CN113634620A - Roller abrasion loss monitoring and self-adaptive feedback adjusting system and method for straightening machine - Google Patents

Roller abrasion loss monitoring and self-adaptive feedback adjusting system and method for straightening machine Download PDF

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Publication number
CN113634620A
CN113634620A CN202110920548.8A CN202110920548A CN113634620A CN 113634620 A CN113634620 A CN 113634620A CN 202110920548 A CN202110920548 A CN 202110920548A CN 113634620 A CN113634620 A CN 113634620A
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abrasion
roll
roller
early warning
module
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CN113634620B (en
Inventor
夏绪辉
王怀
王瞳
张泽琳
李文喜
张欢
陈宝通
李鑫
严旭果
严林
王蕾
曹建华
刘翔
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Wuhan University of Science and Engineering WUSE
Xiangyang Boya Precision Industrial Equipments Co Ltd
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Wuhan University of Science and Engineering WUSE
Xiangyang Boya Precision Industrial Equipments Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The invention belongs to the technical field of straighteners, and discloses a straightener roller abrasion loss monitoring and self-adaptive feedback adjusting system and a straightener roller abrasion loss monitoring and self-adaptive feedback adjusting method. The roller abrasion loss monitoring and self-adaptive feedback adjusting system of the straightening machine provided by the invention realizes real-time adjustment by establishing a comprehensive real-time monitoring system and a decision control system, and solves the problems of unstable contact and stress of a working roller and strip steel under the conditions of uniform roller surface abrasion and non-uniform roller surface abrasion. The invention monitors the surface of the working roll in real time, collects the information of the abrasion condition of the surface of the working roll, and classifies the abrasion condition according to the abrasion condition, including the abrasion caused by the change of the diameter size of the roll, the cylindricity abrasion and the roundness abrasion. Therefore, the technology has the advantages of dynamic and instant adjustment, improvement of the surface quality of the strip steel and the like.

Description

Roller abrasion loss monitoring and self-adaptive feedback adjusting system and method for straightening machine
Technical Field
The invention belongs to the technical field of straightening machines, and particularly relates to a system and a method for monitoring abrasion loss of a roller of a straightening machine and self-adaptive feedback adjustment.
Background
At present, a straightening machine is one of main finishing equipment on a cold-rolled strip steel production line and is used for straightening strip steel, and the strip steel is subjected to continuous multiple stretch bending and springing in the straightening machine, so that the straightness of the strip steel meets the requirements of national standards and customers. In the process of straightening strip steel, after working rolls of a straightening roll and a bending roll work for a period of time, roll bodies are abraded greatly, the abrasion conditions are complex and various, and the quality of the strip steel is influenced if the working rolls are not processed in time. The processing mode of the worn straightening roll and bending roll in the existing straightener is as follows: the wear of the rollers is periodically checked and the rollers are periodically replaced. Therefore, although the problem of quality reduction of the strip steel caused by unstable contact and stress of the roller and the strip steel can be solved, the roller cannot be adjusted immediately, and the unstable contact and stress conditions of the roller and the strip steel cannot be effectively eliminated. Therefore, a new system and method for monitoring the abrasion loss of the roller of the straightener and self-adaptive feedback adjustment are needed.
Through the above analysis, the problems and defects of the prior art are as follows: first, the current process of straightening and bending rolls that are worn out is to periodically replace the rolls, which increases the cost of roll replacement. Secondly, the treatment mode of the worn straightening roll and the worn bending roll in the straightening machine cannot be adjusted immediately, and the unstable contact and stress conditions of the rolls and the strip steel cannot be effectively eliminated.
The difficulty in solving the above problems and defects is: during the straightening process, the roller has a particularly high rotational speed, which makes it difficult to apply the adjustment in a very short time. And if the adjustment is not timely in the roller adjustment process, the strip steel can be greatly damaged in a very short time.
The significance of solving the problems and the defects is as follows: firstly, after the mode of regular roll replacement is changed, the utilization rate of the roll is improved, and the cost of roll replacement is reduced. And secondly, the roller is adjusted immediately, the unstable contact and stress conditions of the roller and the strip steel are improved, and the surface quality of the strip steel is improved.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a straightening machine roller abrasion loss monitoring and self-adaptive feedback adjusting system and method, and particularly relates to a system and method for performing early warning on roller change and immediately adjusting roller insertion amount and deflection amount of a stretch bending straightening machine based on a decision-making system.
The invention is realized in such a way that the straightener roller abrasion loss monitoring and self-adaptive feedback adjusting system comprises a visual monitoring module, a decision control module, an early warning and human-computer interaction module and a servo module.
The visual monitoring module comprises an industrial camera, is positioned on the frame of the straightening machine and is used for comprehensively monitoring the roll surface condition of the working roll, collecting information of the roll surface abrasion condition of the working roll and transmitting the collected information to the decision control module;
the decision control module comprises a computer data processing and control center, is positioned beside the straightener, is communicated with each module through a circuit and a line, is used for processing, analyzing and deciding the information obtained by the visual monitoring module and transmitting a control signal to the next link, namely an early warning and man-machine interaction module and a servo module;
the early warning and man-machine interaction module comprises an early warning bell and a computer display center, wherein the early warning bell is positioned on a frame of the straightening machine, the computer display center is connected with the decision control center and is used for converting and displaying a control command generated by controlling the decision module in a character string or hexadecimal mode through programming selection, the early warning bell rings, an interface early warning lamp turns red to remind a worker to change rolls;
the servo module comprises a speed reducing motor, and the speed reducing motor is positioned on two sides of the straightening machine frame; different parts of the servo module operate according to the command of the decision control module to adjust the straightening machine.
Further, in the visual monitoring module, the information of the wear condition of the surface of the working roll comprises the size change of the diameter of the roll, the cylindricity of the roll and the roundness of the roll.
Further, in the servo module, the operation according to the command of the decision control module and the adjustment of the straightening machine include three conditions:
adjusting the insertion amount: controlling a speed reducing motor through a control command to adjust the upper roller and the lower roller, wherein the adjusted insertion amount is H, and the diameter size abrasion of the rollers is compensated;
adjusting the deflection: controlling a speed reducing motor through a control command to adjust the upper roller and the lower roller, wherein the adjusted deflection is G, and the cylindricity abrasion of the rollers is compensated;
roll changing operation: and after the staff is reminded from the early warning module, stopping the operation of the straightener, manually disassembling the roller box and replacing the rollers.
Further, the roller abrasion loss monitoring and self-adaptive feedback adjusting system of the straightener further comprises an upper straightening speed reducing motor, namely an R series turbine speed reducing motor, an early warning bell, an upper roller box pressing plate, an upper roller box supporting point positioning head, an upper roller box supporting point, a roller box locking mechanism, a lower speed reducing motor, namely an R series turbine speed reducing motor, a pressing oil cylinder, namely SHHAUTO/HOB, a hydraulic pipeline, an industrial camera fixing rod, an industrial camera, namely Keynshi CA-H2100C, a roller surface and a worm gear.
The invention also aims to provide a straightener roller wear amount monitoring and self-adaptive feedback adjusting method applying the straightener roller wear amount monitoring and self-adaptive feedback adjusting system, wherein the straightener roller wear amount monitoring and self-adaptive feedback adjusting method comprises the following steps:
step one, a visual monitoring module collects roll surface information of each working roll from a production line of a straightening machine and transmits the roll surface information to a decision control module;
step two, the decision control module processes the roll surface information to obtain roll diameter size change, cylindricity change, roundness change and roll surface damage condition data;
step three, establishing a wear degree judgment decision model;
inputting the obtained data into a wear degree judgment decision model to perform judgment decision;
step five, if the abrasion is uniform abrasion and is the abrasion of the roller diameter size, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
step six, if the abrasion is non-uniform abrasion and cylindricity abrasion, when the abrasion degree is in a certain range, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the deflection P of the abrasion roller; when the wear degree is in an exceeding range, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sounds and an early warning lamp of a display interface flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll;
step seven, if the abrasion is non-uniform abrasion and roundness abrasion, when the abrasion degree exceeds the abrasion degreeGsAnd when the roll changing machine is used, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sends out a ring and displays that an interface early warning lamp flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll.
Further, the method for monitoring the abrasion loss of the roller of the straightener and self-adaptive feedback adjustment further comprises the following steps:
(1) six industrial cameras of the bending working section and the straightening working section of the straightening machine collect the condition information of the roll surface of each working roll from the straightening machine and transmit the information to a computer control center of a decision control module; wherein, the upper bending roll and the lower bending roll of the bending working section of the straightener are respectively provided with one monitoring camera, and the number of the monitoring cameras is four; the upper straightening roll and the lower straightening roll of the straightening working section are respectively provided with one monitoring camera, and the number of the monitoring cameras is two;
(2) the computer control center of the decision control module processes and classifies the roller surface information through the processing submodule to obtain roller diameter size change, roller cylindricity abrasion change and roller surface roundness abrasion change data;
(3) the processing submodule transmits related data to the judging submodule, the judging submodule analyzes and judges data of the change of the diameter size of the roller, the change of the cylindricity abrasion of the roller and the change of the roundness abrasion of the surface of the roller, and if only the change of the diameter size of the roller is abraded, the uniform abrasion condition is judged; if the cylindricity of the roller surface is worn out in a changing way, the roller surface is judged to be in uneven wear condition; if the roundness of the roller surface is worn variably, judging the roller surface to be uneven wear;
(4) the judgment submodule transmits the result to the decision submodule, and the decision submodule makes a decision according to the wear degree;
(5) different parts of the servo module operate according to the command of the decision control module to adjust the straightening machine.
Further, in step (4), the determining submodule transmits the result to the decision submodule, and the decision by the decision submodule according to the wear degree includes:
1) when the wear is a change in the roll diameter dimension, and the wear amount is Δ R, the insertion amount adjustment is determined:
calculating the insertion quantity required to be adjusted, wherein a calculation model is as follows:
H＝ΔR；
calculating to obtain an insertion quantity H, and then generating an adjusting command;
and the control submodule directly sends the adjusting command to the speed reducing motor, namely the R series turbine speed reducing motor.
2) When the abrasion is changed by cylindricity abrasion, the abrasion amount is F, then the deflection adjustment or the shutdown roll replacement is determined:
calculating a scheme to be adopted according to different abrasion degrees of cylindricity abrasion, wherein a calculation model is as follows:
FMID＝(FMAX-FMIN)/2；
FMID-ΔF<F<FMID+ΔF；
in the formula, FMAXThe maximum abrasion loss of the whole roll surface is obtained; fMINThe maximum abrasion loss of the whole roll surface is obtained; Δ F is the desired amount of change;
if the roll surface abrasion quantity F is in a specified range, obtaining an adjusted deflection quantity P through calculation, and generating an adjusting command; if the roll surface abrasion quantity F exceeds the specified range, stopping the roll changing and generating a command of stopping the roll changing;
the control sub-module directly sends the adjusting command to a speed reducing motor, namely an R series turbine speed reducing motor; and the control submodule sends a roll-changing stopping command to an early warning bell and an early warning interface lamp.
3) When the abrasion is roundness abrasion change, the abrasion amount is G, and then the roller is stopped and replaced:
calculating a scheme to be adopted according to the roundness abrasion degree, wherein a calculation model is as follows:
G>Gs；
if the roundness abrasion amount exceeds the set standard, stopping the roll changing and generating a command for stopping the roll changing;
and the control submodule sends a roll-changing stopping command to an early warning bell and an early warning interface lamp.
Further, in the step (5), different parts of the servo module operate according to the command of the decision control module to adjust the straightening machine, and the operation is divided into the following 3 conditions:
the first condition is as follows: adjusting the insertion amount, and the PLC of the servo module obtains an adjustment command and adjusts the speed reducing motor through a driver; in the bending working section, the speed reducing motors on two sides of the straightening machine adjust the upper position and the lower position of the lower roller box through the worm gear and worm, in the straightening working section, the speed reducing motors on two sides adjust the gap between the upper roller box and the lower roller box through the worm gear and worm, and finally the adjustment amount of the gap insertion amount of the upper roller surface and the lower roller surface reaches H.
Case two: adjusting the deflection amount, obtaining an adjusting command by a PLC (programmable logic controller) of the servo module, and adjusting the speed reducing motor through a driver; in the bending working section, the speed reducing motors on the two sides of the straightening machine adjust the left and right deflection of the lower roller box through the worm gears and the worms, in the straightening working section, the speed reducing motors adjust the left and right deflection of the upper roller box and the lower roller box through the worm gears and the worms, and the upper roller box and the lower roller box act together to finally enable the adjustment amount of the upper roller surface gap deflection amount and the lower roller surface gap deflection amount to reach P.
Case three: and stopping the roll changing, wherein an early warning bell and an early warning interface lamp of the early warning module obtain a command of stopping the roll changing, the early warning bell sounds and the early warning interface lamp flashes red, and a worker obtains roll changing information, stops the work of the straightener and performs manual roll changing.
It is a further object of the invention to provide a computer device comprising a memory and a processor, the memory storing a computer program which, when executed by the processor, causes the processor to perform the steps of:
the visual monitoring module collects the roll surface information of each working roll from the production line of the straightener and transmits the roll surface information to the decision control module; the decision control module processes the roller surface information to obtain roller diameter size change, cylindricity change, roundness change and roller surface damage condition data; establishing a wear degree judgment decision model; inputting the obtained data into a wear degree judgment decision model for judgment decision;
if the abrasion is uniform abrasion and is the abrasion of the roller diameter size, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
if the abrasion is non-uniform abrasion and cylindricity abrasion, when the abrasion degree is in a certain range, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the deflection P of the abrasion roller; when the wear degree is in an exceeding range, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sounds and an early warning lamp of a display interface flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll;
if the abrasion is non-uniform abrasion and roundness abrasion, when the abrasion degree exceeds GsAnd when the roll changing machine is used, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sends out a ring and displays that an interface early warning lamp flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll.
The invention also aims to provide an information data processing terminal which is used for realizing the roller wear monitoring and self-adaptive feedback adjusting system of the straightener.
By combining all the technical schemes, the invention has the advantages and positive effects that: the roller abrasion loss monitoring and self-adaptive feedback adjusting system of the straightening machine provided by the invention realizes real-time adjustment by establishing a comprehensive real-time monitoring system and a decision control system, and solves the problems of unstable contact and stress of a working roller and strip steel under the conditions of uniform roller surface abrasion and non-uniform roller surface abrasion.
The abrasion conditions of the working rolls are complex and various, and the straightening quality of the strip steel is influenced if the working rolls are not processed in time. The technology of the invention carries out real-time monitoring on the surface of the working roll, collects the information of the abrasion condition of the surface of the working roll, and classifies the abrasion condition according to the information, and comprises the following steps: roller diameter dimensional change wear, cylindricity wear and roundness wear. Wherein, the roller diameter size change abrasion and the cylindricity abrasion in a certain range belong to uniform abrasion, and the roundness abrasion and the cylindricity abrasion beyond the range belong to non-uniform abrasion. Under the condition of uniform abrasion, the system can adjust the rollers in a self-adaptive manner to adjust the insertion amount and the deflection amount; under the condition of non-uniform abrasion, the system can send out an early warning signal to remind workers to replace the abraded working roller. Therefore, the invention has the advantages of dynamic and instant adjustment, improvement of the surface quality of the strip steel and the like.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments of the present invention will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a flow chart of a method for monitoring the wear of rolls of a leveler and adjusting adaptive feedback according to an embodiment of the present invention.
FIG. 2 is a schematic diagram of a method for monitoring the wear of rolls of a leveler and adjusting adaptive feedback according to an embodiment of the present invention.
FIG. 3 is a block diagram of a system for monitoring the wear of rolls and adaptively feeding back and adjusting the wear of rolls in a leveler according to an embodiment of the present invention;
in the figure: 1. a vision monitoring module; 2. a decision control module; 3. an early warning and man-machine interaction module; 4. and a servo module.
FIG. 4 is a flow chart showing information flow of a system for monitoring the amount of wear of rolls of a leveler and adjusting the rolls by adaptive feedback according to an embodiment of the present invention.
FIG. 5 is a schematic diagram of the critical structure of the straightening machine according to the embodiment of the present invention.
Fig. 6 is an exemplary graph of three wear conditions provided by an embodiment of the present invention.
Fig. 7 is a schematic circuit diagram according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Aiming at the problems in the prior art, the invention provides a system and a method for monitoring the abrasion loss of a roller of a straightening machine and self-adaptive feedback adjustment, and the invention is described in detail below by combining the attached drawings.
As shown in FIG. 1, the method for monitoring the abrasion loss of the rolls of the straightener and adaptively feeding back and adjusting the abrasion loss of the rolls comprises the following steps:
s101, a visual monitoring module collects roll surface information of each working roll from a production line of a straightening machine and transmits the roll surface information to a decision control module;
s102, processing the roll surface information by a decision control module to obtain roll diameter size change, cylindricity change, roundness change and roll surface damage condition data;
s103, establishing a wear degree judgment decision model;
s104, inputting the obtained data into a wear degree judgment decision model for judgment decision;
s105, if the abrasion is uniform abrasion and is the abrasion of the size of the roll diameter, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
s106, if the abrasion is non-uniform abrasion and cylindricity abrasion, when the abrasion degree is in a certain range, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the deflection P of the abrasion roller; when the wear degree is in an exceeding range, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sounds and an early warning lamp of a display interface flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll;
s107, if the abrasion is non-uniform abrasion and roundness abrasion, when the abrasion degree exceeds GsAnd when the roll changing machine is used, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sends out a ring and displays that an interface early warning lamp flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll.
A schematic diagram of a method for monitoring the abrasion loss of the roller of the straightener and self-adaptive feedback adjustment provided by the embodiment of the invention is shown in FIG. 2.
As shown in fig. 3, the straightener roller wear amount monitoring and adaptive feedback adjusting system provided by the embodiment of the invention comprises a visual monitoring module 1, a decision control module 2, an early warning and human-computer interaction module 3 and a servo module 4.
The vision monitoring module 1 comprises an industrial camera, is positioned on a frame of the straightening machine, and is used for comprehensively monitoring the roll surface condition of the working roll, collecting information of the roll surface abrasion condition of the working roll and transmitting the collected information to the decision control module;
the decision control module 2 comprises a computer data processing and control center, is positioned beside the straightener, is communicated with each module through a circuit and a line, and is used for processing, analyzing and deciding the information obtained by the visual monitoring module and transmitting a control signal to the next link, namely an early warning and man-machine interaction module and a servo module;
the early warning and man-machine interaction module 3 comprises an early warning bell and a computer display center, wherein the early warning bell is positioned on a straightening machine frame, the computer display center is connected with a decision control center and is used for converting and displaying a control command generated by controlling the decision module in a character string or hexadecimal mode through programming selection, the early warning bell rings, an interface early warning lamp turns red to remind a worker to change rolls;
the servo module 4 comprises a speed reducing motor, and the speed reducing motor is positioned on two sides of the straightening machine frame; different parts of the servo module operate according to the command of the decision control module to adjust the straightening machine.
The technical solution of the present invention will be further described with reference to the following examples.
Example 1
The invention provides a system and a method for early warning of roll change of a stretch bending straightener and real-time adjustment of roll insertion amount and deflection amount, which solve the problems of unstable contact and stress of a working roll and strip steel under the conditions of uniform wear of a roll surface and non-uniform wear of the roll surface.
In order to solve the technical problems, the invention adopts the following scheme:
roller abrasion loss monitoring control system and method based on decision system
(1) Introduction to the Main Module
A visual monitoring module:
the module includes an industrial camera.
The module is positioned on a frame of the straightening machine, and can comprehensively monitor the roll surface condition of the working roll. The module mainly functions to collect information (such as roller diameter size change, roller cylindricity, roller roundness and the like) of the roller surface abrasion condition of the working roller and transmit the collected information to the decision control module.
A decision control module:
the module comprises a computer data processing and control center.
The module is positioned beside the straightening machine and is communicated with each module through a circuit, a circuit and the like. The module is mainly used for processing, analyzing and deciding the information obtained by the visual monitoring module and transmitting a control signal to the next link (the early warning module and the servo module). See figure 2 for details.
Early warning module and human-computer interaction module:
the module comprises an early warning bell and a computer display center.
The positions of the devices of the module are as follows: the early warning bell is positioned on the frame of the straightening machine, and the computer display center is connected with the decision control center. The module is mainly used for converting and displaying a control command generated by the control decision module in a character string or hexadecimal mode through programming selection, sending out a ring by the early warning bell, and reminding a worker to change the roller when the interface early warning lamp turns red.
A servo module:
the module comprises a speed reducing motor.
The positions of all parts of the module are as follows: the speed reducing motors are positioned on two sides of the straightening machine frame. The module has the main functions that: different parts of the servo module operate according to the command of the decision control module, and the straightening machine is adjusted by three conditions, wherein one condition is that the insertion amount is adjusted: controlling a speed reducing motor through a control command to adjust the upper roller and the lower roller, wherein the adjusted insertion amount is H, and the diameter size abrasion of the rollers is compensated; adjusting the deflection amount, namely controlling a speed reducing motor to adjust the upper roller and the lower roller through a control command, wherein the adjusted deflection amount is G, and the cylindricity abrasion of the rollers is compensated; and thirdly, roll changing operation is carried out, a worker is reminded from the early warning module, then the worker stops the operation of the straightening machine and manually dismantles the roll box to change the rolls.
(2) Introduction to the basic flow
Step 1: the visual monitoring module collects the roll surface information of each working roll from the production line of the straightener and transmits the roll surface information to the decision control module.
Step 2: and the decision control module processes the roller surface information to obtain data such as roller diameter size change, cylindricity change, roundness change, roller surface damage condition and the like.
And step 3: and establishing a wear degree judgment decision model.
And 4, step 4: and inputting the obtained data into a wear degree judgment decision model for judgment decision.
If the abrasion is uniform abrasion and the abrasion is the roller diameter size.
And 5: the computer control center directly sends the control command to the servo module, and the servo module automatically adjusts the insertion amount H.
If the abrasion is non-uniform abrasion and cylindricity abrasion.
Step 6: when the abrasion degree is in a certain range, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the deflection P of the abrasion roller. When the degree of wear is in the excess range, the computer control center transmits the early warning command to the early warning module, and the early warning bell of the early warning module sends out the sound and shows that the interface early warning lamp flashes red, reminds the staff to change the roll, and the staff stops the operation of the straightener to change the roll.
If the abrasion is non-uniform abrasion and roundness abrasion.
And 7: when the degree of wear exceeds GsAnd when the roll changing machine is used, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sends out a ring and displays that an interface early warning lamp flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll.
Example 2
FIG. 3 is a schematic diagram of the key structure of the straightening machine, showing the positions of the vision monitoring module, the servo module and the early warning module on the straightening machine. Wherein, including straightening gear motor: r series turbine gear motor (1), early warning bell (2), last roller box hold down board (3), go up roller box strong point location head (4), go up roller box strong point (5), roller box locking mechanism (6), gear motor down: r series turbine gear motor (7), push down the hydro-cylinder: SHHAUTO/HOB (8), hydraulic pipeline (9), industrial camera fixing rod (10), industrial camera: the roller comprises a Keynes CA-H2100C (11), a roller surface (12) and a worm gear (13).
The roller abrasion loss monitoring and self-adaptive feedback adjusting method of the straightening machine provided by the embodiment of the invention comprises the following steps:
step 1: six industrial cameras (keyence CA-H2100C) (11) of a bending working section (the upper bending roll and the lower bending roll are respectively provided with one monitoring camera and are four in total) and a straightening working section (the upper straightening roll and the lower straightening roll are respectively provided with one monitoring camera and are two in total) of the straightening machine collect the condition information of the roll surface (12) of each working roll from the straightening machine and transmit the condition information to a computer control center of a decision control module, and the computer control center is shown in figures 4 and 5.
Step 2: and the computer control center of the decision control module processes and classifies the roller surface information through the processing submodule to obtain data such as roller diameter size change, roller cylindricity abrasion change, roller surface roundness abrasion change and the like.
And step 3: the processing submodule transmits related data to the judging submodule, the judging submodule analyzes and judges data of the change of the diameter size of the roller, the change of the cylindricity abrasion of the roller and the change of the roundness abrasion of the surface of the roller, and if only the change of the diameter size of the roller is abraded, the uniform abrasion condition is judged; if the cylindricity of the roller surface is worn out in a changing way, the roller surface is judged to be in uneven wear condition; and if the roundness of the roller surface is worn out in a changing way, judging that the roller surface is unevenly worn. An example of such wear is shown in figure 6.
And 4, step 4: the judgment submodule transmits the result to the decision submodule, and the decision submodule makes a decision according to the wear degree.
Step 4.1: when the wear is a change in the roll diameter dimension, the insertion amount adjustment is determined when the wear amount is Δ R.
Step 4.1.1: calculating the insertion amount required to be adjusted, wherein the calculation model is as follows:
H＝ΔR
and calculating to obtain the insertion quantity H, and then generating an adjusting command.
Step 4.1.2: the control submodule directly sends the adjustment command to a speed reduction motor (R series turbine speed reduction motor).
Step 4.2: when the abrasion is cylindricity abrasion change and the abrasion amount is F, the adjustment of deflection amount or the shutdown roll replacement is determined.
Step 4.2.1: according to different abrasion degrees of cylindricity abrasion, calculating a scheme to be adopted, wherein a calculation model is as follows:
FMID＝(FMAX-FMIN)/2
FMID-ΔF<F<FMID+ΔF
in the above formula FMAXThe maximum abrasion loss of the whole roll surface is obtained; fMINThe maximum abrasion loss of the whole roll surface is obtained; Δ F is the desired amount of change.
If the roll surface wear amount F is within the prescribed range, the adjusted runout amount P is calculated and an adjustment command is generated.
If the roller surface abrasion quantity F is beyond the specified range, the roller needs to be stopped and replaced, and then a roller-replacing stopping command is generated.
Step 4.2.2: the control submodule directly sends the adjusting command to a speed reducing motor (R series turbine speed reducing motor); the control submodule sends a roll-changing stopping command to an early warning bell (2) and an early warning interface lamp.
Step 4.3: when the abrasion is roundness abrasion change, and the abrasion amount is G, the machine is stopped for roll replacement.
Step 4.3.1: according to the roundness wear degree, calculating a scheme to be adopted, wherein a calculation model is as follows:
G>Gs
if the roundness abrasion quantity exceeds the established standard, the roller needs to be stopped and replaced, and then a command for stopping the roller replacement is generated.
Step 4.3.2: the control submodule sends a roll-changing stopping command to an early warning bell (2) and an early warning interface lamp.
And 5: this step is divided into 3 cases to operate:
the first condition is as follows: the PLC (SINAMICS S7-1200 series) of the servo module obtains an adjusting command by adjusting the insertion amount, and adjusts a speed reducing motor (R series turbine speed reducing motor) through a driver (SINAMICS V90 series). In the bending working section, the speed reducing motors on two sides of the straightening machine adjust the upper position and the lower position of the lower roller box through the worm gear and worm, in the straightening working section, the speed reducing motors on two sides adjust the gap between the upper roller box and the lower roller box through the worm gear and worm, and finally the adjustment amount of the gap insertion amount of the upper roller surface and the lower roller surface reaches H.
Case two: when the deflection is adjusted, the PLC (SINAMICS S7-1200 series) of the servo module obtains an adjustment command, and the speed reduction motor (R series turbine speed reduction motor) is adjusted through the driver (SINAMICS V90 series). In the bending working section, the speed reducing motors on the two sides of the straightening machine adjust the left and right deflection of the lower roller box through the worm gears and the worms, in the straightening working section, the speed reducing motors adjust the left and right deflection of the upper roller box and the lower roller box through the worm gears and the worms, and the upper roller box and the lower roller box act together to finally enable the adjustment amount of the upper roller surface gap deflection amount and the lower roller surface gap deflection amount to reach P.
Case three: shutdown roll changing, the early warning bell (2) and the early warning interface lamp of the early warning module obtain the command of stopping roll changing, the early warning bell (2) sends out the sound and shows that the interface early warning lamp dodges red, and the staff obtains roll changing information, stops straightening machine work, carries out artifical roll changing.
In the description of the present invention, "a plurality" means two or more unless otherwise specified; the terms "upper", "lower", "left", "right", "inner", "outer", "front", "rear", "head", "tail", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are only for convenience in describing and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and thus, should not be construed as limiting the invention. Furthermore, the terms "first," "second," "third," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the above embodiments, the implementation may be wholly or partially realized by software, hardware, firmware, or any combination thereof. When used in whole or in part, can be implemented in a computer program product that includes one or more computer instructions. When loaded or executed on a computer, cause the flow or functions according to embodiments of the invention to occur, in whole or in part. The computer may be a general purpose computer, a special purpose computer, a network of computers, or other programmable device. The computer instructions may be stored in a computer readable storage medium or transmitted from one computer readable storage medium to another, for example, the computer instructions may be transmitted from one website site, computer, server, or data center to another website site, computer, server, or data center via wire (e.g., coaxial cable, fiber optic, Digital Subscriber Line (DSL), or wireless (e.g., infrared, wireless, microwave, etc.)). The computer-readable storage medium can be any available medium that can be accessed by a computer or a data storage device, such as a server, a data center, etc., that includes one or more of the available media. The usable medium may be a magnetic medium (e.g., floppy Disk, hard Disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium (e.g., Solid State Disk (SSD)), among others.
The above description is only for the purpose of illustrating the present invention and the appended claims are not to be construed as limiting the scope of the invention, which is intended to cover all modifications, equivalents and improvements that are within the spirit and scope of the invention as defined by the appended claims.

Claims (10)

1. The utility model provides a straightener roller wearing and tearing volume monitoring and self-adaptation feedback governing system which characterized in that, straightener roller wearing and tearing volume monitoring and self-adaptation feedback governing system includes:
the visual monitoring module comprises an industrial camera, is positioned on the frame of the straightening machine and is used for comprehensively monitoring the roll surface condition of the working roll, collecting information of the roll surface abrasion condition of the working roll and transmitting the collected information to the decision control module;
the decision control module comprises a computer data processing and control center, is positioned beside the straightening machine, is communicated with each module through a circuit and a line, is used for processing, analyzing and deciding the information obtained by the visual monitoring module, and transmits a control signal to the early warning and man-machine interaction module and the servo module;
the early warning and man-machine interaction module comprises an early warning bell and a computer display center, wherein the early warning bell is positioned on a frame of the straightening machine, the computer display center is connected with the decision control center and is used for converting and displaying a control command generated by controlling the decision module in a character string or hexadecimal mode through programming selection, the early warning bell rings, an interface early warning lamp turns red to remind a worker to change rolls;
the servo module comprises a speed reducing motor, and the speed reducing motor is positioned on two sides of the straightening machine frame; different parts operate according to the command of the decision control module to adjust the straightening machine.
2. The system for monitoring and adaptively feedback-adjusting the wear of rolls of a leveler as set forth in claim 1, wherein the information on the wear of the roll surfaces of the work rolls includes the change in the size of the roll diameter, the cylindricity of the rolls, and the roundness of the rolls.
3. The straightener roll wear monitoring and adaptive feedback control system of claim 1 wherein said acting on command of the decision control module to adjust the straightener comprises:
adjusting the insertion amount: controlling a speed reducing motor through a control command to adjust the upper roller and the lower roller, wherein the adjusted insertion amount is H, and the diameter size abrasion of the rollers is compensated;
adjusting the deflection: controlling a speed reducing motor through a control command to adjust the upper roller and the lower roller, wherein the adjusted deflection is G, and the cylindricity abrasion of the rollers is compensated;
roll changing operation: and after the staff is reminded from the early warning module, stopping the operation of the straightener, manually disassembling the roller box and replacing the rollers.
4. The straightener roller wear amount monitoring and adaptive feedback adjusting system as claimed in claim 1, wherein the straightener roller wear amount monitoring and adaptive feedback adjusting system further comprises an upper straightener speed reducing motor (R series turbine speed reducing motor), an early warning bell, an upper roller box hold down plate, an upper roller box holding point positioning head, an upper roller box holding point, a roller box locking mechanism, a lower straightener speed reducing motor (R series turbine speed reducing motor), a hold down cylinder (SHHAUTO/HOB), a hydraulic pipeline, an industrial camera fixing rod, an industrial camera (Kingshi CA-H2100C, a roller surface and a worm gear.
5. A method for monitoring and adaptively feeding back and adjusting the abrasion loss of the roller of the straightener by applying the system for monitoring and adaptively feeding back and adjusting the abrasion loss of the roller of the straightener as claimed in any one of claims 1 to 4, wherein the method for monitoring and adaptively feeding back and adjusting the abrasion loss of the roller of the straightener comprises the following steps:
step one, a visual monitoring module collects roll surface information of each working roll from a production line of a straightening machine and transmits the roll surface information to a decision control module;
step two, the decision control module processes the roll surface information to obtain roll diameter size change, cylindricity change, roundness change and roll surface damage condition data;
step three, establishing a wear degree judgment decision model;
inputting the obtained data into a wear degree judgment decision model to perform judgment decision;
step five, if the abrasion is uniform abrasion and is the abrasion of the roller diameter size, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
step six, if the abrasion is non-uniform abrasion and cylindricity abrasion, when the abrasion degree is in a certain range, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the deflection P of the abrasion roller; when the wear degree is in an exceeding range, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sounds and an early warning lamp of a display interface flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll;
step seven, if the abrasion is non-uniform abrasion and roundness abrasion, when the abrasion degree exceeds GsAnd when the roll changing machine is used, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sends out a ring and displays that an interface early warning lamp flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll.
6. The method for monitoring and adaptively feeding back the abrasion loss of the rolls of the leveler as set forth in claim 5, wherein the method for monitoring and adaptively feeding back the abrasion loss of the rolls of the leveler further comprises:
(1) six industrial cameras of the bending working section and the straightening working section of the straightening machine collect the condition information of the roll surface of each working roll from the straightening machine and transmit the information to a computer control center of a decision control module; the upper bending roll and the lower bending roll of the bending working section of the straightening machine are respectively provided with a monitoring camera; the upper straightening roll and the lower straightening roll of the straightening working section are respectively provided with a monitoring camera;
(2) the computer control center of the decision control module processes and classifies the roller surface information through the processing submodule to obtain roller diameter size change, roller cylindricity abrasion change and roller surface roundness abrasion change data;
(3) the processing submodule transmits related data to the judging submodule, the judging submodule analyzes and judges data of the change of the diameter size of the roller, the change of the cylindricity abrasion of the roller and the change of the roundness abrasion of the surface of the roller, and if only the change of the diameter size of the roller is abraded, the uniform abrasion condition is judged; if the cylindricity of the roller surface is worn out in a changing way, the roller surface is judged to be in uneven wear condition; if the roundness of the roller surface is worn variably, judging the roller surface to be uneven wear;
(4) the judgment submodule transmits the result to the decision submodule, and the decision submodule makes a decision according to the wear degree;
(5) different parts of the servo module operate according to the command of the decision control module to adjust the straightening machine.
7. The method for monitoring the abrasion loss of the roller of the straightening machine and adaptively feeding back and adjusting the abrasion loss of the roller as claimed in claim 6, wherein in the step (4), the judgment submodule transmits the result to the decision submodule, and the decision of the decision submodule is carried out according to the abrasion loss degree, and the method comprises the following steps:
1) when the wear is a change in the roll diameter dimension, and the wear amount is Δ R, the insertion amount adjustment is determined:
calculating the insertion quantity required to be adjusted, wherein a calculation model is as follows:
H＝ΔR；
calculating to obtain an insertion quantity H, and then generating an adjusting command;
the control sub-module directly sends the adjusting command to a speed reducing motor, namely an R series turbine speed reducing motor;
2) when the abrasion is changed by cylindricity abrasion, the abrasion amount is F, then the deflection adjustment or the shutdown roll replacement is determined:
calculating a scheme to be adopted according to different abrasion degrees of cylindricity abrasion, wherein a calculation model is as follows:
FMID＝(FMAX-FMIN)/2；
FMID-ΔF<F<FMID+ΔF；
in the formula, FMAXThe maximum abrasion loss of the whole roll surface is obtained; fMINThe maximum abrasion loss of the whole roll surface is obtained; Δ F is the desired amount of change;
if the roll surface abrasion quantity F is in a specified range, obtaining an adjusted deflection quantity P through calculation, and generating an adjusting command; if the roll surface abrasion quantity F exceeds the specified range, stopping the roll changing and generating a command of stopping the roll changing;
the control sub-module directly sends the adjusting command to a speed reducing motor, namely an R series turbine speed reducing motor; the control submodule sends a roll-changing stopping command to an early warning bell and an early warning interface lamp;
3) when the abrasion is roundness abrasion change, the abrasion amount is G, and then the roller is stopped and replaced:
calculating a scheme to be adopted according to the roundness abrasion degree, wherein a calculation model is as follows:
G>Gs；
if the roundness abrasion amount exceeds the set standard, stopping the roll changing and generating a command for stopping the roll changing;
and the control submodule sends a roll-changing stopping command to an early warning bell and an early warning interface lamp.
8. The method for monitoring the abrasion loss of the roller and adaptively feeding back and adjusting the abrasion loss of the roller of the straightening machine as claimed in claim 6, wherein in the step (5), different parts of the servo module operate according to the command of the decision control module to adjust the straightening machine, and the method comprises the following steps:
1) adjusting the insertion amount, and the PLC of the servo module obtains an adjustment command and adjusts the speed reducing motor through a driver; in the bending working section, the speed reducing motors on two sides of the straightening machine adjust the upper position and the lower position of the lower roller box through the worm gear and worm, in the straightening working section, the speed reducing motors on two sides adjust the gap between the upper roller box and the lower roller box through the worm gear and worm, and finally the adjustment amount of the gap insertion amount of the upper roller surface and the lower roller surface reaches H;
2) adjusting the deflection amount, obtaining an adjusting command by a PLC (programmable logic controller) of the servo module, and adjusting the speed reducing motor through a driver; in the bending working section, the speed reducing motors on the two sides of the straightening machine adjust the left and right deflection of the lower roller box through worm gears and worms, in the straightening working section, the speed reducing motors adjust the left and right deflection of the upper roller box and the lower roller box through worm gears and worms, and the upper roller box and the lower roller box act together to finally enable the adjustment amount of the upper roller surface gap deflection amount and the lower roller surface gap deflection amount to reach P;
3) and stopping the roll changing, wherein an early warning bell and an early warning interface lamp of the early warning module obtain a command of stopping the roll changing, the early warning bell sounds and the early warning interface lamp flashes red to obtain roll changing information, the straightening machine stops working, and manual roll changing is carried out.
9. A computer device, characterized in that the computer device comprises a memory and a processor, the memory storing a computer program which, when executed by the processor, causes the processor to carry out the steps of:
the visual monitoring module collects the roll surface information of each working roll from the production line of the straightener and transmits the roll surface information to the decision control module; the decision control module processes the roller surface information to obtain roller diameter size change, cylindricity change, roundness change and roller surface damage condition data; establishing a wear degree judgment decision model; inputting the obtained data into a wear degree judgment decision model for judgment decision;
if the abrasion is uniform abrasion and is the abrasion of the roller diameter size, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
if the abrasion is non-uniform abrasion and cylindricity abrasion, when the abrasion degree is in a certain range, the computer control center directly sends a control command to the servo module, and the servo module automatically adjusts the deflection P of the abrasion roller; when the wear degree is in an exceeding range, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sounds and an early warning lamp of a display interface flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll;
if the abrasion is non-uniform abrasion and roundness abrasion, when the abrasion degree exceeds GsAnd when the roll changing machine is used, the computer control center transmits an early warning command to the early warning module, an early warning bell of the early warning module sends out a ring and displays that an interface early warning lamp flashes red to remind a worker to change the roll, and the worker stops the operation of the straightening machine to change the roll.
10. An information data processing terminal, characterized in that the information data processing terminal is used for realizing the roller abrasion loss monitoring and adaptive feedback adjusting system of the straightening machine according to any one of claims 1-4.
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