CN115318845B - Method and system for tracking branch-by-branch material of whole process of hot-rolled seamless steel tube - Google Patents
Method and system for tracking branch-by-branch material of whole process of hot-rolled seamless steel tube Download PDFInfo
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- CN115318845B CN115318845B CN202211256708.4A CN202211256708A CN115318845B CN 115318845 B CN115318845 B CN 115318845B CN 202211256708 A CN202211256708 A CN 202211256708A CN 115318845 B CN115318845 B CN 115318845B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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- B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
- B21B37/78—Control of tube rolling
Abstract
The invention discloses a method and a system for tracking a hot-rolled seamless steel tube full-flow material branch by branch, belonging to the field of intelligent manufacturing, wherein the method and the system ensure the accuracy of material tracking through the application of a high-precision online identification technology and an industrial robot technology in the whole process from the online to the offline of each blank; meanwhile, advanced detection means and a data management platform are used for collecting data such as raw material states, key processes, finished product detection and the like, and data support is provided for realizing product quality control and full-line production actual performance statistics management.
Description
Technical Field
The invention belongs to the field of metallurgy industry and machine vision technology application, and particularly relates to a method for tracking a whole-process material branch by branch of a hot-rolled seamless steel pipe.
Background
The seamless steel pipe production comprises the production processes of pipe blank preparation and inspection, pipe blank heating, perforation, pipe rolling, steel pipe reheating, diameter fixing (reducing), cooling bed cooling, heat treatment, finished pipe straightening, finishing, inspection (nondestructive, physicochemical and bench inspection), warehousing and the like, and the normal operation of the whole production can be influenced when any link fails.
The seamless steel pipe has the following production characteristics:
1. the seamless steel tube production process is long, the processes are multiple, the rhythm is fast, it is a production line of the flow type;
2. the seamless steel tube belongs to small-batch and multi-product type products, different product specifications have different requirements on incoming materials, process paths and process parameters, and the information relevance of an upstream production line and a downstream production line is large;
3. in the production process of the seamless steel tube, the process route can be temporarily adjusted due to equipment failure and the like;
4. in the process of material circulation between production line equipment, temporary offline phenomenon due to equipment failure or product quality problems can occur, and meanwhile, the phenomenon of re-online after failure or problem solution also occurs;
5. the seamless steel tube continuous rolling production line has the unique characteristics that: changing the long-size blank into a fixed-size blank, producing multiple sizes, and sawing in groups and rows;
6. in the whole line circulation process of the material, the form changes for many times, a single blank becomes a plurality of blanks, a solid blank becomes a hollow material, a single material becomes a group-arranging material, a group-arranging material becomes a plurality of group-arranging materials, a plurality of group-arranging materials become a single material, and a single material becomes a bundle material.
The uncertainty and complexity of the position and the flow direction of the material in the seamless steel tube production process are determined by the existence of the above characteristics, so that the management difficulty of the branch-by-branch tracking of the material is very high only through basic automatic data and manual record.
The following problems exist in the material tracking in the traditional seamless steel tube production process:
1. because the production organization adopts a passive push type production mode, the varieties and the quantity of raw materials, products in production and finished products are numerous, the production material information management difficulty is large, the large quantity of materials occupies more storage space, the management cost is increased, and the material shortage condition sometimes occurs;
2. the management work of the production material information is extensive, the management mode still adopts more manual management modes, the workload is large, the requirement on the number of personnel is more, and the material information statistics error is easily caused;
3. the phenomenon that the information flow and the logistics do not accord with each other sometimes occurs, and the information flow and the logistics cannot be found in time; the problems exposed in the production material information management can not be timely reflected and timely solved, for example: inaccurate material positioning, BOM error and the like, and lack of effective means for automatic problem reporting and timely communication;
4. the coordination among the procedures of product processing is poor, and a complete material branch-by-branch tracking information system is not available.
With the application of the machine vision and industrial robot technology to the seamless steel tube material branch-by-branch tracking system, the problems of real-time tracking of material positions and information management in the seamless steel tube production process can be fundamentally solved. The robot technology solves the problem of material identification in a production line, and the machine vision technology mainly solves the problems of identification, positioning before material identification, rechecking after identification and the like of an auxiliary robot. The application of machine vision and industrial robot technology has realized reducing human cost and has greatly improved work efficiency simultaneously. The establishment of the material branch-by-branch tracking system meets the requirements of continuously increasing information flow and continuously improving information processing speed.
Disclosure of Invention
The seamless steel pipe material successive tracking system mainly aims at ensuring the accuracy of material tracking through the application of a high-precision online identification technology and an industrial robot technology in the whole process from online to offline of each blank; meanwhile, advanced detection means and a data management platform are used for collecting data such as raw material states, key processes, finished product detection and the like, and data support is provided for realizing product quality control and full-line production actual performance statistics management.
The following technical problems are solved macroscopically:
1. when the material form and quantity are changed, different identification schemes and recognition schemes are adopted according to the change condition;
2. the production line belongs to flow type industrial production, material circulation is uninterrupted, rhythm is fast, and accurate identification and recognition can be realized under the condition that the production rhythm is not influenced;
3. when the material fails and is off-line, the system can automatically log out the ID number of the material;
4. the material is on-line again, and the system recovers the material information file;
5. the process route adjustment is carried out in the production process of the product, and the system accurately tracks the material flowing direction;
6. damage to the marking carrier may occur during the production of the product.
The invention is realized by the following technical scheme:
a method for tracking a hot-rolled seamless steel tube full-flow material branch by branch is characterized by comprising a logic tracking mode and a non-logic tracking mode, wherein the logic tracking mode comprises tracking of an uninterrupted equipment interval for continuous production of a single material branch, and the non-logic tracking mode comprises tracking of an uninterrupted equipment area for multi-target production; non-logical tracking also includes identification (labeling and listing) and visual identification of the material by the industrial robot.
The method as described above, wherein the logical tracking determines the material in-place information by a material detection component judgment of the basic automation system.
The method as described above, wherein the non-logical tracking tracks the material through machine depth vision recognition.
The method as described above, wherein the tracking of the full flow material branch by branch comprises the steps of: the method comprises the following steps of pipe blank area tracking, fixed-size blank labeling and identification, furnace entering identification, hot rolling area tracking, cooling bed tracking, blanking tracking, finishing area tracking and finished product processing tracking.
The full-flow material branch-by-branch tracking system for the hot-rolled seamless steel pipe comprises a process control system and a basic automation system, and is characterized by further comprising an industrial robot, an online identification device and a multi-target visual tracking device.
The full-flow material branch-by-branch tracking system for the hot-rolled seamless steel pipe is characterized in that the industrial robot comprises a sizing blank labeling robot, a steel pipe labeling robot, a label supplementing robot and a finished product listing robot.
The hot-rolled seamless steel tube full-process material branch-by-branch tracking system is characterized in that the online visual recognition device comprises: the device comprises a long billet vision recognition device, a fixed billet offline industrial code reading recognition device, a fixed billet online industrial code reading recognition device, a fixed billet furnace entering industrial code reading recognition device, a steel pipe cross-line industrial code reading recognition device, a straightening machine front industrial code reading recognition device, a flaw detection front industrial code reading recognition device, a length measurement weighing front industrial code reading recognition device and a bulk material offline industrial code reading recognition device.
The hot-rolled seamless steel tube full-flow material branch-by-branch tracking system is characterized in that the multi-target visual tracking device comprises: a cold bed feeding visual tracking device, a cold bed discharging visual tracking device and a wide roller way visual tracking device.
The full-process material branch-by-branch tracking system for the hot-rolled seamless steel tube is characterized in that the full-process material branch-by-branch tracking system for the hot-rolled seamless steel tube adopts a method of manual intervention and combined filtering of trigger signals to ensure the accuracy of tracking.
The seamless steel tube production monitoring system has the advantages that through automatic tracking of the whole process, the production condition of materials can be monitored in real time, abnormal information can be processed in time, normal production of seamless steel tubes is guaranteed, manual intervention is reduced, and production efficiency is improved.
Drawings
FIG. 1 is a schematic view of a full-flow material branch-by-branch tracking system for hot-rolled seamless steel pipes according to the present invention;
Detailed Description
The present invention will be further described with reference to the following examples.
Examples
As shown in figure 1, the full-flow material branch-by-branch tracking system for the hot-rolled seamless steel tube comprises a software control system and a basic hardware system, wherein the software is the material branch-by-branch tracking control system, the basic hardware system comprises a plurality of industrial robots, an online identification device and basic hardware, and the software control system and the basic hardware system are used for controlling a basic automatic system of the hot-rolled seamless steel tube to realize automatic production and branch-by-branch tracking of the full-flow material of the hot-rolled seamless steel tube.
The material tracking process of the whole flow of the material branch-by-branch tracking control system is divided into two tracking modes: logical tracking and non-logical tracking. The logic tracking is suitable for the uninterrupted equipment interval of single-branch continuous production of materials. The device comprises a fixed-size billet feeding area, a pipe discharge saw area, a continuous rolling mill area, a sizing mill area, a cooling bed area and a pipe discharge saw area. And in the non-logic tracking area, intelligent equipment based on machine vision and an industrial robot technology is adopted to track the information of the material one by one.
The tracking system for the seamless steel pipe material branch by branch as shown in fig. 1 mainly comprises three aspects: industrial robot, online identification device and multi-target visual tracking device:
industrial robot: a sizing blank labeling robot 1; a steel pipe labeling robot 2; a mark-adding robot 3; and a finished product listing robot 4.
The online visual recognition device comprises: a long billet visual recognition device 5; a fixed-size blank offline industrial code reading identification device 6; an industrial code reading identification device 7 for the on-line fixed-size blank; a fixed-size blank charging industrial code reading identification device 8; a steel pipe overline industrial code reading identification device 9; an industrial code reading identification device 10 in front of the straightening machine; an industrial code reading identification device 11 before flaw detection; an industrial code reading identification device 12 before length measurement and weighing and a bulk cargo offline industrial code reading identification device 13.
Multi-target visual tracking device: a cold bed feeding visual tracking device 14; a cooling bed blanking visual tracking device 15; a wide roller way vision tracking device 16; the device is arranged at the stations No. 1-16 of the corresponding circle shown in the attached figure 1.
The material branch-by-branch tracking system is a basis for realizing accurate execution of a production plan and accurate management and control of a production process, is a transverse and cross-regional connecting line for full-flow production management and control, performs network communication and data interaction with a basic automation system and a software control system, ensures accurate issuing and execution of the production plan and process parameters, and is used as an index line for production achievement statistics and management.
The material branch-by-branch tracking system is based on the detection instrument of a basic automation system, such as: the system tracks the production state of on-line material transfer, judges the material flow direction of the material according to the running state of the equipment and the signals of relevant detection elements, and informs the control system in a material transfer event mode.
The material successive tracking system is provided with a material loading identification mistake-proofing mechanism, the material identification is detected and identified, the material identification is checked with a production plan, and when the material is inconsistent with the plan, an alarm prompt is triggered and return processing is carried out.
And establishing corresponding logic stations in the material branch-by-branch tracking system according to the production process flow. When the on-site on-line tube blank or steel tube moves from one station to the next station, the basic automation system transmits corresponding material moving signals and in-place signals to the material branch-by-branch tracking system through logic judgment, and after the system receives the data, the data are written into corresponding data sets, and the mapping information of the steel tube in the system is updated, so that the branch-by-branch tracking of the steel tube from the tube blank preparation to the pre-finished product offline is realized.
In the material branch-by-branch tracking execution process, the information of materials such as a long-size blank variable-size blank, a long steel pipe variable-magnification tube and the like is greatly changed, and the steel pipe branch-by-branch tracking is realized by adopting a robot labeling and online visual identification method.
The tracking process of the material branches one by one is tracked and executed along with the full-process production steps of the seamless steel tube, and specifically comprises the following steps:
the control system acquires production information of the seamless steel pipe, wherein the production information comprises information such as model, size, category and the like corresponding to the seamless steel pipe in each production flow when being processed;
the method comprises the following steps that a pipe blank area is tracked, a long-size-blank steel pipe is ready to be processed in the pipe blank area, a long-size-blank identification recognition device 5 arranged at a corresponding station tracks and recognizes the long-size-blank steel pipe, material information of the recognized long-size-blank steel pipe is fed back to a control system, the control system tracks the long-size-blank steel pipe corresponding to production information according to the fed-back material information of the long-size-blank steel pipe, and controls a pipe blank saw to cut the long-size-blank steel pipe into a fixed-size-blank steel pipe corresponding to the production information according to the corresponding production information.
And (3) labeling and identifying the fixed size blank, labeling the cut fixed size blank steel pipe by a fixed size blank labeling robot 1, tracking and identifying the fixed size blank off-line industrial code reading identification device and the fixed size blank on-line industrial code reading identification device after labeling, rejecting the off-line fixed size blank steel pipe by a basic automation system, and transferring the on-line fixed size blank steel pipe to a heating furnace.
And (4) furnace entering identification, wherein the fixed-size blank furnace entering industrial code reading identification device 8 identifies the conveyed on-line fixed-size blank steel pipe before furnace entering and judges whether material picking exists in the conveying process before furnace entering.
After the seamless steel tube is taken out of the furnace, tracking a hot rolling area of the seamless steel tube, after the seamless steel tube is subjected to furnace entering heating treatment, transferring the seamless steel tube to a cooling bed area after the process steps of perforation, tube rolling, steel tube reheating, diameter fixing (reducing) and the like, and carrying out cooling bed tracking, wherein the cooling bed area is provided with a multi-target visual tracking device which comprises a cooling bed feeding visual tracking device 14; a visual tracking device 15 for blanking of the cooling bed; the wide roller way visual tracking device 16 and the multi-target visual tracking device mainly track whether abnormal phenomena such as material removal, abnormal off-line, material stacking, abnormal occupation and the like occur in the cooling bed process, and feed back the abnormal phenomena to the control system for early warning and processing.
Aiming at the processing of material on-line and off-line, the logical tracking mode is used for recording and canceling the production information ID number when the material is off-line at stations such as a puncher, a continuous rolling mill, a sizing mill and the like, the material off-line or on-line at other stations is tracked according to the identification information, tracking confusion possibly occurs in field production due to equipment abnormity, and the system adopts a method of manual intervention and combined filtering of trigger signals to ensure the accuracy of tracking.
Blanking tracking, wherein after blanking is carried out by cold bed treatment, the seamless steel pipe is sent to a pipe gang saw by at least one wide roller way for cutting, the seamless steel pipe comprises at least two wide roller ways, and in the wide roller way conveying and pipe gang saw cutting processes, wide roller way visual tracking devices 16 are distributed at the front end and the rear end of the wide roller way for tracking and identifying; after being cut by a pipe gang saw, the seamless steel pipes are respectively transported to at least two finished product processing production lines; the steel pipe is abnormally off-line in a production line cooling bed area, the material in the area is in a high-temperature state, and a multi-target visual tracking mode is adopted. And an industrial camera is arranged at the inlet and the outlet of the cooling bed area for image acquisition. And the multi-target visual tracking system analyzes the image, judges whether the cooling bed station has materials, compares the images with the logical tracking result of the material one-by-one tracking system, and automatically judges the material information of the upper line and the lower line of the cooling bed area.
Tracking in a finishing area, wherein at least two finished product processing production lines respectively comprise production processes of finished product pipe straightening, finishing, inspection and flaw detection (nondestructive, physicochemical and bench inspection), warehousing and the like, and bulk material collection and finished product warehousing are carried out after the finished product pipes pass through a straightening machine, a dust blowing and sucking device, a flaw detection area device, a manual inspection bench and a measuring and weighing device. In the process, a material branch-by-branch tracking system pastes a label on the cut seamless steel pipe through a steel pipe labeling robot 2, after the label is pasted, a steel pipe cross-line industrial code reading recognition device performs steel pipe cross-line industrial code reading recognition on the seamless steel pipe, a straightening machine front industrial code reading recognition device performs straightening machine front industrial code reading recognition on the seamless steel pipe, after straightening and dust blowing and sucking treatment, a flaw detection front industrial code reading recognition device 10 performs flaw detection front industrial code reading recognition, and after flaw detection, a label supplementing robot 3 performs label supplementing on the seamless steel pipe with label falling or unclear label information in the process; after the mark is supplemented, further inspection is carried out through a manual inspection table.
Processing and tracking finished products, and performing code reading identification on the seamless steel pipes by an industrial code reading identification device 12 before length measurement and weighing; after length measurement and weighing, qualified finished products are subjected to listing and warehousing by the finished product listing robot 4, and unqualified bulk materials are collected and reprocessed after being identified by the bulk material offline industrial code reading identification device 13.
The tracking and identification of the material seamless steel tube full flow are realized through the material branch-by-branch tracking system, the basic automation system is controlled through the process control system, the processing and information feedback of the seamless steel tube automatic product material abnormity are realized, and data support is provided for realizing product quality control and full-line production performance statistical management.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are given by way of illustration of the principles of the present invention and that various changes and modifications may be effected therein by one of ordinary skill in the pertinent art without departing from the scope or spirit of the present invention.
Claims (8)
1. A method for tracking a whole-process material branch by branch of a hot-rolled seamless steel pipe is characterized by comprising a logic tracking mode and a non-logic tracking mode, wherein the logic tracking mode comprises tracking of an uninterrupted equipment interval for continuous production of a single material branch, the non-logic tracking mode comprises tracking of an uninterrupted equipment area for multi-target production, and the tracking of the uninterrupted equipment area for the multi-target production is to identify whether abnormal phenomena of material removal, abnormal offline, material stacking and abnormal occupation exist in a cooling bed process; the non-logical tracking also comprises identification and visual recognition of the material by the industrial robot.
2. The method of claim 1, wherein the logical tracking determines the material in place information via a material detection element of the base automation system.
3. The method of claim 1, wherein the non-logical tracking tracks the material by machine depth vision recognition, wherein the identification includes labeling and branding.
4. The method of any one of claims 1-3, wherein the full flow material leg by leg tracking comprises the steps of: the method comprises the following steps of pipe blank area tracking, fixed-size blank labeling and identification, furnace entering identification, hot rolling area tracking, cooling bed tracking, blanking tracking, finishing area tracking and finished product processing tracking.
5. The utility model provides a hot rolling seamless steel pipe full flow material is tracking system gradually, includes process control system and basic automation system, its characterized in that still includes industrial robot, online visual identification device and multi-target visual tracking device, multi-target visual tracking device includes: the system comprises a cooling bed feeding visual tracking device (14), a cooling bed discharging visual tracking device (15) and a wide roller way visual tracking device (16), wherein the multi-target visual tracking device analyzes images of a cooling bed area, judges whether a cooling bed station has materials or not, compares the images with a logic tracking result of a material branch-by-branch tracking system, automatically judges material information of an upper line and a lower line of the cooling bed area, and the hot-rolled seamless steel pipe full-process material branch-by-branch tracking system executes the method of claim 1.
6. The full-process material branch-by-branch tracking system for the hot-rolled seamless steel pipe as claimed in claim 5, wherein the industrial robots comprise a sizing blank labeling robot (1), a steel pipe labeling robot (2), a mark complementing robot (3) and a finished product listing robot (4).
7. The hot-rolled seamless steel tube full-process material branch-by-branch tracking system according to claim 5, wherein the online visual recognition device comprises: the device comprises a long billet vision recognition device (5), a fixed billet offline industrial code reading recognition device (6), an online industrial code reading recognition device (7) of the fixed billet, a fixed billet furnace entering industrial code reading recognition device (8), a steel pipe offline industrial code reading recognition device (9), a straightening machine front industrial code reading recognition device (10), a flaw detection front industrial code reading recognition device (11), a length measurement weighing front industrial code reading recognition device (12) and a bulk material offline industrial code reading recognition device (13).
8. The hot-rolled seamless steel tube full-process material branch-by-branch tracking system according to any one of claims 5 to 7, wherein the hot-rolled seamless steel tube full-process material branch-by-branch tracking system adopts a method of manual intervention and combined filtering of trigger signals to ensure the accuracy of tracking.
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| CN114472527B (en) * | 2021-12-15 | 2024-04-09 | 承德建龙特殊钢有限公司 | Seamless steel pipe is a tracking production system by a tracking |
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| CN114406007B (en) * | 2022-04-01 | 2022-06-03 | 承德建龙特殊钢有限公司 | Seamless steel pipe tracking production system one by one |
| CN115016424B (en) * | 2022-08-08 | 2022-11-25 | 承德建龙特殊钢有限公司 | Seamless steel pipe production line real-time monitoring system |
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