CN114522985B - Roller rolling control method, system and computer readable storage medium - Google Patents
Roller rolling control method, system and computer readable storage medium Download PDFInfo
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- CN114522985B CN114522985B CN202210384091.8A CN202210384091A CN114522985B CN 114522985 B CN114522985 B CN 114522985B CN 202210384091 A CN202210384091 A CN 202210384091A CN 114522985 B CN114522985 B CN 114522985B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
- B21B37/16—Control of thickness, width, diameter or other transverse dimensions
- B21B37/18—Automatic gauge control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
- B21B37/16—Control of thickness, width, diameter or other transverse dimensions
- B21B37/165—Control of thickness, width, diameter or other transverse dimensions responsive mainly to the measured thickness of the product
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B38/00—Methods or devices for measuring, detecting or monitoring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product
- B21B38/04—Methods or devices for measuring, detecting or monitoring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product for measuring thickness, width, diameter or other transverse dimensions of the product
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B2261/00—Product parameters
- B21B2261/02—Transverse dimensions
- B21B2261/04—Thickness, gauge
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B2271/00—Mill stand parameters
- B21B2271/02—Roll gap, screw-down position, draft position
Abstract
The invention provides a method, a system and a computer readable storage medium for controlling rolling of a roller, wherein the method comprises the following steps: setting initial rolling parameters of a roller according to the thickness requirement of a finished product workpiece; adjusting the roll gap of the roll by an adjusting mechanism according to the initial rolling parameters; the driving mechanism drives the roller to roll the workpiece; measuring and analyzing the thickness variation trend of the rolled workpiece along the direction vertical to the rolling path by using a laser thickness measuring instrument; judging whether the thickness variation trend exceeds a preset amplitude range, if so, triggering to generate a thickness adjustment instruction according to the thickness variation trend and the thickness requirement of the finished workpiece; and readjusting by the adjusting mechanism on the basis of the initial rolling parameters according to the thickness adjusting instruction to generate updated roller parameters. The invention can effectively ensure the qualified rate of the rolled workpiece, save the input cost of the workpiece and further improve the economic benefit.
Description
Technical Field
The invention relates to the technical field of automatic processing, in particular to a roller rolling control method, a roller rolling control system and a computer readable storage medium.
Background
Rolls are the primary working components and tools on a rolling mill that produce continuous plastic deformation of metal. The roller mainly comprises a roller body, a roller neck and a shaft head 3. The roll body is the middle part of the roll that actually participates in rolling the metal. It has a smooth cylindrical or grooved surface. The roll neck is mounted in bearings and transmits the rolling force to the stand through a bearing block and a screw down device. The driving end shaft head is connected with the gear seat through a connecting shaft, and the rotating torque of the motor is transmitted to the roller, so that the roller can roll the workpiece.
In a traditional rolling mill control mode, parameters are directly input manually, and a rolling mill performs rolling operation according to the parameters, however, due to errors of servo parts of the rolling mill or defects on a roller, a large number of rolled workpieces are prone to being out of specification requirements, so that the yield of the rolling operation is reduced, and the input cost of the workpieces is increased.
Disclosure of Invention
In order to solve at least one technical problem, the invention provides a roller rolling control method, a roller rolling control system and a computer readable storage medium, which can effectively ensure the qualified rate of rolled workpieces, save the input cost of the workpieces and further improve the economic benefit.
The invention provides a roller rolling control method in a first aspect, which comprises the following steps:
setting initial rolling parameters of a roller according to the thickness requirement of a finished workpiece, wherein the roller comprises an upper roller and a lower roller;
adjusting a roll gap between the upper roll and the lower roll by an adjusting mechanism according to the initial rolling parameters;
the driving mechanism drives the upper roller and the lower roller to roll the workpiece;
measuring the thickness of each position of the rolled workpiece by a laser thickness measuring instrument, and analyzing and obtaining the thickness variation trend of the rolled workpiece along the direction vertical to the rolling path;
judging whether the thickness variation trend exceeds a preset amplitude range, if so, triggering to generate a thickness adjusting instruction according to the thickness variation trend and the thickness requirement of the finished workpiece;
and feeding the thickness adjusting instruction back to the adjusting mechanism, readjusting by the adjusting mechanism on the basis of the initial rolling parameters according to the thickness adjusting instruction to generate updated roller parameters, and enabling the adjusting mechanism to adjust the roller gap between the upper roller and the lower roller according to the updated rolling parameters.
In this scheme, trigger the thickness adjustment instruction of formation according to the thickness variation trend and the thickness requirement of finished product work piece, specifically include:
obtaining the thickness of each position of the rolled workpiece along the direction vertical to the rolling path according to the thickness variation trend;
calculating the difference between the thickness of the finished workpiece and the thickness of each position of the rolled workpiece along the direction vertical to the rolling path;
and taking the difference value as a roll gap adjustment size of each position of the roll in the direction perpendicular to the rolling path, and generating a thickness adjustment instruction based on the roll gap adjustment size.
In this scheme, after the adjusting mechanism adjusts the roll gap between the upper roll and the lower roll according to the updated rolling parameter, the method further includes:
sequentially collecting the workpiece images with the same length output by rolling by an image collector according to a period T, wherein T is the time of one circle of rotation of the roller;
dividing each workpiece image into a plurality of small images with the same shape and size according to a preset dividing mode, wherein each small image corresponds to a specific position on the roller;
respectively comparing and analyzing the difference rate of each small block image with other small block images based on the current workpiece image, judging whether the difference rate is greater than a first preset threshold value, and if so, marking the corresponding small block image as a difference block;
on the basis of the current workpiece image, after each small block image is compared with other small block images in the difference rate, counting the total number of the small block images as the difference blocks, judging whether the total number is greater than a second preset threshold value or not, and if so, marking the corresponding small block image as an abnormal block;
respectively identifying and marking abnormal blocks of the subsequently acquired workpiece images, and outputting the abnormal blocks in the subsequent workpiece images;
judging whether small images at the same position in the current workpiece image and the subsequent workpiece image are marked as abnormal blocks, if so, mapping the corresponding coordinate position on the roller based on the position of the abnormal block in each workpiece image, marking the defect, and simultaneously sending alarm information, wherein the alarm information comprises the coordinate position of the defect mark on the roller.
In this scheme, gather the work piece image of roll-in output same length in proper order according to cycle T by the image collector, specifically include:
acquiring rolling data of the roller in each historical time period, wherein the rolling data at least comprises historical environment data and historical defect actual positions corresponding to the historical time periods;
constructing a defect prediction model, and training the defect prediction model based on rolling data of each historical time period to obtain a trained defect prediction model;
acquiring current environmental data, and inputting the current environmental data into the trained defect prediction model to output a predicted position of the defect on the roller;
if the defect prediction position is one, directly focusing an image collector on the defect prediction position to be mapped to a rolling area on the workpiece for image collection; and if the defect prediction positions are multiple and distributed at different positions, clustering the multiple defect prediction positions through a density clustering algorithm, acquiring a clustering center position, and directly focusing an image collector on the clustering center position to be mapped to a rolling area on the workpiece for image collection.
In this aspect, before the driving mechanism drives the upper roll and the lower roll to perform the rolling operation on the workpiece, the method further includes:
presetting a plurality of workpieces with the same specification to be rolled, and presetting the rotation speed of a roller asAnd has a radius ofAccording to the rotation speedAnd radiusCalculating the linear velocity of the roll;
Obtaining thickness of original single workpieceLength, lengthWidth, widthAnd the required thickness of the rolled workpieceAccording to the thickness of the original individual workpieceLength, lengthWidth ofCalculating the volume of a single workpiece;
According to the principle that the volumes of single workpieces before and after rolling are equal, calculating the length of the rolled workpieceAnd widthProduct of (2);
According to the principle that the rolled workpiece stretches in equal proportion in the length direction and the width direction, a formula is obtainedPush out;
In this scheme, after the adjusting mechanism adjusts the roll gap between the upper roll and the lower roll according to the updated rolling parameter, the method further includes:
the driving mechanism drives the roller to perform rolling operation according to the updated and adjusted roller gap;
analyzing an expansion curve of the roller along with the temperature change, and constructing a deformation prediction model based on the expansion curve;
acquiring a current temperature value of a roller, inputting the current temperature value into a deformation prediction model, and outputting a deformation amount of the roller relative to a reference size, wherein the reference size is the size of the roller at normal temperature;
and dynamically compensating the updated and adjusted roll gap based on the deformation amount to obtain a compensated roll gap, so that the roll rolls the workpiece according to the compensated roll gap.
The second aspect of the present invention further provides a roller rolling control system, including a memory and a processor, where the memory includes a program of a roller rolling control method, and the program of the roller rolling control method, when executed by the processor, implements the following steps:
setting initial rolling parameters of a roller according to the thickness requirement of a finished workpiece, wherein the roller comprises an upper roller and a lower roller;
adjusting a roll gap between the upper roll and the lower roll by an adjusting mechanism according to the initial rolling parameters;
the driving mechanism drives the upper roller and the lower roller to roll the workpiece;
measuring the thickness of each position of the rolled workpiece by a laser thickness measuring instrument, and analyzing and obtaining the thickness variation trend of the rolled workpiece along the direction vertical to the rolling path;
judging whether the thickness variation trend exceeds a preset amplitude range, if so, triggering to generate a thickness adjusting instruction according to the thickness variation trend and the thickness requirement of the finished workpiece;
and feeding the thickness adjusting instruction back to the adjusting mechanism, readjusting by the adjusting mechanism on the basis of the initial rolling parameters according to the thickness adjusting instruction to generate updated roller parameters, and enabling the adjusting mechanism to adjust the roller gap between the upper roller and the lower roller according to the updated rolling parameters.
In this scheme, require to trigger to generate thickness adjustment instruction according to the thickness of thickness variation trend and finished product work piece, specifically include:
obtaining the thickness of each position of the rolled workpiece along the direction vertical to the rolling path according to the thickness variation trend;
calculating the difference between the thickness of the finished workpiece and the thickness of each position of the rolled workpiece along the direction vertical to the rolling path;
and taking the difference value as a roll gap adjustment size of each position of the roll in the direction vertical to the rolling path, and generating a thickness adjustment instruction based on the roll gap adjustment size.
In this embodiment, after the adjusting mechanism adjusts the gap between the upper roll and the lower roll according to the updated rolling parameter, when the processor executes the program of the roll rolling control method, the following steps are further implemented:
sequentially collecting the workpiece images with the same length output by rolling by an image collector according to a period T, wherein T is the time of one circle of rotation of the roller;
dividing each workpiece image into a plurality of small images with the same shape and size according to a preset dividing mode, wherein each small image corresponds to a specific position on the roller;
respectively comparing and analyzing the difference rate of each small block image with other small block images based on the current workpiece image, judging whether the difference rate is greater than a first preset threshold value, and if so, marking the corresponding small block image as a difference block;
on the basis of the current workpiece image, after each small block image is compared with other small block images in the difference rate, counting the total number of the small block images as the difference blocks, judging whether the total number is greater than a second preset threshold value or not, and if so, marking the corresponding small block image as an abnormal block;
respectively identifying and marking abnormal blocks of the subsequently acquired workpiece images, and outputting the abnormal blocks in the subsequently acquired workpiece images;
judging whether small images at the same position in the current workpiece image and the subsequent workpiece image are marked as abnormal blocks, if so, mapping the corresponding coordinate position on the roller based on the position of the abnormal block in each workpiece image, marking the defect, and simultaneously sending alarm information, wherein the alarm information comprises the coordinate position of the defect mark on the roller.
The third aspect of the present invention also provides a computer-readable storage medium, which includes a program of a method for controlling roll rolling, and when the program of the method is executed by a processor, the method for controlling roll rolling realizes the steps of the method for controlling roll rolling.
The roll rolling control method, the roll rolling control system and the computer readable storage medium provided by the invention can effectively ensure the qualified rate of rolled workpieces, save the investment cost of the workpieces and further improve the economic benefit.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
FIG. 1 is a flow chart illustrating a method of roll control according to the present invention;
fig. 2 shows a block diagram of a roll and pressure control system according to the invention.
Detailed Description
In order that the above objects, features and advantages of the present invention can be more clearly understood, a more particular description of the invention will be rendered by reference to the appended drawings. It should be noted that the embodiments and features of the embodiments of the present application may be combined with each other without conflict.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, however, the present invention may be practiced otherwise than as specifically described herein and, therefore, the scope of the present invention is not limited by the specific embodiments disclosed below.
Fig. 1 shows a flow chart of a method for controlling roll rolling according to the invention.
As shown in fig. 1, a first aspect of the present invention provides a roll rolling control method, including:
s102, setting initial rolling parameters of a roller according to the thickness requirement of a finished workpiece, wherein the roller comprises an upper roller and a lower roller;
s104, adjusting a roll gap between the upper roll and the lower roll by an adjusting mechanism according to the initial rolling parameters;
s106, driving an upper roller and a lower roller by a driving mechanism to perform rolling operation on the workpiece;
s108, measuring the thickness of each position of the rolled workpiece by using a laser thickness measuring instrument, and analyzing and obtaining the thickness variation trend of the rolled workpiece along the direction vertical to the rolling path;
s110, judging whether the thickness variation trend exceeds a preset amplitude range, if so, triggering and generating a thickness adjusting instruction according to the thickness variation trend and the thickness requirement of a finished workpiece;
and S112, feeding the thickness adjusting instruction back to the adjusting mechanism, readjusting by the adjusting mechanism on the basis of the initial rolling parameters according to the thickness adjusting instruction to generate updated roller parameters, and enabling the adjusting mechanism to adjust the roller gap between the upper roller and the lower roller according to the updated rolling parameters.
After the initial rolling parameters of the roll are set, the thickness of the rolled workpiece may not meet the thickness requirement of the finished workpiece due to the internal servo components and the influence of roll errors, and if the subsequent rolling operation is continued according to the initial rolling parameters, more defective products are inevitably generated. The invention measures the thickness of each position of the rolled workpiece through a laser thickness measuring instrument, adjusts and updates the initial rolling parameter reversely based on the thickness of each position of the rolled workpiece, enables the updated rolling parameter to compensate the influence of the servo component and the roller error, and enables the rolled workpiece to meet the thickness requirement of the finished workpiece. Thereby improving the yield of the workpieces in the rolling industry, further saving the input cost of the workpieces and improving the economic benefit.
It can be understood that the axes of the upper roll and the lower roll are generally arranged in parallel, but due to the influence of the servo component, the axes of the upper roll and the lower roll are not parallel, so that the rolling thickness of the workpiece at different positions is different.
It can be understood that the thickness of the rolled workpiece at different positions is allowed to vary within a preset floating range according to the requirements of users, and if the thickness is exceeded, the rolled workpiece is determined to be unqualified. The invention judges whether the thickness variation trend exceeds the preset amplitude range, if so, the initial rolling parameters are required to be adjusted and updated; if the frequency does not exceed the preset frequency, adjustment is not needed, so that the adjustment frequency is reduced, and the phenomenon of reduction of the production efficiency of workpieces caused by frequent adjustment is avoided.
According to the embodiment of the invention, the thickness adjusting instruction is triggered and generated according to the thickness variation trend and the thickness requirement of the finished workpiece, and the method specifically comprises the following steps:
obtaining the thickness of each position of the rolled workpiece along the direction vertical to the rolling path according to the thickness variation trend;
calculating the difference between the thickness of the finished workpiece and the thickness of each position of the rolled workpiece along the direction vertical to the rolling path;
and taking the difference value as a roll gap adjustment size of each position of the roll in the direction vertical to the rolling path, and generating a thickness adjustment instruction based on the roll gap adjustment size.
It is understood that the difference can be positive or negative, and if the difference is positive, the thickness of the workpiece at the position after rolling is less than that of the finished workpiece, and the roll gap between the upper and lower rolls at the position needs to be increased. If the negative number indicates that the thickness of the workpiece at the position after rolling exceeds the thickness of the finished workpiece, the roll gap between the upper and lower rolls at the position needs to be reduced. According to the invention, the adjusting mechanism is triggered to update and adjust based on the rolled workpiece thickness, so that the subsequent rolled workpiece meets the thickness requirement of the finished workpiece, and the overall qualification rate of the workpiece is improved.
According to an embodiment of the present invention, after the adjusting mechanism adjusts the roll gap between the upper roll and the lower roll according to the updated rolling parameter, the method further includes:
sequentially collecting the workpiece images with the same length output by rolling by an image collector according to a period T, wherein T is the time of one circle of rotation of the roller;
dividing each workpiece image into a plurality of small images with the same shape and size according to a preset dividing mode, wherein each small image corresponds to a specific position on the roller;
respectively comparing and analyzing the difference rate of each small image with other small images based on the current workpiece image, judging whether the difference rate is greater than a first preset threshold value, and if so, marking the corresponding small image as a difference block;
on the basis of the current workpiece image, after each small block image is compared with other small block images in the difference rate, counting the total number of the small block images as the difference blocks, judging whether the total number is greater than a second preset threshold value or not, and if so, marking the corresponding small block image as an abnormal block;
respectively identifying and marking abnormal blocks of the subsequently acquired workpiece images, and outputting the abnormal blocks in the subsequently acquired workpiece images;
judging whether small images at the same position in the current workpiece image and the subsequent workpiece image are marked as abnormal blocks, if so, mapping the corresponding coordinate position on the roller based on the position of the abnormal block in each workpiece image, marking defects, and simultaneously sending alarm information, wherein the alarm information comprises the coordinate position of the defect mark on the roller.
According to the specific embodiment of the present invention, the comparing and analyzing of the difference rate between each small block image and other small block images includes:
acquiring the gray value of each pixel point of each small image, and performing difference comparison on the gray value of each pixel point of each small image and the gray values of each pixel point of other small images;
if the difference value exceeds a third preset threshold value, judging the corresponding pixel point as a difference pixel point;
and counting the total number of the difference pixels in each small image, and dividing the total number by the total number of all the pixels in each small image to obtain the difference rate of each small image.
It should be noted that the present invention identifies defects (such as bumps or pits) on the roll by performing image acquisition on the workpiece. It can be understood that, usually, a roller is a rotary rolling operation, if a defect point exists on the roller, the defect point is difficult to identify due to the movement of the roller, and the image collector can collect an image of a workpiece and deduce the position of the defect on the roller by analyzing the position of an abnormal block on the image of the workpiece. And when the defect position is analyzed, an alarm can be given out so as to repair the roller and improve the qualification rate of subsequent workpieces.
It can be understood that, since the roll is a periodic roll operation, if a defect occurs on the roll, the abnormal blocks on the workpiece should also be regularly distributed, that is, the small block images of the continuous multiple workpiece images at the same position are all marked as abnormal blocks, otherwise, the defect on the roll cannot be considered.
According to a specific embodiment of the present invention, after marking the corresponding small block image as an abnormal block, the method further comprises:
selecting a small block image which is not an abnormal block from the current workpiece image;
respectively carrying out difference comparison on the small block image of each abnormal block and the small block images which are not abnormal blocks one by one;
judging whether the difference rate of the small block image of a certain abnormal block and the small block image which is not the abnormal block is smaller than a third preset threshold value, if so, recording that the small block image of the abnormal block is judged by mistake once;
and counting the total misjudgment number of the small block images of each abnormal block, judging whether the total misjudgment number of the small block images of each abnormal block is greater than a fourth preset threshold value, and deleting the abnormal block mark corresponding to the small block image if the total misjudgment number of the small block images of each abnormal block is greater than the fourth preset threshold value.
It should be noted that, in the comparison process between the small block images, there may be a certain erroneous determination, for example, if the first preset threshold and the second preset threshold are set to be relatively low, the normal small block image may be erroneously determined as an abnormal block.
According to a specific embodiment of the present invention, after deleting the abnormal block flag of the corresponding small block image, the method further includes:
presetting a workpiece corresponding to each workpiece image, and counting all effective abnormal blocks and corresponding position areas on each workpiece image;
presetting different importance degrees of different position areas to the workpiece, and setting influence weights of the different position areas based on the importance degrees of the different position areas to the workpiece;
accumulating the influence weights of all effective abnormal blocks in each workpiece image to obtain the weight sum of each workpiece image;
and judging whether the weight sum is greater than a preset limit value, if so, judging that the corresponding workpiece is unqualified, sending out prompt information, and conveying the prompt information to an unqualified area by a conveying mechanism.
It can be understood that, according to the position of the abnormal block on each workpiece, and different positions have corresponding influence weights, for example, the weight near the middle is large, and the weight at the edge part is small, the influence weight of the abnormal block of each workpiece is accumulated, the accumulated weight sum is compared with a preset limit value, and if the weight sum is larger than the preset limit value, the workpiece is judged to be unqualified.
According to the embodiment of the invention, the image collector sequentially collects the rolled workpiece images with the same length according to the period T, and the method specifically comprises the following steps:
acquiring rolling data of the roller in each historical time period, wherein the rolling data at least comprises historical environment data and historical defect actual positions corresponding to the historical time periods;
constructing a defect prediction model, and training the defect prediction model based on rolling data of each historical time period to obtain a trained defect prediction model;
acquiring current environmental data, and inputting the current environmental data into the trained defect prediction model to output a predicted position of the defect on the roller;
if the defect prediction position is one, directly focusing an image collector on the defect prediction position to be mapped to a rolling area on the workpiece for image collection; and if the defect prediction positions are multiple and distributed at different positions, clustering the multiple defect prediction positions through a density clustering algorithm, acquiring a clustering center position, and directly focusing an image collector on the clustering center position to be mapped to a rolling area on the workpiece for image collection.
It should be noted that the width of the preset workpiece is large, and the image collector cannot collect a complete workpiece image at one time, and the method and the device construct a defect prediction model of the roller according to historical rolling data, predict a corresponding defect position, and perform focused image collection on the workpiece based on the predicted defect position, so that an abnormal block can be locked quickly, and the defect detection efficiency of the roller is improved.
According to a specific embodiment of the present invention, after outputting the predicted location of the defect on the roll, the method further comprises:
performing characteristic calculation on the historical environment data of each historical time period to obtain first characteristics of the historical environment data of each historical time period;
performing feature calculation on the current environment data to obtain a second feature of the current environment data;
respectively carrying out similarity comparison on the second characteristics of the current environment data and the first characteristics of the historical environment data of each historical time period;
storing the rolling data of the corresponding historical time period with the similarity larger than a fifth preset threshold in a first database;
respectively inputting historical environment data of each historical time period in the first database into a defect prediction model, and outputting historical defect prediction positions of each historical time period in the first database;
respectively calculating vectors between actual positions and predicted positions of the historical defects in each historical time period in the first database, and averaging all the vectors to obtain a correction offset;
and correcting the predicted defect position of the roller based on the correction offset to obtain the corrected predicted defect position.
According to an embodiment of the present invention, before the rolling work of the workpiece is performed by driving the upper and lower rolls by the driving mechanism, the method further includes:
presetting a plurality of workpieces with the same specification to be rolled, wherein the rotation speed of a preset roller isAnd has a radius ofAccording to the rotation speedDegree of rotationAnd radiusCalculating the linear velocity of the roll;
Obtaining thickness of original single workpieceLength, lengthWidth ofAnd the required thickness of the rolled workpieceAccording to the thickness of the original single workpieceLength, lengthWidth, widthCalculating the volume of a single workpiece;
According to the principle that the volumes of single workpieces before and after rolling are equal, calculating the length of the rolled workpieceAnd widthProduct of (2);
According to the principle that the rolled workpiece is stretched in equal proportion in the length direction and the width direction, a formula is obtainedPush out;
It should be noted that, in order to improve the rolling efficiency of a plurality of workpieces, the spacing distance between two adjacent workpieces should be reduced as much as possible, however, if the spacing distance between two adjacent workpieces is excessively reducedThe rolling gap time limit value is calculated to avoid the rolling interference between two adjacent workpieces and influence the rolling yield of each workpieceAnd the rolling interval time range of two adjacent workpieces is set to be more than or equal to。
According to an embodiment of the present invention, after the adjusting mechanism adjusts the roll gap between the upper roll and the lower roll according to the updated rolling parameter, the method further includes:
the driving mechanism drives the roller to perform rolling operation according to the updated and adjusted roller gap;
analyzing an expansion curve of the roller along with the temperature change, and constructing a deformation prediction model based on the expansion curve;
acquiring a current temperature value of a roller, inputting the current temperature value into a deformation prediction model, and outputting a deformation amount of the roller relative to a reference size, wherein the reference size is the size of the roller at normal temperature;
and dynamically compensating the updated and adjusted roll gap based on the deformation amount to obtain a compensated roll gap, so that the roll rolls the workpiece according to the compensated roll gap.
It should be noted that, since the roller is made of a metal material, heat is generated during the rolling process, and the temperature of the roller is further raised, and according to the thermal deformation property of the metal material, the higher the temperature is, the larger the expansion deformation is, and further the gap between the upper roller and the lower roller is reduced. In order to reduce the influence of the change of the roll gap caused by the expansion or contraction of the roll, the current deformation quantity of the roll is predicted through the deformation prediction model, and the roll gap is dynamically compensated based on the deformation quantity, so that the rolling qualified rate of a workpiece is improved.
According to a particular embodiment of the invention, after outputting the amount of deformation of the roll with respect to a reference dimension, the method further comprises:
recording real deformation data of the roller at various historical temperatures;
outputting corresponding predicted deformation data through deformation prediction models based on various historical temperatures;
subtracting the actual deformation data of various historical temperatures from the predicted deformation data to obtain deformation correction values of the various historical temperatures;
constructing a deformation correction prediction model, and training the deformation correction prediction model based on various historical temperatures and corresponding deformation correction values to obtain an optimized deformation correction prediction model;
inputting the current temperature value into the optimized deformation correction prediction model, and outputting the deformation correction value of the current temperature;
and correcting the deformation quantity based on the deformation correction value to obtain the corrected deformation quantity.
It should be noted that, the invention can sense the real deformation data of the roller at various temperatures through the deformation sensor, and then perform difference calculation with the predicted deformation data output by the deformation prediction model to obtain the deformation correction value, it can be understood that the deformation correction values at different temperatures are different.
Fig. 2 shows a block diagram of a roll rolling control system according to the invention.
As shown in fig. 2, the second aspect of the present invention further provides a roll controlling system 2, which includes a memory 21 and a processor 22, where the memory includes a roll controlling method program, and the roll controlling method program, when executed by the processor, implements the following steps:
setting initial rolling parameters of a roller according to the thickness requirement of a finished workpiece, wherein the roller comprises an upper roller and a lower roller;
adjusting a roll gap between the upper roll and the lower roll by an adjusting mechanism according to the initial rolling parameters;
the driving mechanism drives the upper roller and the lower roller to roll the workpiece;
measuring the thickness of each position of the rolled workpiece by a laser thickness measuring instrument, and analyzing and obtaining the thickness variation trend of the rolled workpiece along the direction vertical to the rolling path;
judging whether the thickness variation trend exceeds a preset amplitude range, if so, triggering to generate a thickness adjustment instruction according to the thickness variation trend and the thickness requirement of the finished workpiece;
and feeding the thickness adjusting instruction back to the adjusting mechanism, readjusting by the adjusting mechanism on the basis of the initial rolling parameters according to the thickness adjusting instruction to generate updated roller parameters, and enabling the adjusting mechanism to adjust the roller gap between the upper roller and the lower roller according to the updated rolling parameters.
According to the embodiment of the invention, the thickness adjusting instruction is triggered and generated according to the thickness variation trend and the thickness requirement of the finished workpiece, and the method specifically comprises the following steps:
obtaining the thickness of each position of the rolled workpiece along the direction vertical to the rolling path according to the thickness variation trend;
calculating the difference between the thickness of the finished workpiece and the thickness of each position of the rolled workpiece along the direction vertical to the rolling path;
and taking the difference value as a roll gap adjustment size of each position of the roll in the direction vertical to the rolling path, and generating a thickness adjustment instruction based on the roll gap adjustment size.
According to an embodiment of the present invention, after the adjusting mechanism adjusts the roll gap between the upper roll and the lower roll according to the updated rolling parameter, the roll rolling control method program further implements the following steps when executed by the processor:
sequentially collecting the workpiece images with the same length output by rolling by an image collector according to a period T, wherein T is the time of one circle of rotation of the roller;
dividing each workpiece image into a plurality of small images with the same shape and size according to a preset dividing mode, wherein each small image corresponds to a specific position on the roller;
respectively comparing and analyzing the difference rate of each small image with other small images based on the current workpiece image, judging whether the difference rate is greater than a first preset threshold value, and if so, marking the corresponding small image as a difference block;
on the basis of the current workpiece image, after each small block image is compared with other small block images in the difference rate, counting the total number of the small block images as the difference blocks, judging whether the total number is greater than a second preset threshold value or not, and if so, marking the corresponding small block image as an abnormal block;
respectively identifying and marking abnormal blocks of the subsequently acquired workpiece images, and outputting the abnormal blocks in the subsequently acquired workpiece images;
judging whether small images at the same position in the current workpiece image and the subsequent workpiece image are marked as abnormal blocks, if so, mapping the corresponding coordinate position on the roller based on the position of the abnormal block in each workpiece image, marking defects, and simultaneously sending alarm information, wherein the alarm information comprises the coordinate position of the defect mark on the roller.
The third aspect of the present invention further provides a computer-readable storage medium, where the computer-readable storage medium includes a program of a roll rolling control method, and when the program of the roll rolling control method is executed by a processor, the steps of the roll rolling control method are implemented.
The roll rolling control method, the roll rolling control system and the computer readable storage medium provided by the invention can effectively ensure the qualified rate of rolled workpieces, save the investment cost of the workpieces and further improve the economic benefit.
In the several embodiments provided in the present application, it should be understood that the disclosed apparatus and method may be implemented in other manners. The above-described device embodiments are merely illustrative, for example, the division of the unit is only one logical function division, and there may be other division ways in actual implementation, such as: multiple units or components may be combined, or may be integrated into another system, or some features may be omitted, or not implemented. In addition, the coupling, direct coupling or communication connection between the components shown or discussed may be through some interfaces, and the indirect coupling or communication connection between the devices or units may be electrical, mechanical or in other forms.
The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units; can be located in one place or distributed on a plurality of network units; some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment.
In addition, all the functional units in the embodiments of the present invention may be integrated into one processing unit, or each unit may be separately regarded as one unit, or two or more units may be integrated into one unit; the integrated unit may be implemented in the form of hardware, or in the form of hardware plus a software functional unit.
Those of ordinary skill in the art will understand that: all or part of the steps for realizing the method embodiments can be completed by hardware related to program instructions, the program can be stored in a computer readable storage medium, and the program executes the steps comprising the method embodiments when executed; and the aforementioned storage medium includes: a mobile storage device, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, and various media capable of storing program codes.
Alternatively, the integrated unit of the present invention may be stored in a computer-readable storage medium if it is implemented in the form of a software functional module and sold or used as a separate product. Based on such understanding, the technical solutions of the embodiments of the present invention may be essentially implemented or a part contributing to the prior art may be embodied in the form of a software product, which is stored in a storage medium and includes several instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the methods described in the embodiments of the present invention. And the aforementioned storage medium includes: a removable storage device, a ROM, a RAM, a magnetic or optical disk, or various other media that can store program code.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (8)
1. A method of roll control, the method comprising:
setting initial rolling parameters of a roller according to the thickness requirement of a finished workpiece, wherein the roller comprises an upper roller and a lower roller;
adjusting a roll gap between the upper roll and the lower roll by an adjusting mechanism according to the initial rolling parameters;
the driving mechanism drives the upper roller and the lower roller to perform rolling operation on the workpiece;
measuring the thickness of each position of the rolled workpiece by a laser thickness measuring instrument, and analyzing and obtaining the thickness variation trend of the rolled workpiece along the direction vertical to the rolling path;
judging whether the thickness variation trend exceeds a preset amplitude range, if so, triggering to generate a thickness adjusting instruction according to the thickness variation trend and the thickness requirement of the finished workpiece;
feeding the thickness adjusting instruction back to the adjusting mechanism, readjusting by the adjusting mechanism on the basis of the initial rolling parameters according to the thickness adjusting instruction to generate updated roller parameters, and enabling the adjusting mechanism to adjust the roller gap between the upper roller and the lower roller according to the updated rolling parameters;
sequentially collecting the workpiece images with the same length output by rolling by an image collector according to a period T, wherein T is the time of one circle of rotation of the roller;
dividing each workpiece image into a plurality of small images with the same shape and size according to a preset dividing mode, wherein each small image corresponds to a specific position on the roller;
respectively comparing and analyzing the difference rate of each small image with other small images based on the current workpiece image, judging whether the difference rate is greater than a first preset threshold value, and if so, marking the corresponding small image as a difference block;
on the basis of the current workpiece image, after each small block image is compared with other small block images in the difference rate, counting the total number of the small block images as the difference blocks, judging whether the total number is greater than a second preset threshold value or not, and if so, marking the corresponding small block image as an abnormal block;
respectively identifying and marking abnormal blocks of the subsequently acquired workpiece images, and outputting the abnormal blocks in the subsequently acquired workpiece images;
judging whether small images at the same position in the current workpiece image and the subsequent workpiece image are marked as abnormal blocks, if so, mapping the corresponding coordinate position on the roller based on the position of the abnormal block in each workpiece image, marking the defect, and simultaneously sending alarm information, wherein the alarm information comprises the coordinate position of the defect mark on the roller.
2. The method for controlling rolling of the roller according to claim 1, wherein triggering generation of the thickness adjustment instruction according to the thickness variation trend and the thickness requirement of the finished workpiece specifically comprises:
obtaining the thickness of each position of the rolled workpiece along the direction vertical to the rolling path according to the thickness variation trend;
calculating the difference between the thickness of the finished workpiece and the thickness of each position of the rolled workpiece along the direction vertical to the rolling path;
and taking the difference value as a roll gap adjustment size of each position of the roll in the direction perpendicular to the rolling path, and generating a thickness adjustment instruction based on the roll gap adjustment size.
3. The method for controlling roll pressing according to claim 1, wherein the image collector sequentially collects the images of the workpieces with the same length output by roll pressing according to a period T, and specifically comprises:
obtaining rolling data of the roller in each historical time period, wherein the rolling data at least comprises historical environment data and historical defect actual positions of corresponding historical time periods;
constructing a defect prediction model, and training the defect prediction model based on rolling data of each historical time period to obtain a trained defect prediction model;
acquiring current environmental data, and inputting the current environmental data into the trained defect prediction model to output a predicted position of the defect on the roller;
if the defect prediction position is one, directly focusing an image collector on the defect prediction position to be mapped to a rolling area on the workpiece for image collection; and if the defect prediction positions are multiple and distributed at different positions, clustering the multiple defect prediction positions through a density clustering algorithm, acquiring a clustering center position, and directly focusing an image collector on the clustering center position to be mapped to a rolling area on the workpiece for image collection.
4. A method for controlling roll pressure according to claim 1, wherein before the upper roll and the lower roll are driven by the driving mechanism to perform the rolling operation on the workpiece, the method further comprises:
presetting a plurality of workpieces with the same specification to be rolled, presetting the rotation speed of a roller as omega and the radius as r, and calculating the linear speed v = omega x r of the roller according to the rotation speed omega and the radius r;
obtaining the thickness h of the original single workpiece 1 Length x 1 Width y 1 And the required thickness h of the rolled workpiece 2 According to the thickness h of the original individual workpiece 1 Length x 1 Width y of 1 Calculating the volume p = h of a single workpiece 1 ×x 1 ×y 1 ;
Calculating the length x of the rolled workpiece according to the principle that the volumes of single workpieces are equal before and after rolling 2 And width y 2 Product of (2)
According to the principle that the rolled workpiece is stretched in equal proportion in the length direction and the width direction, a formula is obtainedPush out
X obtained by calculation 2 Dividing by the linear velocity v to obtain the rolling interval time limit value
5. The method of claim 1, wherein after the adjusting mechanism adjusts the gap between the upper roll and the lower roll according to the updated rolling parameter, the method further comprises:
the driving mechanism drives the roller to perform rolling operation according to the updated and adjusted roller gap;
analyzing an expansion curve of the roller along with the temperature change, and constructing a deformation prediction model based on the expansion curve;
acquiring a current temperature value of a roller, inputting the current temperature value into a deformation prediction model, and outputting a deformation amount of the roller relative to a reference size, wherein the reference size is the size of the roller at normal temperature;
and dynamically compensating the updated and adjusted roll gap based on the deformation amount to obtain a compensated roll gap, so that the roll rolls the workpiece according to the compensated roll gap.
6. The roll rolling control system is characterized by comprising a memory and a processor, wherein the memory comprises a roll rolling control method program, and the roll rolling control method program realizes the following steps when being executed by the processor:
setting initial rolling parameters of a roller according to the thickness requirement of a finished workpiece, wherein the roller comprises an upper roller and a lower roller;
adjusting a roll gap between the upper roll and the lower roll by an adjusting mechanism according to the initial rolling parameters;
the driving mechanism drives the upper roller and the lower roller to roll the workpiece;
measuring the thickness of each position of the rolled workpiece by a laser thickness measuring instrument, and analyzing and obtaining the thickness variation trend of the rolled workpiece along the direction vertical to the rolling path;
judging whether the thickness variation trend exceeds a preset amplitude range, if so, triggering to generate a thickness adjusting instruction according to the thickness variation trend and the thickness requirement of the finished workpiece;
feeding the thickness adjusting instruction back to the adjusting mechanism, readjusting by the adjusting mechanism on the basis of the initial rolling parameters according to the thickness adjusting instruction to generate updated roller parameters, and enabling the adjusting mechanism to adjust the roller gap between the upper roller and the lower roller according to the updated rolling parameters;
sequentially collecting the workpiece images with the same length output by rolling by an image collector according to a period T, wherein T is the time of one circle of rotation of the roller;
dividing each workpiece image into a plurality of small images with the same shape and size according to a preset dividing mode, wherein each small image corresponds to a specific position on the roller;
respectively comparing and analyzing the difference rate of each small image with other small images based on the current workpiece image, judging whether the difference rate is greater than a first preset threshold value, and if so, marking the corresponding small image as a difference block;
on the basis of the current workpiece image, after each small block image is compared with other small block images in the difference rate, counting the total number of the small block images as the difference blocks, judging whether the total number is greater than a second preset threshold value or not, and if so, marking the corresponding small block image as an abnormal block;
respectively identifying and marking abnormal blocks of the subsequently acquired workpiece images, and outputting the abnormal blocks in the subsequently acquired workpiece images;
judging whether small images at the same position in the current workpiece image and the subsequent workpiece image are marked as abnormal blocks, if so, mapping the corresponding coordinate position on the roller based on the position of the abnormal block in each workpiece image, marking defects, and simultaneously sending alarm information, wherein the alarm information comprises the coordinate position of the defect mark on the roller.
7. The roll rolling control system according to claim 6, wherein the triggering generation of the thickness adjustment command according to the thickness variation trend and the thickness requirement of the finished workpiece specifically comprises:
obtaining the thickness of each position of the rolled workpiece along the direction vertical to the rolling path according to the thickness variation trend;
calculating the difference between the thickness of the finished workpiece and the thickness of each position of the rolled workpiece along the direction vertical to the rolling path;
and taking the difference value as a roll gap adjustment size of each position of the roll in the direction vertical to the rolling path, and generating a thickness adjustment instruction based on the roll gap adjustment size.
8. A computer-readable storage medium, characterized in that the computer-readable storage medium includes a program of a method of controlling roll rolling, which when executed by a processor, implements the steps of a method of controlling roll rolling as claimed in any one of claims 1 to 5.
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Denomination of invention: A roll rolling control method, system and computer-readable storage medium Effective date of registration: 20230113 Granted publication date: 20221014 Pledgee: Bank of China Co.,Ltd. Dongguan Branch Pledgor: DONGGUAN HIGEN-BYTEK INTELLIGENT EQUIPMENT CO.,LTD. Registration number: Y2023980030769 |