CN114410956A - Online control system and method for intermittent aluminum coil annealing furnace - Google Patents
Online control system and method for intermittent aluminum coil annealing furnace Download PDFInfo
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- CN114410956A CN114410956A CN202111493536.8A CN202111493536A CN114410956A CN 114410956 A CN114410956 A CN 114410956A CN 202111493536 A CN202111493536 A CN 202111493536A CN 114410956 A CN114410956 A CN 114410956A
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D11/00—Process control or regulation for heat treatments
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/26—Methods of annealing
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
- C21D9/54—Furnaces for treating strips or wire
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
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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
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- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The embodiment of the invention discloses an online control system and method for an intermittent aluminum coil annealing furnace, which comprises the following steps: the mathematical model calculation module and the real-time aluminum coil temperature correction module are connected to the online monitoring module, and the online monitoring module is connected to the aluminum coil annealing furnace through various measuring couples; the control mode of the online control system comprises the following steps: the mathematical model calculation module calculates an aluminum coil temperature field in real time, the online monitoring module obtains an actually measured aluminum coil temperature value at the high-temperature point of the aluminum coil through an aluminum coil temperature measuring thermocouple arranged at the high-temperature point of the aluminum coil, and the aluminum coil temperature real-time correction module corrects the calculated aluminum coil temperature field in real time by judging a mathematical model calculation error. The technical scheme provided by the embodiment of the invention solves the problems that the existing aluminum coil temperature control method of differential heating has higher risk of overtemperature of the aluminum coil, is difficult to ensure the annealing quality of the aluminum coil, cannot exert the maximum production efficiency of the annealing furnace and the like.
Description
Technical Field
The invention relates to the technical field of metal heat treatment, in particular to an online control system and method for an intermittent aluminum coil annealing furnace.
Background
The selection of the annealing process of the aluminum coil and the accurate control of the temperature are main factors for restricting the annealing quality of the aluminum coil and the production efficiency of the annealing furnace; the aluminum coil annealing process mainly comprises three stages: a heating stage, a soaking stage and a cooling stage.
In order to shorten the production period, reduce energy consumption and improve production efficiency, an enterprise usually adopts a differential heating mode to heat the aluminum coil in a heating stage and a soaking stage. The "differential heating" is that: firstly, setting the furnace gas temperature to be higher than the target temperature of the aluminum coil, when the detected temperature of the aluminum coil reaches a certain temperature, setting the furnace gas temperature to be reduced to the target temperature of the aluminum coil, and when the temperature of the aluminum coil reaches the target temperature requirement, finishing the differential heating process. The aluminum coil temperature control method of the differential heating has the following problems:
firstly, the temperature reduction point and the temperature reduction rate are basically selected through experience, the method is not scientific and rigorous, when the material model or the production process is changed, the higher risk of overtemperature of the aluminum coil exists, and the annealing quality of the aluminum coil is difficult to ensure;
secondly, a corresponding mathematical model and a theoretical basis are lacked as guidance, a standard process curve is established mainly by virtue of production experience to set the furnace temperature, and the maximum production efficiency of the annealing furnace cannot be exerted.
Disclosure of Invention
The purpose of the invention is as follows: in order to solve the technical problems, embodiments of the present invention provide an online control system and method for an intermittent aluminum coil annealing furnace, so as to solve the problems that the existing "differential heating" aluminum coil temperature control method has a high risk of over-temperature of an aluminum coil, is difficult to ensure the annealing quality of the aluminum coil, cannot exert the maximum production efficiency of the annealing furnace, and the like.
The technical scheme of the invention is as follows: the embodiment of the invention provides an online control system and method for an intermittent aluminum coil annealing furnace, which comprises the following steps: the device comprises a mathematical model calculation module, an online monitoring module, an aluminum coil temperature real-time correction module and an aluminum coil annealing furnace; the mathematical model calculation module and the real-time aluminum coil temperature correction module are connected to the online monitoring module through an upper computer, and the online monitoring module is connected to the aluminum coil annealing furnace through various measuring couples; the on-line control system controls the heat treatment process through on-line control logic of the aluminum coil annealing furnace, and the control mode of the on-line control system comprises the following steps:
the mathematical model calculation module is a mathematical model established based on a heat conduction theory and used for calculating the temperature field of the aluminum coil in real time, and the temperature field of the aluminum coil comprises temperature values of each point position in the aluminum coil;
the online monitoring module is used for acquiring an actually measured aluminum coil temperature value (T) at the high-temperature point position of the aluminum coil through an aluminum coil temperature thermocouple arranged at the high-temperature point position of the aluminum coil1) The method is also used for acquiring furnace temperature and fan frequency; wherein, the furnace temperature and the fan frequency are used for a mathematical model calculation module to calculate the temperature field of the aluminum coil;
the real-time aluminum coil temperature correction module is used for correcting the aluminum coil temperature field obtained by the mathematical model calculation module through calculation in real time by judging the mathematical model calculation error (delta T); wherein the mathematical model calculation error (Delta T) is the actually measured aluminum coil temperature value (T) of the online monitoring point1) And the calculated aluminum coil temperature value (T) calculated by adopting a mathematical model calculation module2) A difference of (d); wherein the temperature value (T) of the aluminum coil is calculated2) With said measured aluminium coil temperature value (T)1) The temperature value of the same point position on the aluminum coil.
Optionally, in the above-mentioned on-line control system for batch type aluminum coil annealing furnace, the mathematical model calculation module is established by:
according to the known surface heat transfer coefficient and the internal heat transfer coefficient of the workpiece, a discretization solving formula of a heat conduction differential equation is established through discretization treatment, and a mathematical model with an aluminum coil temperature field as a dependent variable and furnace temperature and fan frequency as independent variables is obtained.
Optionally, in the above-mentioned on-line control system for batch type aluminum coil annealing furnace, the on-line monitoring module comprises: the device comprises an aluminum coil temperature thermocouple arranged at the position of a high-temperature point of an aluminum coil, a furnace gas temperature thermocouple arranged in a hearth, a fan frequency monitor arranged on a fan, an upper computer and a programmable controller, wherein each thermocouple and each fan frequency monitor are respectively connected with the programmable controller;
the online monitoring module is specifically used for acquiring an actually-measured aluminum coil temperature value (T) of the position of a high-temperature point of an aluminum coil through an aluminum coil temperature thermocouple1) The furnace gas temperature is obtained through the furnace gas temperature thermocouple, the fan frequency is obtained through the fan frequency monitoring device, and the measured data is transmitted to the upper computer for processing through the aluminum coil temperature thermocouple, the furnace gas temperature thermocouple and the fan frequency monitor through the programmable controller.
Optionally, in the above online control system for an intermittent aluminum coil annealing furnace, the manner of correcting and calculating the temperature field of the aluminum coil by the real-time aluminum coil temperature correction module is as follows:
when the mathematical model calculation error (delta T) is larger than the error threshold epsilon, the corrected aluminum coil temperature field is equal to the correction coefficient kX the aluminum coil temperature field before correction;
wherein the correction coefficient k is the measured aluminum coil temperature value (T)1) Aluminum coil temperature value (T) calculated by divorce mathematical model calculation module2)。
Optionally, in the above-mentioned online control system for batch-type aluminum coil annealing furnace, the value of the error threshold epsilon ranges from 0.1 ℃ to 5 ℃.
Optionally, in the above-mentioned on-line control system for batch type aluminum coil annealing furnace, the heat treatment process controlled by the line control system includes: a heating stage, a soaking stage and a cooling stage; the online control system controls the heat treatment process in the following mode:
in the heating stage and the cooling stage, the mathematical model calculation module does not participate in furnace temperature control, only tracks the furnace temperature in real time and calculates the temperature field of the aluminum coil at the next moment;
in the soaking stage, the mathematical model calculation module calculates the optimal furnace temperature set value at the next moment in a gradual optimization mode to participate in furnace temperature control of the soaking stage; wherein, the optimal furnace temperature set value is as follows: and ensuring that the surface temperature of the aluminum coil is not higher than the furnace temperature set value when the target temperature of the aluminum coil is kept in the soaking stage.
The embodiment of the invention also provides an online control method of the intermittent aluminum coil annealing furnace, which is implemented by adopting the online control system of the intermittent aluminum coil annealing furnace, and the implementation steps of the online control method of the intermittent aluminum coil annealing furnace comprise:
step a, giving an initial value to an aluminum coil temperature field, starting an aluminum coil annealing furnace and heating;
b, acquiring the furnace temperature, the fan frequency and the actually measured aluminum coil temperature value by the online monitoring module;
c, correcting the temperature field of the aluminum coil in real time by an aluminum coil temperature real-time correction module to obtain a corrected temperature field of the aluminum coil;
d, calculating by a mathematical model calculation module to obtain an aluminum coil temperature field of the whole workpiece at the next moment;
step e, judging whether the surface of the aluminum coil temperature field calculated by the mathematical model calculation module is not over-temperature and the core part is not over-temperature; if the temperature is not reached, transmitting the current furnace temperature set value to the controller through the upper computer, participating in furnace temperature control at the next moment, and continuing to circulate the steps b-c-d-e; if not, executing the step f;
f, judging whether the surface of the aluminum coil is over-heated and the core part is not heated; if yes, setting the furnace gas temperature at the next moment according to the surface temperature of the current aluminum coil in a step-by-step optimization mode by the mathematical model calculation module, participating in furnace temperature control at the next moment, and continuing to circulate the steps b-c-d-e; if the core of the aluminum coil is warm, the cooling stage is entered.
Optionally, in the above method for controlling an on-line batch aluminum coil annealing furnace, after determining that none of the steps is up to the temperature in step e and before entering the circulating steps b-c-d-e, the method further includes:
judging whether the furnace temperature is still in a temperature rise stage; when the furnace temperature is still in the temperature-rising and heating stage, directly entering the next moment without modifying the furnace temperature, and entering the circulating steps b-c-d-e; and when the furnace temperature exceeds the maximum temperature set in the temperature-raising and heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, and then entering the circulating steps b-c-d-e.
Optionally, in the above-mentioned method for on-line control of a batch type aluminum coil annealing furnace, the step-by-step optimization of the mathematical model calculation module in step f includes:
the mathematical model calculation module sets furnace gas temperature value at the next moment to be reduced by delta e according to the current surface temperature of the aluminum coil so as to calculate the temperature field of the aluminum coil of the whole workpiece at the next moment, judges whether the calculated surface of the aluminum coil is not over-heated any more, if the calculated surface of the aluminum coil is over-heated, the furnace gas temperature value at the next moment is continuously reduced by delta e so as to calculate the temperature field of the aluminum coil at the next moment, and if the calculated surface temperature of the aluminum coil is lower than the target temperature, the furnace gas temperature value which is calculated to meet the condition that the surface temperature of the aluminum coil is lower than the target temperature is taken as the furnace temperature set value at the next moment to participate in furnace temperature control;
wherein, the value range of the reduction delta e of the furnace gas temperature value is between 0.1 ℃ and 5 ℃.
The invention has the beneficial effects that: the embodiment of the invention provides an online control system and method of an intermittent aluminum coil annealing furnace, and particularly establishes an online control method of the aluminum coil annealing furnace based on an annealing mathematical model, in the technical scheme of the embodiment of the invention, the calculated temperature field of the aluminum coil is continuously corrected in a mode of comparing the temperature of the aluminum coil monitored online with the temperature of the aluminum coil calculated by the mathematical model in real time; on one hand, in the heating stage and the cooling stage, the mathematical model does not participate in furnace temperature control, only tracks the furnace temperature in real time, and is specifically used for calculating the temperature field of the aluminum coil at the next moment; on the other hand, in the soaking stage, the optimal furnace temperature set value at the next moment is calculated in a gradual optimization mode to participate in furnace temperature control in the soaking stage; specifically, the gradual optimization mode can realize the process of calculating the temperature of the furnace gas back to the known temperature of the aluminum coil. The technical scheme of the embodiment of the invention is adopted to carry out furnace temperature on-line control, in a soaking stage, the furnace gas temperature is continuously reduced, the core part temperature of the aluminum coil is continuously increased, but the surface temperature of the aluminum coil is always maintained at a target temperature position, and the process is continued until the core part temperature of the aluminum coil reaches the target temperature; the control process can ensure that the aluminum coil annealing furnace is heated fastest in the soaking stage and consumes the shortest time, so that the production efficiency of the annealing furnace is higher.
The intermittent aluminum coil annealing furnace on-line control system and the control method implemented by the on-line control system provided by the embodiment of the invention overcome the defects of the existing control process, realize the on-line accurate control of the furnace temperature of the aluminum coil annealing furnace, ensure the quality of the aluminum coil in the annealing process, search the optimal furnace temperature control process in the soaking stage, increase the heating temperature difference and improve the production efficiency of the annealing furnace to the maximum extent.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the example serve to explain the principles of the invention and not to limit the invention.
FIG. 1 is a schematic structural diagram of an on-line control system of a batch type aluminum coil annealing furnace according to an embodiment of the present invention;
FIG. 2 is a schematic flow chart of the control logic of the on-line control system for the batch type aluminum coil annealing furnace provided in the embodiment shown in FIG. 1;
FIG. 3 is a schematic diagram of the arrangement position of an aluminum coil temperature thermocouple on an aluminum coil in the embodiment of the invention;
FIG. 4 is a flow chart illustrating a step-by-step optimization method according to an embodiment of the present invention;
fig. 5 is a graph of furnace temperature test data in an aluminum coil annealing process obtained by using the online control method of the aluminum coil annealing furnace provided by the embodiment of the invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be noted that the embodiments and features of the embodiments in the present application may be arbitrarily combined with each other without conflict.
The above background art has demonstrated that the existing "differential heating" temperature control method for aluminum coils has the problems of high risk of overtemperature of the aluminum coils, difficulty in ensuring annealing quality of the aluminum coils, incapability of exerting maximum production efficiency of the annealing furnace, and the like.
Aiming at the problem of the temperature control method of the aluminum coil of the differential heating, the method for setting the annealing process by the annealing process calculation software is greatly improved compared with the method for setting the standard curve by experience. In the previous research, the patent application with the publication number of CN101139652A provides an off-line prediction method in a bell-type furnace steel coil annealing process, and off-line prediction is carried out on the flue gas temperature and the steel coil temperature in a steel coil heating stage, a soaking stage and a cooling stage; the patent with publication number CN102994736B provides a correction method of a bell-type furnace annealing model on the basis of the patent, and the calculation precision of the mathematical model in the annealing process is further improved. However, in the application process of the above patent, the actual process and the offline prediction condition are inconsistent due to complex process conditions and more variables, while the offline prediction software can only predict the real-time material temperature according to the given production process, so that a certain deviation exists in the offline prediction result in the application process, and the deviation gradually accumulates and increases with the increase of the heat treatment time, and becomes an uncontrollable factor in the heat treatment process.
In addition, patents CN96109537.7 and CN102392119A propose a more flexible and adjustable online control method for continuous annealing furnaces, and a dynamic mathematical model of the temperature of the whole furnace plate strip of an annealing furnace is established through a heat conduction theory.
In conclusion, the control process of the conventional aluminum coil annealing aluminum process still has the following problems:
1. the calculation software applied to the field production basically carries out the off-line prediction of an annealing process system by processing a large amount of data and modeling the data into an empirical formula, and cannot adapt to the changes of product models, equipment performance and the like in the production;
2. the basic theory of the mathematical model of the aluminum coil annealing furnace is mature, but the online real-time correction is lacked, and the accurate regulation and control of the furnace temperature can not be carried out online;
3. the calculation of the mathematical model of the existing aluminum coil annealing furnace is unidirectional, namely, the temperature of the aluminum coil is calculated according to the temperature of furnace gas, but the temperature of the furnace gas cannot be calculated according to the temperature of the aluminum coil, when the heat treatment process requirement or the model of the aluminum coil changes, the furnace temperature control process cannot be determined, so that the applicability of the current mathematical model is reduced, and the purpose of online control cannot be met;
4. in the differential temperature heating process, the setting of the furnace gas temperature still has an optimization space, and the maximum capacity advantage of the aluminum coil annealing furnace cannot be exerted.
The embodiment of the invention provides an on-line control system and method for an intermittent aluminum coil annealing furnace aiming at the problems in the control process of the conventional aluminum coil annealing aluminum process,
the following specific embodiments of the present invention may be combined, and the same or similar concepts or processes may not be described in detail in some embodiments.
Fig. 1 is a schematic structural diagram of an on-line control system of a batch type aluminum coil annealing furnace according to an embodiment of the present invention. FIG. 2 is a schematic flow chart of the control logic of the on-line control system of the batch type aluminum coil annealing furnace provided by the embodiment shown in FIG. 1.
Referring to fig. 1 and 2, the online control system of the batch type aluminum coil annealing furnace mainly comprises: the device comprises a mathematical model calculation module, an online monitoring module, an aluminum coil temperature real-time correction module and an aluminum coil annealing furnace.
In the overall structure of the intermittent aluminum coil annealing furnace on-line control system shown in fig. 1, a mathematical model calculation module and an aluminum coil temperature real-time correction module are connected to an on-line monitoring module through an upper computer, and the line monitoring module is connected to the aluminum coil annealing furnace through each measuring couple.
Based on the specific structure of the on-line control system provided by the embodiment of the invention, the on-line control system controls the heat treatment process through the on-line control logic of the aluminum coil annealing furnace, and the control mode of the on-line control system comprises the following steps:
the mathematical model calculation module is a mathematical model established based on a heat conduction theory and used for calculating the temperature field of the aluminum coil in real time, wherein the temperature field of the aluminum coil comprises temperature values of each point position in the aluminum coil;
the online monitoring module is used for acquiring an actually measured aluminum coil temperature value (T) at the high-temperature point position of the aluminum coil through an aluminum coil temperature thermocouple arranged at the high-temperature point position of the aluminum coil1) The method is also used for acquiring furnace temperature and fan frequency; wherein, the furnace temperature and the fan frequency are used for the mathematical model calculation module to calculate the temperature field of the aluminum coil;
the real-time correction module of the aluminum coil temperature is used for correcting the aluminum coil temperature field obtained by the mathematical model calculation module through calculation in real time by judging the mathematical model calculation error (delta T); wherein, the mathematical model calculation error (Delta T) is the actually measured aluminum coil temperature value (T) of the online monitoring point1) And the calculated aluminum coil temperature value (T) calculated by adopting a mathematical model calculation module2) A difference of (d); wherein the temperature value (T) of the aluminum coil is calculated2) And the measured temperature value (T) of the aluminum coil1) The temperature value of the same point position on the aluminum coil.
In an implementation manner of the embodiment of the present invention, the mathematical model calculation module may be established in a manner of:
according to the known surface heat transfer coefficient and the internal heat transfer coefficient of the workpiece, a discretization solving formula of a heat conduction differential equation is established through discretization treatment, and a corresponding solving program is worked out to obtain a mathematical model taking an aluminum coil temperature field as a dependent variable and furnace temperature and fan frequency as independent variables.
In an implementation manner of the embodiment of the present invention, the online monitoring module in the embodiment of the present invention may include: the device comprises an aluminum coil temperature thermocouple arranged at the position of a high-temperature point of an aluminum coil, a furnace gas temperature thermocouple arranged in a hearth, a fan frequency monitor arranged on a fan, an upper computer and a programmable controller, wherein each thermocouple and each fan frequency monitor are respectively connected with the programmable controller.
In this implementation, the online monitoring module is specifically configured to obtain an actually measured aluminum coil temperature value (T) at a high temperature point of the aluminum coil through the aluminum coil temperature thermocouple1) Acquiring furnace gas temperature through a furnace gas temperature thermocouple, acquiring fan frequency through a fan frequency monitoring device, and acquiring furnace gas temperature through an aluminum coil temperature thermocouple and a furnace gas temperature thermocoupleAnd the fan frequency monitor transmits the measured data to an upper computer for processing through a programmable controller.
In the embodiment of the invention, in the specific implementation, the mode of correcting and calculating the temperature field of the aluminum coil by the real-time aluminum coil temperature correction module is specifically as follows:
when the mathematical model calculation error (delta T) is larger than the error threshold epsilon, the corrected aluminum coil temperature field is equal to the correction coefficient kX the aluminum coil temperature field before correction;
wherein, the correction coefficient k is the measured temperature value (T) of the aluminum coil1) Aluminum coil temperature value (T) calculated by divorce mathematical model calculation module2)。
Optionally, the value range of the error threshold epsilon in the embodiment of the invention can be selected from 0.1-5 ℃.
It should be noted that the thermal process controlled by the line control system provided by the embodiment of the present invention includes: a heating stage, a soaking stage and a cooling stage; the on-line control system can control the heat treatment process in the following modes:
on one hand, in the heating stage and the cooling stage, the mathematical model calculation module does not participate in furnace temperature control, only tracks the furnace temperature in real time and calculates the temperature field of the aluminum coil at the next moment; the two stages are: and calculating the material temperature in the furnace temperature forward direction.
On the other hand, in the soaking stage, the mathematical model calculation module calculates the optimal furnace temperature set value at the next moment in a gradual optimization mode to participate in furnace temperature control of the soaking stage; wherein, the optimal furnace temperature set value is as follows: ensuring that the surface temperature of the aluminum coil in the soaking stage is just not higher than the furnace temperature set value when the target temperature of the aluminum coil is reached; the stage is as follows: the furnace temperature is calculated in a mode of reversely calculating the temperature of the furnace through the material temperature.
Based on the online control system of the batch-type aluminum coil annealing furnace provided by each embodiment of the invention, the embodiment of the invention also provides an online control method of the batch-type aluminum coil annealing furnace, which can be implemented by adopting the online control system of the batch-type aluminum coil annealing furnace provided by any embodiment of the invention. As shown in fig. 2, the implementation steps of the on-line control method for the batch type aluminum coil annealing furnace provided by the embodiment of the invention include:
step a, giving an initial value to an aluminum coil temperature field, starting an aluminum coil annealing furnace and heating;
b, acquiring the furnace temperature, the fan frequency and the actually measured aluminum coil temperature value by the online monitoring module;
it should be noted that, since the aluminum coil annealing furnace is turned on in step a, the aluminum coil has an initial temperature field after the aluminum coil annealing furnace is turned on in step b.
C, correcting the temperature field of the aluminum coil in real time by an aluminum coil temperature real-time correction module; obtaining a corrected aluminum coil temperature field;
the step c is executed circularly, and the circularly executed correction comprises the correction of the initial temperature field and the subsequently calculated temperature field of the aluminum coil.
D, calculating by a mathematical model calculation module to obtain an aluminum coil temperature field of the whole workpiece at the next moment; the step d is a calculation mode of calculating the material temperature in the forward direction of the right furnace temperature.
Step e, judging whether the surface of the aluminum coil temperature field calculated by the mathematical model calculation module is not over-temperature and the core part is not over-temperature; if the temperature is not reached, transmitting the current furnace temperature set value to the controller through the upper computer, participating in furnace temperature control at the next moment, and continuing to circulate the steps b-c-d-e; if not, executing the step f;
f, judging whether the surface of the aluminum coil is over-heated and the core part is not heated; if yes, setting the furnace gas temperature at the next moment according to the surface temperature of the current aluminum coil in a step-by-step optimization mode by the mathematical model calculation module (the process is a calculation mode of calculating the furnace temperature in a material temperature reverse direction), participating in furnace temperature control at the next moment, and continuing to circulate the steps b-c-d-e; and if the temperature of the aluminum coil core part is up, which indicates that the soaking stage is finished, entering the cooling stage.
In an implementation manner of the embodiment of the present invention, in the step e, after determining that the temperature is not reached, and before entering the loop steps b-c-d-e, the following determination is further included:
judging whether the furnace temperature is still in a temperature rise stage; when the furnace temperature is still in the temperature-rising and heating stage, directly entering the next moment without modifying the furnace temperature, and entering the circulating steps b-c-d-e; and when the furnace temperature exceeds the maximum temperature set in the temperature-raising and heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, and then entering the circulating steps b-c-d-e.
In an implementation manner of the embodiment of the present invention, a specific implementation process of the stepwise optimization manner of the mathematical model calculation module in step f may be:
and the mathematical model calculation module sets furnace gas temperature value reduction delta e at the next moment according to the current surface temperature of the aluminum coil to calculate the temperature field of the aluminum coil of the whole workpiece at the next moment, judges whether the calculated surface of the aluminum coil is not overtemperature any more, if the calculated surface of the aluminum coil is overtemperature, indicates that the currently assumed furnace gas temperature value is still too high, continuously reduces the furnace gas temperature value set at the next moment by delta e to calculate the temperature field of the aluminum coil at the next moment until the surface temperature of the aluminum coil is lower than the target temperature, indicates that the furnace gas temperature at the moment is just the optimal set value which does not overtemperature of the aluminum coil, and takes the furnace gas temperature value calculated when the surface temperature of the aluminum coil is lower than the target temperature as the furnace temperature set value at the next moment to participate in furnace temperature control.
Optionally, the value range of the reduction Δ e of the furnace gas temperature value in the embodiment of the present invention may be between 0.1 ℃ and 5 ℃.
The embodiment of the invention provides an online control system and method of an intermittent aluminum coil annealing furnace, and particularly establishes an online control method of the aluminum coil annealing furnace based on an annealing mathematical model, in the technical scheme of the embodiment of the invention, the calculated temperature field of the aluminum coil is continuously corrected in a mode of comparing the temperature of the aluminum coil monitored online with the temperature of the aluminum coil calculated by the mathematical model in real time; on one hand, in the heating stage and the cooling stage, the mathematical model does not participate in furnace temperature control, only tracks the furnace temperature in real time, and is specifically used for calculating the temperature field of the aluminum coil at the next moment; on the other hand, in the soaking stage, the optimal furnace temperature set value at the next moment is calculated in a gradual optimization mode to participate in furnace temperature control in the soaking stage; specifically, the gradual optimization mode can realize the process of calculating the temperature of the furnace gas back to the known temperature of the aluminum coil. The technical scheme of the embodiment of the invention is adopted to carry out furnace temperature on-line control, in a soaking stage, the furnace gas temperature is continuously reduced, the core part temperature of the aluminum coil is continuously increased, but the surface temperature of the aluminum coil is always maintained at a target temperature position, and the process is continued until the core part temperature of the aluminum coil reaches the target temperature; the control process can ensure that the aluminum coil annealing furnace is heated fastest in the soaking stage and consumes the shortest time, so that the production efficiency of the annealing furnace is higher.
The intermittent aluminum coil annealing furnace on-line control system and the control method implemented by the on-line control system provided by the embodiment of the invention overcome the defects of the existing control process, realize the on-line accurate control of the furnace temperature of the aluminum coil annealing furnace, ensure the quality of the aluminum coil in the annealing process, search the optimal furnace temperature control process in the soaking stage, increase the heating temperature difference and improve the production efficiency of the annealing furnace to the maximum extent.
The following describes a specific implementation manner of the on-line control system and the method for the batch type aluminum coil annealing furnace according to the embodiment of the invention in detail through a specific implementation example.
Referring to fig. 1, the on-line control system for the batch type aluminum coil annealing furnace provided by the embodiment also comprises: the system comprises a mathematical model calculation module, an online monitoring module, an aluminum coil temperature real-time correction module and an aluminum coil annealing furnace, wherein the modules are combined with the aluminum coil annealing furnace, and the control logics of the modules are combined to form an intermittent aluminum coil annealing furnace online control system in the specific embodiment.
In this embodiment, two preparation tasks need to be completed before performing online control:
firstly, a mathematical model for calculating the temperature field of the aluminum coil needs to be established, and specifically a mathematical model calculation module is established; and secondly, determining an online aluminum coil monitoring point. The method comprises the following steps:
step one, due to the axially symmetric structure of the aluminum winding process, the following simplification is made according to the heating characteristics in the annealing process: 1) no heat source is arranged in the aluminum coil; 2) the heat exchange between the boundary of the aluminum coil and the outside meets the third type of heat exchange boundary condition; according to the heating condition of the aluminum coil, establishing a two-dimensional heat conduction control equation in the aluminum coil under polar coordinates as follows:
the relevant parameters in formula (1) are shown in table 1 below.
TABLE 1
In this embodiment, the initial conditions of the aluminum coil heat conduction control equation are set as follows:
Ti(r,z,τ)＝T0(r,z)τ＝0； (2)
besides the initial conditions of the aluminum coil heat conduction control equation, the boundary conditions of the aluminum coil also need to be known; specifically, according to the actual thermal process of the aluminum coil annealing furnace, the inner surface, the outer surface and the two end surfaces of the aluminum coil are all the third type of thermal boundary conditions, and the specific embodiment specifically includes the following boundary conditions:
the boundary conditions of r ═ Ri (inner surface of aluminum coil) are:
the boundary conditions of r ═ Ro (outer surface of aluminum coil) are:
the boundary condition of z ═ 0 (central symmetry plane of aluminum coil) is as follows:
the boundary conditions for z ═ L/2 (end faces of aluminum coils) are:
in the above formula, hi、ho、hdThe heat exchange coefficients of the inner surface of the aluminum coil, the outer surface of the aluminum coil and the end surface of the aluminum coil are respectively.
Axial thermal conductivity coefficient lambda in aluminum coilzNamely the heat conductivity coefficient of the aluminum material, and the radial heat conductivity coefficient lambdarThe self thermal conductivity coefficient, lambda, of the aluminum materialgThe comprehensive effect of the heat conductivity coefficient of the protective gas between two adjacent layers of strips, the radiation coefficient epsilon between two adjacent layers of aluminum strips and the heat conduction of contact points is obtained. The following equation (7) is used for calculation:
wherein the parameters
The actual contact surface factor of the adjacent plates; and is
The calculation method is as follows:
b is an intermediate process quantity of the formula (7);
b＝42.7×10-3 exp(-5×10-2P)； (9)
the meaning of each parameter in the above formula is shown in table 2 below.
TABLE 2
The aluminum coil annealing furnace is in a side blowing mode, and the nozzle is a slit nozzle. Therefore, the convection heat transfer coefficient h of the end face of the aluminum coildA calculation formula of the related criterion of the slit convection heat transfer can be adopted, and the calculation mode is as follows:
in the formula (10), ζdIs a heat transfer correction coefficient of the aluminum coil section, Ar、Ar,0Are process variables, Nu is the nussel number, Pr is the prandtl number, Re is the reynolds number; and the above variables are calculated as shown in the following formula (11):
in the above formulas, DhIs a characteristic dimension, HwThe distance from the nozzle to the end face of the aluminum coil is m; nwid is the width of the slit nozzle, and the unit is m; ns is the total length of the adjacent slits in m; nlong is the total length of the end slit, and the unit is m; v is the air outlet speed of the slit nozzle, and the unit is m/s; v. ofg、μg、αg、λg、ρgAnd CgRespectively the dynamic viscosity, kinematic viscosity, thermal diffusivity, thermal conductivity, density and specific heat capacity of the gas; qgIs the amount of wind
The convection heat exchange process of the slightly circular tube has the following rule relation (12):
in formula (12), DoThe unit is the outer diameter of the aluminum coil, and the unit is m; dNuzzleDesigning a circular diameter for the end face nozzle, wherein the unit is m; for this structure, DNuzzleIs 2.85, in m; zeta0For the correction coefficient, 1 is defaulted.
Temperature of each point in aluminum coil in heat treatment processAnd the internal part of the aluminum coil conducts heat in an unsteady state continuously along with the change of time. In the solving process, discretization treatment needs to be carried out on the aluminum coil, and the discretization treatment mode is as follows: dividing grid units in a solution domain, dividing a radial r direction (a longitudinal coordinate direction) of the aluminum coil into m parts and an axial z direction (a horizontal coordinate direction) of the aluminum coil into n parts by taking a rectangular coordinate system as a space coordinate, and obtaining m nodes and n nodes in space; assuming that τ is a time coordinate, the heat treatment time is divided into p parts, the time step is Δ τ, the total number of the space grid and the time grid is (m, n, p) by the above-mentioned manner of dividing the grid cells, and the coordinate of each space-time point is (i, j, k), where i is from 1 to m, j is from 1 to n, and k is from 1 to p. The temperature of the node (i, j) of the aluminum coil at time k is recorded as tAl(i,j,k)。
Discretizing the internal heat conduction formula of the aluminum coil by adopting a thermal balance method to obtain a difference equation of each discrete point as follows:
the boundary node discretization equation is not described in detail. The above formula (13) is a mathematical model for calculating the temperature field of the aluminum coil.
And step two, selecting the position of a high-temperature point of the whole aluminum coil in the heating process from the position of the online aluminum coil monitoring point.
In this step, the method for determining the position of the high-temperature point comprises the following steps: and (3) giving the furnace gas temperature and the fan frequency, calculating the temperature distribution of the aluminum coil after the temperature is raised for 1 hour according to the mathematical model, namely a formula (13), determining the position of a high-temperature monitoring point according to the calculation result, taking the point as a temperature measuring point of the aluminum coil temperature, and arranging 1-2 hot aluminum coil temperature measuring thermocouples. The general high temperature point is located on the boundary between the end face and the outer surface of the aluminum coil, and as shown in fig. 3, the general high temperature point is a schematic diagram of the arrangement position of the aluminum coil temperature thermocouple on the aluminum coil in the embodiment of the present invention, and the arrangement position is specifically the high temperature point position of the aluminum coil.
After the two steps are completed, the online control system is completely built, and then the online monitoring and the online temperature control of the aluminum coil annealing furnace are completed through the flow of the online control logic shown in fig. 2.
Firstly, setting the furnace gas temperature to be 245 ℃ and the aluminum coil target temperature to be 155 ℃, starting the furnace to heat, adopting an online monitoring module, and transmitting and monitoring the furnace temperature, the fan frequency and the aluminum coil temperature value (T) in real time1)。
And secondly, calculating the temperature field of the aluminum coil by using the actually measured parameters transmitted in real time in the first step as independent variables by adopting a mathematical model calculation module to obtain the calculated temperature field of the aluminum coil at the current moment.
Thirdly, judging the actually measured temperature value (T) of the aluminum coil1) The temperature value (T) of the aluminum coil calculated by the mathematical model calculation module corresponding to the point2) Whether the difference value (delta T) is in the range of minus 1.0 ℃ to plus 1.0 ℃ or not is judged, if not, the real-time correction module for the temperature of the aluminum coil is firstly adopted to carry out the temperature field of the aluminum coil, and then the next step is carried out, and if so, the next step is directly carried out.
The real-time aluminum coil temperature correction module is used for correcting the aluminum coil temperature field obtained by calculation in the second step, and the correction formula is as follows:
the corrected aluminum coil temperature field is equal to the correction coefficient kX the aluminum coil temperature field before correction;
correction coefficient k is measured aluminium coil temperature value (T)1) Calculation of aluminium coil temperature value (T)2)。
And fourthly, judging whether the high temperature point (surface) of the aluminum coil does not exceed the metal target temperature or not, and calculating whether the low temperature point (core) of the aluminum coil does not exceed the metal target temperature or not.
If the judgment result is yes, namely the two temperatures do not exceed the metal target temperature, continuously judging whether the furnace temperature is still in the temperature-raising stage, if the furnace temperature is still in the temperature-raising and heating stage, not modifying the furnace temperature, directly entering the next moment, repeating the second step and the third step, if the furnace temperature exceeds the maximum temperature set in the temperature-raising and heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, then repeating the second step and the third step until the judgment result is no, and entering the next step.
And fifthly, judging whether the high temperature point (surface) of the aluminum coil exceeds the target temperature of the metal, but the low temperature point (coil core) does not reach the target temperature.
In the step, if yes, searching the optimal furnace temperature set value at the next moment in a gradual optimization mode, controlling the temperature of furnace gas by using the optimal furnace temperature set value obtained by calculation, and executing the second step, the third step, the fourth step and the fifth step in a circulating mode until the judgment condition is no, namely the temperature of the core part of the aluminum coil is reached, indicating that the soaking stage is ended, and entering the cooling stage. When the temperature of the aluminum coil is reduced to be below 100 ℃, the annealing process is finished.
As shown in fig. 4, which is a schematic flow chart of a gradual optimization manner in an embodiment of the present invention, the gradual optimization manner is implemented as follows:
supposing that the furnace gas temperature at the next moment is reduced by 1 ℃, calculating by using a mathematical model calculation module to obtain the temperature field of the aluminum coil at the next moment, judging whether the calculated surface of the aluminum coil is not overtemperature any more, if the calculated surface of the aluminum coil is overtemperature, showing that the currently supposed furnace gas temperature value is still too high, continuously reducing the supposed furnace gas temperature value by 1 ℃, calculating by using the mathematical model calculation module to obtain the temperature field of the aluminum coil at the next moment until the surface temperature of the aluminum coil is lower than the target temperature, showing that the furnace gas temperature at the moment is just the optimal set value for not overtemperature of the aluminum coil, and taking the temperature at the moment as the furnace temperature set value at the next moment to participate in furnace temperature control.
It should be noted that, by adopting the gradual optimization mode in the embodiment of the present invention, the process of calculating the furnace gas temperature back to the known aluminum coil temperature can be realized.
Fig. 5 is a graph of furnace temperature test data in an aluminum coil annealing process obtained by using the online control method of the aluminum coil annealing furnace provided by the embodiment of the invention. As can be seen from fig. 5, there is a significant turning point from the heating stage to the soaking stage, such as "furnace temperature decrease starting point" in fig. 5. At the turning point, the surface temperature of the aluminum coil just reaches the target temperature (155 ℃), and the core temperature of the aluminum coil is still in a temperature rising state; and from this moment, the furnace gas temperature is continuously reduced, the core temperature of the aluminum coil is continuously increased, but the surface temperature of the aluminum coil is always maintained at the target temperature position, the overtemperature and the temperature drop are avoided, the process is continued until the core temperature of the aluminum coil reaches the target temperature, at this moment, the soaking process is finished, and the cooling stage is entered.
The mode of controlling the temperature on line in the embodiment of the invention can ensure that the aluminum coil annealing furnace has the fastest temperature rise and the shortest time consumption in the soaking stage, thereby ensuring that the production efficiency of the annealing furnace is higher.
Although the embodiments of the present invention have been described above, the above description is only for the convenience of understanding the present invention, and is not intended to limit the present invention. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (9)
1. An on-line control system of an intermittent aluminum coil annealing furnace is characterized by comprising: the device comprises a mathematical model calculation module, an online monitoring module, an aluminum coil temperature real-time correction module and an aluminum coil annealing furnace; the mathematical model calculation module and the real-time aluminum coil temperature correction module are connected to the online monitoring module through an upper computer, and the online monitoring module is connected to the aluminum coil annealing furnace through various measuring couples; the on-line control system controls the heat treatment process through on-line control logic of the aluminum coil annealing furnace, and the control mode of the on-line control system comprises the following steps:
the mathematical model calculation module is a mathematical model established based on a heat conduction theory and used for calculating the temperature field of the aluminum coil in real time, and the temperature field of the aluminum coil comprises temperature values of each point position in the aluminum coil;
the online monitoring module is used for acquiring an actually measured aluminum coil temperature value (T) at the high-temperature point position of the aluminum coil through an aluminum coil temperature thermocouple arranged at the high-temperature point position of the aluminum coil1) The method is also used for acquiring furnace temperature and fan frequency; wherein, the furnace temperature and the fan frequency are used for a mathematical model calculation module to calculate the temperature field of the aluminum coil;
the real-time correction module for the aluminum coil temperature is used for calculating the mathematical model calculation error (delta T) through judging the mathematical model to obtain the result of calculation by the mathematical model calculation moduleCorrecting the temperature field of the aluminum coil in real time; wherein the mathematical model calculation error (Delta T) is the actually measured aluminum coil temperature value (T) of the online monitoring point1) And the calculated aluminum coil temperature value (T) calculated by adopting a mathematical model calculation module2) A difference of (d); wherein the temperature value (T) of the aluminum coil is calculated2) With said measured aluminium coil temperature value (T)1) The temperature value of the same point position on the aluminum coil.
2. The on-line control system of a batch type aluminum coil annealing furnace according to claim 1, wherein the mathematical model calculation module is established in a manner that:
according to the known surface heat transfer coefficient and the internal heat transfer coefficient of the workpiece, a discretization solving formula of a heat conduction differential equation is established through discretization treatment, and a mathematical model with an aluminum coil temperature field as a dependent variable and furnace temperature and fan frequency as independent variables is obtained.
3. The on-line control system of a batch type aluminum coil annealing furnace according to claim 2, wherein the on-line monitoring module comprises: the device comprises an aluminum coil temperature thermocouple arranged at the position of a high-temperature point of an aluminum coil, a furnace gas temperature thermocouple arranged in a hearth, a fan frequency monitor arranged on a fan, an upper computer and a programmable controller, wherein each thermocouple and each fan frequency monitor are respectively connected with the programmable controller;
the online monitoring module is specifically used for acquiring an actually-measured aluminum coil temperature value (T) of the position of a high-temperature point of an aluminum coil through an aluminum coil temperature thermocouple1) The furnace gas temperature is obtained through the furnace gas temperature thermocouple, the fan frequency is obtained through the fan frequency monitoring device, and the measured data is transmitted to the upper computer for processing through the aluminum coil temperature thermocouple, the furnace gas temperature thermocouple and the fan frequency monitor through the programmable controller.
4. The on-line control system of the batch type aluminum coil annealing furnace of claim 3, wherein the real-time aluminum coil temperature correction module corrects and calculates the aluminum coil temperature field in a manner that:
when the mathematical model calculation error (delta T) is larger than the error threshold epsilon, the corrected aluminum coil temperature field is equal to the correction coefficient kX the aluminum coil temperature field before correction;
wherein the correction coefficient k is the measured aluminum coil temperature value (T)1) Aluminum coil temperature value (T) calculated by divorce mathematical model calculation module2)。
5. The on-line control system of a batch type aluminum coil annealing furnace according to claim 4, characterized in that the value range of the error threshold epsilon is 0.1-5 ℃.
6. An on-line control system for a batch type aluminum coil annealing furnace according to any one of claims 1 to 5, wherein the heat treatment process controlled by the line control system comprises: a heating stage, a soaking stage and a cooling stage; the online control system controls the heat treatment process in the following mode:
in the heating stage and the cooling stage, the mathematical model calculation module does not participate in furnace temperature control, only tracks the furnace temperature in real time and calculates the temperature field of the aluminum coil at the next moment;
in the soaking stage, the mathematical model calculation module calculates the optimal furnace temperature set value at the next moment in a gradual optimization mode to participate in furnace temperature control of the soaking stage; wherein, the optimal furnace temperature set value is as follows: and ensuring that the surface temperature of the aluminum coil is not higher than the furnace temperature set value when the target temperature of the aluminum coil is kept in the soaking stage.
7. An online control method of a batch type aluminum coil annealing furnace, which is characterized in that the online control method of the batch type aluminum coil annealing furnace is executed by the online control system of the batch type aluminum coil annealing furnace according to any one of claims 1 to 6, and the execution steps of the online control method of the batch type aluminum coil annealing furnace comprise:
step a, giving an initial value to an aluminum coil temperature field, starting an aluminum coil annealing furnace and heating;
b, acquiring the furnace temperature, the fan frequency and the actually measured aluminum coil temperature value by the online monitoring module;
c, correcting the temperature field of the aluminum coil in real time by an aluminum coil temperature real-time correction module to obtain a corrected temperature field of the aluminum coil;
d, calculating by a mathematical model calculation module to obtain an aluminum coil temperature field of the whole workpiece at the next moment;
step e, judging whether the surface of the aluminum coil temperature field calculated by the mathematical model calculation module is not over-temperature and the core part is not over-temperature; if the temperature is not reached, transmitting the current furnace temperature set value to the controller through the upper computer, participating in furnace temperature control at the next moment, and continuing to circulate the steps b-c-d-e; if not, executing the step f;
f, judging whether the surface of the aluminum coil is over-heated and the core part is not heated; if yes, setting the furnace gas temperature at the next moment according to the surface temperature of the current aluminum coil in a step-by-step optimization mode by the mathematical model calculation module, participating in furnace temperature control at the next moment, and continuing to circulate the steps b-c-d-e; if the core of the aluminum coil is warm, the cooling stage is entered.
8. The on-line control method for a batch type aluminum coil annealing furnace according to claim 7, wherein the step e, after judging that the temperature is not reached, and before entering the circulating step b-c-d-e, further comprises:
judging whether the furnace temperature is still in a temperature rise stage; when the furnace temperature is still in the temperature-rising and heating stage, directly entering the next moment without modifying the furnace temperature, and entering the circulating steps b-c-d-e; and when the furnace temperature exceeds the maximum temperature set in the temperature-raising and heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, and then entering the circulating steps b-c-d-e.
9. An on-line control method for a batch type aluminum coil annealing furnace according to claim 7, wherein the stepwise optimizing manner of the mathematical model calculation module in the step f comprises:
the mathematical model calculation module sets furnace gas temperature value at the next moment to be reduced by delta e according to the current surface temperature of the aluminum coil so as to calculate the temperature field of the aluminum coil of the whole workpiece at the next moment, judges whether the calculated surface of the aluminum coil is not over-heated any more, if the calculated surface of the aluminum coil is over-heated, the furnace gas temperature value at the next moment is continuously reduced by delta e so as to calculate the temperature field of the aluminum coil at the next moment, and if the calculated surface temperature of the aluminum coil is lower than the target temperature, the furnace gas temperature value which is calculated to meet the condition that the surface temperature of the aluminum coil is lower than the target temperature is taken as the furnace temperature set value at the next moment to participate in furnace temperature control;
wherein, the value range of the reduction delta e of the furnace gas temperature value is between 0.1 ℃ and 5 ℃.
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