operation box remains unchanged.
The data analysis system is as follows:
performing data docking with an L1 system and an L2 system of each device in the original production line to perfect tracking data feedback;
the large data acquisition capacity of each instrument is improved, the mass data acquisition capacity is provided, the data acquisition frequency of less than 50ms is supported, and the data is stored for a long time at a high compression ratio;
the multi-angle data analysis function is used for performing fault early warning, process curve analysis, capacity analysis, energy consumption analysis and the like on the acquired high-frequency data, and visually checking the acquired high-frequency data through a digital billboard;
the production process capability evaluation function is used for statistically evaluating key process parameters of each grade specification and ensuring the production quality;
the key process parameter abnormity counting function is used for counting whether key process parameters such as heating time, tapping temperature and anti-red temperature in a time range meet the upper and lower limits set by the process or not and counting the process overrun abnormity;
and the report export push function supports export operation of all display data reports, reserves interfaces and supports pushing to an ERP system and an MES system.
After the invention is reformed, before the steel plate enters the furnace, the number is not required to be manually read and input, the calculation is carried out according to the average saved 24.5 seconds each time, and the annual time is saved: 0.41 min/110/337.7 days (days of annual plant operation)/60 min =152.06 hours, average heat treatment output per hour of about 22.2 tons, annual increase output: 152.06 hours 22.2 tons/hour =3375.8 tons, annual gain: 3375.8 tons 0.05 ten thousand yuan/ton =168.79 ten thousand yuan.
The marking errors due to manual input errors can be reduced five times a year. And the steel plates are delivered to a customer destination, after the customer finds out, the customer needs to send a person to a confirmation process with a marking tool, and if a real object is wrong, the steel plates need to be changed, so that the average cost is 8000 yuan/time. This avoids quality loss: 0.8 ten thousand yuan/5 × 4 ten thousand yuan.
The direct benefits are in total: 168.79 ten thousand yuan +4 ten thousand yuan =172.79 ten thousand yuan.
In addition to the above embodiments, the present invention may have other embodiments. All technical solutions formed by adopting equivalent substitutions or equivalent transformations fall within the protection scope of the claims of the present invention.
Claims (7)
1. A full-line automatic tracking method for wide and thick plates is characterized by comprising the following steps: comprises that
No. 5 heat treatment furnace, quenching machine area
1) Adding 1 set of plate number identification equipment at the inlet of the No. 5 heat treatment furnace, automatically reading the number of the steel plate and transmitting the number to a No. 5 heat treatment furnace secondary system, automatically issuing an operation instruction and a heat treatment process by the secondary system according to a production plan, and starting a roller way by the system and automatically feeding the steel plate into the furnace after the determination is finished;
2) the added steel plate has the function of comparing the actual in-furnace process with the technical requirement process, and the process does not conform to the requirements, and has a prompt and an error report;
3) automatically generating a heating trend curve of the steel plates of the heat treatment furnace, and inquiring and exporting the heating trend curve in an MES (manufacturing execution system) corresponding to each steel plate;
(II) straightener area
The straightening machine is additionally provided with 1 meter spraying machine on a front roller way, and the meter spraying machines are used for spraying and printing the quenched steel plate number and used for the data tracking of materials; meanwhile, 1 set of plate number identification equipment is additionally arranged and is used for automatically identifying the number of the steel plate by a system when the steel plate is on-line and back corrected;
(III) marking machine area
Adding 1 set of plate number identification equipment in front of an inlet roller way of the marking machine to automatically identify the number of the steel plate;
(IV) newly-added heat treatment line full-automatic material tracking system full line L2
1) The full line L2 is used for material tracking, and the material tracking starts from a roller way in front of a No. 5 heat treatment furnace and a No. 6 heat treatment furnace to cover a feeding roller way in front of the No. 5 heat treatment furnace to a centering position, behind a quenching machine, in a transverse moving, straightening, cooling bed and marking area;
2) a communication interface of a newly-added full line L2 and an MES, an interface of a full line L2 and a quenching machine L2, an interface of a full line L2 and a straightening machine L2, an interface of a full line L2 and a marking machine L2, an interface of a full line L2 and a newly-added 6# heat treatment furnace, and an interface of a newly-added marking machine L2;
3) the communication function of the newly added full line L2 and the newly added full line L1 system;
(V) transformation of heat treatment full-line basic automation control system full line L1
1) Adding 22 sets of hardware facilities and field sensing equipment of basic automation systems such as a laser range finder, a computer operation terminal, a switch and the like;
2) the original basic automation L1 system application software is modified, automatic and semi-automatic functions are added, and the interfaces of a network system matched with the original basic automation L1 system and other related systems, namely the full line L2, the newly-added 6# heat treatment furnace, the newly-added table spraying machine, the marking machine of the newly-added 6# heat treatment furnace project, the newly-added board number identification equipment and each equipment L1 are completed.
2. The full-line automatic tracking method for the wide and thick plate according to claim 1, wherein the method comprises the following steps: the MES was modified as follows:
the steel plate operation instruction data throwing full line L2;
the steel plate flows to the planned throwing full line L2;
automatically receiving the actual performance data of the steel plate flow by the MES;
collecting and counting the actual flow direction performance of the steel plate;
the MES automatically receives the straightening actual results and the marking results;
and (6) reporting.
3. The full-line automatic tracking method for the wide and thick plate according to claim 1, wherein the method comprises the following steps: the plate number identification system is as follows:
shooting a steel plate running on a roller way through visual collection equipment, capturing a character area for content identification, identifying a plate number in a visual detection mode, and supporting the content identification of two writing modes, namely handwriting and jet printing;
and (4) checking the plate number: automatically retrieving the production plan according to the identification information, and performing secondary confirmation of the identification plate number through plan database information;
panel number grab show: besides displaying the detection result, the HMI also displays a panel number screenshot, and an operator can check the original panel number information through the screenshot to perform secondary confirmation;
fuzzy matching: when the writing quality of the plate numbers is poor and the plate numbers can only be partially identified due to smearing and scratches, fuzzy query is carried out through a production plan database, and information of several plate numbers with high matching degree is pushed and displayed for operators to select;
and (3) voice prompt: after the plate number identification process is executed, the system sends out a prompt tone to remind an operator to execute plate number confirmation operation.
4. The full-line automatic tracking method for the wide and thick plate according to claim 1, wherein the method comprises the following steps: the surface spraying system is as follows:
after the steel plate reaches the spray printing position and stops, a position detector of a full line L1 sends a steel plate in-place signal to a meter spraying machine, the meter spraying machine receives steel plate spray number information input by a full line L2/manual work, the meter spraying machine automatically enters a spray number process cycle, the meter spraying machine is started, a conveying roller way stops running, the meter spraying machine is interlocked with a roller way signal, after all characters are sprayed, the interlocking between the roller way and the meter spraying machine is released, the steel plate continues the next material flow direction through a straightening machine, and the meter spraying machine waits for the next steel plate to be sprayed with a number;
and (3) carrying out spray mark identification on the quenched steel plate after heat treatment, enabling the steel plate to correspond to the data before heat treatment one by one, identifying the temperature of the steel plate to be 0-100 ℃, and identifying the finished steel plate to be hung off line by a magnetic conveyor.
5. The full-line automatic tracking method for the wide and thick plate according to claim 1, wherein the method comprises the following steps: the full line L2 system is as follows:
1) system function module
Managing a production plan: receiving a steel plate PDI, a production plan and production process information issued by an MES;
material on-line tracking: micro-tracking and positioning the steel plate within the production line area;
and (3) production actual performance management: recording actual results of all procedures of material feeding, charging, discharging, transverse moving and the like;
production trend management: acquiring and visually displaying large data such as a heat treatment furnace plate temperature change trend, a furnace temperature change trend, a pyrometer detection trend, a quenching machine flow trend and the like;
data report management: information data such as production information, process information and tracking support the export of reports, and meanwhile, the automatic generation and pushing of daily reports, class reports and monthly reports are supported;
HMI human machine operation screen: the method comprises the following steps of area positive line tracking, production planning, up-down display verification, communication state maintenance, production actual performance, trend data and other interfaces;
2) system architecture
The whole line L2 hardware system mainly comprises 1 Server, engineer station, 2 clients, namely, 1 configured in each of the straightening and marking operation room, and network equipment to form a Client/Server system structure, wherein the Server end adopts distributed deployment, and adopts independent service methods for issuing on-line tracking, data acquisition, model control and the like, and performs message interaction by adopting a data bus; the client adopts a lightweight design and supports simultaneous login and operation of multiple terminals;
3) service terminal
Core service: the system is responsible for business management of information such as production plans, material tracking, production actual results, production trends and the like, and an intermediate result adopts Redis as a cache medium to support two persistence modes of an internal memory and a hard disk;
the communication control module: responsible for communication management with MES, L1 and other L2 process control systems;
a trend data management module: providing furnace temperature, plate temperature and other energy consumption trend data access functions, wherein the storage mode adopts a time sequence database;
application service interface: the server is connected to an L2/L3 central switch through a twisted pair and is connected with an MES host through the central switch, the server is connected to an L1 network through an optical fiber so as to be communicated with an HMI server of basic automation, and a firewall is added between the entire line L2 and the MES for isolation.
6. The full-line automatic tracking method for the wide and thick plate according to claim 1, wherein the method comprises the following steps:
the full line L1 system is as follows:
1) the transformation range of the L1 system is from the furnace front input roller way of the No. 5 heat treatment furnace to the area of the heat treatment marking machine P11 roller way, and comprises an online roller way control device, a transverse moving device and a cooling bed;
2) area range: the automatic marking machine comprises a 5# heat treatment furnace input roller way, a transverse moving device output roller way, a straightening machine inlet roller way, a straightening machine outlet roller way, a cooling bed input roller way, a cooling bed body, a cooling bed output roller way, a finished product marking machine inlet roller way, a finished product marking machine rear roller way, a 6# heat treatment furnace input roller way, a 6# heat treatment furnace output roller way, a newly-added finished product marking machine rear extension roller way and a newly-added cooling bed output extension roller way;
3) tracking of steel plates on the area line:
the tracking area includes: all on-line roller ways, transverse moving devices and cooling beds in the heat treatment area;
the following functions are implemented by the tracking:
designing the whole heat treatment area as a continuous coordinate system;
the steel plate in the area has the tracking function in the X direction, namely the roller way direction, and the Y direction, namely the traversing device direction/cooling bed direction;
the tracking information of the steel plate comprises a head position (X, Y), a length, a width and a steel plate number;
the steel plate swings on the transverse moving feeding roller way;
the steel plate swings on a transverse blanking roller way;
the control of the roller path is prolonged after a finished product marking machine is newly added;
newly adding control of an output extension roller way of the cooling bed;
interlocking between the newly-added cooling bed output extension roller way and the newly-added marking machine of the No. 6 heat treatment furnace project; interlocking between the output roller way of the No. 6 heat treatment furnace and the transverse moving blanking device and the transverse moving blanking roller way;
the steel plate has the function of prolonging the swing of the roller way at the output of the cooling bed;
4) the L1 system completes the automatic logistics control of the steel plate according to the full-line L2 instruction, and the main functions are as follows:
the L1 receives a next plate area instruction issued by the full-line L2 system, and completes the automatic conveying function of the steel plate according to the instruction;
l1 receives a steel plate off-line instruction issued by a full-line L2 system, and finishes off-line of the steel plate according to the instruction;
l1 receives a steel plate on-line instruction issued by a full-line L2 system, and finishes the steel plate on-line according to the instruction;
5) the control system comprises the following components:
PLC switch board and HMI: the PLC system utilizes an original full-line L1-level system, adopts a TCP/IP Ethernet to complete data mutual transmission, signal communication and communication with a heat treatment rear control system, expands an existing remote slave station ET200MI/O module, is used for collecting signals of a newly added sensor on site, and adopts a PROFIBUS DP network to perform data exchange and communication with a controller;
the HMI system adopts a running version, 3 HMI operator stations are newly configured in an operating room, and the HMI system adopts programmable software WINCC V7.2;
the HMI operator station mainly implements the following functions:
reflecting the production line flow operation and control pictures;
the production line main picture reflects the working state of the main equipment;
reflecting logistics information and equipment state information;
displaying process data, displaying and correcting set values;
data input, data storage and invocation;
a device calibration function;
selecting class operation, including operation mode selection;
control operation, directly controlling the running and stopping of the equipment;
the maintenance operation is used for monitoring and maintaining the system;
displaying the state of the network system and diagnosing faults;
PLC module diagnosis information;
displaying an interlocking state;
displaying, recording and printing operation event information, various faults and alarm information;
PDA: upgrading original configuration data by using an original PDA hardware system for signal acquisition and data analysis of a heat treatment area;
the remote IO cabinet expands a remote IO module;
the in-place operation box IO cabinet in-place operation box remains unchanged.
7. The full-line automatic tracking method for the wide and thick plate according to claim 1, wherein the method comprises the following steps: the data analysis system is as follows:
performing data docking with an L1 system and an L2 system of each device in the original production line to perfect tracking data feedback;
the large data acquisition capacity of each instrument is improved, the mass data acquisition capacity is provided, the data acquisition frequency of less than 50ms is supported, and the data is stored for a long time at a high compression ratio;
the multi-angle data analysis function is used for performing fault early warning, process curve analysis, capacity analysis, energy consumption analysis and the like on the acquired high-frequency data, and visually checking the acquired high-frequency data through a digital billboard;
the production process capability evaluation function is used for statistically evaluating key process parameters of each grade specification and ensuring the production quality;
the key process parameter abnormity counting function is used for counting whether key process parameters such as heating time, tapping temperature and anti-red temperature in a time range meet the upper and lower limits set by the process or not and counting the process overrun abnormity;
and the report export push function supports export operation of all display data reports, reserves interfaces and supports pushing to an ERP system and an MES system.
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Cited By (1)
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