CN117265449A - Steel pipe galvanization wind ring control system - Google Patents
Steel pipe galvanization wind ring control system Download PDFInfo
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- CN117265449A CN117265449A CN202311549828.8A CN202311549828A CN117265449A CN 117265449 A CN117265449 A CN 117265449A CN 202311549828 A CN202311549828 A CN 202311549828A CN 117265449 A CN117265449 A CN 117265449A
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 137
- 239000010959 steel Substances 0.000 title claims abstract description 137
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 74
- 239000011701 zinc Substances 0.000 claims abstract description 74
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 74
- 238000005259 measurement Methods 0.000 claims abstract description 32
- 230000006872 improvement Effects 0.000 claims abstract description 23
- 238000002474 experimental method Methods 0.000 claims abstract description 20
- 230000006698 induction Effects 0.000 claims abstract description 11
- 239000000463 material Substances 0.000 claims abstract description 11
- 230000000694 effects Effects 0.000 claims abstract description 9
- 238000001514 detection method Methods 0.000 claims description 44
- 238000000034 method Methods 0.000 claims description 32
- 239000007788 liquid Substances 0.000 claims description 18
- 238000001228 spectrum Methods 0.000 claims description 12
- 230000008859 change Effects 0.000 claims description 8
- 229910052751 metal Inorganic materials 0.000 claims description 8
- 239000002184 metal Substances 0.000 claims description 8
- 238000009825 accumulation Methods 0.000 claims description 7
- 238000004364 calculation method Methods 0.000 claims description 7
- 238000007747 plating Methods 0.000 claims description 7
- 238000012545 processing Methods 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 6
- 230000005674 electromagnetic induction Effects 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000000523 sample Substances 0.000 claims description 6
- 238000004458 analytical method Methods 0.000 claims description 5
- 238000009826 distribution Methods 0.000 claims description 4
- 238000011156 evaluation Methods 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 3
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 230000007613 environmental effect Effects 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 claims description 3
- 239000011572 manganese Substances 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 claims description 3
- 229910052698 phosphorus Inorganic materials 0.000 claims description 3
- 239000011574 phosphorus Substances 0.000 claims description 3
- 238000012163 sequencing technique Methods 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 239000010703 silicon Substances 0.000 claims description 3
- 238000001179 sorption measurement Methods 0.000 claims description 3
- 239000006185 dispersion Substances 0.000 claims 1
- 230000002452 interceptive effect Effects 0.000 claims 1
- 230000006870 function Effects 0.000 description 27
- 230000008569 process Effects 0.000 description 5
- 230000001276 controlling effect Effects 0.000 description 4
- 230000009471 action Effects 0.000 description 3
- 230000001105 regulatory effect Effects 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000005246 galvanizing Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 206010028980 Neoplasm Diseases 0.000 description 1
- 230000005856 abnormality Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000013135 deep learning Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000012886 linear function Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/14—Removing excess of molten coatings; Controlling or regulating the coating thickness
- C23C2/16—Removing excess of molten coatings; Controlling or regulating the coating thickness using fluids under pressure, e.g. air knives
- C23C2/18—Removing excess of molten coatings from elongated material
- C23C2/185—Tubes; Wires
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
- C23C2/06—Zinc or cadmium or alloys based thereon
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B11/00—Automatic controllers
- G05B11/01—Automatic controllers electric
- G05B11/36—Automatic controllers electric with provision for obtaining particular characteristics, e.g. proportional, integral, differential
- G05B11/42—Automatic controllers electric with provision for obtaining particular characteristics, e.g. proportional, integral, differential for obtaining a characteristic which is both proportional and time-dependent, e.g. P.I., P.I.D.
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Abstract
The invention discloses a steel pipe galvanization wind ring control system which comprises an information acquisition module, a wind ring improvement module, a turbulence experiment module and a main control module, wherein the information acquisition module is used for inputting various indexes of a use scene, collecting material components and surface characteristic features of a steel pipe, the wind ring improvement module is used for generating a wind ring pressure control function model by analyzing various indexes of the use scene, material information and specific conditions of the surface characteristic features of the steel pipe, improving the control model according to feedback information of various channels, the turbulence experiment module is used for evaluating and feeding back the actual condition of an actual application scene after the wind ring effect control model is improved, real-time adjusting the output state, forming a closed loop system with consistent algorithm control and actual output, and the induction thickness measurement module is used for measuring the thickness of a zinc layer after the steel pipe is processed.
Description
Technical Field
The invention relates to the technical field of galvanization processes, in particular to a steel pipe galvanization wind ring control system.
Background
The galvanization is to immerse the preheated steel pipe into molten zinc liquid along a certain angle to form a uniform zinc layer on the surface. The immersion plating time varies from a few minutes to tens of minutes, depending on the size of the steel pipe and the required zinc layer thickness. After the steel pipe leaves the zinc liquid, the wind ring is adopted to thin the zinc liquid attached to the steel pipe by a wind knife, and the zinc liquid attached to the steel pipe is removed, so that the zinc layer on the surface of the steel pipe is smooth, the thickness is uniform, no zinc layer falls off, no bubbles exist, zinc tumors are reduced, and the purposes of attractive appearance, durability, zinc consumption reduction and cost saving are achieved. The reaction time and the reaction effect of the steel tube and the zinc liquid in hot galvanizing are related to the metal material and the processing condition of the steel tube. The wind ring is a conical ring-shaped object placed at the edge of the galvanizing bath and in the middle of the magnetic roller, a cavity is arranged in the middle, and small holes with cone angles of 58-62 degrees are densely distributed on the periphery. The zinc coating device is used for carrying out zinc coating operation on the floating zinc on the surface of the steel pipe from which the zinc liquid is just discharged.
The currently used wind ring control mostly adopts manual control or monomer switch control, and the pressure in the whole process is divided into three sections or constant pressure at most. The wind pressure is not subjected to linear function adjustment function in the process that the steel pipe passes through the wind ring, so that the uniformity of the zinc layer on the surface of the whole steel pipe is low. The analysis of steel pipe metal components influencing the reaction of zinc liquid and steel pipes and production scene factors is not introduced, and the feedback control for adjusting the wind ring is not introduced to the zinc layer after the processing is completed. Therefore, it is necessary to design a steel pipe galvanization wind ring control system with high galvanization uniformity.
Disclosure of Invention
The invention aims to provide a steel pipe galvanized wind ring control system for solving the problems in the background technology.
In order to solve the technical problems, the invention provides the following technical scheme: the utility model provides a steel pipe galvanization wind ring control system, includes information acquisition module, wind ring improvement module, turbulent flow experiment module, main control module, information acquisition module is used for entering each index of usage scene, gather the material composition of steel pipe, surface characteristics characteristic, wind ring improvement module is used for through the specific circumstances of each index of analysis usage scene, steel pipe's material information, surface characteristics characteristic, generate wind ring pressure control function model to improve control model according to each channel feedback information, turbulent flow experiment module is used for carrying out evaluation, feedback to the actual condition of actual application scene after wind ring effect control model improves, carries out real-time adjustment to the output state, forms the closed loop system that algorithm control is unanimous with actual output, response thickness measurement module is measured zinc layer thickness after steel pipe processing finishes to with information feedback wind ring improvement module, intervene wind ring improvement module's function and produce, main control module is used for controlling each module orderly work.
According to the technical scheme, the information acquisition module comprises a use scene detection module, an induction thickness measurement module and a spectrum detection module, wherein the use scene detection module is connected with the induction thickness measurement module in a network manner, the use scene detection module is used for detecting the temperature, the humidity degree and the acid-base degree of a steel pipe use scene, so that the influence of the recommended content of oxides on the surface of zinc liquid and the temperature scattering and losing change on the change of the adsorption force of the zinc liquid on the surface of the steel pipe is roughly given, the induction thickness measurement module is used for measuring the thickness of a zinc layer on the surface of the steel pipe through electromagnetic induction, and is used for overall evaluation of the zinc plating of the steel pipe after being transmitted to a system, and the spectrum detection module is used for detecting the components of the steel pipe;
the turbulence experiment module comprises a wind pressure detection module, a PID control module, a pressure control unit and a laser detection module, wherein the wind pressure detection module comprises a pressure sensor and is used for detecting the outlet pressure change condition of the wind ring in real time, the laser detection module comprises a laser sensor and is used for monitoring the reaching position of a steel pipe in real time and transmitting information to the PID control module, the PID control module adjusts the pressure of the wind ring according to a function model and a pressure feedback condition given by the wind ring improvement module, so that the output pressure is kept consistent with the function model, and the pressure control unit is used for adjusting the pressure distribution of the wind ring by controlling each proportion adjusting valve.
Based on the steel pipe galvanized air ring control system, the control method comprises the following steps:
s0, information acquisition: before the system works, an information acquisition module inputs steel pipe specifications, materials, wind ring basic pressure, basic time paragraphs, flow parameters and protection parameters through parameters, a spectrum detection module acquires the metal components of the steel pipe processed at the time, and a scene detection module acquires the environmental temperature, humidity and acid-base degree and is used for establishing a steel pipe information file for later analysis and matching;
s1, preparing: when the main control module is started for the first time, after detecting that a laser distance sensor signal is a pipe, the air ring opens a proportional control valve according to default, if the information of the information acquisition module is matched with a system history file, the system calls matching parameters, when the distance sensor signal is invalid, namely, a steel pipe is not arranged, after the end delay time passes, the proportional control valve enters an idle state, pressure is continuously output in the idle state, the pressure is smaller than the pressure in the main control stage, and mainly, the outlet of the air ring is not blocked by zinc liquid and sundries which can fall off;
s2, calculating the steel pipe passing time by the main control module in the period from the pressure opening to the pressure closing in the main control stageAfter the distance sensor signals are detected by the main control module for the second time and later, the main control module carries out function control on the pressure according to the time point calculated last time, and corrects the time by continuously detecting>Ensuring that the time axis of the control function is consistent with the actual passing time of the steel pipe;
s3, generating a wind ring effect control model: after receiving the information of the information acquisition module, the wind ring improvement module matches parameters, calculates a pressure given value in real time through a time axis according to a basic control function model of pressure output of the system, and gives a pressure value to the pressure control unit;
s4, stable pressure output: the turbulence experiment module regulates output pressure in real time according to given information transmitted by the upper system and the gas pressure of the gas supply unit, and forms PID control through the pressure sensor, when the steel pipe passes through the wind ring at a constant speed, the wind ring blows zinc to the steel pipe at an accurate pressure;
s5, measuring a zinc layer of the steel tube: the electromagnetic thickness measuring module is used for measuring thickness, cooling and passivating the steel pipe after the steel pipe is blown with zinc through the wind ring, then the steel pipe is transmitted to the detection cooling bed, nondestructive detection is carried out on the plating layer according to an electromagnetic induction method and an eddy current method, and the patterns are stored and analyzed and then transmitted to the system through a network.
According to the above technical solution, in the step S0, the method for establishing the steel pipe information file includes:
s0-1, adopting spectrum scanning to obtain a diffraction pattern of the steel pipe, and determining the metal components of the steel pipe;
s0-2, scanning the whole steel pipe in 3 to 5 sections, determining the content of silicon, carbon, manganese and phosphorus in the components, and sequencing the content along the air circulation direction of the steel pipe;
s0-3, building a processing scene file according to the measured use scene temperature, humidity, acid-base degree, steel pipe components and input information, and then performing preliminary setting on a first control function.
According to the technical proposal, in the step S2, when the time axis is determined, the time of the steel pipe passing through the laser measuring point is automatically measured by the laser sensor,
when abs (Tna-Tnb)<At Ts, the time is entered into the queue for calculation,；
when abs (Tn-Tc) > Ts, the value of Tna-Tnb is abandoned, the last Tc is continuously adopted, and the error condition is eliminated;
wherein Tna and Tnb are respectively the time of the steel tube passing through the laser measuring point, tna is the time of the ending point, tnb is the time of the starting point, tc is the effective time axis of calculation, ts is a relatively constant, n is the number of measurements,the number of the wind ring groups.
According to the technical scheme, in the step S2, the system simultaneously controls 1 to N groups of wind rings, each group of wind rings is respectively added with the laser sensor, 3 to 6 steel pipes are plated at a time in a zinc plating production line with a small pipe, 3 to 6 groups of wind rings are placed side by side, but the time of each steel pipe passing through the corresponding wind ring is slightly different, the wind rings control the grouping mode, and the accuracy of the time axis of each wind ring is effectively controlled.
According to the technical scheme, in the step S4, the turbulence experiment module tracks and adjusts the pressure in a time slice of 1-10ms according to the pressure instruction transmitted by the upper system, and follows the output pressure by the pressure sensor, and compensates the pressure difference in the time slice by adopting a PID adjustment mode, and because the time slice is very short, the turbulence experiment module rapidly adjusts by adopting a limited historical data accumulation mode;
the specific determination method of the compensation value Δg (k) is as follows: Δg (K) =kp { [ pid (K) -pid (K-1) ] } +ki { [ pid (K) +kd [ pid (K) -2pid (K-1) +pid (K-2) ] +kj [ pid (K-3) -pid (K-4) ] };
at this time, G (k) = (k-1) +Δg (k) +kc, where G (k) is the actual output, pid () is the history error, kp, ki, kj, kc is the compensation coefficient, the error accumulation value is subtracted, and k is the adjustment number.
According to the technical scheme, in the step S5, the electromagnetic thickness measuring module is used for measuring the thickness of the zinc layer, the system is used for detecting the thickness of 3 to P zinc layers of the steel pipe, 1 to P probes are adopted for each group of detection, 3 to P groups of data are collected by each probe, and the system is used for analyzing the data to obtain a stable value;
，/>；
wherein the method comprises the steps ofFor the effective value of the Mth measurement section, vx is the value in the Mth measurement section and the x-th measurement, MAX (), MIN () is the maximum value and the minimum value in the measurement data queue of the measurement point respectively, and is discarded, vz is the effective value of the zinc layer thickness of the steel pipe section, and after receiving the information, the information statistics module estimates the zinc layer data curve to determine the functional relation model Y=AX+BX of the function zinc layer thickness and the position 2 +CX 3 +D, time axis in the system, according to the function, the system controls the zinc layer in each time sliceThe thickness is estimated, wherein Y is the zinc layer thickness, X is the coordinates of each part of the steel pipe, in the system, the position coordinates are replaced by a time axis, A, B and C are estimated function coefficients, D is the zinc layer thickness base number and is constant.
Compared with the prior art, the invention has the following beneficial effects: according to the invention, the wind pressure can be linearly regulated when the steel pipe is galvanized, the pressure is rapidly regulated in a limited historical data accumulation mode, the processed zinc layer is introduced into the feedback control for regulating the wind ring, and the uniformity of the zinc layer on the surface of the whole steel pipe is high.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention. In the drawings:
FIG. 1 is a schematic diagram of the principles of the present invention;
fig. 2 is a schematic view of the overall module structure of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1 and 2, the present invention provides the following technical solutions: the system comprises an information acquisition module, a wind ring improvement module, a turbulence experiment module and a main control module, wherein the information acquisition module is used for inputting various indexes of a use scene, collecting material components and surface characteristic features of a steel pipe, the wind ring improvement module is used for generating a wind ring pressure control function model by analyzing various indexes of the use scene, material information and specific conditions of the surface characteristic features of the steel pipe, improving the control model according to feedback information of various channels, the turbulence experiment module is used for evaluating and feeding back the actual condition of an actual application scene after the wind ring effect control model is improved, real-time adjustment is carried out on an output state, a closed-loop system with the same algorithm control and actual output is formed, the induction thickness measurement module is used for measuring the thickness of a zinc layer after the steel pipe is processed, the information is fed back to the wind ring improvement module, the wind ring improvement module is interfered, and the main control module is used for controlling the orderly work of the modules;
the information acquisition module comprises a use scene detection module, an induction thickness measurement module and a spectrum detection module, wherein the use scene detection module is connected with the induction thickness measurement module in a network manner, the use scene detection module is used for detecting the temperature, the humidity degree and the acid-base degree of a steel pipe use scene, so that the proposed content of oxides on the surface of zinc liquid and the influence of temperature scattering and losing changes on the change of the adsorption force of the zinc liquid on the surface of the steel pipe are roughly given out, the induction thickness measurement module is used for measuring the thickness of the zinc layer on the surface of the steel pipe through electromagnetic induction, and the total evaluation is carried out on the galvanization of the steel pipe after the zinc layer is transmitted to the system, and the spectrum detection module is used for detecting the components of the steel pipe;
the turbulence experiment module comprises a wind pressure detection module, a PID control module, a pressure control unit and a laser detection module, wherein the wind pressure detection module comprises a pressure sensor and is used for detecting the change condition of the outlet pressure of the wind ring in real time, the laser detection module comprises a laser sensor and is used for monitoring the reaching position of the steel pipe in real time and transmitting information to the PID control module, the PID control module is used for adjusting the pressure of the wind ring according to a function model and a pressure feedback condition given by the wind ring improvement module, so that the output pressure is consistent with the function model, and the pressure control unit is used for adjusting the pressure distribution of the wind ring by controlling each proportion adjusting valve;
based on the steel pipe galvanized air ring control system, the control method comprises the following steps:
s0, information acquisition: before the system works, an information acquisition module inputs steel pipe specifications, materials, wind ring basic pressure, basic time paragraphs, flow parameters and protection parameters through parameters, a spectrum detection module acquires the metal components of the steel pipe processed at the time, and a scene detection module acquires the environmental temperature, humidity and acid-base degree and is used for establishing a steel pipe information file for later analysis and matching;
s1, preparing: when the main control module is started for the first time, after detecting that a laser distance sensor signal is a pipe, the air ring opens a proportional control valve according to default, if the information of the information acquisition module is matched with a system history file, the system calls matching parameters, when the distance sensor signal is invalid, namely, a steel pipe is not arranged, after the end delay time passes, the proportional control valve enters an idle state, pressure is continuously output in the idle state, the pressure is smaller than the pressure in the main control stage, and mainly, the outlet of the air ring is not blocked by zinc liquid and sundries which can fall off;
s2, calculating the steel pipe passing time by the main control module in the period from the pressure opening to the pressure closing in the main control stageAfter the distance sensor signals are detected by the main control module for the second time and later, the main control module carries out function control on the pressure according to the time point calculated last time, and corrects the time by continuously detecting>Ensuring that the time axis of the control function is consistent with the actual passing time of the steel pipe;
s3, generating a wind ring effect control model: after receiving the information of the information acquisition module, the wind ring improvement module matches parameters, calculates a pressure given value in real time through a time axis according to a basic control function model of pressure output of the system, and gives a pressure value to the pressure control unit;
s4, stable pressure output: the turbulence experiment module regulates output pressure in real time according to given information transmitted by the upper system and the gas pressure of the gas supply unit, and forms PID control through the pressure sensor, when the steel pipe passes through the wind ring at a constant speed, the wind ring blows zinc to the steel pipe at an accurate pressure;
s5, measuring a zinc layer of the steel tube: the electromagnetic thickness measuring module is used for measuring thickness, cooling and passivating the steel pipe after zinc blowing is completed through the wind ring, then the steel pipe is transmitted to the detection cooling bed, nondestructive detection is carried out on the plating layer according to an electromagnetic induction method and an eddy current method, and the patterns are stored and analyzed and then transmitted to the system through a network;
in the step S0, the method for establishing the steel pipe information file comprises the following steps:
s0-1, adopting spectrum scanning to obtain a diffraction pattern of the steel pipe, and determining the metal components of the steel pipe;
s0-2, scanning the whole steel pipe in 3 to 5 sections, determining the content of silicon, carbon, manganese and phosphorus in the components, and sequencing the content along the air circulation direction of the steel pipe;
s0-3, a processing scene file is established according to the measured use scene temperature, humidity and acid-base degree, steel pipe components and input information, and then a primary control function is preliminarily set;
in the above step S2, when the time axis is determined, the time for the steel pipe to pass through the laser measuring point is automatically measured by the laser sensor,
when abs (Tna-Tnb)<At Ts, the time is entered into the queue for calculation,；
when abs (Tn-Tc) > Ts, the value of Tna-Tnb is abandoned, the last Tc is continuously adopted, and the error condition is eliminated;
wherein Tna and Tnb are respectively the time of the steel tube passing through the laser measuring point, tna is the time of the ending point, tnb is the time of the starting point, tc is the effective time axis of calculation, ts is a relatively constant, n is the number of measurements,the number of the wind ring groups is;
in the step S2, the system simultaneously controls 1 to N groups of wind rings, each group of wind rings is respectively added with a laser sensor, 3 to 6 steel pipes are plated at one time in a production line of a small pipe in a galvanization production line, 3 to 6 groups of wind rings are placed side by side, but the time of each steel pipe passing through the corresponding wind ring is slightly different, and the wind rings are controlled in a grouping mode, so that the accuracy of the time axis of each wind ring is effectively controlled;
in the step S4, the turbulence experiment module tracks and adjusts the pressure in a time slice of 1-10ms according to the pressure command transmitted by the upper system, follows the output pressure by the pressure sensor, compensates the pressure difference in the time slice by adopting a PID adjustment mode, and rapidly adjusts by adopting a limited historical data accumulation mode because the time slice is very short;
the specific determination method of the compensation value Δg (k) is as follows: Δg (K) =kp { [ pid (K) -pid (K-1) ] } +ki { [ pid (K) +kd [ pid (K) -2pid (K-1) +pid (K-2) ] +kj [ pid (K-3) -pid (K-4) ] };
at this time, G (k) = (k-1) +Δg (k) +kc, where G (k) is the actual output, pid () is the history error, kp, ki, kj, kc is the compensation coefficient, the error accumulation value is subtracted, and k is the adjustment number;
in the step S5, the electromagnetic thickness measuring module finishes zinc layer thickness measurement, the system detects the thickness of 3 to P zinc layers of the steel pipe, each group of detection adopts 1 to P probes, each probe collects 3 to P groups of data each time, and the system analyzes the data to obtain a stable value;
，/>；
wherein the method comprises the steps ofFor the effective value of the Mth measurement section, vx is the value in the Mth measurement section and the x-th measurement, MAX (), MIN () is the maximum value and the minimum value in the measurement data queue of the measurement point respectively, and is discarded, vz is the effective value of the zinc layer thickness of the steel pipe section, and after receiving the information, the information statistics module estimates the zinc layer data curve to determine the functional relation model Y=AX+BX of the function zinc layer thickness and the position 2 +CX 3 And +D, wherein a time axis is arranged in the system, the system estimates the thickness of the zinc layer in each time slice according to the function, Y is the thickness of the zinc layer, X is the coordinates of each part of the steel pipe, in the system, the position coordinates are replaced by the time axis, A, B and C are estimated function coefficients, D is the thickness base of the zinc layer and is constant.
The turbulence experiment module comprises an upper end part and a lower end part of the wind ring. Each part comprises a wind pressure detection module, a PID control module, a pressure control unit and a laser detection module. Because the distribution conditions of the gravity effect liquid zinc on the upper end and the lower end of the metal surface are different, based on the characteristics, two turbulence experiment modules at the upper end and the lower end are established, and different function models are matched.
The control method further includes:
s6, deep learning: according to the steel pipe information, the scene information and the thickness information after steel pipe processing in the database, continuously calculating, transmitting the calculation result to the system in real time, analyzing and transmitting to the wind ring improvement module, wherein the wind ring improvement module gradually modifies the control model parameters according to the information;
s7, protection and forcing functions: the system is designed with a protection pressure output function, namely when the steel pipe does not pass through the wind ring according to normal time, the system judges that the abnormality occurs, and the protection function is automatically started, namely, the system outputs pressure higher than normal wind pressure to protect the wind ring from being blocked by sundries such as zinc liquid which can drop, and the function can also be started through a button and a touch pad.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: the foregoing description is only a preferred embodiment of the present invention, and the present invention is not limited thereto, but it is to be understood that modifications and equivalents of some of the technical features described in the foregoing embodiments may be made by those skilled in the art, although the present invention has been described in detail with reference to the foregoing embodiments. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. A steel pipe galvanization wind ring control system is characterized in that: the system comprises an information acquisition module, a wind ring improvement module, a turbulence experiment module and a main control module, wherein the information acquisition module is used for inputting various indexes of a use scene, collecting material components and surface characteristic features of a steel pipe, the wind ring improvement module is used for generating a wind ring pressure control function model by analyzing the various indexes of the use scene, the material information of the steel pipe and the specific conditions of the surface characteristic features, improving the control model according to feedback information of various channels, the turbulence experiment module is used for evaluating and feeding back the actual condition of an actual application scene after the wind ring effect control model is improved, real-time adjustment is carried out on an output state, a closed-loop system with algorithm control consistent with actual output is formed, and the main control module is used for controlling the orderly work of the modules;
the information acquisition module comprises a use scene detection module, an induction thickness measurement module and a spectrum detection module, wherein the use scene detection module is connected with the induction thickness measurement module in a network manner, the use scene detection module is used for detecting the temperature, the humidity degree and the acid-base degree of a steel pipe use scene, so that the influence of the suggested content of oxides on the surface of zinc liquid and the temperature dispersion change on the change of the adsorption force of the zinc liquid on the surface of the steel pipe is roughly given, the induction thickness measurement module is used for measuring the thickness of a zinc layer on the surface of the steel pipe through electromagnetic induction, transmitting the thickness to a system, carrying out overall evaluation on the zinc plating of the steel pipe, feeding information back to the wind ring improvement module, interfering the function generation of the wind ring improvement module, and the spectrum detection module is used for detecting the components of the steel pipe;
the turbulence experiment module comprises a wind pressure detection module, a PID control module, a pressure control unit and a laser detection module, wherein the wind pressure detection module comprises a pressure sensor and is used for detecting the outlet pressure change condition of the wind ring in real time, the laser detection module comprises a laser sensor and is used for monitoring the reaching position of a steel pipe in real time and transmitting information to the PID control module, the PID control module adjusts the pressure of the wind ring according to a function model and a pressure feedback condition given by the wind ring improvement module, so that the output pressure is kept consistent with the function model, and the pressure control unit is used for adjusting the pressure distribution of the wind ring by controlling each proportion adjusting valve.
2. The control method of the steel pipe galvanized wind ring control system according to claim 1, characterized by comprising the following steps: the control method comprises the following steps:
s0, information acquisition: before the system works, an information acquisition module inputs steel pipe specifications, materials, wind ring basic pressure, basic time paragraphs, flow parameters and protection parameters through parameters, a spectrum detection module acquires the metal components of the steel pipe processed at the time, and a scene detection module acquires the environmental temperature, humidity and acid-base degree and is used for establishing a steel pipe information file for later analysis and matching;
s1, preparing: when the main control module is started for the first time, after detecting that a laser distance sensor signal is a pipe, the air ring opens a proportional control valve according to default, if the information of the information acquisition module is matched with a system history file, the system calls matching parameters, when the distance sensor signal is invalid, namely, a steel pipe is not arranged, after the end delay time passes, the proportional control valve enters an idle state, pressure is continuously output in the idle state, the pressure is smaller than the pressure in the main control stage, and mainly, the outlet of the air ring is not blocked by zinc liquid and sundries which can fall off;
s2, calculating the steel pipe passing time by the main control module in the period from the pressure opening to the pressure closing in the main control stageAfter the distance sensor signals are detected by the main control module for the second time and later, the main control module carries out function control on the pressure according to the time point calculated last time, and corrects the time by continuously detecting>Ensuring that the time axis of the control function is consistent with the actual passing time of the steel pipe;
s3, generating a wind ring effect control model: after receiving the information of the information acquisition module, the wind ring improvement module matches parameters, calculates a pressure given value in real time through a time axis according to a basic control function model of pressure output of the system, and gives a pressure value to the pressure control unit;
s4, stable pressure output: the turbulence experiment module regulates output pressure in real time according to given information transmitted by the upper system and the gas pressure of the gas supply unit, and forms PID control through the pressure sensor, when the steel pipe passes through the wind ring at a constant speed, the wind ring blows zinc to the steel pipe at an accurate pressure;
s5, measuring a zinc layer of the steel tube: the electromagnetic thickness measuring module is used for measuring thickness, cooling and passivating the steel pipe after the steel pipe is blown with zinc through the wind ring, then the steel pipe is transmitted to the detection cooling bed, nondestructive detection is carried out on the plating layer according to an electromagnetic induction method and an eddy current method, and the patterns are stored and analyzed and then transmitted to the system through a network.
3. The control method of the steel pipe galvanized wind ring control system according to claim 2, characterized by comprising the following steps: in the step S0, the method for establishing the steel pipe information file comprises the following steps:
s0-1, adopting spectrum scanning to obtain a diffraction pattern of the steel pipe, and determining the metal components of the steel pipe;
s0-2, scanning the whole steel pipe in 3 to 5 sections, determining the content of silicon, carbon, manganese and phosphorus in the components, and sequencing the content along the air circulation direction of the steel pipe;
s0-3, building a processing scene file according to the measured use scene temperature, humidity, acid-base degree, steel pipe components and input information, and then performing preliminary setting on a first control function.
4. A control method of a steel pipe galvanization wind ring control system according to claim 3, characterized by: in the above step S2, when the time axis is determined, the time for the steel pipe to pass through the laser measuring point is automatically measured by the laser sensor,
when abs (Tna-Tnb)<At Ts, the time is entered into the queue for calculation,；
when abs (Tn-Tc) > Ts, the value of Tna-Tnb is abandoned, the last Tc is continuously adopted, and the error condition is eliminated;
wherein Tna and Tnb are respectively the time of the steel tube passing through the laser measuring point, tna is the time of the ending point, tnb is the time of the starting point, tc is the effective time axis of calculation, ts is a relatively constant, n is the number of measurements,the number of the wind ring groups.
5. The control method of the steel pipe galvanized wind ring control system according to claim 4, characterized by comprising the following steps: in the step S2, the system simultaneously controls 1 to N groups of wind rings, each group of wind rings is respectively added with a laser sensor, and as a production line of small pipes is arranged in a galvanization production line, 3 to 6 steel pipes are plated at a time, and 3 to 6 groups of wind rings are placed side by side, but the time of each steel pipe passing through the corresponding wind ring is slightly different, and the wind rings are controlled in a grouping mode, so that the accuracy of the time axis of each wind ring is effectively controlled.
6. The control method of the steel pipe galvanized wind ring control system according to claim 5, characterized by comprising the following steps: in the step S4, the turbulence experiment module tracks and adjusts the pressure in a time slice of 1-10ms according to the pressure command transmitted by the upper system, follows the output pressure by the pressure sensor, compensates the pressure difference in the time slice by adopting a PID adjustment mode, and rapidly adjusts by adopting a limited historical data accumulation mode because the time slice is very short;
the specific determination method of the compensation value Δg (k) is as follows: Δg (K) =kp { [ pid (K) -pid (K-1) ] } +ki { [ pid (K) +kd [ pid (K) -2pid (K-1) +pid (K-2) ] +kj [ pid (K-3) -pid (K-4) ] };
at this time, G (k) = (k-1) +Δg (k) +kc, where G (k) is the actual output, pid () is the history error, kp, ki, kj, kc is the compensation coefficient, the error accumulation value is subtracted, and k is the adjustment number.
7. The control method of the steel pipe galvanized wind ring control system according to claim 6, characterized by comprising the following steps: in the step S5, the electromagnetic thickness measuring module finishes zinc layer thickness measurement, the system detects the thickness of 3 to P zinc layers of the steel pipe, each group of detection adopts 1 to P probes, each probe collects 3 to P groups of data each time, and the system analyzes the data to obtain a stable value;
，/>；
wherein the method comprises the steps ofFor the effective value of the Mth measurement section, vx is the value in the Mth measurement section and the x-th measurement, MAX (), MIN () is the maximum value and the minimum value in the measurement data queue of the measurement point respectively, and is discarded, vz is the effective value of the zinc layer thickness of the steel pipe section, and after receiving the information, the information statistics module estimates the zinc layer data curve to determine the functional relation model Y=AX+BX of the function zinc layer thickness and the position 2 +CX 3 And +D, wherein a time axis is arranged in the system, the system estimates the thickness of the zinc layer in each time slice according to the function, Y is the thickness of the zinc layer, X is the coordinates of each part of the steel pipe, in the system, the position coordinates are replaced by the time axis, A, B and C are estimated function coefficients, D is the thickness base of the zinc layer and is constant. />
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