CN115759995A - Cold rolling hot galvanizing process zinc resource management and control platform and management and control method - Google Patents
Cold rolling hot galvanizing process zinc resource management and control platform and management and control method Download PDFInfo
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Abstract
The invention discloses a zinc resource control platform and a zinc resource control method for a cold-rolling hot-galvanizing process, belonging to the technical field of cold-rolled strip steel continuous hot galvanizing; the management and control platform comprises a data center platform and a service center platform, wherein the data center platform comprises warehousing sampling inspection data, a zinc ingot grading system, loading and unloading scanning weighing data, an optimal path, an ingot adding sequence and period and zinc pot components; the service center station comprises: the system comprises a warehousing system, a ex-warehouse system, a transportation system, an operation system and a refinement system; the warehousing system comprises a purchasing early warning module, a zinc ingot sampling inspection module, a zinc ingot grading system module, a zinc slag warehousing module and a code scanning weighing module; the ex-warehouse system comprises an ex-warehouse code scanning module, a zinc ingot positioning module, an unmanned warehouse moving unit and a zinc ingot direction-going management module; the transport system comprises an AGV multi-vehicle cooperation module; the operation system comprises an automatic ingot hanging device and a zinc ingot turning device; the refining system comprises a purchasing prediction module, a liquid zinc ingredient management and control module, a zinc slag amount metering and management and control module and an intelligent production auxiliary module.
Description
Technical Field
The invention belongs to the technical field of cold-rolled strip steel continuous hot galvanizing, and particularly relates to a zinc resource control platform and a zinc resource control method for a cold-rolled hot galvanizing process.
Background
The hot galvanizing production process is to make molten metal zinc react with an iron matrix to generate a zinc-iron alloy layer, so that the matrix and a coating form tight combination, and the corrosion resistance of the steel plate strip product is further improved. The process comprises the following steps: before hot galvanizing, the steel plate strip product needs to be pickled to remove iron oxide particles on the surface of the steel product; rolling after acid cleaning to make the plate and strip material reach the target thickness; removing residual oil and residual iron pollutants on the surface of the strip steel after rolling through degreasing treatment; after cleaning, the strip steel enters an annealing furnace for quenching and tempering, so that the internal stress of the strip steel is eliminated, and the strip steel is in a preparation state before hot dipping; after coming out of the annealing furnace, the strip steel is sent into a hot-dip plating tank to finish the hot-dip plating process.
The hot galvanizing product generally has the advantages of stable and uniform coating, strong adhesive force, long service life and the like. The main raw material cost of the hot-dip coating production line is the consumption of zinc. The hot galvanizing production line of the existing mainstream adopts the method that the strip steel to be treated continuously passes through a zinc pot containing molten zinc liquid, and hot galvanizing is finished by depending on the attachment of zinc, so that the zinc liquid can be continuously consumed in the production process and needs to be supplemented in time. The supplement in the production mainly adopts zinc ingots with the purity of more than 99.2 percent, the weight of the zinc ingots can reach about 2 tons to the maximum, and the maximum length of the zinc ingots exceeds 2m. Because of the continuous consumption of zinc, the zinc is supplemented in a mode of dynamically tracking ingot adding operation on site. There are two main aspects to zinc consumption: one is the hot galvanizing coating on the surface of the strip steel, which is the normal consumption; the other is that the molten zinc and iron powder particles on the surface of the strip steel are subjected to metallurgical reaction to form zinc slag or are oxidized to form ZnO, which is abnormally consumed. On one hand, the generated zinc slag can be partially accumulated on the surface of strip steel to cause product objections, and simultaneously, the slag dragging operation causes the most main zinc loss, thereby causing very adverse effects on the product quality and the cost control of the hot-dip galvanized strip.
The main problems of zinc resource management of cold rolling hot galvanizing in the steel industry at the present stage are as follows: the management surrounding zinc resources is more disordered, and the total consumption of zinc ingots cannot be balanced due to multi-head management; the manual mode is adopted for registration in and out of the warehouse, and zinc ingots are easy to miss and leak in circulation; zinc slag management flows into a form, and closed-loop management of zinc resources is not realized; influencing the optimization and process adjustment of abnormal consumption of zinc.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a zinc resource control platform and a zinc resource control method for a cold rolling and hot galvanizing process.
The purpose of the invention can be realized by the following technical scheme:
a cold rolling hot dip galvanizing process zinc resource management and control platform comprises a data center platform and a service center platform, wherein the data center platform comprises: warehousing sampling inspection data, a zinc ingot grading system, loading and unloading code scanning weighing, an optimal path, an ingot adding sequence and period and zinc pot components; the service center station comprises: the system comprises a warehousing system, a ex-warehouse system, a transportation system, an operation system and a refinement system;
the warehousing system comprises a purchasing early warning module, a zinc ingot sampling inspection module, a zinc ingot grading system, a zinc slag warehousing module and a code scanning weighing module; the ex-warehouse system comprises an ex-warehouse code scanning module, a zinc ingot positioning module, an unmanned warehouse moving unit and a zinc ingot destination management module; the transportation system comprises an AGV multi-vehicle cooperative module, covers the range of a whole base, and realizes the transportation of zinc ingots and zinc slag in a production line and in a reservoir area; the operation system comprises an automatic ingot hanging device and a zinc ingot turning device; the refined system comprises a purchasing prediction module, a liquid zinc ingredient management and control module, a zinc slag amount metering and management and control module and an intelligent production auxiliary module.
Further, the purchase early warning module reminds in advance when the zinc ingot inventory is less than the required amount of the order;
the zinc ingot spot check module performs spot check on a batch of products according to a random spot check algorithm, and a spot check result is automatically fed to the system;
the zinc ingot grading system comprises zinc ingot coding management, large and small ingot setting, warehousing batch setting and supplier management of different varieties;
the zinc slag warehousing module finishes the collection work of zinc slag of different bases, branch plants and production lines and finishes the association of different hot galvanizing product varieties with zinc slag amount and on-site zinc pot process conditions;
and the code scanning weighing module is used for weighing the zinc ingots which are put in storage one by one, scanning the codes and putting the codes into the storage, extracting the weight and the type information of the zinc ingots which are put in storage, and establishing the positioning information of each zinc ingot in the zinc ingot storage.
And further, when the zinc ingots are taken out of the warehouse, the zinc ingots are taken according to the positioning information of the zinc ingots, and the zinc ingots are tracked in the direction by a transportation system.
Furthermore, an unmanned navigation vehicle unit is arranged in the AGV multi-vehicle cooperation module and is composed of a plurality of AGVs, and information connection of material sending and receiving of production lines to different branch plants is achieved.
Further, the automatic ingot hanging device carries out ingot hanging operation, and carries out data recording and upward throwing on different types of zinc ingot hanging time, ingot adding frequency and total ingot adding sequence;
the zinc ingot turnover device can meet the requirements of flexible turnover of large zinc ingots and switching of large and small ingots.
Further, for mature products, the purchasing prediction module automatically matches zinc ingot purchasing quantities of different types according to zinc ingot consumption quantities extracted by the production line order and historical data;
for a new product, the purchasing prediction module performs fitting on the basis of the proportion of different zinc ingot consumptions of the existing mature product to approach the minimum stock, and a zinc ingot purchasing order is automatically formed.
Furthermore, the liquid zinc component control module measures liquid zinc components in real time, throws data up to a data intermediate station for processing, tracks the liquid zinc quality, and can provide optimization suggestions for a zinc adding sequence;
further, the zinc slag amount metering and controlling module evaluates the zinc resource controlling capability and level based on different zinc slag data of each base, branch plant or production line and each group.
Furthermore, the intelligent production auxiliary module optimizes the zinc adding operation and the ingot adding sequence.
A zinc resource control method for a cold rolling hot galvanizing process uses the control platform to control.
The invention has the beneficial effects that: the resource management and control platform provided by the invention can realize the overall management and control of zinc resources of a hot galvanizing production line, and ensure that all zinc resource related services are clear and controllable and the total amount is balanced; a package solution is provided for the zinc ingot in cold rolling hot galvanizing from purchasing, warehousing, ex-warehouse, use, zinc slag recovery and zinc pot process improvement; the method improves the product quality defect caused by the zinc slag, reduces the inventory cost of zinc ingots, further improves the pricing accuracy of hot-dip galvanized products, improves the intelligent level of unit operation, and reduces the unnecessary zinc consumption of the zinc slag.
Drawings
In order to more clearly illustrate the embodiments or technical solutions in the prior art of the present invention, the drawings used in the description of the embodiments or prior art will be briefly described below, and it is obvious for those skilled in the art that other drawings can be obtained based on these drawings without creative efforts.
FIG. 1 is a schematic diagram of an overall framework structure of the management and control platform of the present invention;
fig. 2 is a block diagram of an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. 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, a zinc resource management and control platform for a cold rolling and hot galvanizing process is divided into three management and control levels, namely a manufacturing base level, a factory level and a production line level; the management and control platform includes platform in data and platform in the business, and wherein, the platform includes in the data: warehousing sampling inspection data, a zinc ingot grading system, loading and unloading code scanning weighing, an optimal path, an ingot adding sequence and period and zinc pot components; the service center station comprises: the system comprises a warehousing system, a ex-warehouse system, a transportation system, an operation system and a refinement system; main data related to zinc resources are placed in a data center, services are placed in a service center, time and space limits of different unit levels are opened by utilizing the data center and service center platform technologies, data linking and sharing of different services are formed, the use efficiency and the use capacity of the zinc resources in the whole system are evaluated, and a new service form driven by zinc resource control data is formed.
The warehousing system comprises a purchasing early warning module, a zinc ingot sampling inspection module, a zinc ingot grading module, a zinc slag warehousing module and a code scanning weighing module;
the purchase early warning module is used for reminding in advance when the stock of the zinc ingot storehouse is obviously less than the required amount of the order (the data reference of the purchase early warning module is from a purchase prediction module in a fine system); the zinc ingot spot check module can form a random spot check algorithm according to the requirements of a company purchasing department, carry out spot check on a batch of products, automatically throw the spot check result to the system, manage the zinc ingots on site and form continuous evaluation on the quality of the products of suppliers; the zinc ingot grading system comprises submodules of zinc ingot coding management, large and small ingot setting, warehousing batch setting, supplier management and the like of different varieties; the zinc dross warehousing module finishes the collection work of zinc dross in different bases, branch plants and production lines, and finishes the association of different hot galvanizing product varieties with zinc dross amount and on-site zinc pot process conditions, thereby providing support for the subsequent zinc dross reduction process adjustment; the code scanning weighing module mainly performs block-by-block weighing and code scanning warehousing on the zinc ingots which are warehoused, extracts warehousing weight and type information, and can also establish positioning information of each zinc ingot in the zinc ingot warehouse to realize digital management and control of the warehoused zinc ingots.
The warehouse-out system realizes the reverse action of warehouse-in, the same equipment is adopted as the warehouse-in system, and only code scanning is carried out during warehouse-out without weighing; and the zinc ingot is taken immediately according to the warehousing zinc ingot positioning information, and the zinc ingot direction tracking is realized by depending on a transportation system. The ex-warehouse system comprises an ex-warehouse code scanning module, a zinc ingot positioning module, an unmanned warehouse moving unit and a zinc ingot destination management module. The ex-warehouse code scanning module is mainly used for ex-warehouse management and dynamically tracking the service condition of the zinc ingots. The zinc ingot positioning module is mainly used for recording the spatial position of a certain zinc ingot, is convenient to find quickly, and can optimize the placement of the zinc ingot according to historical data so as to be convenient for quick access. The unmanned garage moving unit is a hoisting and carrying operation unit consisting of an AGV trolley and an unmanned crane, and realizes the functions of warehouse entry and exit, in-warehouse transfer and zinc ingot outward delivery. The zinc ingot destination management module is used for acquiring different units and consumption conditions sent by the zinc ingot and completing automatic information throwing.
The transportation system comprises an AGV multi-vehicle cooperation module, covers a plurality of branch plants and a plurality of production lines in the range of a whole base, and realizes the transportation of zinc ingots and zinc slag in the storage area and the production lines; if the zinc ingot is conveyed, the connection of information such as the type and the weight of the zinc ingot needs to be automatically completed, and the zinc slag needs to be associated with hot galvanizing product variety information, unit information and the like. An unmanned navigation vehicle unit is arranged in the AGV multi-vehicle cooperation module, is a main execution unit for realizing the real zinc ingot object entering/exiting from a warehouse, consists of a plurality of AGV (automatic navigation vehicles), and realizes the information connection of material sending and receiving to different branch plants and production lines; and conveying the zinc ingots or the zinc slag to a zinc ingot warehouse, a production line or a zinc slag warehouse respectively through a conveying system, and placing according to the standard requirements. The AGV workshop can complete self-organization and self-coordination, and complete the carrying and transferring functions in a cooperation manner.
The operation system comprises an automatic ingot hanging device and a zinc ingot overturning device, and unmanned ingot adding operation is realized; the automatic ingot hanging device not only completes the specific ingot hanging operation, but also needs to specifically realize data recording and upward throwing of different types of zinc ingot hanging time, ingot adding frequency and total ingot adding sequence; the zinc ingot turnover device can realize flexible turnover of large zinc ingots. The two functions belong to the key technology of the zinc ingot operation level.
The refining system is the brain of a zinc resource control platform in the hot galvanizing process and comprises a purchasing prediction module, a zinc liquid component control module, a zinc slag amount metering and control module and an intelligent production auxiliary module;
for mature products, the purchasing prediction module is mainly used for automatically matching zinc ingot purchasing quantities of different types according to zinc ingot consumption extracted by the production line order system according to historical data, so that the hit rate of the types and the quantity of the zinc ingots is improved, and the inventory is reduced; for a new product, the purchasing prediction module can perform fitting on the basis of the proportion of different zinc ingot consumptions of the existing mature product, the lowest stock quantity is approached to the maximum extent, a purchasing order of the zinc ingot is automatically formed, manual intervention can be performed for adjustment and recording, and the final result is recorded in the system and is conveniently suboptimal and invoked; the module can also provide optimized data for the ingot adding operation, so that support can be provided for the improvement of ingot adding processes such as ingot adding speed, large and small ingot use and ingot adding.
The liquid zinc ingredient control module adopts real-time determination of liquid zinc ingredients, and throws data up to a data center for processing, the data tracks the liquid zinc quality, and optimization suggestions can be provided for a zinc adding sequence;
the zinc slag amount metering and controlling module evaluates the zinc resource controlling capacity and level based on different zinc slag data of each base, branch plant or production line and each group, so as to further improve the utilization efficiency of zinc;
the intelligent production auxiliary module mainly realizes getting through the multi-dimensional heterogeneous data and provides optimization for the zinc adding operation and the ingot adding sequence, so that the total amount of abnormal zinc consumption of zinc slag is reduced, and the surface quality of a hot galvanizing product is improved.
As shown in fig. 2, the implementation process of the zinc resource management and control platform in the cold rolling and hot galvanizing process is specifically described below;
firstly, cleaning a production plan of the next production stage according to the order condition, and determining the total amount and variety of zinc ingots by adopting data from a purchasing prediction module in a fine system; the purchasing prediction module is mainly used for properly optimizing the zinc pot according to the process conditions and equipment state conditions of the zinc pot by collecting historical data of zinc ingot consumption of the products, and determining the final purchasing amount and the type of the zinc ingot through weighting adjustment according to the data of the two aspects. When the purchased zinc ingots are delivered to a warehouse, the warehousing operation is firstly carried out. The zinc ingot of the type specification is managed according to a uniform coding mode, such as "manufacturer code + detection date (20221029) + zinc ingot type (a-E) + large and small ingots (0/1) + storage area code + single ingot weight (an example of a coding mode), and the code scanning information needs to include the above information. Each zinc ingot is warehoused by a code scanning weighing module, and the weight of each zinc ingot is compared with the inventory; the counting system counts the zinc ingots of the same type again; and the random spot check algorithm of the company purchasing department is adopted to carry out spot check and test, the data information is brought into the supplier for management, and the position of each zinc ingot is managed through the storage area code, so that any zinc ingot in the zinc ingot library can be positioned at any time.
After the production plan is made, different production lines are divided, different hot galvanizing product varieties are produced by the production lines, ingot adding sequences with the best history (comprehensive optimal zinc consumption and zinc slag generation) are automatically matched according to the process and equipment states of a zinc liquid component control module in a refined system for a zinc pot, and the requirement of lowest zinc slag generation is met. After the ingot adding sequence is clear, the unmanned navigation vehicle unit carries out zinc ingot positioning according to the storage area code and sends the zinc ingots to a demand production line. When the zinc ingots are taken out of the warehouse, the heading of the zinc ingots needs to be recorded, and the zinc ingots are checked and sold after arriving, and then the zinc ingots are taken out of the warehouse.
Therefore, automatic matching of warehousing and ex-warehouse services and production line production is completed. The transportation system utilizes AGV multi-car cooperation module to realize producing more and send the spindle and get the sediment operation, through optimal path tracking, can adopt the mode of multistage concatenation, realizes the gradual transport of polylith zinc spindle to retrieve the zinc sediment to the zinc sediment storehouse when returning, improve the operating efficiency. The information connection of the material sending and receiving to different branch plants and production lines is realized. Zinc ingots or zinc slag are conveyed to a zinc ingot warehouse, a production line or a zinc slag warehouse respectively through a conveying system and are placed according to the standard requirements, and the zinc slag warehouse also needs to adopt a uniform coding mode, such as: "(base code + production line code + unit code) + date + storage area code + weight information + steel coil number", and associate the corresponding weight data with production line and product quality grading module, the data is used as the evaluation basis to the production line/team zinc utilization ratio after processing.
After the zinc ingot is sent to a zinc pot area through an AGV trolley, the preparation work of adding the zinc ingot is completed by using a zinc ingot turnover device, and the zinc ingot is automatically on-line without human intervention by using an automatic ingot hanging device. Besides completing specific ingot hanging operation, the automatic ingot hanging device also needs to specifically realize data recording and upward throwing of different types of zinc ingots in ingot hanging time, ingot adding frequency and total ingot adding sequence. These data provide support for optimization and tuning of the latter stage ingot feeding process.
On the one hand, modeling is carried out on the zinc consumption of mature products based on the accumulation of a large amount of data of a zinc resource control platform, and the zinc pot component control is carried out according to the optimal process configuration and a zinc ingot zinc adding sequence when the products are produced, so that the occurrence of zinc slag can be obviously improved; on the other hand, for a new product, data comparison can be carried out on a mature product which is closest to the product, a balance point is quickly found for the process control of the new product by increasing the weight of the control factor, the process exploration transition period of the new product is shortened, and the product percent of pass of the personalized new product is improved.
Therefore, the whole process of controlling the zinc resource is effectively processed, all key multidimensional heterogeneous data related to zinc consumption are organized in the system, and data support is provided for optimizing the ingot adding sequence and reducing the total amount of abnormal zinc consumption of zinc slag. Meanwhile, related data are communicated, and the problem of information distortion in the process of manual recording and information transmission is reduced; finally, the system provides data support for the purchase of zinc resources of different grades, and further perfects pricing mechanisms of hot galvanizing products of different specifications and varieties.
In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The foregoing shows and describes the general principles, principal 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 described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed.
Claims (10)
1. The utility model provides a cold rolling hot dip galvanizing process zinc resource management and control platform which characterized in that, platform and business are put in including the data, and the platform includes in the data: warehousing random inspection data, a zinc ingot grading system, entering and exiting scanning code weighing, an optimal path, an ingot adding sequence and period and zinc pot components; the service center station comprises: the system comprises a warehousing system, a ex-warehouse system, a transportation system, an operation system and a refinement system;
the warehousing system comprises a purchasing early warning module, a zinc ingot sampling inspection module, a zinc ingot grading system, a zinc slag warehousing module and a code scanning weighing module; the ex-warehouse system comprises an ex-warehouse code scanning module, a zinc ingot positioning module, an unmanned warehouse moving unit and a zinc ingot direction-going management module; the transportation system comprises an AGV multi-vehicle cooperation module, covers the whole base range, and realizes the transportation of moving in the reservoir area and producing zinc ingots and zinc slag in a production line; the operation system comprises an automatic ingot hanging device and a zinc ingot overturning device; the refining system comprises a purchasing prediction module, a liquid zinc ingredient management and control module, a zinc slag amount metering and management and control module and an intelligent production auxiliary module.
2. The zinc resource management and control platform for the cold rolling hot galvanizing process according to claim 1, wherein the purchase early warning module is used for reminding in advance when the zinc ingot inventory is less than the required amount of an order;
the zinc ingot spot inspection module performs spot inspection on a batch of products according to a random spot inspection algorithm, and a spot inspection result is automatically fed to the system;
the zinc ingot grading system module comprises zinc ingot coding management, large and small ingot setting, warehousing batch setting and supplier management of different varieties;
the zinc slag warehousing module finishes the collection work of zinc slag of different bases, branch plants and production lines and finishes the association of different hot galvanizing product varieties with zinc slag amount and on-site zinc pot process conditions;
and the code scanning weighing module is used for weighing the zinc ingots which are put in storage one by one, scanning the codes and putting the codes into the storage, extracting the weight and the type information of the zinc ingots which are put in storage, and establishing the positioning information of each zinc ingot in the zinc ingot storage.
3. The zinc resource control platform for the cold rolling hot galvanizing process according to claim 2, characterized in that when the zinc ingot is taken out of a warehouse, the zinc ingot is taken according to the positioning information of the zinc ingot, and the zinc ingot is tracked by a transportation system.
4. The zinc resource management and control platform for the cold rolling and hot galvanizing process according to claim 1, wherein an unmanned navigation vehicle unit is arranged in the AGV multi-vehicle cooperation module, and the unmanned navigation vehicle unit is composed of a plurality of AGVs, so that information connection of sending and receiving of materials to different branch plants and production lines is realized.
5. The zinc resource control platform for the cold rolling and hot galvanizing process according to claim 1, wherein the automatic ingot hanging device carries out ingot hanging operation, and carries out data recording and upward throwing on different types of zinc ingot hanging time, ingot adding frequency and total ingot adding sequence;
the zinc ingot turnover device can meet the requirements of flexible turnover of large zinc ingots and switching of large and small ingots.
6. The zinc resource management and control platform for the cold rolling and hot galvanizing process according to claim 1, wherein for mature products, the purchasing prediction module automatically matches zinc ingot purchasing quantities of different types according to zinc ingot consumption quantities extracted by the production line order and historical data;
for a new product, the purchasing prediction module performs fitting on the basis of the proportion of different zinc ingot consumptions of the existing mature product to approach the lowest stock, and a zinc ingot purchasing order is automatically formed.
7. The zinc resource control platform for the cold rolling and hot galvanizing process according to claim 1, wherein the zinc liquid component control module measures zinc liquid components in real time, and throws data to a data center for processing, and the data tracks zinc liquid quality and can provide optimization suggestions for a zinc adding sequence.
8. The platform for managing and controlling zinc resources in the cold rolling and hot galvanizing process according to claim 1, wherein the zinc slag amount metering and controlling module evaluates the capacity and level of zinc resource management and control based on different zinc slag data of each base, branch plant or production line and each group.
9. The zinc resource management and control platform for the cold rolling and hot galvanizing process according to claim 1, wherein the intelligent production auxiliary module optimizes a zinc adding operation and an ingot adding sequence.
10. A zinc resource management and control method for a cold rolling hot galvanizing process uses the management and control platform of any one of claims 1 to 9 to perform management and control.
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