CN114410956B - 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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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 349
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 349
- 238000000137 annealing Methods 0.000 title claims abstract description 107
- 238000000034 method Methods 0.000 title claims abstract description 99
- 238000004364 calculation method Methods 0.000 claims abstract description 81
- 238000013178 mathematical model Methods 0.000 claims abstract description 79
- 238000010438 heat treatment Methods 0.000 claims abstract description 57
- 238000012937 correction Methods 0.000 claims abstract description 43
- 238000012544 monitoring process Methods 0.000 claims abstract description 35
- 238000002791 soaking Methods 0.000 claims description 30
- 238000001816 cooling Methods 0.000 claims description 17
- 238000012546 transfer Methods 0.000 claims description 11
- 238000012545 processing Methods 0.000 claims description 7
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims description 6
- 238000005259 measurement Methods 0.000 claims description 5
- 230000001419 dependent effect Effects 0.000 claims description 3
- 238000012806 monitoring device Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 17
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- 239000000463 material Substances 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000005457 optimization Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
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- 238000012360 testing method Methods 0.000 description 2
- NAWXUBYGYWOOIX-SFHVURJKSA-N (2s)-2-[[4-[2-(2,4-diaminoquinazolin-6-yl)ethyl]benzoyl]amino]-4-methylidenepentanedioic acid Chemical compound C1=CC2=NC(N)=NC(N)=C2C=C1CCC1=CC=C(C(=O)N[C@@H](CC(=C)C(O)=O)C(O)=O)C=C1 NAWXUBYGYWOOIX-SFHVURJKSA-N 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
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- 238000004886 process control Methods 0.000 description 1
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- 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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- 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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- 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
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Abstract
The embodiment of the invention discloses an online control system and method for an intermittent aluminum coil annealing furnace, wherein the online control system comprises the following steps: the mathematical model calculation module and the aluminum coil temperature real-time correction module are connected to the online monitoring module, and the online monitoring module is connected to the aluminum coil annealing furnace through each measuring couple; 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 acquires an actually measured aluminum coil temperature value of the aluminum coil high temperature point position through an aluminum coil temperature thermocouple arranged on the aluminum coil high temperature point position, 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 'differential heating' aluminum coil temperature control method 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 on-line control system and method of an intermittent aluminum coil annealing furnace.
Background
The selection of the aluminum coil annealing process 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 annealing process of the aluminum coil mainly comprises three stages: a heating stage, a soaking stage and a cooling stage.
In order to shorten the production period, reduce the energy consumption and improve the production efficiency, enterprises often adopt a 'differential heating' mode to heat the aluminum coil in the heating stage and the soaking stage. "differential heating" is: the furnace gas temperature is set to be larger than the target temperature of the aluminum coil, when the temperature of the aluminum coil is detected to reach a certain temperature, the furnace gas temperature is set to be reduced to the target temperature of the aluminum coil, and when the temperature of the aluminum coil reaches the target temperature requirement, the differential heating process is ended. The aluminum coil temperature control method of the differential heating has the following problems:
the first, cooling points and cooling rates are basically selected through experience, are not scientific and strict, and have higher risk of overtemperature of the aluminum coil when the material model or the production process is changed, so that the annealing quality of the aluminum coil is difficult to ensure;
secondly, the corresponding mathematical model and theoretical basis are lacked as guidance, and the maximum production efficiency of the annealing furnace can not be exerted mainly by making a standard process curve through production experience to set the furnace temperature.
Disclosure of Invention
The purpose of the invention is that: in order to solve the technical problems, the embodiment of the invention provides an online control system and an online control method for an intermittent aluminum coil annealing furnace, which are used for solving the problems that the existing aluminum coil temperature control method adopting 'differential heating' has higher risk of over-temperature of aluminum coils, the annealing quality of the aluminum coils is difficult to ensure, the maximum production efficiency of the annealing furnace cannot be exerted, 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, comprising 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 aluminum coil temperature real-time 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 each measuring couple; the online control system controls the heat treatment process through online control logic of the aluminum coil annealing furnace, and the control mode of the online control system comprises the following steps:
the mathematical model calculation module is a mathematical model established based on a heat conduction theory and is used for calculating an aluminum coil temperature field in real time, wherein the aluminum coil temperature field comprises temperature values of each point position in an aluminum coil;
the on-line monitoring module is used for obtaining the actually measured aluminum coil temperature value (T) of the aluminum coil high temperature point position through the aluminum coil temperature thermocouple arranged on the aluminum coil high temperature point position 1 ) And also used for obtaining the furnace temperatureFan frequency; the furnace temperature and the fan frequency are used for calculating an aluminum coil temperature field by a mathematical model calculation module;
the aluminum coil temperature real-time correction module is used for carrying out real-time correction on the aluminum coil temperature field obtained by calculation through the mathematical model calculation module 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 point 1 ) And the calculated aluminum coil temperature value (T) calculated by adopting the mathematical model calculation module 2 ) Is a difference in (2); wherein, calculate the temperature value (T 2 ) And the measured aluminum coil temperature value (T 1 ) Is the temperature value at the same point on the aluminum coil.
Optionally, in the online control system of the intermittent aluminum coil annealing furnace as described above, the mathematical model calculation module is established in the following manner:
according to the known surface heat transfer coefficient and internal heat transfer coefficient of the workpiece, a discretization solving formula of a heat transfer differential equation is established through discretization processing, and a mathematical model taking an aluminum coil temperature field as a dependent variable and taking furnace temperature and fan frequency as independent variables is obtained.
Optionally, in the online control system of the intermittent aluminum coil annealing furnace as described above, the online monitoring module includes: the device comprises an aluminum coil temperature thermocouple arranged at the high temperature point of the aluminum coil, a furnace gas temperature thermocouple arranged in a furnace, a fan frequency monitor arranged on a fan, an upper computer and a programmable controller, wherein each thermocouple and the fan frequency monitor are respectively connected with the programmable controller;
the on-line monitoring module is particularly used for acquiring an actually measured aluminum coil temperature value (T) of the high temperature point position of the aluminum coil through an aluminum coil temperature thermocouple 1 ) 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 measurement data are 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 online control system of the intermittent aluminum coil annealing furnace, the mode of correcting and calculating the aluminum coil temperature field by the aluminum coil temperature real-time 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=the correction coefficient k×the aluminum coil temperature field before correction;
wherein the correction coefficient k=the measured aluminum coil temperature value (T 1 ) The temperature value (T 2 )。
Optionally, in the online control system of the intermittent aluminum coil annealing furnace, the value range of the error threshold epsilon is 0.1-5 ℃.
Optionally, in the batch aluminum coil annealing furnace online control system as described above, the heat treatment process controlled by the online control system includes: a heating stage, a soaking stage and a cooling stage; the on-line control system controls the heat treatment process in the following way:
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 aluminum coil temperature field at the next moment;
in the soaking stage, a mathematical model calculation module calculates the optimal furnace temperature set value at the next moment in a step-by-step optimizing mode, and participates in the furnace temperature control in the soaking stage; wherein, the optimal furnace temperature set value is as follows: the surface temperature of the aluminum coil in the soaking stage is always not higher than the furnace temperature set value when the target temperature of the aluminum coil is ensured.
The embodiment of the invention also provides an online control method for the intermittent aluminum coil annealing furnace, which is implemented by adopting the online control system for the intermittent aluminum coil annealing furnace, and comprises the following implementation steps:
step a, giving an initial value to an aluminum coil temperature field, starting an aluminum coil annealing furnace and heating;
step b, acquiring the furnace temperature, the fan frequency and the measured aluminum coil temperature value by an online monitoring module;
c, an aluminum coil temperature real-time correction module corrects the aluminum coil temperature field in real time to obtain a corrected aluminum coil temperature field;
step 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 obtained by calculation of the mathematical model calculation module is not overtemperature, and the core is not warmed; if the temperature is not reached, transmitting the current furnace temperature set value to a controller through an 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 overtemperature or not, wherein the core part is not warmed; if yes, setting the temperature of the furnace gas at the next moment by a mathematical model calculation module in a gradual optimizing mode according to the current surface temperature of the aluminum coil, participating in the control of the furnace temperature at the next moment, and continuing to circulate the steps b-c-d-e; if the core of the aluminum coil is already warm, a cooling stage is entered.
Optionally, in the method for controlling the batch aluminum coil annealing furnace online as described above, in the step e, after judging that none of the annealing furnaces is at the temperature, and before entering the circulating step b-c-d-e, the method further includes:
judging whether the furnace temperature is still in the heating stage; when the furnace temperature is still in the heating stage, the furnace temperature is not modified, the next moment is directly entered, and the circulation steps b-c-d-e are entered; and c, when the furnace temperature exceeds the highest temperature set in the heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, and then entering a circulation step b-c-d-e.
Optionally, in the method for online control of an intermittent aluminum coil annealing furnace as described above, the step-by-step optimizing manner of the mathematical model calculation module in the step f includes:
the mathematical model calculation module sets a furnace gas temperature value at the next moment to reduce delta e according to the current aluminum coil surface temperature so as to calculate an aluminum coil temperature field of the whole workpiece at the next moment, judges whether the calculated aluminum coil surface is over-heated or not, if so, continuously reduces the furnace gas temperature value at the next moment to be set by delta e so as to calculate an aluminum coil temperature field at the next moment until the aluminum coil surface temperature is lower than the target temperature, and takes the calculated furnace gas temperature value meeting the condition that the aluminum coil surface temperature is lower than the target temperature as a furnace temperature set value at the next moment to participate in furnace temperature control;
wherein the reduction delta e of the furnace gas temperature value is in the range of 0.1-5 ℃.
The invention has the beneficial effects that: according to the technical scheme provided by the embodiment of the invention, the aluminum coil temperature field obtained by calculation is continuously corrected in a manner of comparing the online monitoring aluminum coil temperature with the aluminum coil temperature obtained by calculation of 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, but only tracks the furnace temperature in real time, and is particularly used for calculating the aluminum coil temperature field at the next moment; on the other hand, in the soaking stage, calculating an optimal furnace temperature set value at the next moment in a step-by-step optimizing mode, and participating in furnace temperature control in the soaking stage; specifically, the step-by-step optimizing mode can realize the process of back-calculating the temperature of the furnace gas by knowing the temperature of the aluminum coil. By adopting the technical scheme of the embodiment of the invention, the furnace temperature is controlled on line, the furnace gas temperature is continuously reduced, the core temperature of the aluminum coil is continuously increased in the soaking stage, but the surface temperature of the aluminum coil is always maintained at the target temperature position, and the process is continued until the core temperature of the aluminum coil reaches the target temperature; the control process can ensure that the aluminum coil annealing furnace has the fastest temperature rise and the shortest time consumption in the soaking stage, so that the production efficiency of the annealing furnace is higher.
The online control system of the intermittent aluminum coil annealing furnace and the control method executed by the online control system overcome the defects of the existing control process, realize online 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 difference temperature and furthest improve the production efficiency of the annealing furnace.
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 and do not limit the invention.
FIG. 1 is a schematic structural diagram of an on-line control system of an intermittent aluminum coil annealing furnace provided by an embodiment of the invention;
FIG. 2 is a schematic flow chart of control logic of the on-line control system of the intermittent aluminum coil annealing furnace provided by the embodiment shown in FIG. 1;
FIG. 3 is a schematic diagram of the arrangement position of an aluminum coil thermocouple on an aluminum coil in an embodiment of the invention;
FIG. 4 is a flow chart of a step-by-step optimization method according to an embodiment of the present invention;
FIG. 5 is a graph of furnace temperature test data during an annealing process of an aluminum coil obtained by the online control method of an aluminum coil annealing furnace provided by the embodiment of the invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail hereinafter with reference to the accompanying drawings. It should be noted that, in the case of no conflict, the embodiments and features in the embodiments may be arbitrarily combined with each other.
The background art already shows that the existing temperature control method for the aluminum coil by 'differential heating' has the problems that the higher risk of the overtemperature of the aluminum coil is existed, the annealing quality of the aluminum coil is difficult to ensure, the maximum production efficiency of the annealing furnace cannot be exerted, and the like.
Aiming at the problem of the temperature control method of the aluminum coil by 'differential heating', the method for setting the annealing process by annealing process calculation software and the method for setting the standard curve by experience are greatly improved. In the prior study, the patent application with the publication number of CN101139652A provides an off-line prediction method in the bell-type furnace steel coil annealing process, and the flue gas temperature and the steel coil temperature in the steel coil heating stage, the soaking stage and the cooling stage are predicted off-line; the patent with publication number of CN102994736B provides a bell-type furnace annealing model correction method based on the patent, and the calculation accuracy of the mathematical model in the annealing process is further improved. However, in the application process of the above patent, the real process and the offline prediction condition are inconsistent due to the complex process condition and more variables, and 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 increases in a cumulative way along with the increase of the heat treatment time, so that the deviation becomes an uncontrollable factor of the heat treatment process.
In addition, patent CN96109537.7 and CN102392119a propose more flexible and adjustable on-line control methods of continuous annealing furnaces, and through the theory of heat conduction, a dynamic mathematical model of the temperature of the whole annealing furnace plate band is established.
To sum up, the existing aluminum coil annealing aluminum process control process still has the following problems:
1. the calculation software applied to on-site production basically carries out 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 changes of product types, equipment performances and the like in production;
2. the mathematical model basic theory of the aluminum coil annealing furnace is mature, but lacks online real-time correction, and cannot accurately regulate and control the furnace temperature online;
3. the calculation of the existing mathematical model of the aluminum coil annealing furnace is unidirectional, namely, the temperature of the aluminum coil is calculated through the temperature of the furnace air, but the temperature of the furnace air cannot be calculated through the temperature of the aluminum coil, when the heat treatment process is required or the aluminum coil type number is changed, 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 process of differential heating, the setting of the furnace gas temperature still has an optimization space, and the maximum productivity advantage of the aluminum coil annealing furnace can not be exerted.
Aiming at the problems existing in the control process of the aluminum coil annealing aluminum process at present, the embodiment of the invention provides an on-line control system and method of an intermittent aluminum coil annealing furnace,
the following specific embodiments may be combined with each other, and some embodiments may not be repeated for the same or similar concepts or processes.
Fig. 1 is a schematic structural diagram of an online control system of an intermittent aluminum coil annealing furnace according to an embodiment of the invention. Fig. 2 is a schematic flow chart of control logic of the online control system of the intermittent aluminum coil annealing furnace provided in the embodiment shown in fig. 1.
Referring to fig. 1 and 2, the on-line control system of the intermittent aluminum coil annealing furnace mainly comprises: the device comprises a mathematical model calculation module, an on-line monitoring module, an aluminum coil temperature real-time correction module and an aluminum coil annealing furnace.
In the overall structure of the online control system of the intermittent aluminum coil annealing furnace shown in fig. 1, a mathematical model calculation module and an aluminum coil temperature real-time correction module are connected to an online monitoring module through an upper computer, and the online monitoring module is connected to the aluminum coil annealing furnace through measurement couples.
Based on the specific structure of the online control system provided by the embodiment of the invention, the online control system controls the heat treatment process through the online control logic of the aluminum coil annealing furnace, and the control mode of the online control system comprises the following steps:
the mathematical model calculation module is a mathematical model established based on a heat conduction theory and is used for calculating an aluminum coil temperature field in real time, wherein the aluminum coil temperature field comprises temperature values of each point position in the aluminum coil;
the on-line monitoring module is used for obtaining the actually measured aluminum coil temperature value (T) of the aluminum coil high temperature point position through the aluminum coil temperature thermocouple arranged on the aluminum coil high temperature point position 1 ) The method is also used for acquiring the furnace temperature and the fan frequency; the furnace temperature and the fan frequency are used for calculating an aluminum coil temperature field by a mathematical model calculation module;
the aluminum coil temperature real-time correction module is used for carrying out real-time correction on the aluminum coil temperature field obtained by calculation through the mathematical model calculation module by judging the mathematical model calculation error (delta T); wherein, the calculation error (delta T) of the mathematical model is the actually measured aluminum coil temperature value (T) of the online monitoring point 1 ) And the calculated aluminum coil temperature value (T) calculated by adopting the mathematical model calculation module 2 ) Is a difference in (2); wherein, calculate the temperature value (T 2 ) With the measured aluminum coil temperature value (T 1 ) Is the temperature value at the same point on the aluminum coil.
In one implementation manner of the embodiment of the present invention, the establishing manner of the mathematical model calculation module may be:
according to the known heat transfer coefficients of the surface and the internal of the workpiece, a discretization solving formula of a heat conduction differential equation is established through discretization processing, and a corresponding solving program is compiled, so that a mathematical model taking an aluminum coil temperature field as a dependent variable and taking furnace temperature and fan frequency as independent variables is obtained.
In one 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 high temperature point of the aluminum coil, a furnace gas temperature thermocouple arranged in a furnace chamber, a fan frequency monitor arranged on a fan, an upper computer and a programmable controller, wherein each thermocouple and the fan frequency monitor are respectively connected with the programmable controller.
In the implementation mode, the on-line monitoring module is specifically configured to obtain an actually measured aluminum coil temperature value (T 1 ) 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 measurement data are 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.
In the specific implementation of the embodiment of the invention, the mode of correcting and calculating the aluminum coil temperature field by the aluminum coil temperature real-time 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=the correction coefficient k×the aluminum coil temperature field before correction;
wherein the correction coefficient k=the measured aluminum coil temperature value (T 1 ) The temperature value (T 2 )。
Optionally, in the embodiment of the present invention, the value range of the error threshold epsilon may be selected between 0.1 ℃ and 5 ℃.
It should be noted that, the heat treatment 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 manner in which the on-line control system controls the heat treatment process may be:
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 aluminum coil temperature field at the next moment; the two stages are: and the material temperature is calculated in a forward direction through the furnace temperature.
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 step-by-step optimizing mode, and participates in the furnace temperature control in the soaking stage; wherein, the optimal furnace temperature set value is: 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; the stage is as follows: and the furnace temperature is calculated in a reverse way through the material temperature.
Based on the online control system of the intermittent aluminum coil annealing furnace provided by the embodiments of the invention, the embodiment of the invention also provides an online control method of the intermittent aluminum coil annealing furnace, which can be implemented by adopting the online control system of the intermittent aluminum coil annealing furnace provided by any embodiment. As shown in fig. 2, the method for performing the on-line control of the intermittent aluminum coil annealing furnace provided by the embodiment of the invention comprises the following steps:
step a, giving an initial value to an aluminum coil temperature field, starting an aluminum coil annealing furnace and heating;
step b, acquiring the furnace temperature, the fan frequency and the measured aluminum coil temperature value by an online monitoring module;
it should be noted that, since the aluminum coil annealing furnace is turned on in the step a, the aluminum coil has an initial temperature field after the aluminum coil annealing furnace is turned on in the step b for the first time.
C, carrying out real-time correction on an aluminum coil temperature field by an aluminum coil temperature real-time correction module; obtaining a corrected aluminum coil temperature field;
the step c is performed cyclically, and the correction of the initial temperature field and the subsequently calculated aluminum coil temperature field is included in the correction performed cyclically.
Step 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 specifically a calculation mode for calculating the material temperature in the right furnace temperature forward direction.
Step e, judging whether the surface of the aluminum coil temperature field obtained by calculation of the mathematical model calculation module is not overtemperature, and the core is not warmed; if the temperature is not reached, transmitting the current furnace temperature set value to a controller through an 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 overtemperature or not, wherein the core part is not warmed; if yes, setting the temperature of the furnace gas at the next moment by a mathematical model calculation module according to the current aluminum coil surface temperature in a gradual optimizing mode (the process is a calculation mode of reversely calculating the furnace temperature through the material temperature), participating in the control of the furnace temperature at the next moment, and continuing to circulate the steps b-c-d-e; if the core of the aluminum coil is at a temperature, which means that the soaking stage is finished, the cooling stage is entered.
In one implementation manner of the embodiment of the present invention, in the step e, after judging that the temperature is not reached, and before entering the circulation step b-c-d-e, the method further includes the following steps:
judging whether the furnace temperature is still in the heating stage; when the furnace temperature is still in the heating stage, the furnace temperature is not modified, the next moment is directly entered, and the circulation steps b-c-d-e are entered; and c, when the furnace temperature exceeds the highest temperature set in the heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, and then entering a circulation step b-c-d-e.
In an implementation manner of the embodiment of the present invention, a specific implementation process of the step-by-step optimization manner of the mathematical model calculation module in the step f may be:
the mathematical model calculation module sets a furnace gas temperature value at the next moment to reduce delta e according to the current aluminum coil surface temperature so as to calculate an aluminum coil temperature field of the whole workpiece at the next moment, judges whether the calculated aluminum coil surface is over-heated or not, if so, the furnace gas temperature value at the next moment is set to continue to reduce delta e, so as to calculate the aluminum coil temperature field at the next moment until the aluminum coil surface temperature is lower than the target temperature, and the furnace gas temperature at the moment is just the optimal set value meeting the non-over-temperature of the aluminum coil, and takes the furnace gas temperature value calculated when the aluminum coil surface temperature is lower than the target temperature as the furnace temperature set value at the next moment to participate in furnace temperature control.
Alternatively, the reduction Δe of the furnace gas temperature value in the embodiment of the present invention may be in the range of 0.1 ℃ to 5 ℃.
According to the technical scheme provided by the embodiment of the invention, the aluminum coil temperature field obtained by calculation is continuously corrected in a manner of comparing the online monitoring aluminum coil temperature with the aluminum coil temperature obtained by calculation of 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, but only tracks the furnace temperature in real time, and is particularly used for calculating the aluminum coil temperature field at the next moment; on the other hand, in the soaking stage, calculating an optimal furnace temperature set value at the next moment in a step-by-step optimizing mode, and participating in furnace temperature control in the soaking stage; specifically, the step-by-step optimizing mode can realize the process of back-calculating the temperature of the furnace gas by knowing the temperature of the aluminum coil. By adopting the technical scheme of the embodiment of the invention, the furnace temperature is controlled on line, the furnace gas temperature is continuously reduced, the core temperature of the aluminum coil is continuously increased in the soaking stage, but the surface temperature of the aluminum coil is always maintained at the target temperature position, and the process is continued until the core temperature of the aluminum coil reaches the target temperature; the control process can ensure that the aluminum coil annealing furnace has the fastest temperature rise and the shortest time consumption in the soaking stage, so that the production efficiency of the annealing furnace is higher.
The online control system of the intermittent aluminum coil annealing furnace and the control method executed by the online control system overcome the defects of the existing control process, realize online 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 difference temperature and furthest improve the production efficiency of the annealing furnace.
The following describes in detail a specific implementation manner of an online control system and method for an intermittent aluminum coil annealing furnace provided by an embodiment of the present invention through a specific implementation example.
Referring to fig. 1, the online control system of the intermittent aluminum coil annealing furnace provided in this embodiment also includes: the system comprises a mathematical model calculation module, an on-line 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 logic of the modules is combined to form the on-line control system of the intermittent aluminum coil annealing furnace in the specific embodiment.
In this particular embodiment, two preparations are required before on-line control is performed:
1. a mathematical model for calculating the aluminum coil temperature field is required to be established, and a mathematical model calculation module is specifically established; 2. it is necessary to determine online aluminum coil monitoring points. The method comprises the following steps:
step one, due to the axisymmetric structure of the aluminum coil, the following simplification is made according to the heating characteristics in the annealing process: 1) No heat source exists in the aluminum coil; 2) The heat exchange between the aluminum coil boundary and the outside meets the third type of heat exchange boundary conditions; according to the heating condition of the aluminum coil, establishing a two-dimensional heat conduction control equation in the aluminum coil under polar coordinates is as follows:
the relevant parameters in the formula (1) are shown in the following table 1.
TABLE 1
In this embodiment, the initial conditions of the aluminum coil heat conduction control equation are set as follows:
T i (r,z,τ)＝T 0 (r,z)τ＝0； (2)
besides the initial conditions of the aluminum coil heat conduction control equation, the aluminum coil boundary conditions 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 third type of thermal boundary conditions, and the specific embodiment specifically comprises the following boundary conditions:
the boundary conditions for r=ri (inner surface of aluminum coil) are:
the boundary conditions for r=ro (aluminum roll outer surface) are:
the boundary conditions for z=0 (aluminum coil central symmetry plane) are:
the boundary conditions for z=l/2 (end face of aluminum coil) are:
in the above, h i 、h o 、h d The 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 heat conductivity coefficient lambda inside aluminum coil z Namely the heat conductivity coefficient of the aluminum material and the radial heat conductivity coefficient lambda r Then the heat conductivity coefficient of the aluminum material is lambda g The heat conduction effect of the shielding gas between two adjacent layers of strips, the radiation coefficient epsilon between two adjacent layers of aluminum strips and the heat conduction effect of the contact point is achieved. The calculation was performed using the following formula (7):
wherein the parameters are
The actual contact surface factor of the adjacent plates is calculated; and->
The calculation mode of (a) is as follows:
b is the intermediate process quantity of formula (7);
b＝42.7×10 -3 exp(-5×10 -2 P)； (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 aluminum coil end face d The calculation formula of the slit convection heat transfer related criterion can be adopted, and the following calculation mode is adopted:
zeta in the formula (10) d Heat transfer correction coefficient for aluminum coil section A r 、A r,0 Are process variables, nu is the Nuzier number, pr is the Plantt number, and Re is the Reynolds number; and the calculation modes of the variables are shown in the following formula (11):
in the above formulae, D h For characteristic dimensions, H w The unit of the distance from the nozzle to the end face of the aluminum coil is m; nwid is the width of the slit nozzle in m; ns is the total length of adjacent slits, and the unit is m; nlong is the total length of the end face slit, and the unit is m; v is the air outlet speed of the slit nozzle, and the unit is m/s; v g 、μ g 、α g 、λ g 、ρ g And C g Respectively the dynamic viscosity, the kinematic viscosity, the thermal diffusivity, the heat conductivity coefficient, the density and the specific heat capacity of the gas; q (Q) g Is the air quantity
The convective heat transfer process of the outer circular tube has the following criterion relation (12):
in the formula (12), D o The unit is m, which is the outer diameter of the aluminum coil; d (D) Nuzzle Designing a circle diameter for an end face nozzle, wherein the unit is m; for the present structure, D Nuzzle 2.85, in m; zeta type 0 For correction coefficients, default to 1.
The temperature of each point in the aluminum coil continuously changes along with time in the heat treatment process, and the inside of the aluminum coil is unsteady heat conduction. In the solving process, discretization treatment is needed to be carried out on the aluminum coil, wherein the discretization treatment mode is as follows: dividing grid units in a solving domain, taking a rectangular coordinate system as a space coordinate, dividing the radial r direction (the ordinate direction) of the aluminum coil into m parts, dividing the axial z direction (the abscissa direction) into n parts, and obtaining m x n nodes in space; assuming τ as a time coordinate, the heat treatment time is divided into p copies, the time step is Δτ, the total number of space grids and time grids is (m, n, p) by the above-described grid cell division method, and the coordinates of each space-time point are (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 aluminum roll node (i, j) at time k is noted as t Al (i,j,k)。
Discretizing an aluminum coil internal heat conduction formula by adopting a thermal balance method to obtain a difference equation of each discrete point, wherein the difference equation is as follows:
the above 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 a high-temperature point position of the whole aluminum coil in the heating process at the online aluminum coil monitoring point position.
In the step, the determination method of the height Wen Dianwei device comprises the following steps: given the furnace gas temperature and the fan frequency, according to the mathematical model, namely the formula (13), calculating the temperature distribution of the aluminum coil after the temperature is raised for 1 hour, 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 to 2 hot aluminum coil temperature thermocouples. The location of the high temperature point is generally located on the boundary between the end face and the outer surface of the aluminum coil, as shown in fig. 3, and is a schematic diagram of the location of the aluminum coil thermocouple for measuring temperature on the aluminum coil in the embodiment of the invention, where the location of the thermocouple for measuring temperature of the aluminum coil is specifically the location of the high temperature point of the aluminum coil.
After the two steps are completed, the online control system is 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 temperature of furnace gas to 245 ℃, the target temperature of aluminum coil to 155 ℃, starting the furnace to raise the temperature, and adopting an on-line monitoring module to transmit and monitor the furnace temperature, the fan frequency and the aluminum coil temperature value (T) 1 )。
And secondly, calculating an aluminum coil temperature field by adopting a mathematical model calculation module and taking the actual measurement parameters transmitted in real time in the first step as independent variables to obtain the calculated aluminum coil temperature field at the current moment.
Third step, the measured aluminum coil temperature value (T 1 ) And the aluminum coil temperature value (T) calculated by the mathematical model calculation module of the corresponding point 2 ) If the difference value (delta T) of the aluminum coil temperature is within the range of minus 1.0 ℃ to plus 1.0 ℃, if not, the aluminum coil temperature real-time correction module is adopted to carry out the aluminum coil temperature field, then the next step is carried out, if yes, the next step is directly carried outOne step.
The aluminum coil temperature real-time correction module specifically corrects the aluminum coil temperature field calculated in the second step, and the correction formula is as follows:
corrected aluminum coil temperature field = correction coefficient k x aluminum coil temperature field before correction;
correction coefficient k=actually measured aluminum coil temperature value (T 1 ) Calculate the temperature value of the aluminum coil (T 2 )。
Fourth, it is judged whether the calculated aluminum coil high temperature point (surface) does not exceed the metal target temperature, and whether the calculated aluminum coil low temperature point (coil core) does not exceed the metal target temperature.
If yes, that is, if the two temperatures do not exceed the target metal temperature, continuing to judge whether the furnace temperature is still in the heating stage, if the furnace temperature is still in the heating stage, directly entering the next moment without modifying the furnace temperature, repeating the second step and the third step, and if the furnace temperature exceeds the highest temperature set in the heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, and then repeating the second step and the third step until the judgment result is no, and entering the next step.
Fifth, it is judged whether the high temperature point (surface) of the aluminum roll has exceeded the metal target temperature, but the low temperature point (core) has not reached the target temperature.
If yes, searching an optimal furnace temperature set value at the next moment in a step-by-step optimizing mode, controlling the furnace gas temperature by using the calculated optimal furnace temperature set value, and circularly executing the second step, the third step, the fourth step and the fifth step until the judging condition is no, namely that the core part of the aluminum coil is at the temperature, and ending the soaking stage and entering the cooling stage. When the temperature of the aluminum coil is reduced to below 100 ℃, the annealing process is finished.
As shown in fig. 4, a flow chart of a step-by-step optimization method in an embodiment of the present invention is shown, where the step-by-step optimization method is implemented as follows:
assuming that the temperature of the furnace gas at the next moment is reduced by 1 ℃, adopting a mathematical model calculation module to calculate the temperature field of the aluminum coil at the next moment, judging whether the surface of the aluminum coil obtained by calculation is not overtemperature any more, if the surface of the aluminum coil is still overtemperature, indicating that the currently assumed furnace gas temperature value is still too high, continuing to reduce the assumed furnace gas temperature value by 1 ℃ continuously, adopting the mathematical model calculation module 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, indicating that the furnace gas temperature at the moment is just the optimal set value meeting the condition that the aluminum coil is not overtemperature, taking the temperature at the moment as the furnace temperature set value at the next moment, and participating in furnace temperature control.
It should be noted that, by adopting the step-by-step optimizing mode in the embodiment of the invention, the process of back-calculating the furnace gas temperature of the known aluminum coil temperature can be realized.
FIG. 5 is a graph of furnace temperature test data during an annealing process of an aluminum coil obtained by the online control method of an 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 the "furnace temperature decrease start 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 heating 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 temperature cannot be overtemperature or drop, the process is continued until the core temperature of the aluminum coil reaches the target temperature, at this moment, the soaking process is ended, and the cooling stage is entered.
The online temperature control mode in the embodiment of the invention can ensure that the temperature rise of the aluminum coil annealing furnace is fastest in the soaking stage and the time consumption is shortest, so that the production efficiency of the annealing furnace is higher.
Although the embodiments of the present invention are described above, the embodiments are only used for facilitating understanding of the present invention, and are not intended to limit the present invention. Any person skilled in the art can make any modification and variation in form and detail without departing from the spirit and scope of the present disclosure, but the scope of the present disclosure is to be determined by the appended claims.
Claims (9)
1. An on-line control system of an intermittent aluminum coil annealing furnace, which 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 aluminum coil temperature real-time 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 each measuring couple; the online control system controls the heat treatment process through online control logic of the aluminum coil annealing furnace, and the control mode of the online control system comprises the following steps:
the mathematical model calculation module is a mathematical model established based on a heat conduction theory and is used for calculating an aluminum coil temperature field in real time, wherein the aluminum coil temperature field comprises temperature values of each point position in an aluminum coil;
the on-line monitoring module is used for obtaining the actually measured aluminum coil temperature value (T) of the aluminum coil high temperature point position through the aluminum coil temperature thermocouple arranged on the aluminum coil high temperature point position 1 ) The method is also used for acquiring the furnace temperature and the fan frequency; the furnace temperature and the fan frequency are used for calculating an aluminum coil temperature field by a mathematical model calculation module;
the aluminum coil temperature real-time correction module is used for carrying out real-time correction on the aluminum coil temperature field obtained by calculation through the mathematical model calculation module 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 point 1 ) And the calculated aluminum coil temperature value (T) calculated by adopting the mathematical model calculation module 2 ) Is a difference in (2); wherein, calculate the temperature value (T 2 ) And the measured aluminum coil temperature value (T 1 ) Is the temperature value at the same point on the aluminum coil.
2. The online control system of an intermittent aluminum coil annealing furnace according to claim 1, wherein the mathematical model calculation module is established in the following manner:
according to the known surface heat transfer coefficient and internal heat transfer coefficient of the workpiece, a discretization solving formula of a heat transfer differential equation is established through discretization processing, and a mathematical model taking an aluminum coil temperature field as a dependent variable and taking furnace temperature and fan frequency as independent variables is obtained.
3. The batch aluminum coil annealing furnace on-line control system of claim 2, wherein the on-line monitoring module comprises: the device comprises an aluminum coil temperature thermocouple arranged at the high temperature point of the aluminum coil, a furnace gas temperature thermocouple arranged in a furnace, a fan frequency monitor arranged on a fan, an upper computer and a programmable controller, wherein each thermocouple and the fan frequency monitor are respectively connected with the programmable controller;
the on-line monitoring module is particularly used for acquiring an actually measured aluminum coil temperature value (T) of the high temperature point position of the aluminum coil through an aluminum coil temperature thermocouple 1 ) 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 measurement data are 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 online control system of an intermittent aluminum coil annealing furnace according to claim 3, wherein the mode of correcting and calculating the aluminum coil temperature field by the aluminum coil temperature real-time 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=the correction coefficient k×the aluminum coil temperature field before correction;
wherein the correction coefficient k=the measured aluminum coil temperature value (T 1 ) The temperature value (T 2 )。
5. The on-line control system of an intermittent aluminum coil annealing furnace according to claim 4, wherein the error threshold epsilon has a value ranging from 0.1 ℃ to 5 ℃.
6. The batch aluminum coil annealing furnace on-line control system according to any one of claims 1 to 5, wherein the heat treatment process controlled by the line control system includes: a heating stage, a soaking stage and a cooling stage; the on-line control system controls the heat treatment process in the following way:
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 aluminum coil temperature field at the next moment;
in the soaking stage, a mathematical model calculation module calculates the optimal furnace temperature set value at the next moment in a step-by-step optimizing mode, and participates in the furnace temperature control in the soaking stage; wherein, the optimal furnace temperature set value is as follows: the surface temperature of the aluminum coil in the soaking stage is always not higher than the furnace temperature set value when the target temperature of the aluminum coil is ensured.
7. An online control method for an intermittent aluminum coil annealing furnace, which is characterized in that an online control system for the intermittent aluminum coil annealing furnace according to any one of claims 1 to 6 is adopted to execute the online control method for the intermittent aluminum coil annealing furnace, and the execution steps of the online control method for 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;
step b, acquiring the furnace temperature, the fan frequency and the measured aluminum coil temperature value by an online monitoring module;
c, an aluminum coil temperature real-time correction module corrects the aluminum coil temperature field in real time to obtain a corrected aluminum coil temperature field;
step 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 obtained by calculation of the mathematical model calculation module is not overtemperature, and the core is not warmed; if the temperature is not reached, transmitting the current furnace temperature set value to a controller through an 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 overtemperature or not, wherein the core part is not warmed; if yes, setting the temperature of the furnace gas at the next moment by a mathematical model calculation module in a gradual optimizing mode according to the current surface temperature of the aluminum coil, participating in the control of the furnace temperature at the next moment, and continuing to circulate the steps b-c-d-e; if the core of the aluminum coil is already warm, a cooling stage is entered.
8. The method for controlling an on-line annealing furnace for aluminum coil according to claim 7, wherein in said step e, after judging that none of them is at temperature and before entering the circulating step b-c-d-e, further comprising:
judging whether the furnace temperature is still in the heating stage; when the furnace temperature is still in the heating stage, the furnace temperature is not modified, the next moment is directly entered, and the circulation steps b-c-d-e are entered; and c, when the furnace temperature exceeds the highest temperature set in the heating stage, controlling the furnace temperature at the next moment to be equal to the current furnace temperature, and then entering a circulation step b-c-d-e.
9. The online control method of the intermittent aluminum coil annealing furnace according to claim 7, wherein the step-by-step optimizing mode of the mathematical model calculation module in the step f comprises:
the mathematical model calculation module sets a furnace gas temperature value at the next moment to reduce delta e according to the current aluminum coil surface temperature so as to calculate an aluminum coil temperature field of the whole workpiece at the next moment, judges whether the calculated aluminum coil surface is over-heated or not, if so, continuously reduces the furnace gas temperature value at the next moment to be set by delta e so as to calculate an aluminum coil temperature field at the next moment until the aluminum coil surface temperature is lower than the target temperature, and takes the calculated furnace gas temperature value meeting the condition that the aluminum coil surface temperature is lower than the target temperature as a furnace temperature set value at the next moment to participate in furnace temperature control;
wherein the reduction delta e of the furnace gas temperature value is in the range of 0.1-5 ℃.
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