CN115007662A - Seamless steel tube production control device - Google Patents
Seamless steel tube production control device Download PDFInfo
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- CN115007662A CN115007662A CN202210942989.2A CN202210942989A CN115007662A CN 115007662 A CN115007662 A CN 115007662A CN 202210942989 A CN202210942989 A CN 202210942989A CN 115007662 A CN115007662 A CN 115007662A
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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
- B21B37/78—Control of tube rolling
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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
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P23/00—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
- B23P23/06—Metal-working plant comprising a number of associated machines or apparatus
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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
- B21B2038/004—Measuring scale thickness
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention belongs to the technical field of steel pipe production control, and provides a seamless steel pipe production control device, which comprises: the device comprises a pipe blank area production control unit, a hot rolling area production control unit, a pipe row saw area production control unit and a finishing area production control unit. The production control unit of the finishing area carries out finishing treatment and detection on the seamless steel pipe entering the finishing area, and the production control unit of the tube gang saw area is provided with a steel pipe quality online judging system for judging the quality of the seamless steel pipe after the sizing and reducing. According to the invention, the on-line size detection in the production process of the steel pipe can be realized while the steel pipe in the production process is tracked one by one, and the timeliness, the accuracy and the integrity of the tracking of the material one by one and the production are ensured.
Description
Technical Field
The invention belongs to the technical field of steel pipe production control, and particularly relates to a seamless steel pipe production control device.
Background
The processing technology of the seamless steel tube is complex, and at least relates to relevant equipment such as long-scale blank sawing, annular furnace, perforating machine, rolling mill, sizing mill, cooling bed, tube row sawing, straightening machine, dust blowing and sucking, flaw detector, length measuring weighing machine, packing machine and the like, wherein generally, each equipment is provided by different manufacturers, each equipment is provided with independent PLC control work, the PLC of each equipment is connected with MES (production execution system), the MES is used for carrying out flow control among the equipment, and obtaining relevant production information and the like is implemented. The material moving path is changeable when one long billet passes through each device for processing, and relates to a technological process that one long billet is changed into a plurality of fixed billets, and after the fixed billets are rolled into steel pipes, the steel pipes are sawed into a plurality of steel pipes.
In the quality standard of seamless steel pipes, the requirements on the product quality mainly comprise several aspects: geometric accuracy, surface quality, chemical composition, physical and chemical properties, technological properties, metallographic structure and the like. Among them, the geometric accuracy of seamless steel pipes is most important for measuring the quality of products, especially the wall thickness and the outer diameter of the steel pipe.
A large amount of long-term work is carried out on the aspect of the dimensional accuracy of the seamless steel tube by a plurality of scholars and experts, methods and theories for improving the dimensional accuracy are formed, and production process parameters are optimized. For example, a paper "hot-rolled seamless steel tube wall thickness accuracy control strategy and method" (china metallurgy, 2020, 11 th) studies a deformation process of hot-rolled seamless steel tube wall thickness accuracy in a typical three-step process, finds out influence factors influencing the wall thickness accuracy, and applies a quality control chart to hot-rolled wall thickness accuracy analysis to obtain a corresponding relation between the influence factors and wall thickness accuracy indexes. The thesis of wall thickness precision control of seamless steel pipes (pressure processing, 5 th 2009) combines theory and field actual situation to perform and analysis on the wall thickness deviation product reasons of seamless steel pipes, so as to obtain the main reasons of wall thickness deviation, such as pipe billet heating temperature, core rod precision, rolling tool installation precision and the like, and optimize and improve the wall thickness deviation band, so that the wall thickness deviation band is reduced.
However, the above researches on the dimensional accuracy of the steel pipe are based on off-line data analysis, and have time lag, most of the researches depend on manual off-line detection in an actual field, the measurement result has deviation, the field working condition can change along with time, and the data of the off-line steel pipe dimensional accuracy analysis can not well reflect the actual situation of the steel pipe one by one. In the production process of seamless steel pipes, at present, a batch of steel pipes are selected, several steel pipes are checked, offline measurement and recording are carried out, judgment is not carried out, and when the judgment is required, special quality inspection personnel comprehensively consider all factors and then judge. The quality testing personnel can only give final judgment through a small amount of data (an off-line sampling mode), the condition of wrong judgment often occurs, and quality disputes also exist when the quality testing personnel judge the qualified outgoing products.
Therefore, the on-line detection of the steel pipes one by one can correspond to the size detection of each steel pipe and can reflect the size data of the steel pipes in real time, and the method has great significance for improving the size precision of the steel pipes. At present, the tracking condition of the steel pipes one by one is that the end part of each long billet is written or sprayed with a furnace platform number, a furnace sequence number, a billet flow number and a material, but the steel pipe production still adopts the furnace organization. Although the automation degree of the rolling process is high, the single-line conveying is performed from the long-sized blank entering the annular furnace to the lower cooling bed, the subsequent production process has more off-line processes, the marks are easy to wear, and the multiple stations of the production process are frequently subjected to on-line and off-line processes, so that the tracking of the whole process is difficult to realize one by one.
Under the background that the industrial automation degree is continuously improved, the steel pipe quality on-line detection is needed to be realized while the steel pipe in the production process is tracked one by one, and at present, no better solution is available.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a seamless steel tube production control device which can realize online detection of the quality of a steel tube while tracking the steel tube by using an identifier and a logic station, and ensure the timeliness, accuracy and integrity of material tracking by one branch.
A seamless steel pipe production control apparatus comprising:
the tube blank area production control unit is used for performing branch-by-branch tracking production control on the seamless steel tube blank entering the tube blank area by using the mark on the tube blank;
the hot rolling area production control unit is used for performing branch-by-branch tracking production control on the fixed-size blanks entering the hot rolling area, and is provided with a roller reduction control device;
the tube array sawing area production control unit is used for carrying out tracking production control on the plurality of sub-tubes cut in the tube array sawing area one by one; and
the finishing area production control unit is used for finishing and detecting the seamless steel pipe entering the finishing area,
the production control unit of the tube bank sawing area comprises a steel tube quality online judging system, is used for judging the quality of the seamless steel tube after the diameter is reduced, and comprises the following components:
the steel pipe size acquisition module: the device is used for collecting actually measured curve data in the production process of the seamless steel pipe and filing the actually measured curve data on the branch-by-branch steel pipe, wherein the actually measured curve data at least comprises wall thickness data of the steel pipe;
a quality determination module: the quality judging module judges the quality of the steel pipe according to the actually measured curve data and the judging rule;
a judgment result transmission module: and transmitting the judged quality of the steel pipe to a production execution system.
Optionally, the quality determination module at least includes a single steel pipe wall thickness qualification rate determination rule, and the single steel pipe wall thickness qualification rate determination rule is as follows:
wherein, the wall thickness of a plurality of points is measured at intervals along the axial direction of the steel pipe,
the wall thickness of a certain point of the steel pipe;
the total measuring point number of the wall thickness along the axial direction on the steel pipe is measured;
H_
the qualified rate of the wall thickness of the steel pipe is obtained;
Optionally, the quality determination module further comprises a standard deviation rule，The standard deviation rule is as follows:
wherein, the wall thickness of a plurality of points is measured at intervals along the axial direction of the steel pipe,
in order to measure the average value of the wall thickness,
is the wall thickness standard deviation;
Optionally, the quality determination module further includes a range value determination rule, and the range value rule is as follows:
wherein, along the axial line segment of the steel pipe
The wall thickness of a plurality of points is measured at intervals in sequence,
、
for measuring wall thickness
The first step
Wall thickness values of the individual measurement points;
Optionally, the quality determination module further includes a maximum value and a minimum value determination rule, and the rule is as follows:
wherein the content of the first and second substances,
the wall thickness value of any point measured in the axial direction of the steel pipe is obtained;
Optionally, the quality determination module further includes a determination rule that the continuous points exceed an upper limit, which is expressed as follows:
wherein the content of the first and second substances,
the wall thickness value of any point measured in the axial direction of the steel pipe,nin order to limit the maximum number of out-of-tolerance points,
the upper limit value of the wall thickness;
Optionally, the quality determination module further comprises a wall thickness mean minimum determination rule expressed as follows:
wherein
For the first and last wall thickness values measured,
the lower limit value of the wall thickness is,
to calculate the average value of the wall thickness;
Optionally, the production control unit of the pipe gang saw area further comprises a steel pipe cutting control device for controlling the cutting length of the head and the tail of the pipe, and the steel pipe cutting control device calculates the cutting length L of the head and the tail of the steel pipe according to the following formula 2 q ：
L q =
（2）
Wherein the content of the first and second substances,
the pass coefficient is in the range of 0.65-0.75;
S n is the number of participating rolling stands, and S n Greater than 3;
Z m is the average tension coefficient of the parent tube;
y is a tension superposition coefficient, and the value range is as follows: 0.65 to 0.67;
D z is the distance between adjacent racks;
alpha is the thermal expansion coefficient of the mother tube and takes 1.01
；
Δ X is the varying temperature from the sizer outlet to the tube row saw area.
Optionally, the steel pipe size acquisition module calculates the length L of the end-to-end of the actually measured curve data according to formula 2 q 。
Optionally, the communication mode between the determination result transmission module and the production execution system is one of rockmq, RestAPI, and DBLink.
According to the structure, the seamless steel tube production control device can track steel tubes in the production process one by utilizing the marks and the logic stations on the steel tubes, meanwhile, the size data (wall thickness and outer diameter) of the seamless steel tubes are collected from large-scale instruments (thickness gauges and diameter gauges), online judgment is carried out according to the size judgment rule, the quality judgment result is transmitted to a production execution system, data support is provided for final quality judgment, and the outgoing risk of unqualified products and the product judgment rate can be effectively reduced.
Drawings
FIG. 1 is a schematic configuration diagram showing a seamless steel pipe production control apparatus according to an embodiment of the present invention.
FIG. 2 is a block diagram showing the structure of a seamless steel pipe production control apparatus according to an embodiment of the present invention.
Fig. 3 is a flowchart showing a seamless steel pipe production process in a pipe blank zone according to an example of the invention.
FIG. 4 is a flowchart showing a process for producing a seamless steel pipe in a hot rolling zone according to an embodiment of the present invention.
FIG. 5 is a flowchart showing the judgment of the pass percentage of the wall thickness of a single steel pipe according to the embodiment of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, the seamless steel pipe production control device according to the present invention includes production devices such as a pipe blank sawing machine, a ring furnace, a piercing mill, a rolling mill, a sizing mill, a cooling bed, a pipe row sawing machine, a straightening machine, an inner surface detection device, a dust blowing and sucking device, a flaw detector, a length measuring and weighing device, and PLCs connected to the production devices, wherein the PLCs of the production devices are respectively connected to corresponding devices to control the operations of the corresponding devices, and are further connected to a production execution system through an ethernet network, the production execution system controls the operations of the PLCs according to a steel pipe production process flow, and the PLCs control the operations of the corresponding devices.
The seamless steel tube production control device also comprises a tracking production server, a switch, a detection element, a fixed-size blank identification robot, a cooling bed identification robot, a post-saw identification robot, a mark supplementing robot, a listing robot, a long-size blank code reading module, a fixed-size blank code reading module, a license plate code reading module, a gang saw inlet code reading module, a before-straightening off-line code reading module and a finishing code reading module. The PLC of each production facility is connected to the corresponding facility, such as a position switch, an instrument, a frequency converter, etc., for controlling the corresponding facility, and the PLC of each production facility is connected to the MES, which is a system for controlling each production facility of the entire seamless steel pipe, through the industrial ethernet, and a description thereof is omitted. The PLC, the detection element, the robots and the code reading modules of each production device are all connected with the tracking production server one by one through the switchboard. Each detection element is used for detecting whether a material enters a station or not, the code reading module is used for reading the identification on the material, and the robot performs corresponding action according to the identification read by the code reading module. Thickness gauges, surface sensing equipment, and other equipment may also be included, all connected to the MES via an industrial ethernet network.
The PLC of each production device comprises a pipe blank area PLC, an annular furnace area PLC, a puncher area PLC, a rolling mill area PLC, a sizing mill area PLC, a cooling bed area PLC, a pipe row sawing area PLC, a straightening machine area PLC, an ash blowing and sucking area PLC, a flaw detector area PLC and a length measuring and weighing area PLC.
The annular furnace zone PLC, the puncher zone PLC, the rolling mill zone PLC, the sizing mill zone PLC and the cooling bed zone PLC belong to hot rolling zone process equipment, and as shown by a dotted line frame in figure 1, the temperature of a blank in the zone is high, and the blank cannot be identified in a code pasting mode. A straightener area PLC, a blowing and suction area PLC, a flaw detector area PLC and a length measuring and weighing area PLC belong to finishing area process equipment, and as shown by a thin solid line frame in figure 1, blanks can be marked in the area through a code pasting or code spraying mode.
A plurality of logic stations are arranged in the tracking production server one by one, the logic stations correspond to actual physical stations of a production field, each logic station is provided with a section of storage space in a system, and the logic stations can be imagined as virtual stations with the same form as the actual physical stations. The tracking production server can adopt a visual interface, and can display the logic stations on the interface so as to visually watch the real-time position of the material (namely the pipe) on the interface. Important information of the whole process of the materials can be stored in the branch-by-branch tracking production server, each material can have an independent space for storing the information, and the stored information comprises material identification, logical stations and time passed by the materials, relevant important production parameters of the materials in each process and the like.
The state change condition of the steel pipe blank in the production process is as follows:
(1) long-size blank, original round bar blank;
(2) the fixed-length blank is formed by sawing the long-length blank;
(3) a blank pipe is a pipe material formed after a through hole is machined in a fixed size blank through a punching machine;
(4) the pierced billet comes out of the outlet of the rolling mill and is called a pierced billet;
(5) seamless steel pipe, pipe material after the outlet of sizing mill.
FIG. 2 is a block diagram showing the construction of a seamless steel pipe production control apparatus according to an embodiment of the present invention, and FIG. 3 is a flowchart showing a seamless steel pipe production process in a pierced blank zone according to an embodiment of the present invention; FIG. 4 is a flow chart showing a process for producing a seamless steel pipe in a hot rolling zone according to an example of the present invention. Next, an implementation of the seamless steel pipe production control apparatus will be described with reference to fig. 2, 3, and 4.
The seamless steel pipe production control apparatus according to the present invention includes a pipe blank zone production control unit 101, a hot rolling zone production control unit 102, a pipe row saw zone production control unit 103, and a finishing zone production control unit 104.
The tube blank area production control unit 101 performs branch-by-branch tracking production control on the seamless steel tube blank entering the tube blank area. In the tube blank area, a continuously cast cold long blank is taken as an example, the mark is ABCD1234 which is arranged on the end surface of the blank during continuous casting, and when the cold long blank is conveyed to a feeding rack in front of a sawing machine, the long blank code reading module reads the mark on the end surface of the blank. The long-length blank code reading module is that the branch-by-branch tracking production server obtains the identifier ABCD1234 of the blank for the first time, and sends a request to an MES system (production execution system) according to the identifier, and the MES system sends the original blank information (such as the external dimension, the alloy parameters, the steel grade, the process parameters and the like) of the identifier to the branch-by-branch tracking production server, and stores the original blank information corresponding to the identifier, so that all the information about the blank can be viewed through the identifier in the branch-by-branch tracking production server. And the long ruler blank code reading module adopts an OCR visual recognition technology to recognize the product information pasted on the end surface of the long ruler blank. And preferably, a machine vision combined deep learning mode is adopted, so that damaged and missing characters can be identified. Preferably, the two ends of the long ruler blank are respectively provided with a long ruler blank code reading module so as to ensure that the relevant information of the long ruler blank is obtained.
The tube blank area PLC is connected with the MES system, and can monitor the action of the sawing machine, and after the cold long size blank enters the sawing machine, the sawing machine saw cuts the cold long size blank according to the length requirement of the fixed size blank. For example, the length of the cold long billet is 12m, if the length of the fixed billet is 3m, the cold long billet needs to be cut into 4 sections, the tube blank area PLC monitors the actions of the sawing machine, such as clamping the cold long billet, descending the saw blade to start sawing, ascending the saw blade and loosening the fixed billet formed by sawing. The logical judgment of the completion of a sawing action process is carried out in a tube blank area PLC, when a sawing action is completed, a fixed-size blank is generated, the tube blank area PLC sends a signal of the completion of sawing to a branch-by-branch tracking production server, the branch-by-branch tracking production server generates a new mark such as ABCD1234-1 on the basis of the mark ABCD1234 of the original cold long blank, the new mark corresponds to the fixed-size blank and is stored in a logic station after sawing, and meanwhile, original blank information such as alloy, steel type, process parameters and the like is stored in the mark, so that the fixed-size blank which is newly sawn has a mark corresponding to the mark in the branch-by-branch tracking production server.
Although the mark corresponding to the fixed size blank is formed in the logic station, the mark is not formed on the surface of the fixed size blank, the mark can be formed by a fixed size blank marking robot after the sawing process, the fixed size blank marking robot is connected with a branch-by-branch tracing production server, when the fixed size blank is conveyed to the fixed size blank marking robot station, the branch-by-branch tracing production server sends a newly generated mark ABCD1234-1 to the given size blank marking robot, and the fixed size blank marking robot makes the mark into a label to be attached to the end part of the blank, so that the fixed size blank has the mark corresponding to the mark. Because the outer diameter, the length, the concave-convex end surface and the like of the sizing blank are uncertain, the sizing blank marking robot can adopt a visual optimization means, meet the requirements of complex working conditions on site and improve the self-adaptability of equipment. Preferably, the fixed size blank identification robots are arranged at both ends of the fixed size blank, and the identifications are pasted at both ends, so that the subsequent process identification is facilitated.
To this end, each billet from the cold elongated billet to the forming of the fixed billet in the billet zone has a unique tracking identifier. In the above, one sawing machine is taken as an example, and a plurality of sawing machines each having a sizing bar marking robot corresponding thereto may be provided in parallel. The identification can be transmitted to the next logic station at one logic station of the tracking production server one by one, and a signal for triggering transmission comes from the logic judgment of a tube blank area PLC, such as a material shifting hook action process, a roller way rotation process and the like. The sawing of one segment is taken as an example for illustration, the rest three segments are coded and labeled according to the first segment, so that the marks of 4 sizing blanks, ABCD1234-1, ABCD1234-2, ABCD1234-3 and ABCD1234-4, cut by the cold long blank sawing are formed, and the original blank information of the long blank is stored behind each sizing blank mark.
The fixed size blanks can enter the annular furnace or enter the fixed size blank storage from a lower line, and fixed size blank code reading modules are respectively arranged at the upper line and the lower line of the fixed size blanks and used for tracking the information of all the fixed size blanks.
The hot rolling zone production control unit 102 performs branch-by-branch follow-up production control of the fixed-length billet in the hot rolling zone. The first cooling bed and the second cooling bed of the annular furnace, the puncher, the rolling mill zone, the sizing mill and the cooling bed zone are hot rolling zones, the temperature is high, labeling and other ways cannot be adopted for identifying and tracking blanks, but the blanks in the section of the process flow in a single line and one direction, namely, the situation that a plurality of paths are changed does not exist, the blanks are in first-out, so that the marks can be tracked by monitoring the change of physical stations based on the PLC, the judgment on the change of the physical stations is that the PLC judges the change of the physical stations according to the change of field detection elements or transmission loads and the like, the logic judgment forms of all the stations are different, after the PLC judges the switching of the physical stations, the PLC sends a signal to the branch-by-branch tracking production server to tell the branch-by-branch tracking production server that the physical stations of the blanks change, and the logic stations of the branch-by-branch tracking production server also change correspondingly, thereby tracking the physical station of the blank all the time so that the identification of the blank can correspond to it. It should be noted that, due to the difference in the structures of the devices with different specifications, the determination of the physical workstation recited in this embodiment is only exemplary, and is not used to limit the method for the PLC to determine the physical workstation, and the method for the PLC to determine the change of the physical workstation is correspondingly set according to the difference in the structures of the different devices.
The fixed-size blank reading module is used for identifying identification information of the end face of a fixed-size blank entering a furnace of the annular furnace by adopting an industrial code reader identification technology before the fixed-size blank enters the heating furnace, the fixed-size blank reading module sends the identification to the branch-by-branch tracking production server after reading the identification, when a furnace charging action is completed, the branch-by-branch tracking production server sends the read identification (such as ABCD1234-3, which is described by taking the identification as an example hereinafter) to the annular furnace area PLC, the annular furnace is annular, the fixed-size blank can be heated to about 1200 ℃, and the annular furnace is generally composed of a rotatable furnace bottom, a fixed furnace top, an inner furnace wall and an outer furnace wall. The annular furnace makes the blank placed on the bottom of the furnace move from the charging opening to the discharging opening along the annular tunnel by means of the rotation of the bottom of the furnace, and continuously heats the blank in sections in the moving process. The annular furnace is provided with an encoder for tracking the rotating position of the furnace bottom, the PLC in the annular furnace area can determine the position of the fixed size blank rotating to the annular furnace according to the reading of the encoder, the position of the fixed size blank determined by the PLC in the annular furnace area corresponds to a logic station, the position information is fed back to the branch-by-branch tracking production server, and the branch-by-branch tracking production server stores the identification of the fixed size blank to the logic station corresponding to the annular furnace. For example, the ring furnace can be used for placing 10 fixed size blanks, placing one fixed size blank at a time from the charging opening, rotating a certain angle, and removing one fixed size blank from the discharging opening. Although the labeling can not be identified any more due to the influence of high temperature and deformation in the annular furnace, the labeling can be used as a physical station by corresponding to a certain angle of rotation of the annular furnace, a logical station is arranged in each tracking production server one by one corresponding to each physical station, and each sizing blank entering the annular furnace can be in one-to-one correspondence with the physical station through the logical station, so that the identification of the sizing blank is kept to be corresponding to the sizing blank.
After the fixed size blank is heated, the fixed size blank is transferred to a steel tapping machine, and the action process of the steel tapping machine is as follows: the steel tapping machine advances, descends, clamps steel, ascends, retreats and loosens, so that the fixed size blank reaches the position of the material poking hook of the chain bed. The PLC in the annular furnace area sends a completion signal to the branch-by-branch tracking production server, the branch-by-branch tracking production server transmits the identification ABCD1234-3 to a logic station of the chain bed material shifting hook, the chain bed material shifting hook shifts the fixed size blank, the fixed size blank is moved to the chain bed, and the fixed size blank can be transmitted to the puncher area through the chain bed. Specifically, the ABCD1234-3 coming out of the annular furnace is turned over to the chain bed by the material shifting hook, the hydraulic cylinder drives the material shifting hook to act, the proximity switch detects the position of the material shifting hook, the judgment of an action process of the material shifting hook is that the material shifting hook is detected to have a blank, the material shifting hook acts, the material shifting hook is lifted, the lower position of the proximity switch disappears, the upper position disappears, the lower position disappears, and the lower position shows that one material shifting action is completed. The PLC finally sends a completion signal to the branch-by-branch tracking production server by judging the action process of the proximity switch and a signal of thermal detection (a high-temperature metal detector, namely a detection element suitable for a high-temperature environment), the branch-by-branch tracking production server transmits the ABCD1234-3 to the next logic station, namely a chain bed, and the PLC also makes corresponding changes.
By analogy, the marks are sequentially transmitted one by one at the logic stations, the logic stations in the perforating machine area also comprise a perforating machine front roller way, a blank pushing machine, a perforating machine body, a perforating machine outlet roller way and a borax spraying position, if the judgment of the mark ABCD1234-3 on the logical station of the puncher body is that the puncher area PLC judges whether the puncher body is provided with blanks or not according to the position of the blank pushing machine (by means of encoder feedback associated with position information) and a heat detection signal, further, the steel biting signal of the puncher can be combined, the steel biting signal is judged by judging the current fed back by transmission, the information is integrated to send a signal to a tracking production server one by one, the puncher bites steel, and the fixed-size blank is definitely on the logical station of the puncher body, the branch-by-branch tracking production server then passes the ABCD1234-3 to the logical station of the perforator body.
The fixed size blank of the puncher area is about 1000 ℃, the fixed size blank passing through the puncher area is changed into a capillary with a through hole, the capillary is moved to the rolling mill area through the capillary transverse moving vehicle, the capillary transverse moving vehicle is driven by a motor, the position is fed back through an encoder, the puncher area PLC judges that the capillary is at a spraying sand position through a thermal detection signal, a sand spraying system sends a completion signal to the puncher area PLC, and in addition, a material poking hook action is performed, the material poking action is basically similar to the previous material poking hook action, so that the tracking production server one by one judges that the capillary is on the capillary transverse moving vehicle, and the tracking production server one by one can transmit the ABCD1234-3 to a logic station of the capillary transverse moving vehicle. The capillary transverse moving vehicle is used for moving the capillary to a rolling mill foreground, and the logical stations in the rolling mill area comprise the following steps: a capillary tube transverse moving vehicle, a capillary tube feeding revolving arm, a rolling mill inlet, a rolling mill body and a rolling mill outlet roller way. The mandrel is penetrated into the hollow billet by the limiting trolley and then enters the rolling mill for rolling, the pipe is taken off by the pipe removing machine, the mandrel returns, and the hollow billet is called from the outlet of the rolling mill.
The pierced billet moves to a sizing mill through a roller way, and the sizing mill further performs sizing rolling on the steel pipe rolled by the rolling mill to obtain the external dimension with higher precision. The temperature of the rolling mill zone and the sizing mill zone is about 1000 ℃, and the sizing zone also adopts a form that a logic station corresponds to a physical station to transmit the identification. And the inlet and the outlet of the sizing area are provided with hot tests to assist the tracking of the logic station.
After the above processing of the hot rolling area, the blank marked as ABCD1234-3 becomes a seamless steel tube, the mark of which is still unchanged, and the process information of each process is stored corresponding to the mark.
The cooling bed is of a walking beam type rack structure and is used for transportation and rotary cooling of the seamless steel pipe. Each stepping position of the rack of the cooling bed corresponds to one logic station in the system, the PLC of the cooling bed area can determine the position of the seamless steel tube on the cooling bed according to the stepping distance of the rack, the position of the seamless steel tube determined by the PLC of the cooling bed area corresponds to one logic station, the position information is fed back to the branch-by-branch tracking production server, and the branch-by-branch tracking production server stores the identification of the seamless steel tube to the logic station corresponding to the cooling bed.
In addition, the production control unit 102 further includes a roll reduction amount control device 201 in the hot rolling zone. When a pipe is rolled, the temperatures of rollers corresponding to different pipes are different, particularly after the rollers are replaced by the rolling mill, the whole system of the rolling mill is in a normal-temperature state, the temperature of the rolling mill rises when the rolling mill reaches a working state, parameters of mechanical equipment change correspondingly, particularly the rollers, so that the wall thickness of the pipe in the period from the normal-temperature state to the good working state of the rolling mill is difficult to control, generally, the process needs to roll a plurality of steel pipes, such as about 3 steel pipes, after the 3 steel pipes are rolled, the pipe is sampled, then, according to a sampling result, a shunting is performed, and then, continuous rolling is performed, and the 3 steel pipes are scrapped under normal conditions. However, the invention can make the steel pipes correspond to each other by marking one by one due to the branch-by-branch tracking control production, thereby clearly obtaining various production related data in the production process of each steel pipe.
The roll reduction control device 201 calculates the roll reduction adjustment value of the rolling mill according to the following formula 1, and then adjusts the roll reduction according to the roll reduction adjustment value, so that the rejection rate of the three tubes can be effectively reduced.
t: the temperature of the roller is controlled by the temperature of the roller,
is the temperature of a roller before rolling the (n-1) th steel pipe,
is the temperature of the roller before the rolling of the nth steel pipe,
t: the wall thickness of the pipe is determined by the thickness of the pipe,
the actual wall thickness is such that,
the given value of the wall thickness is in mm;
k: the characteristic coefficient of the roller shape of the roller corresponds to different values of different series of rollers, and the value range is 0.5-1.
The rolling reduction of the roller during the rolling of the first steel pipe is obtained according to the data counted by the branch-by-branch tracking control system, specifically, because the system can identify each steel pipe one by one, the related production information of the steel pipes which are rolled in sequence can be distinguished, instead of identifying the information of the steel pipes according to the batch of one furnace, the rolling reduction of the roller can be calculated according to the related production information of the steel pipes at the front and the rear by adopting the formula 1. Thereby effectively reducing the rejection rate of the three tubes. And the complicated steps of sampling the pipe, shunting according to the sampling result and then continuously rolling are also reduced. The rolling reduction of the second and third steel pipe rolls is also calculated according to the formula 1, and the temperature of the rolls after the third steel pipe is rolled is basically stable, and the roll temperature during the rolling of the front and rear steel pipes has no influence on the adjustment value of the rolling reduction. In addition, whether the calculation is wrong can also be judged by comparing the rolling history data with better rolling history data under the same roll system.
Then, the tube gang saw area production control unit 103 performs branch-by-branch follow-up production control on the plurality of sub tubes cut in the tube gang saw area.
The seamless steel pipe sequentially passes through a first cooling bed, a second cooling bed and a third cooling bed to be cooled, the temperature of the seamless steel pipe is between normal temperature and 600 ℃ when the seamless steel pipe reaches the inlet of the third cooling bed, a cooling bed identification robot is arranged at the inlet of the third cooling bed, when the pipe ABCD1234-3 moves to the inlet of the third cooling bed, the identification ABCD1234-3 is sent to the cooling bed identification robot by the tracking production server one by one, and the cooling bed identification robot sprays bar codes on the identification along the circumferential direction of the main pipe. The seamless steel pipe moves towards the tube bank sawing machine, a bar saw inlet code reading module is designed before the saw, when the seamless steel pipe is conveyed to a tube bank sawing machine station, the bar saw inlet code reading module reads information of a bar code on the surface of the pipe, and the ABCD1234-3 identifier is conveyed to a logic station of a tube bank sawing machine body.
The cold bed identification robot adopts a bar code to identify the seamless steel tube, and the bar code corresponds to the identification. The cooling bed identification robot can be provided with 3 sets of cloth covering a single-row cloth mode of inlet alignment, middle alignment and outlet alignment of a third cooling bed and a double-row cloth mode of inlet alignment and outlet alignment. The printing ink for spraying the bar codes is divided into two types, one type is suitable for the temperature range of 150-600 ℃, and the other type is suitable for the temperature range of 0-150 ℃. The spray gun is divided into 2 ink paths which are respectively suitable for spraying of normal-temperature ink and high-temperature ink.
In addition, the tube gang saw area production control unit 103 further includes a steel tube cutting control device 202.
The length L of the head and the tail of the steel pipe is cut off q The invention relates to a seamless steel tube production control device, which is an important factor influencing the steel tube yield.
The pipes can be identified and corresponded one by one due to tracking production one by one, so that the optimized control is realized through process adjustment
By controlling the number S of participating rolling stands n To optimize the length L of the head and the tail q In the process, the adjusted process parameters can be correspondingly consistent with the pipes tracked one by one. Here, the steel pipe cutting control device 202 calculates the length L of the cut end and the cut end of the steel pipe according to the following formula 2 q 。
L q =
（2）
Wherein the content of the first and second substances,
the pass coefficient is in the range of 0.65-0.75;
S n is the number of participating rolling stands, and S n More than 3, because the last three racks are racks for controlling the roundness of the steel pipe, the length deformation is not involved;
Z m is the average tension coefficient of the parent tube;
y is a tension superposition coefficient, and the value range is as follows: 0.65 to 0.67;
D z is the distance between adjacent racks;
alpha is the thermal expansion coefficient of the mother tube and takes 1.01
；
Δ X is the varying temperature from the sizer outlet to the tube row saw area.
Wherein the content of the first and second substances,
and calculating the size of the head and tail cutting length in a hot state.
Through accurate tracking of the branch-by-branch tracking system, after the main pipe enters the pipe gang sawing area, optimized data of the branch-by-branch tracking system are received, and optimized sawing of the length of the head and tail length data of each main pipe is achieved.
A seamless steel pipe (main pipe) is possibly cut into a plurality of sections (sub pipes), if the seamless steel pipe (main pipe) is cut into 3 sections of fixed-length pipes, according to the complete action of the cutting, a cutting completion signal is sent to a branch-by-branch tracking production server by the PLC, the branch-by-branch tracking production server automatically generates a new mark on the basis of the ABCD1234-3-3, such as the ABCD1234-3-1, and 3 new marks are generated by analogy, the ABCD1234-3-1, the ABCD1234-3-2 and the ABCD1234-3-3, the process information of the main pipe is transmitted to the sub pipes for storage, the seamless steel pipe moves from an outlet of a pipe gang cutting machine to a blanking revolving arm and then to an inlet of a chain machine, a post-cutting marking robot is arranged at the inlet of the chain machine, when the seamless steel pipe is conveyed to the inlet of the chain machine, the branch-by-branch tracking production server sequentially sends the 3 newly generated marks to the post-cutting marking robot, the mark is manufactured into a label form by the mark robot after sawing and is sequentially pasted on the inner surface of the seamless steel tube, so that the mark is not damaged by friction with equipment in the moving process of the seamless steel tube, the situation that the number of the seamless steel tube is increased can not happen, the blank marks the ABCD1234 from the beginning, 12 new marks are changed into, such as the ABCD1234-3-1 and the like, and the mark is pasted on the seamless steel tube. The post-sawing marking robot adopts a high-speed code scanner, and can read the marking information of the inner wall of the end part of the steel pipe in real time at the linear speed of 2.5 m/s. And preferably, in order to reduce the breakage rate of the mark, two marks are stuck on the inner wall of the steel pipe, and the mark is chamfered so as to reduce the probability of scratching.
The tracking control system can track the identification of each main pipe in real time, so that the relevant production information such as the length, the wall thickness distribution and the like corresponding to the main pipe can be mastered, the selection of the sawing position can be realized, and the yield is improved. For rolled steel pipes, pipe heads and pipe tails of the rolled steel pipes need to be sawed off, and then the rest parts of the rolled steel pipes can be sawed into required sub-pipes. The branch-by-branch tracking control system can visually display the distribution condition of the length and the wall thickness of the pipe, so that the MES can make an optimal sawing scheme according to a product plan.
And, the finishing area production control unit 104 performs detection and finishing processing on the seamless steel pipe entering the finishing area. The inspection and finishing items may include straightening, blowing and sucking ash, flaw detection, inner surface inspection, length measurement and weighing, automatic packaging, and the like.
The inner surfaces of seamless steel tubes transmitted from a chain bed behind a tube bank sawing machine are all pasted with marks, a code reading robot which is arranged before straightening and is lower than the straightening machine is arranged in front of the straightening machine, the code reading robot which is arranged before straightening and lower than the straightening machine sends information of the seamless steel tubes to a branch-by-branch tracking production server, the information is stored on a logic station of the straightening machine and is sent to a PLC (programmable logic controller) at the same time, and the PLC informs the PLC of the information of the current seamless steel tubes of the straightening machine.
After the straightening machine finishes straightening, the straightening machine PLC sends a message to inform the branch-by-branch tracking production server, and the branch-by-branch tracking production server stores relevant information of the straightening process to the identifier.
Inside blowing and inhaling grey PLC control compressed air and sweeping seamless steel pipe, this process destroys the sign of internal surface easily because follow first-in first-out's principle at next process, in order to prevent that the identification code of internal surface from being blown off, can check whether the label of internal surface exists and the damage through mending the mark robot, can just carry out one time and mend the sign indicating number operation through mending the mark robot if the disappearance to guarantee the existence of seamless steel pipe sign.
The flaw detector PLC controls flaw detection on the seamless steel pipe, flaw detection is carried out on the seamless steel pipe one by one in the flaw detection process, and damage to the mark is avoided. And the roller way can also supplement the damaged steel pipe of label after magnetic leakage flaw detection.
In addition, the production control unit of the pipe gang saw area further comprises a steel pipe quality online judging system 402 for judging the quality of the seamless steel pipe after the diameter is determined and reduced, mainly comprising the outer diameter and the wall thickness of the steel pipe. The steel pipe quality online determination system 402 is described below with reference to fig. 5, and includes a steel pipe size acquisition module, a quality determination module, and a determination result transmission module.
The steel pipe size acquisition module is used for collecting key data required by quality judgment of steel pipes in the production process of the steel pipes, such as steel pipe wall thickness data detected by a thickness gauge and steel pipe outer diameter data detected by a diameter gauge, obtained from a large-scale measuring instrument, so that actual measurement curve data can be obtained, and the actual measurement curve data is filed on a material with steel pipes one by one as a unit according to key signals of field production to form accurate data correspondence. The key signals refer to signals of the thickness of the steel pipe captured by a thickness gauge, for example. And after the thickness gauge detects the steel pipe thickness data, the steel pipe thickness data and the steel pipe identification are correspondingly stored according to the steel pipe data in the production execution system.
Preferably, the steel pipe size acquisition module guarantees the authenticity of the judgment curve for removing some pseudo data, and can remove the head and the tail of the actual measurement curve according to the steel grade and the product specification (wall thickness and outer diameter) of the steel pipe. The calculation formula is as follows:
wherein, the first and the second end of the pipe are connected with each other,
、
the steel is the steel grade of different steel pipes,
、
for different wall thickness specifications of the steel tube,
、
for different specifications of the outer diameter of the steel pipe,
the length of the steel pipe after the head and the tail are removed is shown,
the length of the head removal is indicated,
indicating the tail removal length. The removal length of the head and tail may be, for example, 20 gauge steel, 18mm wall thickness, 245 outer diameter, and 0.65m cut head and tail length (head 350mm, tail 300 mm). Or the steel grade is 20, the wall thickness is 8mm, the outer diameter is 273, the length of the head and the tail is 0.85m (the head is 350mm, the tail is 500 mm), and the length of the head and the tail of the steel pipe can be calculated according to the formula 2 q As the measured curve decap-mantissa value herein.
Wherein the quality judgment module at least comprises a single steel pipe wall thickness qualification rate judgment rule corresponding to different quality judgment rules according to different quality judgment contents,
the qualification rate of the wall thickness of the single steel pipe is determined according to the following rules:
wherein, the wall thickness of a plurality of points is measured at intervals along the axial direction of the steel pipe,
the wall thickness of a certain point of the steel pipe;
H_
the qualified rate of the wall thickness of the steel pipe is obtained;
Similarly, the determination of the outer diameter yield of a single steel pipe may be performed by measuring the outer diameters of a plurality of points at intervals in the steel pipe axial direction, and performing the determination according to the similar rule, similarly to the determination rule of the wall thickness yield of a single steel pipe, to obtain the result of determining the outer diameter of a steel pipe.
The quality determination module further comprises a standard deviation rule，The standard deviation reflects the degree of dispersion of a data set, and the larger the value is, the more dispersion is, i.e. the larger the difference of the wall thickness of the steel pipe is, the standard deviation rule is as follows:
wherein, the wall thickness of a plurality of points is measured at intervals along the axial direction of the steel pipe,
in order to measure the average value of the wall thickness,
Similarly, the standard deviation of the outer diameter of the single steel pipe may be determined by measuring the outer diameters of a plurality of points at intervals in the steel pipe axial direction, and determining the standard deviation of the outer diameter of the steel pipe according to the similar rule, similarly to the standard deviation determination rule of the wall thickness of the single steel pipe.
The quality judgment module further comprises a range value judgment rule which is as follows:
wherein, along the axial line segment of the steel pipe
The wall thickness of a plurality of points is measured at intervals in sequence,
、
for measuring wall thickness
The first step
Wall thickness values of the individual measurement points;
The quality judgment module also comprises a maximum value and minimum value judgment rule which is as follows:
wherein the content of the first and second substances,
the wall thickness value of any point measured in the axial direction of the steel pipe is obtained;
Similarly, the steel pipe outer diameter maximum and minimum determination rules are similar to the wall thickness rule, and are not described again.
The quality determination module further comprises a determination rule that the continuous points exceed the upper limit, which is expressed as follows:
wherein the content of the first and second substances,
the wall thickness value of any point measured in the axial direction of the steel pipe,nin order to limit the maximum number of out-of-tolerance points,
is on the wall thicknessA limit value;
The quality determination module further comprises a wall thickness mean minimum determination rule expressed as follows:
wherein
For the first and last wall thickness values measured,
the lower limit value of the wall thickness is,
to calculate the average value of the wall thickness;
The wall thickness average maximum value and the range value are judged similarly to the minimum value judgment rule, and are not described again.
And the judgment result transmission module transmits the online judgment result to the production execution system to provide data support for final product quality judgment. The communication mode between the judgment result transmission module and the production execution system at least comprises one of communication modes such as RockeMQ, RestAPI, DBLink and the like.
The present invention is capable of other embodiments, and various changes and modifications can be made by one skilled in the art without departing from the spirit and scope of the invention.
Claims (10)
1. A seamless steel tube production control device is characterized by comprising:
the tube blank area production control unit is used for performing branch-by-branch tracking production control on the seamless steel tube blank entering the tube blank area by using the mark on the tube blank;
the hot rolling area production control unit is used for performing branch-by-branch tracking production control on the fixed-size billets entering the hot rolling area, and a roll reduction control device is arranged in the hot rolling area production control unit;
the tube array sawing area production control unit is used for carrying out tracking production control on the plurality of sub-tubes cut in the tube array sawing area one by one; and
the finishing area production control unit is used for finishing and detecting the seamless steel pipe entering the finishing area,
the production control unit of the tube bank sawing area comprises a steel tube quality online judging system, is used for judging the quality of the seamless steel tube after the diameter is reduced, and comprises the following components:
the steel pipe size acquisition module: the device is used for collecting actually measured curve data in the production process of the seamless steel pipe and filing the actually measured curve data on the branch-by-branch steel pipe, wherein the actually measured curve data at least comprises wall thickness data of the steel pipe;
a quality determination module: the quality judging module judges the quality of the steel pipe according to the actually measured curve data and the judging rule;
a judgment result transmission module: and transmitting the judged quality of the steel pipe to a production execution system.
2. The seamless steel tube production control device according to claim 1, wherein the quality determination module at least includes a single steel tube wall thickness qualification rate determination rule as follows:
wherein, the wall thickness of a plurality of points is measured at intervals along the axial direction of the steel pipe,
the wall thickness of a certain point of the steel pipe;
3. The seamless steel pipe production control apparatus according to claim 1,
the quality determination module further comprises a standard deviation rule，The standard deviation rule is as follows:
wherein, the wall thickness of a plurality of points is measured at intervals along the axial direction of the steel pipe,
for measuring the average wall thicknessThe value of the one or more of the one,
4. The seamless steel pipe production control apparatus according to claim 1,
the quality judgment module further comprises a range value judgment rule which is as follows:
wherein, along the axial line segment of the steel pipe
The wall thickness of a plurality of points is measured at intervals in sequence,
、
for measuring wall thickness
The first step
Wall thickness values of the individual measurement points;
5. The seamless steel pipe production control apparatus according to claim 1,
the quality judgment module also comprises a maximum value and minimum value judgment rule which is as follows:
wherein the content of the first and second substances,
the wall thickness value of any point measured in the axial direction of the steel pipe is obtained;
6. The seamless steel pipe production control apparatus according to claim 1,
the quality determination module further comprises a determination rule that the continuous points exceed the upper limit, which is expressed as follows:
wherein the content of the first and second substances,
the wall thickness value of any point measured in the axial direction of the steel pipe,nin order to limit the maximum number of out-of-tolerance points,
the upper limit value of the wall thickness;
7. The seamless steel pipe production control apparatus according to claim 1,
the quality determination module further comprises a wall thickness mean minimum determination rule expressed as follows:
wherein
For the first and last wall thickness values measured,
the lower limit value of the wall thickness is,
to calculate the average value of the wall thickness;
8. The seamless steel pipe production control apparatus according to any one of claims 1 to 6,
the production control unit of the pipe gang saw area further comprises a steel pipe cutting control device for controlling the cutting length of the head and the tail of the pipe, and the steel pipe cutting control device calculates the cutting length L of the head and the tail of the steel pipe according to the following formula 2 q ：
L q =
（2）
Wherein the content of the first and second substances,
the pass coefficient is in the range of 0.65-0.75;
S n is the number of participating rolling stands, and S n Greater than 3;
Z m is the average tension coefficient of the parent tube;
y is a tension superposition coefficient, and the value range is as follows: 0.65 to 0.67;
D z is the distance between adjacent racks;
alpha is the thermal expansion coefficient of the mother tube and takes 1.01
；
Δ X is the varying temperature from the sizer outlet to the tube row saw area.
9. The seamless steel tube production control device according to claim 8, wherein the steel tube size acquisition module calculates the length L of the end-to-end of the actual measurement curve data according to formula 2 q 。
10. The seamless steel pipe production control apparatus according to claim 1,
the communication mode of the judgment result transmission module and the production execution system is one of RockMQ, RestAPI and DBLink.
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| CN115841478A (en) * | 2022-12-16 | 2023-03-24 | 浙江科达利实业有限公司 | Quality detection system applied to vehicle-mounted air conditioner hose production management and control |
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Application publication date: 20220906 |