CN113985799A - Process control system based on programmable controller - Google Patents
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- CN113985799A CN113985799A CN202110820266.0A CN202110820266A CN113985799A CN 113985799 A CN113985799 A CN 113985799A CN 202110820266 A CN202110820266 A CN 202110820266A CN 113985799 A CN113985799 A CN 113985799A
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- 238000004886 process control Methods 0.000 title claims abstract description 26
- 238000004364 calculation method Methods 0.000 claims abstract description 51
- 238000007405 data analysis Methods 0.000 claims abstract description 22
- 238000004891 communication Methods 0.000 claims abstract description 15
- 238000007639 printing Methods 0.000 claims abstract description 14
- 238000005096 rolling process Methods 0.000 claims abstract description 14
- 230000008054 signal transmission Effects 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 20
- 238000005259 measurement Methods 0.000 claims description 12
- 230000005540 biological transmission Effects 0.000 claims description 6
- 238000012937 correction Methods 0.000 claims description 6
- 230000002159 abnormal effect Effects 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 abstract description 6
- 239000010959 steel Substances 0.000 abstract description 6
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- 238000005098 hot rolling Methods 0.000 abstract description 4
- 238000010586 diagram Methods 0.000 description 7
- 238000012423 maintenance Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/11—Plc I-O input output
- G05B2219/1135—Profibus
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Abstract
The invention provides a process control system based on a programmable controller, and relates to the technical field of hot rolling of H-shaped steel and rail beam rolling. The process control system based on the programmable controller comprises a remote station terminal, a field bus communication terminal, a controller, a roll gap calculation unit, a data acquisition unit, a data analysis unit, a data output unit and printing equipment, wherein the remote station terminal is connected with the field bus communication terminal through wireless signal transmission, the output end of the field bus communication terminal is electrically connected with the input end of the controller, and the output end of the controller is electrically connected with the input end of the roll gap calculation unit. The invention provides a process control system based on a programmable controller, which is more stable, the condition of host machine halt is not easy to occur, the production efficiency is greatly improved, and the development software adopted by the system is a popular product, so that the system is simpler to maintain and more convenient and reliable to use.
Description
Technical Field
The invention relates to the technical field of hot rolling of H-shaped steel and rail beam rolling, in particular to a process control system based on a programmable controller.
Background
In the hot rolling H shaped steel, rail beam rolling field, process control system is whole control system important component, is responsible for converting the product size (from rolling regulation) into control model, drive servo valve control hydraulic cylinder stroke, finally realizes roll gap control, in the nineties of last century because PLC technique lags behind, this system realizes on the computer following drawback:
1. because the industrial production field environment is severe, the unstable host of the operating system often crashes, which seriously affects the production efficiency;
2. the computer technology is updated quickly, the system in use at present can not purchase spare parts, and the system is not compatible with the current mainstream system;
3. the system hardware adopts non-standard products, spare parts are not easy to purchase and maintain;
4. development software adopted by the system is a small product, and maintenance is difficult.
In order to solve the above problems, it is therefore desirable to provide a process control system based on a programmable controller to improve the production efficiency and reduce the maintenance cost of the equipment.
Disclosure of Invention
Technical problem to be solved
Aiming at the defects of the prior art, the invention provides a process control system based on a programmable controller, which solves the problem that the process control system has many defects in the field of hot rolling of H-shaped steel and rail beam due to the lagging technology.
(II) technical scheme
In order to achieve the purpose, the invention is realized by the following technical scheme: the utility model provides a process control system based on programmable controller, includes remote station terminal, field bus communication terminal, controller, roll gap calculation unit, data acquisition unit, data analysis unit, data output unit and printing apparatus, remote station terminal and field bus communication terminal are connected through wireless signal transmission, field bus communication terminal's output and the input electric connection of controller, the output of controller and the input electric connection of roll gap calculation unit, the output of data acquisition unit and the input electric connection of data analysis unit, the output of data analysis unit and the input electric connection of data output unit.
Preferably, the remote station terminal employs ET200 sp.
Preferably, the field bus communication terminal adopts Profinet.
Preferably, the controller adopts Siemens S7-400 hardware and PCS7 software development platform, the CPU of the Siemens S7-400 hardware adopts SIEMENS S7-410H, and the development software of the PCS7 software development platform adopts PCS 7.
Preferably, the roll gap calculating unit comprises a horizontal roll gap calculating unit, a vertical roll gap calculating unit, a horizontal roll gap compensating unit, a vertical roll gap compensating unit, a horizontal roll hydraulic roll gap control unit, a vertical roll hydraulic roll gap control unit and an automatic roll gap calibration and frame bounce measuring unit.
Preferably, the automatic roll gap calibration and frame bounce measurement unit comprises a horizontal roll gap calibration and vertical roll gap calibration unit and a frame bounce measurement unit.
Preferably, the rear end of the data output unit is electrically connected with a printing device, and the printing device can be controlled by a controller.
Preferably, the process control system based on the programmable controller comprises the following processes:
s1, remotely exchanging signals with a field bus control terminal by a remote station terminal, and controlling a roll gap calculation unit to calculate various roll gaps by a field bus control terminal control controller;
each roll gap calculation includes the following calculations:
1) calculating the roll gap of the horizontal roll: calculating horizontal upper-HtpRefParSrg and lower-HboRefParSrg roll gaps through a roll gap set value-SrgHx, a roll line offset-PasslOff and a roll gap correction value;
2) calculating the roll gap of the vertical roll: calculating roll gaps of an operation side VosRefParSrg and a transmission side VdsRefParSrg of the vertical roller according to a roll gap set value-HSrgHx, a vertical roller taper angle VosAnglelph and a roll gap correction value;
3) roll gap compensation of a horizontal roll: calculating the elastic flattening of the roller according to the roller diameter-WrDiam, the rolling force HDsFr and the contact area CntctLength, and calculating the roller deflection according to the rolling force-FrTot, the hole pattern position-GroovePos, the roller diameter-RollDia, the roller body length-BarrelLgth, the hydraulic cylinder distance-CyDsCyOsDist at two sides and the main shaft diameter-DiaShaft;
4) roll gap compensation of the vertical roll: the calculation mode and the calculation process are the same as the roll gap compensation of the horizontal roll;
5) controlling a horizontal roller hydraulic roller gap: the control is carried out by three control modes of roll gap position closed-loop control, hydraulic cylinder stroke position closed-loop control, rolling force closed-loop control and the like;
6) controlling a vertical roll hydraulic roll gap: the calculation mode and the control process are the same as the horizontal roller hydraulic roll gap control;
7) automatic roll gap calibration (horizontal roll gap and vertical roll gap) and frame bounce measurement: after a calibration command is sent out, a calibration process is started, an upper roller and a lower roller (a transmission side vertical roller and an operation side vertical roller) are attached to reach 250kN, a roller gap of '0' is set, then the pressure is increased to 500kN, 750kN, 1000kN, 1250kN, 1500kN, 1750kN, 2000kN, 2500kN, 5000kN and 10000kN, and the deformation of the rack is measured at each pressure point
S2, the data acquisition unit acquires calculation data in the roll gap calculation unit, acquires related parameter data of horizontal roll gap calculation, horizontal roll gap compensation, vertical roll gap compensation, horizontal roll hydraulic roll gap control, vertical roll hydraulic roll gap control, automatic roll gap calibration (horizontal roll gap and vertical roll gap) and frame bounce measurement, and sends the acquired data to the data analysis unit for data analysis;
s3, judging whether the received parameter data have abnormal conditions or not by the data analysis unit, and comparing and optimizing the obtained multiple groups of data so as to obtain effective calculation results of various roll gaps;
s4, the data analysis unit transmits the effective calculation result to the data output unit, the data output unit stores and backups roll gap calculation data, and the control device converts the product size into a control model and drives a servo valve to control the stroke of a hydraulic cylinder, so that roll gap control is finally realized;
and S5, printing the effective calculation result of the roll gap by using printing equipment.
(III) advantageous effects
The invention provides a process control system based on a programmable controller. The method has the following beneficial effects:
1. the invention provides a process control system based on a programmable controller, which is developed based on Siemens S7-400 hardware and a PCS7 software platform and is applied to a process control system of a hot-rolled H-shaped steel and steel rail rolling mill, wherein a hardware CPU of the system adopts SIEMENS S7-410H, a remote station terminal adopts ET200sp, a field bus communication terminal adopts Profinet, and the PCS7 software development platform adopts PCS7, so that the control system is more stable, the condition of host computer crash is not easy to occur, the production efficiency is greatly improved, and the development software adopted by the system is a popular product, is simpler to maintain and more convenient and reliable to use.
2. The invention provides a process control system based on a programmable controller, which is used for controlling the system through the programmable controller, realizing data calculation such as horizontal roll gap calculation, horizontal roll gap compensation, vertical roll gap compensation, horizontal roll hydraulic roll gap control, vertical roll hydraulic roll gap control, automatic roll gap calibration (horizontal roll gap and vertical roll gap), frame bounce measurement and the like, converting the product size into a control model through a control device, and driving a servo valve to control the stroke of a hydraulic cylinder, and finally realizing accurate control of the roll gap, so that the production efficiency is improved, and the cost and difficulty of equipment maintenance are reduced.
Drawings
FIG. 1 is a schematic diagram of the system of the present invention;
FIG. 2 is a diagram of a horizontal roll gap calculation process of the present invention;
FIG. 3 is a diagram of a vertical roll gap calculation process of the present invention;
FIG. 4 is a diagram of the roll elastic flattening process of horizontal roll gap compensation and vertical roll gap compensation according to the present invention;
FIG. 5 is a roll deflection process diagram for horizontal roll gap compensation and vertical roll gap compensation of the present invention;
FIG. 6 is a process diagram of the horizontal roll hydraulic roll gap control and the vertical roll hydraulic roll gap control of the present invention;
FIG. 7 is a diagram of the automatic roll gap calibration (horizontal roll gap and vertical roll gap) and frame bounce measurement process of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example (b):
as shown in fig. 1 to 7, an embodiment of the present invention provides a process control system based on a programmable controller, including a remote station terminal, a fieldbus communication terminal, a controller, a roll gap calculation unit, a data acquisition unit, a data analysis unit, a data output unit, and a printing device, where the remote station terminal is connected to the fieldbus communication terminal through wireless signal transmission, an output end of the fieldbus communication terminal is electrically connected to an input end of the controller, an output end of the controller is electrically connected to an input end of the roll gap calculation unit, an output end of the data acquisition unit is electrically connected to an input end of the data analysis unit, and an output end of the data analysis unit is electrically connected to an input end of the data output unit.
The roll gap calculating unit comprises a horizontal roll gap calculating unit, a vertical roll gap calculating unit, a horizontal roll gap compensating unit, a vertical roll gap compensating unit, a horizontal roll hydraulic roll gap control unit, a vertical roll hydraulic roll gap control unit and an automatic roll gap calibrating and frame bounce measuring unit.
A programmable controller based process control system comprising the following processes:
s1, remotely exchanging signals with a field bus control terminal by a remote station terminal, and controlling a roll gap calculation unit to calculate various roll gaps by a field bus control terminal control controller;
each roll gap calculation includes the following calculations:
1) calculating the roll gap of the horizontal roll: calculating horizontal upper-HtpRefParSrg and lower-HboRefParSrg roll gaps through a roll gap set value-SrgHx, a roll line offset-PasslOff and a roll gap correction value;
2) calculating the roll gap of the vertical roll: calculating roll gaps of an operation side VosRefParSrg and a transmission side VdsRefParSrg of the vertical roller according to a roll gap set value-HSrgHx, a vertical roller taper angle VosAnglelph and a roll gap correction value;
3) roll gap compensation of a horizontal roll: calculating the elastic flattening of the roller according to the roller diameter-WrDiam, the rolling force HDsFr and the contact area CntctLength, and calculating the roller deflection according to the rolling force-FrTot, the hole pattern position-GroovePos, the roller diameter-RollDia, the roller body length-BarrelLgth, the hydraulic cylinder distance-CyDsCyOsDist at two sides and the main shaft diameter-DiaShaft;
4) roll gap compensation of the vertical roll: the calculation mode and the calculation process are the same as the roll gap compensation of the horizontal roll;
5) controlling a horizontal roller hydraulic roller gap: the control is carried out by three control modes of roll gap position closed-loop control, hydraulic cylinder stroke position closed-loop control, rolling force closed-loop control and the like;
6) controlling a vertical roll hydraulic roll gap: the calculation mode and the control process are the same as the horizontal roller hydraulic roll gap control;
7) automatic roll gap calibration (horizontal roll gap and vertical roll gap) and frame bounce measurement: after a calibration command is sent out, a calibration process is started, an upper roller and a lower roller (a transmission side vertical roller and an operation side vertical roller) are attached to reach 250kN, a roller gap of '0' is set, then the pressure is increased to 500kN, 750kN, 1000kN, 1250kN, 1500kN, 1750kN, 2000kN, 2500kN, 5000kN and 10000kN, and the deformation of the rack is measured at each pressure point
S2, the data acquisition unit acquires calculation data in the roll gap calculation unit, acquires related parameter data of horizontal roll gap calculation, horizontal roll gap compensation, vertical roll gap compensation, horizontal roll hydraulic roll gap control, vertical roll hydraulic roll gap control, automatic roll gap calibration (horizontal roll gap and vertical roll gap) and frame bounce measurement, and sends the acquired data to the data analysis unit for data analysis;
s3, judging whether the received parameter data have abnormal conditions or not by the data analysis unit, and comparing and optimizing the obtained multiple groups of data so as to obtain effective calculation results of various roll gaps;
s4, the data analysis unit transmits the effective calculation result to the data output unit, the data output unit stores and backups roll gap calculation data, and the control device converts the product size into a control model and drives a servo valve to control the stroke of a hydraulic cylinder, so that roll gap control is finally realized;
s5, printing the effective calculation result of the roll gap through printing equipment
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (8)
1. A process control system based on a programmable controller comprises a remote station terminal, a field bus communication terminal, a controller, a roll gap calculation unit, a data acquisition unit, a data analysis unit, a data output unit and printing equipment, and is characterized in that: the remote station terminal is connected with the field bus communication terminal through wireless signal transmission, the output end of the field bus communication terminal is electrically connected with the input end of the controller, the output end of the controller is electrically connected with the input end of the roll gap calculation unit, the output end of the data acquisition unit is electrically connected with the input end of the data analysis unit, and the output end of the data analysis unit is electrically connected with the input end of the data output unit.
2. The programmable controller based process control system of claim 1, wherein: the remote station terminal employs ET200 sp.
3. The programmable controller based process control system of claim 1, wherein: the field bus communication terminal adopts Profinet.
4. The programmable controller based process control system of claim 1, wherein: the controller adopts Siemens S7-400 hardware and PCS7 software development platform, the CPU of the Siemens S7-400 hardware adopts SIEMENS S7-410H, and the development software of the PCS7 software development platform adopts PCS 7.
5. The programmable controller based process control system of claim 1, wherein: the roll gap calculating unit comprises a horizontal roll gap calculating unit, a vertical roll gap calculating unit, a horizontal roll gap compensating unit, a vertical roll gap compensating unit, a horizontal roll hydraulic roll gap control unit, a vertical roll hydraulic roll gap control unit and an automatic roll gap calibrating and frame bounce measuring unit.
6. The programmable controller based process control system of claim 5, wherein: the automatic roll gap calibration and frame bounce measurement unit comprises a horizontal roll gap calibration and vertical roll gap calibration unit and a frame bounce measurement unit.
7. The programmable controller based process control system of claim 1, wherein: the rear end of the data output unit is electrically connected with a printing device, and the printing device can be controlled by a controller.
8. The programmable controller based process control system of claim 1, wherein: the control system includes the following processes:
s1, remotely exchanging signals with a field bus control terminal by a remote station terminal, and controlling a roll gap calculation unit to calculate various roll gaps by a field bus control terminal control controller;
each roll gap calculation includes the following calculations:
1) calculating the roll gap of the horizontal roll: calculating horizontal upper-HtpRefParSrg and lower-HboRefParSrg roll gaps through a roll gap set value-SrgHx, a roll line offset-PasslOff and a roll gap correction value;
2) calculating the roll gap of the vertical roll: calculating roll gaps of an operation side VosRefParSrg and a transmission side VdsRefParSrg of the vertical roller according to a roll gap set value-HSrgHx, a vertical roller taper angle VosAnglelph and a roll gap correction value;
3) roll gap compensation of a horizontal roll: calculating the elastic flattening of the roller according to the roller diameter-WrDiam, the rolling force HDsFr and the contact area CntctLength, and calculating the roller deflection according to the rolling force-FrTot, the hole pattern position-GroovePos, the roller diameter-RollDia, the roller body length-BarrelLgth, the hydraulic cylinder distance-CyDsCyOsDist at two sides and the main shaft diameter-DiaShaft;
4) roll gap compensation of the vertical roll: the calculation mode and the calculation process are the same as the roll gap compensation of the horizontal roll;
5) controlling a horizontal roller hydraulic roller gap: the control is carried out by three control modes of roll gap position closed-loop control, hydraulic cylinder stroke position closed-loop control, rolling force closed-loop control and the like;
6) controlling a vertical roll hydraulic roll gap: the calculation mode and the control process are the same as the horizontal roller hydraulic roll gap control;
7) automatic roll gap calibration (horizontal roll gap and vertical roll gap) and frame bounce measurement: after a calibration command is sent out, a calibration process is started, an upper roller and a lower roller (a transmission side vertical roller and an operation side vertical roller) are attached to reach 250kN, a roller gap of '0' is set, then the pressure is increased to 500kN, 750kN, 1000kN, 1250kN, 1500kN, 1750kN, 2000kN, 2500kN, 5000kN and 10000kN, and the deformation of the rack is measured at each pressure point
S2, the data acquisition unit acquires calculation data in the roll gap calculation unit, acquires related parameter data of horizontal roll gap calculation, horizontal roll gap compensation, vertical roll gap compensation, horizontal roll hydraulic roll gap control, vertical roll hydraulic roll gap control, automatic roll gap calibration (horizontal roll gap and vertical roll gap) and frame bounce measurement, and sends the acquired data to the data analysis unit for data analysis;
s3, judging whether the received parameter data have abnormal conditions or not by the data analysis unit, and comparing and optimizing the obtained multiple groups of data so as to obtain effective calculation results of various roll gaps;
s4, the data analysis unit transmits the effective calculation result to the data output unit, the data output unit stores and backups roll gap calculation data, and the control device converts the product size into a control model and drives a servo valve to control the stroke of a hydraulic cylinder, so that roll gap control is finally realized;
and S5, printing the effective calculation result of the roll gap by using printing equipment.
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3648494A (en) * | 1969-08-06 | 1972-03-14 | Helmut Lautenschlager | System for applying pilot control to the roll gap adjustment of a gauge-controlled cold rolling stand |
| CN101470428A (en) * | 2007-12-27 | 2009-07-01 | 上海欧达电气成套设备工程有限公司 | Method for on-line drafting elastic curve of rolling mill |
| CN201765503U (en) * | 2010-09-03 | 2011-03-16 | 武汉迈科机电物资工程有限公司 | Electrical control system of hot rolling reeling machine pinch roll on-line grinding and rolling apparatus |
| CN106623444A (en) * | 2017-02-16 | 2017-05-10 | 中冶华天工程技术有限公司 | AMESim-based roll gap control model for rolling machine |
| CN107363105A (en) * | 2017-07-20 | 2017-11-21 | 首钢集团有限公司 | A kind of control method and device of hot rolled coil head thickness |
| CN110278137A (en) * | 2019-06-12 | 2019-09-24 | 山西大学 | A kind of upper-level control system and field level telecommunication system and method |
-
2021
- 2021-07-20 CN CN202110820266.0A patent/CN113985799A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3648494A (en) * | 1969-08-06 | 1972-03-14 | Helmut Lautenschlager | System for applying pilot control to the roll gap adjustment of a gauge-controlled cold rolling stand |
| CN101470428A (en) * | 2007-12-27 | 2009-07-01 | 上海欧达电气成套设备工程有限公司 | Method for on-line drafting elastic curve of rolling mill |
| CN201765503U (en) * | 2010-09-03 | 2011-03-16 | 武汉迈科机电物资工程有限公司 | Electrical control system of hot rolling reeling machine pinch roll on-line grinding and rolling apparatus |
| CN106623444A (en) * | 2017-02-16 | 2017-05-10 | 中冶华天工程技术有限公司 | AMESim-based roll gap control model for rolling machine |
| CN107363105A (en) * | 2017-07-20 | 2017-11-21 | 首钢集团有限公司 | A kind of control method and device of hot rolled coil head thickness |
| CN110278137A (en) * | 2019-06-12 | 2019-09-24 | 山西大学 | A kind of upper-level control system and field level telecommunication system and method |
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