CN113634620B - Roller wear monitoring and self-adaptive feedback adjusting system and method for straightener - Google Patents
Roller wear monitoring and self-adaptive feedback adjusting system and method for straightener Download PDFInfo
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- CN113634620B CN113634620B CN202110920548.8A CN202110920548A CN113634620B CN 113634620 B CN113634620 B CN 113634620B CN 202110920548 A CN202110920548 A CN 202110920548A CN 113634620 B CN113634620 B CN 113634620B
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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
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- 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 system and a method for monitoring and self-adapting feedback adjustment of roller wear of a straightener. According to the roller wear monitoring and self-adaptive feedback regulating system of the straightener, a comprehensive real-time monitoring system and a decision control system are established to realize instant regulation, so that the problems of unstable contact and stress of a working roller and strip steel under the conditions of uniform roller surface wear and uneven roller surface wear are solved. The invention monitors the surface of the working roll in real time, gathers the information of the abrasion condition of the surface of the working roll, and classifies the information according to the abrasion condition, including the abrasion of the diameter and the size change 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
Technical Field
The invention belongs to the technical field of straightener, and particularly relates to a roller wear monitoring and self-adaptive feedback adjusting system and method of a straightener.
Background
At present, the straightener 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 repeated stretch bending and elastic recovery in the straightener, so that the flatness of the strip steel meets the requirements of national standards and clients. In the strip steel straightening process, after a working roll of the straightening roll and a working roll of the bending roll work for a period of time, the roll body is worn relatively greatly, the wearing conditions are complex and various, and the quality of the strip steel can be influenced if the strip steel is not treated in time. The processing modes of worn straightening rollers and bending rollers in the straightening machine at present are as follows: the roller wear is checked periodically and the rollers are replaced periodically. Therefore, although the problem of strip steel quality reduction caused by unstable contact and stress of the roller and the strip steel can be solved, the instant adjustment cannot be realized, and the unstable contact and stress condition of the roller and the strip steel cannot be effectively eliminated. Therefore, a new system and method for monitoring and adaptively adjusting the wear of the roller of a straightener is needed.
Through the above analysis, the problems and defects existing in the prior art are as follows: first, the current worn straightening and bending rolls are treated by periodic roll replacement, which increases the cost of roll replacement. And secondly, the worn straightening roller and bending roller in the straightener cannot be adjusted in real time, and the unstable contact and stress condition of the roller and the strip steel cannot be effectively eliminated.
The difficulty of solving the problems and the defects is as follows: in the straightening process, the rotating speed of the roller is particularly high, and the adjustment is difficult to apply in a 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 meaning of solving the problems and the defects is as follows: firstly, after the mode of periodic roll replacement is changed, the roll utilization rate is improved, and the roll replacement cost is reduced. And secondly, the roller is adjusted immediately, the unstable contact and stress condition 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 existing in the prior art, the invention provides a system and a method for monitoring and self-adaptive feedback adjustment of roller wear of a straightener, in particular to a system and a method for early warning of roller changing and instant adjustment of roller insertion and deflection of a stretch bending straightener based on a decision system.
The invention discloses a straightening machine roller wear amount monitoring and self-adaptive feedback regulating system, which comprises a visual monitoring module, a decision control module, an early warning and man-machine interaction module and a servo module.
The visual monitoring module comprises an industrial camera, is positioned on the straightening machine frame, and is used for comprehensively monitoring the roller surface condition of the working roller, collecting information on the roller surface abrasion condition of the working roller 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 and is communicated with each module through a circuit and a circuit, 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 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 the control decision module in a character string or hexadecimal form through programming selection, the early warning bell sounds, an interface early warning lamp starts to turn red, and a worker is reminded of roll changing;
the servo module comprises a speed reducing motor, and the speed reducing motor is positioned at two sides of the straightening machine frame; and the different parts of the servo module operate according to the command of the decision control module to adjust the straightener.
Further, in the visual monitoring module, the roll surface abrasion condition information of the working roll comprises roll diameter size change, roll cylindricity and roll roundness.
Further, in the servo module, the adjustment of the straightener according to the command operation of the decision control module includes three cases:
(1) and (3) adjusting the insertion amount: the gear motor is controlled by a control command to adjust the upper roller and the lower roller, the adjusted insertion amount is H, and the diameter size abrasion of the rollers is compensated;
(2) and (3) deflection amount adjustment: the gear motor is controlled by a control command to adjust the upper roller and the lower roller, the adjusted deflection is G, and cylindricity abrasion of the rollers is compensated;
(3) roll changing operation: after the worker is reminded from the early warning module, stopping the operation of the straightener, manually disassembling the roller box, and replacing the roller.
Further, the roller wear 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, a pre-alarm 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 Kidney CA-H2100C, a roller surface and a worm gear.
Another object of the present invention is to provide a method for monitoring and adaptively adjusting the wear amount of a straightener roller using the system for monitoring and adaptively adjusting the wear amount of a straightener roller, which comprises the steps of:
step one, a visual monitoring module collects roll surface information of each working roll from a straightener production line 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 carry out judgment decision;
fifthly, if the abrasion is uniform abrasion and the abrasion is the abrasion of the roller diameter size, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
step six, if the abrasion is uneven abrasion and cylindricity abrasion, when the abrasion degree is within a certain range, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the deflection quantity P of the abrasion roller; when the abrasion degree is in an out-of-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 a display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops running of the straightener to change rolls;
step seven, if the abrasion is non-uniform abrasion and circular abrasion, when the abrasion degree exceeds G s And when the computer control center transmits an early warning command to the early warning module, the early warning bell of the early warning module sounds and the display interface early warning lamp flashes red, so that a worker is reminded to change the roll, and the worker stops the operation of the straightener to change the roll.
Further, the method for monitoring and adaptively feeding back the wear amount of the roller of the straightener further comprises the following steps:
(1) Six industrial cameras of the bending working section and the straightening working section of the straightener collect the condition information of the roller surfaces of all working rollers from the straightener and transmit the condition information to a computer control center of a decision control module; wherein, the upper and lower bending rollers of the bending working section of the straightener are respectively provided with a monitoring camera, and the number of the monitoring cameras is four; the upper straightening roller and the lower straightening roller of the straightening working section are respectively provided with a monitoring camera, and the number of the two monitoring cameras is two;
(2) The computer control center of the decision control module processes and classifies the roll surface information through the processing submodule to obtain roll diameter size change, roll cylindricity wear change and roll surface roundness wear change data;
(3) The processing submodule transmits the related data to the judging submodule, the judging submodule analyzes and judges the data of the roller diameter size change, the roller cylindricity abrasion change and the roller surface roundness abrasion change, and if only the roller diameter size change abrasion exists, the uniform abrasion condition is judged; if the cylindricity of the roller surface is changed and worn, judging that the roller surface is unevenly worn; if the roundness of the roller surface is subjected to variable abrasion, judging that the roller surface is subjected to uneven abrasion;
(4) The judging sub-module transmits the result to the decision sub-module, and the decision sub-module decides according to the abrasion degree;
(5) And the different parts of the servo module operate according to the command of the decision control module to adjust the straightener.
Further, in step (4), the judging sub-module transmits the result to a decision sub-module, and the decision sub-module decides according to the wear degree, including:
1) When the wear is a change in the wear of the roll diameter, and the wear amount is Δr, it is determined to adjust the insertion amount:
(1) calculating the insertion amount required to be adjusted, wherein a calculation model is as follows:
H＝ΔR；
calculating to obtain the insertion quantity H, and then generating an adjustment command;
(2) the control submodule directly reduces the adjustment command to the gear motor, namely the R series turbine gear motor.
2) When the abrasion is cylindricity abrasion change, the abrasion loss is F, and then deflection quantity adjustment or shutdown roll replacement is determined:
(1) according to different wear degrees of cylindricity wear, calculating a scheme to be adopted, wherein a calculation model is as follows:
F MID ＝(F MAX -F MIN )/2；
F MID -ΔF<F<F MID +ΔF；
wherein F is MAX The maximum abrasion loss of the whole roller surface is achieved; f (F) MIN The maximum abrasion loss of the whole roller surface is achieved; Δf is the desired amount of change;
if the roll surface abrasion loss F is in a specified range, an adjustment command is generated by calculating an adjusted deflection quantity P; if the roll surface abrasion loss F exceeds the specified range, stopping roll changing and generating a command for stopping roll changing;
(2) the control submodule directly transmits the adjustment command to a gear motor, namely an R-series turbine gear motor; the control sub-module will stop the roll change command to reach the alarm bell and the alarm interface lamp.
3) When the abrasion is roundness abrasion change and the abrasion loss is G, the shutdown roller replacement is determined:
(1) according to the roundness abrasion degree, calculating a scheme to be adopted, wherein a calculation model is as follows:
G>G s ；
if the roundness abrasion loss exceeds the formulated standard, stopping roll replacement and generating a command for stopping roll replacement;
(2) the control sub-module will stop the roll change command to reach the alarm bell and the alarm interface lamp.
In step (5), the different parts of the servo module operate according to the command of the decision control module to adjust the straightener, and the operation is performed under the following 3 conditions:
case one: adjusting the insertion amount, obtaining an adjustment command by a PLC of the servo module, and adjusting the speed reducing motor through a driver; in the bending working section, the gear motors at two sides of the straightener adjust the upper and lower positions of the lower roller box through the worm gear, in the straightening working section, the gear motors at two sides adjust the gap between the upper and lower roller boxes through the worm gear, and finally the adjustment amount of the gap insertion amount of the upper and lower roller surfaces reaches H.
And a second case: adjusting the deflection amount, obtaining an adjustment command by a PLC of the servo module, and adjusting a speed reducing motor through a driver; in the bending working section, gear motors on two sides of the straightener adjust the left and right deflection of the lower roller box through worm gears, in the straightening working section, the gear motors adjust the left and right deflection of the upper roller box and the lower roller box through worm gears, the upper roller box and the lower roller box act together, and finally the adjustment quantity of the gap deflection quantity of the upper roller surface and the lower roller surface reaches P.
And a third case: the machine is stopped for roll replacement, a warning bell and a warning interface lamp of the warning module obtain a command for stopping roll replacement, the warning bell sounds and a display interface warning lamp flashes red, a worker obtains roll replacement information, the work of the straightener is stopped, and manual roll replacement is performed.
It is a further object of the present 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 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 roll surface information to obtain roll diameter size change, cylindricity change, roundness change and roll surface damage condition data; establishing a wear degree judging decision model; inputting the obtained data into a wear degree judgment decision model to carry out judgment decision;
if the abrasion is uniform abrasion and the abrasion is the abrasion of the roller diameter size, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
if the abrasion is uneven abrasion and cylindricity abrasion, when the abrasion degree is within a certain range, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the deflection quantity P of the abrasion roller; when the abrasion degree is in an out-of-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 a display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops running of the straightener to change rolls;
if the wear is uneven and circular, the degree of wear exceeds G s And when the computer control center transmits an early warning command to the early warning module, the early warning bell of the early warning module sounds and the display interface early warning lamp flashes red, so that a worker is reminded to change the roll, and the worker stops the operation of the straightener to change the roll.
Another object of the present invention is to provide an information data processing terminal for implementing the leveler roller wear monitoring and adaptive feedback adjustment system.
By combining all the technical schemes, the invention has the advantages and positive effects that: according to the roller wear monitoring and self-adaptive feedback regulating system of the straightener, a comprehensive real-time monitoring system and a decision control system are established to realize instant regulation, so that the problems of unstable contact and stress of a working roller and strip steel under the conditions of uniform roller surface wear and uneven roller surface wear are solved.
The abrasion condition of the working roller is complex and various, and the straightening quality of the strip steel can be affected if the working roller is not processed in time. The technology of the invention monitors the roller surface of the working roller in real time, gathers the abrasion condition information of the roller surface, classifies the abrasion condition information, and comprises the following steps: roller diameter dimension change wear, cylindricity wear, and roundness wear. Wherein, roller diameter size change wearing and certain range cylindricity wearing and tearing belong to even wearing and tearing, roundness wearing and the cylindricity wearing and tearing of out of range belong to inhomogeneous wearing and tearing. Under the condition of uniform wear, the system can adaptively adjust the roller to adjust the insertion amount and the deflection amount; under the condition of uneven wear, the system can send out an early warning signal to remind the staff to replace the worn 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 that are needed 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 other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flowchart of a method for monitoring and adaptively adjusting the wear amount of a roller of a straightener, which is provided by the embodiment of the invention.
FIG. 2 is a schematic diagram of a method for monitoring and adaptively adjusting the wear amount of a roller of a straightener according to an embodiment of the invention.
FIG. 3 is a block diagram of a system for monitoring and adaptively adjusting the wear amount of a roller of a straightener according to an embodiment of the present invention;
in the figure: 1. a visual monitoring module; 2. a decision control module; 3. early warning and man-machine interaction module; 4. and a servo module.
FIG. 4 is a flow chart showing the information of the system for monitoring the wear amount of the roller and adjusting the self-adaptive feedback according to the embodiment of the invention.
FIG. 5 is a schematic diagram of a key structure of a leveler according to an embodiment of the present invention.
Fig. 6 is an exemplary view 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
The present invention will be described in further detail with reference to the following examples in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Aiming at the problems existing in the prior art, the invention provides a system and a method for monitoring and self-adapting feedback adjustment of roller wear of a straightener, and the invention is described in detail below with reference to the accompanying drawings.
As shown in FIG. 1, the method for monitoring and adaptively adjusting the wear amount of the roller of the straightener provided by the embodiment of the invention comprises the following steps:
s101, a visual monitoring module collects roll surface information of each working roll from a straightener production line and transmits the roll surface information to a decision control module;
s102, processing 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 to carry out judgment decision;
s105, if the abrasion is uniform abrasion and the abrasion is the abrasion of the roller diameter size, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
s106, if the abrasion is uneven abrasion and cylindrical abrasion, when the abrasion degree is within a certain range, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the deflection quantity P of the abrasion roller; when the abrasion degree is in an out-of-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 a display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops running of the straightener to change rolls;
s107, if the wear is uneven and circular, the degree of wear exceeds G s And when the computer control center transmits an early warning command to the early warning module, the early warning bell of the early warning module sounds and the display interface early warning lamp flashes red, so that a worker is reminded to change the roll, and the worker stops the operation of the straightener to change the roll.
The schematic diagram of the method for monitoring and self-adaptive feedback regulating the roller wear amount of the straightener provided by the embodiment of the invention is shown in fig. 2.
As shown in FIG. 3, the system for monitoring and adaptively feeding back the wear amount of the roller of the straightener provided by the embodiment of the invention comprises a visual monitoring module 1, a decision control module 2, an early warning and man-machine interaction module 3 and a servo module 4.
The visual monitoring module 1 comprises an industrial camera, is positioned on a rack of the straightener, and is used for comprehensively monitoring the roller surface condition of the working roller, collecting information on the roller surface abrasion condition of the working roller 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 and is communicated with each module through a circuit and a circuit, and is used for processing, analyzing and deciding the information obtained by the vision 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 the control decision module in a character string or hexadecimal form through programming selection, the early warning bell sounds, an interface early warning lamp starts to turn red, and a worker is reminded of roll changing;
the servo module 4 comprises a gear motor which is positioned at two sides of the straightening machine frame; and the different parts of the servo module operate according to the command of the decision control module to adjust the straightener.
The technical scheme of the invention is further described below by combining the embodiments.
Example 1
The invention provides a roll change early warning and roll insertion quantity and deflection quantity instant adjusting system and method for a stretch bending straightener, 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 uneven wear of the roll surface.
The invention adopts the following scheme for solving the technical problems:
roller wear amount monitoring control system and method based on decision system
(1) Description of the main Module
Visual monitoring module:
the module includes an industrial camera.
The module is positioned on the straightening machine frame, and can comprehensively monitor the roller surface condition of the working roller. The module is mainly used for collecting information (such as roll diameter size change, roll cylindricity, roll roundness and the like) on the roll surface abrasion condition of the working roll and transmitting the collected information to the decision control module.
Decision control module:
the module comprises a computer data processing and control center.
The module is positioned beside the straightener and is communicated with each module through circuits, circuits 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 in detail.
Early warning module and man-machine interaction module:
the module comprises a pre-alarm bell and a computer display center.
The positions of the equipment of the module are as follows: the pre-alarm bell is positioned on the straightening machine frame, and the computer display center and the decision control center are together. The control command generated by the control decision module is converted and displayed in a character string or hexadecimal form through programming, the early warning bell sounds, the interface early warning lamp starts to turn red, and workers are reminded to change rolls.
And a servo module:
the module comprises a gear motor.
The position of each part of the module is as follows: the gear motor is positioned at two sides of the straightening machine frame. The module has the main functions that: the different parts of the servo module operate according to the command of the decision control module, and the adjustment of the straightener comprises three conditions, namely, the adjustment of the insertion amount: the gear motor is controlled by a control command to adjust the upper roller and the lower roller, the adjusted insertion amount is H, and the diameter size abrasion of the rollers is compensated; secondly, regulating the deflection quantity, controlling a gear motor through a control command to regulate the upper roller and the lower roller, wherein the regulated deflection quantity is G, and compensating cylindricity abrasion of the rollers; thirdly, the roll changing operation is carried out, the worker is reminded from the early warning module, then the worker stops the operation of the straightener and manually removes the roll box to change the roll.
(2) Description of basic flow
Step 1: the visual monitoring module collects 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: the decision control module processes the roll surface information to obtain data such as roll diameter size change, cylindricity change, roundness change, roll surface damage condition and the like.
Step 3: and establishing a wear degree judging and deciding model.
Step 4: and inputting the obtained data into a wear degree judgment decision model to carry out judgment decision.
If the wear is uniform and the roll diameter is sized.
Step 5: the computer control center directly transmits the control command to the servo module, and the servo module automatically adjusts the insertion amount H.
If the wear is non-uniform and cylindricity.
Step 6: when the abrasion degree is within a certain range, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the deflection quantity P of the abrasion roller. When the abrasion degree is in an out-of-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 a display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops the operation of the straightener to change rolls.
If the wear is non-uniform and circular.
Step 7: when the abrasion degree exceeds G s And when the computer control center transmits an early warning command to the early warning module, the early warning bell of the early warning module sounds and the display interface early warning lamp flashes red, so that a worker is reminded to change the roll, and the worker stops the operation of the straightener to change the roll.
Example 2
FIG. 3 is a schematic diagram of the key structure of the straightener, showing the positions of the visual monitoring module, the servo module and the early warning module on the straightener. Wherein, include the speed reducing motor of straightening: r series turbine gear motor (1), early warning bell (2), go up roller box hypoplastron (3), go up roller box supporting point locating head (4), go up roller box supporting point (5), roller box locking mechanism (6), gear motor down: r series turbine gear motor (7), depressing cylinder: shauto/HOB (8), hydraulic pipe (9), industrial camera fixing rod (10), industrial camera: the novel roller comprises a Kidney-style CA-H2100C (11), a roller surface (12) and a worm gear (13).
The method for monitoring and self-adapting feedback adjusting the roller wear of the straightener provided by the embodiment of the invention comprises the following steps:
step 1: six industrial cameras (KiEnshi CA-H2100C) (11) of the straightening machine bending working section (four upper and lower bending rollers respectively) and the straightening working section (two upper and lower straightening rollers respectively) collect the condition information of the roller surfaces (12) of the working rollers from the straightening machine and transmit the condition information to a computer control center of a decision control module, see fig. 4 and 5.
Step 2: and the computer control center of the decision control module processes and classifies the roll surface information through the processing submodule to obtain data such as roll diameter size change, roll cylindricity abrasion change, roll surface roundness abrasion change and the like.
Step 3: the processing submodule transmits the related data to the judging submodule, the judging submodule analyzes and judges the data of the roller diameter size change, the roller cylindricity abrasion change and the roller surface roundness abrasion change, and if only the roller diameter size change abrasion exists, the uniform abrasion condition is judged; if the cylindricity of the roller surface is changed and worn, judging that the roller surface is unevenly worn; if the roundness of the roll surface is changed and worn, the uneven wear condition is judged. An example of wear is shown in fig. 6.
Step 4: the judging sub-module transmits the result to the decision sub-module, and the decision sub-module decides according to the abrasion degree.
Step 4.1: when the wear is a change in the wear of the roll diameter, the insertion amount is adjusted if the wear amount is Δr.
Step 4.1.1: calculating the insertion amount required to be adjusted, wherein a calculation model is as follows:
H＝ΔR
the insertion amount H is calculated and then an adjustment command is generated.
Step 4.1.2: the control submodule directly lowers the adjustment command to a gear motor (an R-series turbine gear motor).
Step 4.2: when the abrasion is cylindricity abrasion change, the abrasion loss is F, and then the deflection quantity adjustment or the shutdown roll replacement is determined.
Step 4.2.1: according to different wear degrees of cylindricity wear, calculating a scheme to be adopted, wherein a calculation model is as follows:
F MID ＝(F MAX -F MIN )/2
F MID -ΔF<F<F MID +ΔF
f in the above MAX Is the whole roll surfaceMaximum amount of wear; f (F) MIN The maximum abrasion loss of the whole roller surface is achieved; Δf is the desired amount of change.
If the roll surface abrasion F is within the specified range, an adjusted deflection P is obtained through calculation, and then an adjustment command is generated.
If the roll surface abrasion F exceeds the specified range, stopping roll replacement is needed, and then a command for stopping roll replacement is generated.
Step 4.2.2: the control submodule directly transmits the adjustment command to a gear motor (R series turbine gear motor); the control sub-module reaches the pre-alarm bell (2) and the pre-alarm interface lamp under the command of stopping roll changing.
Step 4.3: when the abrasion is roundness abrasion change, the abrasion amount is G, and the shutdown roll replacement is determined.
Step 4.3.1: according to the roundness abrasion degree, calculating a scheme to be adopted, wherein a calculation model is as follows:
G>G s
if the roundness abrasion loss exceeds the established standard, stopping roll replacement is needed, and then a command for stopping roll replacement is generated.
Step 4.3.2: the control sub-module reaches the pre-alarm bell (2) and the pre-alarm interface lamp under the command of stopping roll changing.
Step 5: the steps are divided into 3 cases:
case one: the PLC (SINAMICS S-1200 series) of the servo module obtains an adjustment command to adjust the insertion amount, and adjusts the gear motor (R series turbine gear motor) by the driver (SINAMICS V series). In the bending working section, the gear motors at two sides of the straightener adjust the upper and lower positions of the lower roller box through the worm gear, in the straightening working section, the gear motors at two sides adjust the gap between the upper and lower roller boxes through the worm gear, and finally the adjustment amount of the gap insertion amount of the upper and lower roller surfaces reaches H.
And a second case: the PLC (SINAMICS S-1200 series) of the servo module obtains an adjustment command to adjust the deflection amount, and adjusts a gear motor (R series turbine gear motor) through a driver (SINAMICS V series). In the bending working section, gear motors on two sides of the straightener adjust the left and right deflection of the lower roller box through worm gears, in the straightening working section, the gear motors adjust the left and right deflection of the upper roller box and the lower roller box through worm gears, the upper roller box and the lower roller box act together, and finally the adjustment quantity of the gap deflection quantity of the upper roller surface and the lower roller surface reaches P.
And a third case: the machine is stopped for roll replacement, an early warning bell (2) and an early warning interface lamp of the early warning module obtain a roll replacement stopping command, the early warning bell (2) sounds and the display interface early warning lamp flashes red, a worker obtains roll replacement information, the work of the straightener is stopped, and manual roll replacement is performed.
In the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front," "rear," "head," "tail," and the like are used as an orientation or positional relationship based on that shown in the drawings, merely to facilitate description of the invention and to simplify the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore 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, it may be implemented in whole or in part by software, hardware, firmware, or any combination thereof. When used in whole or in part, is implemented in the form of a computer program product comprising one or more computer instructions. When loaded or executed on a computer, produces a flow or function in accordance with embodiments of the present invention, in whole or in part. The computer may be a general purpose computer, a special purpose computer, a computer network, or other programmable apparatus. The computer instructions may be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another computer-readable storage medium, for example, the computer instructions may be transmitted from one website, computer, server, or data center to another website, computer, server, or data center by a wired (e.g., coaxial cable, fiber optic, digital Subscriber Line (DSL), or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer readable storage medium may be any available medium that can be accessed by a computer or a data storage device such as a server, data center, etc. that contains an integration of one or more 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)), etc.
The foregoing is merely illustrative of specific embodiments of the present invention, and the scope of the invention is not limited thereto, but any modifications, equivalents, improvements and alternatives falling within the spirit and principles of the present invention will be apparent to those skilled in the art within the scope of the present invention.
Claims (9)
1. The system for monitoring and adaptively feeding back the wear amount of the roller of the straightener is characterized by comprising the following components:
the visual monitoring module comprises an industrial camera, is positioned on the straightening machine frame, and is used for comprehensively monitoring the roller surface condition of the working roller, collecting information on the roller surface abrasion condition of the working roller 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 and is communicated with each module through a circuit and a circuit, and is used for processing, analyzing and deciding the information obtained by the visual monitoring module and transmitting 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 straightening machine frame, the computer display center is connected with a control center of the decision control module and is used for converting and displaying a control command generated by the control decision module in a character string or hexadecimal form through programming selection, the early warning bell sounds, an interface early warning lamp starts to turn red, and a worker is reminded of roll changing;
the servo module comprises a speed reducing motor, and the speed reducing motor is positioned at two sides of the straightening machine frame; different parts operate according to the command of the decision control module to adjust the straightener;
the step of adjusting the straightener according to the command operation of the decision control module comprises the following steps:
(1) and (3) adjusting the insertion amount: the gear motor is controlled by a control command to adjust the upper roller and the lower roller, the adjusted insertion amount is H, and the diameter size abrasion of the rollers is compensated;
(2) and (3) deflection amount adjustment: the gear motor is controlled by a control command to adjust the upper roller and the lower roller, the adjusted deflection is G, and cylindricity abrasion of the rollers is compensated;
(3) roll changing operation: after the staff is reminded from the early warning and man-machine interaction module, the operation of the straightener is stopped, the roller box is manually disassembled, and roller replacement is performed.
2. The leveler roller wear monitoring and adaptive feedback adjustment system according to claim 1, wherein the work roll surface wear information includes roll diameter size change, roll cylindricity, and roll roundness.
3. The system for monitoring and adaptively feeding back the wear amount of the roller of the straightener according to claim 1, further comprising an upper straightening gear motor, namely an R-series turbine gear motor, a pre-alarm 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 gear motor, namely an R-series turbine gear motor, a pressing oil cylinder, namely SHHAUTO/HOB, a hydraulic pipeline, an industrial camera fixing rod, an industrial camera, namely Kirschner CA-H2100C, a roller surface and a worm gear.
4. A method for monitoring and adaptively adjusting the wear amount of a straightener roller by using the system for monitoring and adaptively adjusting the wear amount of a straightener roller according to any one of claims 1 to 3, characterized in that the method for monitoring and adaptively adjusting the wear amount of a straightener roller comprises the following steps:
step one, a visual monitoring module collects roll surface information of each working roll from a straightener production line 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 carry out judgment decision;
fifthly, if the abrasion is uniform abrasion and the abrasion is the abrasion of the roller diameter size, the computer control center directly transmits a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
step six, if the abrasion is uneven abrasion and cylindricity abrasion, when the abrasion degree is within a certain range, a computer control center of the decision control module directly transmits a control command to the servo module, and the servo module automatically adjusts the deflection quantity P of the abrasion roller; when the abrasion degree is in an out-of-range, a computer control center of the decision control module transmits an early warning command to the early warning and man-machine interaction module, an early warning bell of the early warning and man-machine interaction module sounds and a display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops running the straightener to change rolls;
step seven, if the abrasion is non-uniform abrasion and circular abrasion, when the abrasion degree exceeds G s And when the computer control center transmits an early warning command to the early warning and man-machine interaction module, the early warning bell of the early warning and man-machine interaction module sounds and the display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops the operation of the straightener to change rolls.
5. The method for monitoring and adaptively adjusting the wear amount of a roller of a leveler according to claim 4, further comprising:
(1) Six industrial cameras of the bending working section and the straightening working section of the straightener collect the condition information of the roller surfaces of all working rollers from the straightener and transmit the condition information to a computer control center of a decision control module; the upper bending roller and the lower bending roller of the bending working section of the straightener are respectively provided with a monitoring camera; the upper straightening roller and the lower straightening roller 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 roll surface information through the processing submodule to obtain roll diameter size change, roll cylindricity wear change and roll surface roundness wear change data;
(3) The processing submodule transmits the related data to the judging submodule, the judging submodule analyzes and judges the data of the roller diameter size change, the roller cylindricity abrasion change and the roller surface roundness abrasion change, and if only the roller diameter size change abrasion exists, the uniform abrasion condition is judged; if the cylindricity of the roller surface is changed and worn, judging that the roller surface is unevenly worn; if the roundness of the roller surface is subjected to variable abrasion, judging that the roller surface is subjected to uneven abrasion;
(4) The judging sub-module transmits the result to the decision sub-module, and the decision sub-module decides according to the abrasion degree;
(5) And the different parts of the servo module operate according to the command of the decision control module to adjust the straightener.
6. The method for monitoring and adaptively feeding back the wear amount of a roller of a straightener according to claim 5, wherein in the step (4), the judging sub-module transmits the result to the deciding sub-module, and the deciding sub-module decides according to the wear degree, comprising:
1) When the wear is a change in the wear of the roll diameter, and the wear amount is Δr, it is determined to adjust the insertion amount:
(1) calculating the insertion amount required to be adjusted, wherein a calculation model is as follows:
H=ΔR；
calculating to obtain the insertion quantity H, and then generating an adjustment command;
(2) the control submodule directly transmits the adjustment command to a gear motor, namely an R-series turbine gear motor;
2) When the abrasion is cylindricity abrasion change, the abrasion loss is F, and then deflection quantity adjustment or shutdown roll replacement is determined:
(1) according to different wear degrees of cylindricity wear, calculating a scheme to be adopted, wherein a calculation model is as follows:
F MID =(F MAX -F MIN )/2；
F MID -ΔF<F<F MID +ΔF；
wherein F is MAX The maximum abrasion loss of the whole roller surface is achieved; f (F) MIN The minimum abrasion loss of the whole roll surface is achieved; Δf is the desired amount of change;
if the roll surface abrasion loss F is in a specified range, an adjustment command is generated by calculating an adjusted deflection quantity P; if the roll surface abrasion loss F exceeds the specified range, stopping roll changing and generating a command for stopping roll changing;
(2) the control submodule directly transmits the adjustment command to a gear motor, namely an R-series turbine gear motor; the control sub-module reaches an early warning bell and an early warning interface lamp under a roller changing stopping command;
3) When the abrasion is roundness abrasion change and the abrasion loss is G, the shutdown roller replacement is determined:
(1) according to the roundness abrasion degree, calculating a scheme to be adopted, wherein a calculation model is as follows:
G>G s ；
if the roundness abrasion loss exceeds the formulated standard, stopping roll replacement and generating a command for stopping roll replacement;
(2) the control sub-module will stop the roll change command to reach the alarm bell and the alarm interface lamp.
7. The method for monitoring and adaptively adjusting the wear of rollers of a straightener according to claim 5, wherein in the step (5), different parts of the servo module operate according to the command of the decision control module to adjust the straightener, comprising:
1) Adjusting the insertion amount, obtaining an adjustment command by a PLC of the servo module, and adjusting the speed reducing motor through a driver; in the bending working section, the gear motors at two sides of the straightener adjust the upper and lower positions of the lower roller box through the worm gear, in the straightening working section, the gear motors at two sides adjust the gap between the upper and lower roller boxes through the worm gear, and finally the adjustment amount of the gap insertion amount of the upper and lower roller surfaces reaches H;
2) Adjusting the deflection amount, obtaining an adjustment command by a PLC of the servo module, and adjusting a speed reducing motor through a driver; in the bending working section, the gear motors at two sides of the straightener adjust the left and right deflection of the lower roller box through the worm gear, in the straightening working section, the gear motors adjust the left and right deflection of the upper roller box and the lower roller box through the worm gear, the upper roller box and the lower roller box act together, and finally the adjustment quantity of the gap deflection quantity of the upper roller surface and the lower roller surface reaches P;
3) The machine is stopped for roll replacement, a warning bell and a warning interface lamp of the warning and man-machine interaction module obtain a roll replacement stopping command, the warning bell sounds and a display interface warning lamp flashes red to obtain roll replacement information, the straightener is stopped to work, and manual roll replacement is performed.
8. 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 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 roll surface information to obtain roll diameter size change, cylindricity change, roundness change and roll surface damage condition data; establishing a wear degree judging decision model; inputting the obtained data into a wear degree judgment decision model to carry out judgment decision;
if the abrasion is uniform abrasion and the abrasion is the abrasion of the roller diameter size, the computer control center of the decision control module directly transmits a control command to the servo module, and the servo module automatically adjusts the insertion amount H;
if the abrasion is uneven abrasion and cylindricity abrasion, when the abrasion degree is within a certain range, a computer control center of the decision control module directly transmits a control command to the servo module, and the servo module automatically adjusts the deflection quantity P of the abrasion roller; when the abrasion degree is in an out-of-range, a computer control center of the decision control module transmits an early warning command to the early warning and man-machine interaction module, an early warning bell of the early warning and man-machine interaction module sounds and a display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops running the straightener to change rolls;
if the wear is uneven and circular, the degree of wear exceeds G s And when the computer control center transmits an early warning command to the early warning and man-machine interaction module, the early warning bell of the early warning and man-machine interaction module sounds and the display interface early warning lamp flashes red, so that a worker is reminded of roll changing, and the worker stops the operation of the straightener to change rolls.
9. An information data processing terminal, characterized in that the information data processing terminal is used for realizing the straightening machine roller wear monitoring and self-adaptive feedback adjusting system according to any one of claims 1-3.
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