CN117732891A - Intelligent diagnosis system and method for state monitoring of coiling machine - Google Patents

Abstract

The invention belongs to the technical field of steel rolling, and discloses an intelligent diagnosis system and method for monitoring the state of a coiling machine. The system comprises: the bearing vibration state monitoring subsystem is configured for monitoring and intelligently diagnosing the vibration state of the coiling machine bearing; the transmission shaft temperature on-line monitoring subsystem is configured for automatically monitoring and early warning the temperature state of the transmission shaft; the on-line monitoring subsystem for the lubrication state of the speed reducer is configured to perform on-line monitoring and intelligent diagnosis on the lubrication state of the speed reducer of the coiling machine; the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem are configured to carry out on-line monitoring and intelligent diagnosis on a hydraulic lubrication pump station and a control system of the coiling machine; and the fat lubrication on-line monitoring and intelligent diagnosis subsystem is configured for on-line monitoring and intelligent diagnosis of the fat lubrication of each device of the coiling machine. The system and the method realize maintenance-free management of the coiling machine equipment, and improve the precision of the operation function of the coiling machine equipment and the foreseeing the preventive maintenance management level.

Description

Intelligent diagnosis system and method for state monitoring of coiling machine

Technical Field

The invention belongs to the technical field of steel rolling, and particularly relates to an intelligent diagnosis system and method for monitoring the state of a coiling machine.

Background

At present, some domestic and foreign steel rolling enterprises use on-line monitoring equipment on a coiling machine transmission equipment speed reducer and an executing element, perform the functions of super-threshold alarming and automatic control, but do not cover on-line monitoring of complete equipment, have a plurality of monitoring holes, and operate in an uncontrolled state. The reason is mainly that the automation and the intelligent degree of the equipment are not high, and the automatic acquisition, quantification, early warning and prediction means are few. The main point verification and repair work of the coiling machine still depends on the judgment of the equipment state information by manpower. The equipment point inspection is mainly based on experience, has frequent faults, limited point inspection repair mode development, frequent equipment and production scrap steel, more product quality defects, point inspection manpower resource waste, long-term high-cost high-residence production and difficult control, and does not match the requisite conditions of modern production enterprises.

The product quality and the cost are the forever topics of steel enterprise benefits, the functional precision of coiling machine equipment is inevitably dependent on the product quality by combining the high-precision thin-specification, high-strength and specialized high-end market positioning of the current plate products, the intelligent monitoring and diagnosing system of the coiling machine equipment is a powerful guarantee for ensuring the functional precision and the low-cost stable operation of the equipment, the intelligent monitoring and diagnosing method of the coiling machine is also an important premise for enterprises to realize the re-optimal configuration of production elements and improve the market competitiveness, a platform for intelligent manufacturing application and development of modern enterprises is created, and a solid foundation is laid for enterprises to develop and iterate an international abortion line. Modern advanced enterprises have higher requirements on the coiling machine equipment process, the production safe and stable operation, the intelligent management of equipment, the high quality of products and the production and maintenance cost, and the coiling machines with the lagging productivity, high cost and low benefit are supposed to be phased out.

In view of this, the prior art is in need of improvement.

Disclosure of Invention

The invention aims to provide an intelligent diagnosis system and method for monitoring the state of a coiling machine, which are used for realizing maintenance-free management of coiling machine equipment, comprehensively improving the precision of the running function of the coiling machine equipment and predicting the digital management level of preventive maintenance.

In order to achieve the technical purpose, the invention adopts the following technical scheme:

according to a first aspect of the present invention, there is provided a coiler condition monitoring intelligent diagnosis system, comprising:

the bearing vibration state monitoring subsystem is configured for monitoring and intelligently diagnosing the vibration state of the coiling machine bearing;

the transmission shaft temperature on-line monitoring subsystem is configured for automatically monitoring and early warning the temperature state of the transmission shaft of the coiling machine;

the on-line monitoring subsystem is configured for on-line monitoring and intelligent diagnosis of the lubrication state of the speed reducer of the coiling machine;

the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem are configured to carry out on-line monitoring and intelligent diagnosis on a hydraulic lubrication pump station and a control system of the coiling machine;

and the fat lubrication on-line monitoring and intelligent diagnosis subsystem is configured for on-line monitoring and intelligent diagnosis of the fat lubrication of specific points of each equipment of the coiling machine.

According to one embodiment of the invention, the bearing vibration condition monitoring subsystem comprises:

the auxiliary roll roller assembly state monitoring module is configured to carry out online monitoring and intelligent diagnosis on the auxiliary roll roller assembly state, and is used for carrying out integrated online monitoring of temperature vibration through a Wen Zhen sensor arranged on an auxiliary roll roller bearing seat;

a spool head bearing vibration state monitoring module configured to monitor a spool head bearing vibration state, the spool head bearing vibration state monitoring module performing vibration monitoring via a vibration sensor mounted to a spool head bearing mount, the vibration sensor being equipped with a high temperature protection structure;

the auxiliary roll and pinch roll motor speed reducer five-in-one vibration state monitoring module is configured to monitor temperature and vibration of the auxiliary roll and the pinch roll motor, the speed reducer, the rear bearing of the transmission shaft, the middle bearing and the head bearing on line;

the pinch roll roller assembly state monitoring module is configured to carry out on-line monitoring and intelligent diagnosis on the pinch roll roller assembly state, and the pinch roll roller assembly state monitoring module carries out integrated on-line monitoring of temperature vibration through a Wen Zhen sensor arranged on a pinch roll bearing seat.

According to one embodiment of the present invention, the high temperature protection structure includes:

a sensor high temperature protection cable connected with the main body sensing part of the vibration sensor;

the sensor high-temperature-preventing protection tube is arranged outside the sensor high-temperature-preventing protection cable;

a sensor high temperature prevention shield at least partially shielding the body sensing portion and connected with the sensor high temperature prevention shield;

a sensor guard water supply line connected to the sensor guard for supplying cooling water thereto.

According to one embodiment of the invention, the transmission shaft temperature on-line monitoring subsystem is a transmission shaft infrared imaging temperature on-line monitoring subsystem and is configured to conduct cross package infrared imaging temperature on-line monitoring on a pinch roll and a wrapper roll transmission shaft, and infrared automatically captures temperature change conditions caused by cross package lubrication and abrasion and pushes early warning information timely.

According to one embodiment of the invention, the transmission shaft temperature on-line monitoring subsystem is configured for monitoring the temperature of the reel transmission shaft bearing through a platinum thermal resistance temperature sensor penetrating into the outer ring of the bearing, a deep hole is formed in a bearing seat for adding lubricating grease for heat transfer, and the platinum thermal resistance temperature sensor penetrates into the outer ring of the bearing through the deep hole.

According to one embodiment of the present invention, the on-line monitoring subsystem for lubrication state of the speed reducer is configured to perform on-line monitoring for lubrication state of bearings and gears of the spool speed reducer, the pinch roll speed reducer, and the auxiliary roll speed reducer, and includes:

a thermal flow switch arranged on the oil inlet main pipe;

a pressure transmitter arranged on the oil inlet main pipe;

and the oil flow annunciator is arranged on the speed reducer bearing and used for monitoring the state of oil flow break.

According to one embodiment of the invention, the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem comprise:

the hydraulic system pump station online monitoring and intelligent diagnosis module is configured to monitor abnormal parameters of the hydraulic system, and is used for intelligently diagnosing system abnormality and giving an abnormality alarm;

and the gear lubrication system pump station on-line monitoring and intelligent diagnosis module is configured to monitor abnormal parameters of the gear lubrication system, and perform intelligent diagnosis system abnormality and abnormal alarm.

According to one embodiment of the invention, the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem comprise:

the thermal detection monitoring and analyzing module is configured to comprehensively analyze the thermal detection monitoring quality through the thermal detection signal and the rolling line strip steel tracking signal so as to realize the early warning of the strip steel tracking state;

The servo valve monitoring and analyzing module is configured to correlate a servo valve setting signal, a feedback signal, a zero drift signal and an equipment action instruction, comprehensively evaluate the state of the servo valve in the rolling process and realize the early warning of the state of the servo valve;

the transient analog sensor monitoring and analyzing module is configured to analyze fluctuation conditions, maximum values, minimum values and average values of data in the rolling process by correlating transient analog sensor signals with production rolling states, and realize sensor overrun and jump alarming reminding through configuration rules;

the button monitoring and analyzing module is configured to assist in analyzing the operation strategy and the coiling state of an operator by counting the operation times and the operation time of the buttons;

the servo oil cylinder monitoring and analyzing module is configured to analyze impact characteristics, control performance and production state characteristics of the servo oil cylinder by transmitting displacement, pressure, servo valve and steel biting signal information of the servo oil cylinder into the servo oil cylinder monitoring model, so as to realize servo oil cylinder state early warning and intelligent diagnosis;

and the electric transmission monitoring and analyzing module is configured to extract transmission impact, current amplitude limiting, torque amplitude limiting and speed difference characteristics by analyzing the speed, current and torque of the transmission device and the biting steel production signals, timely feed back abnormal production conditions and realize early warning and intelligent diagnosis of the transmission characteristics of the transmission device.

According to one embodiment of the invention, the fat lubrication online monitoring and intelligent diagnosis subsystem comprises:

the roll key equipment grease lubrication on-line monitoring and intelligent diagnosis module is configured to automatically switch a roll lubrication mode into continuous oiling of the roll when the roll is unreeled, and recover normal oiling after cooling for a period of time after the roll is unreeled;

and the auxiliary roll and pinch roll key equipment grease lubrication on-line monitoring and intelligent diagnosis module is configured to sense blockage and oil leakage conditions and send alarm signals through the flow sensor.

According to a second aspect of the present invention, there is provided a coiler condition monitoring intelligent diagnosis method, comprising:

monitoring and intelligently diagnosing the vibration state of the coiling machine bearing through a bearing vibration state monitoring subsystem;

the temperature state of the whole life cycle of the transmission shaft of the coiling machine is automatically monitored through the transmission shaft temperature on-line monitoring subsystem;

the lubrication state of the coiling machine speed reducer is monitored on line and intelligently diagnosed through a speed reducer lubrication state on-line monitoring subsystem;

the hydraulic lubrication pump station and the control system of the coiling machine are monitored and diagnosed intelligently on line through the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem;

And the on-line monitoring and intelligent diagnosis of the grease lubrication of each device of the coiling machine are carried out through the on-line monitoring and intelligent diagnosis subsystem of the grease lubrication.

By adopting the technical scheme, the system and the method provided by the invention have the following beneficial effects compared with the prior art:

the intelligent diagnosis system and the intelligent diagnosis method for monitoring the state of the coiling machine can effectively realize maintenance-free management of the coiling machine equipment, improve the operation function precision of the coiling machine equipment and predict the preventive maintenance management level, ensure the high-quality stable operation of the coiling machine and the coil shape quality of products, ensure the service life of the equipment, reduce the abnormal shutdown time, reduce the maintenance cost, avoid the potential safety hazard of site manual maintenance spot inspection, and truly realize the safe and environment-friendly production of modern enterprises.

The intelligent diagnosis system and the intelligent diagnosis method for the state monitoring of the coiling machine, provided by the invention, have the advantages that the defect of judgment of manual spot inspection experience is reduced, the whole life cycle management of the coiling machine equipment is developed and perfected from the aspect of technical progress, the intelligent diagnosis for the state monitoring is realized, the safe and environment-friendly running environment of the coiling machine is improved, the equipment running and production process requirements can be met, and the intelligent diagnosis system and the intelligent diagnosis method are suitable for popularization and use.

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 description serve to explain, without limitation, the invention. In the drawings:

FIG. 1 is a schematic view of a prior art coiler;

FIG. 2 is a schematic diagram of a coiler condition monitoring intelligent diagnostic system according to the present invention;

FIG. 3 is a schematic diagram of a measurement point of the vibration state of a winding-up assisting roller system of a winding machine;

FIG. 4 is a schematic diagram of a coiler head bearing vibration state measurement point;

FIGS. 5A and 5B are schematic diagrams of a coiler head bearing measurement point high temperature protection structure;

FIG. 6 is a schematic diagram of a coiler drum and a drive vibration state measurement station;

FIG. 7 is a schematic diagram of a coiler pinch roll roller assembly station;

FIG. 8 is a schematic diagram of monitoring the infrared imaging state of the coiler drive shaft;

FIGS. 9A and 9B are schematic diagrams of a temperature monitoring assembly of a spool drive shaft socket;

FIG. 10 is a schematic diagram of intelligent lubrication of thin oil of a drum speed reducer;

FIG. 11 is a schematic illustration of two layers of thin oil intelligent lubrication of a wrapper roller speed reducer;

FIG. 12 is a schematic illustration of intelligent lubrication of pinch roll reducers with thin oil;

FIG. 13 is a schematic diagram of a hydraulic lubrication control system and an electric drive operation integrated information on-line monitoring subsystem display interface.

Detailed Description

Specific embodiments of the present disclosure are described in detail below with reference to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating and illustrating the disclosure, are not intended to limit the disclosure.

Furthermore, references herein to "an embodiment" mean that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Those of skill in the art will explicitly and implicitly appreciate that the embodiments described herein may be combined with other embodiments.

It will be understood by those skilled in the art that all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs unless defined otherwise. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

The coiler is an important device for the curling treatment of hot-rolled or cold-rolled steel. Fig. 1 shows a specific construction of the coiler as a three-wrapper roll. The coiling machine comprises a pair of pinch rolls 1-5, a winding drum 6-8 and three auxiliary winding rolls 9-17. The novel high-speed rolling machine comprises a 1-upper pinch roll motor, a 2-upper pinch roll speed reducer, a 3-upper pinch roll roller assembly, a 4-lower pinch roll motor, a 5-lower pinch roll roller assembly, a 6-reel motor, a 7-reel speed reducer, an 8-reel support bearing seat assembly, a 9-1 auxiliary roll motor, a 10-1 auxiliary roll speed reducer, a 11-1 auxiliary roll roller assembly, a 12-2 auxiliary roll motor, a 13-2 auxiliary roll speed reducer, a 14-2 auxiliary roll roller assembly, a 15-3 auxiliary roll motor, a 16-3 auxiliary roll speed reducer and a 17-3 auxiliary roll roller assembly. The pinch roll is used for applying certain clamping force to the strip steel and simultaneously performing the 1 st bending deformation on the strip steel. The auxiliary winding roller is used for applying bending deformation to the steel so as to tightly wind the strip steel on the winding drum. The winding drum is used for winding the strip steel.

Typically, the drive system for the pinch roll, the reel, the auxiliary roll comprises: motor, speed reducer, transmission shaft etc. Because the moment or vibration born by the coiling machine in the running process is larger, the fault of a transmission system is often caused, and the positioning precision of a bearing, a gear and a roller system is commonly worn, the precise spot inspection and repair work of coiling machine equipment is required, so that the equipment fault can be found out in time and maintained, and the normal running of production and the rolling quality of products are ensured.

However, as mentioned in the background art, the online monitoring device for a coiler can only monitor part of the equipment of the coiler, does not cover the online monitoring of the complete equipment, has a plurality of monitoring holes, and is easy to operate in an uncontrolled state. In view of the above, the invention provides a coiler state monitoring intelligent diagnosis system and method for realizing online monitoring of coiler complete equipment.

As shown in fig. 2, the coiler state monitoring intelligent diagnosis system provided by the present invention includes: the bearing vibration state monitoring subsystem 10 is configured for monitoring and intelligently diagnosing the vibration state of the coiling machine bearing; the transmission shaft temperature on-line monitoring subsystem 20 is configured to automatically monitor and pre-warn the temperature state of the transmission shaft of the coiling machine; the on-line monitoring subsystem 30 for the lubrication state of the speed reducer is configured to perform on-line monitoring and intelligent diagnosis on the lubrication state of the speed reducer of the coiling machine; the hydraulic lubrication control system and electric transmission operation integrated information on-line monitoring subsystem 40 is configured to perform on-line monitoring and intelligent diagnosis on a hydraulic lubrication pump station and a control system of the coiling machine; the grease lubrication on-line monitoring and intelligent diagnosing subsystem 50 is configured to perform on-line monitoring and intelligent diagnosing on the grease lubrication of each device of the coiling machine.

The respective subsystems are described in detail below.

The bearing vibration state monitoring subsystem 10 is configured to perform vibration state monitoring and intelligent diagnosis on all high-speed gear bearings of the coiling machine, specifically, to perform vibration state monitoring on the whole life cycle of the bearings of the auxiliary roller, the winding drum and the pinch roller, analyze the running states of the motor transmission and the roller gear shafts, and timely predict the degradation trend of the diagnosis equipment for preventive maintenance.

The bearing vibration status monitoring subsystem 10 includes a wrapper roller assembly status monitoring module configured for on-line monitoring and intelligent diagnostics of the wrapper roller assembly status. In some embodiments, the roll-up roll assembly status monitoring module performs temperature vibration integrated on-line monitoring via Wen Zhen sensors mounted to the roll-up roll bearing housing. Wen Zhen sensors can be mounted to the backup roll bearing housing by perforations in the roll arm. The Wen Zhen sensor mounted in this way is closer to the bearing, is optimally arranged on the front surface of the impact stress, accurately monitors vibration waves at the non-isolation interface, is beneficial to obtaining a more accurate bearing vibration state, and is convenient for accurately monitoring the assembly running state of the auxiliary winding roller. Fig. 3 is a schematic diagram of a measuring point of vibration state of a winding machine auxiliary winding roller system, as shown in the drawing, (1) indicates a No. 1 auxiliary winding roller arm perforation design and installation Wen Zhenchuan sensor, (2) indicates a No. 2 auxiliary winding roller arm perforation design and installation Wen Zhen sensor, and (3) indicates a No. 3 auxiliary winding roller arm perforation design and installation Wen Zhenchuan sensor.

Since the spool head bearing is the high incidence of spool bearing accidents, the bearing vibration condition monitoring subsystem 10 includes a spool head bearing vibration condition monitoring module configured for vibration condition monitoring of the spool head bearing. In some embodiments, the spool head bearing vibration condition monitoring module monitors the spool head bearing vibration condition via a vibration sensor mounted to the spool head bearing mount. Because the high temperature of the head bearing of the winding drum reaches 150-300 ℃, a high-temperature protection structure is provided for the vibration sensor in the position in order to ensure that the vibration sensor in the position can work normally. FIG. 4 is a schematic view of a coiler head bearing vibration state measurement point, as shown, (1) indicating a coiler head bearing measurement point, (2) indicating a portion of a high temperature protection structure, and (3) indicating a coiler head bearing.

Fig. 5A and 5B are schematic views of a coiler head bearing measurement point high temperature protection structure, in which fig. 5A shows a mounting position of the high temperature protection structure, and fig. 5B shows a specific structure of the high temperature protection structure, with a lower left-hand separate part being a partial enlarged view of an upper left-hand part. In the illustrated embodiment, the high temperature protective structure includes: a sensor high temperature prevention protection cable 12 connected to the main body sensing part 11 of the vibration sensor; a sensor high temperature prevention shield pipe 14 provided outside the sensor high temperature prevention shield cable 12; a sensor high temperature prevention shield 13 at least partially shielding the sensing portion of the main body and connected to the sensor high temperature prevention shield tube 14; a sensor shield water supply line 15 connected to the sensor high temperature preventing shield pipe 14 for supplying cooling water thereto. Therefore, the sensor high-temperature protection pipe 14 and the sensor high-temperature protection cover 13 are combined with the sensor protection water supply pipeline 15 to form a water cooling cover for the vibration sensor, and the vibration sensor is installed in the water cooling cover, so that the vibration sensor and a circuit thereof are protected, and the vibration sensor can work normally under severe conditions.

The bearing vibration state monitoring subsystem 10 comprises a five-in-one vibration state monitoring module of a wrapper roller and a pinch roller motor reducer, and is configured to perform temperature and vibration on-line monitoring on the wrapper roller, the pinch roller motor, the reducer, a transmission shaft rear bearing, a middle bearing and a head bearing. The five-in-one vibration state monitoring module of the auxiliary roll and the pinch roll motor reducer monitors temperature and vibration on line through Wen Zhen sensors arranged at the positions of the motor, the reducer, the rear bearing of the transmission shaft, the middle bearing and the head bearing. FIG. 6 is a schematic diagram of a coiling block and a transmission vibration state measuring point, as shown, (1) indicates a non-transmission end of a motor, (2) indicates a transmission end of the motor, (3) indicates an input end of a speed reducer I, (4) indicates an output end of the speed reducer I, (5) indicates an input end of a hollow shaft of the speed reducer II, (6) indicates an output end of the hollow shaft of the speed reducer II, (7) indicates an input end of a shaft of the speed reducer II, (8) indicates an output end of the shaft of the speed reducer II, (9) indicates a bearing at the rear part of the coiling block, indicates a bearing at the middle part of the coiling block,indicating the spool head bearing.

The bearing vibration condition monitoring subsystem 10 includes a pinch roll roller assembly condition monitoring module configured for on-line monitoring and intelligent diagnostics of pinch roll roller assembly conditions. The pinch roll roller assembly state monitoring module monitors temperature vibration integrally on line through a Wen Zhen sensor arranged on a pinch roll bearing seat, monitors the high failure point of the pinch roll bearing constantly, and can early warn bearing failure timely. FIG. 7 is a schematic diagram of the coiler pinch roll assembly station, as shown, (1) indicating the upper pinch roll bearing station, and (2) indicating the lower pinch roll chock station.

The bearing vibration condition monitoring subsystem 10 may be comprised of the vibration sensors, lines, acquisition stations, network boxes, servers, field terminals, analysis systems, fault alarm systems mentioned above. And the degradation trend management is carried out through time domain and frequency domain analysis, abnormal data is transmitted in real time in an early warning mode through a PC and a mobile phone nudge alarm center, and the fault diagnosis function is realized through computer algorithm combined with a case library and big data model learning rule judgment, so that the controllable operation of the coiling machine bearing is ensured.

The on-line monitoring subsystem 20 of the temperature of the transmission shaft is configured to automatically monitor the temperature state of the full life cycle of all high-speed main transmission shafts of the coiling machine, automatically capture the temperature change condition of the main transmission shafts in real time, accurately analyze the running state of the transmission shaft of the coiling machine, and timely predict the degradation trend of the intelligent diagnosis equipment for preventive maintenance. In some embodiments, the transmission shaft temperature on-line monitoring subsystem 20 is a transmission shaft infrared imaging temperature on-line monitoring subsystem, and is configured to perform cross package infrared imaging temperature on-line monitoring on the transmission shafts of the pinch roll and the auxiliary roll, and infrared automatically captures temperature change conditions caused by cross package lubrication and abrasion, and timely pushes early warning information. Fig. 8 is a schematic diagram of monitoring the infrared imaging state of the coiler drive shaft.

In some embodiments, the drive shaft temperature on-line monitoring subsystem 20 is configured to monitor the condition of the spool drive shaft bearing Wen Zhen via a platinum-thermal resistance temperature sensor that extends deep into the bearing outer race. Because the roller transmission bearing component is positioned in the bearing seat, the temperature of the outer surface is not easy to monitor and abnormal, grease is added to the bearing seat for heat transfer, a platinum thermal resistance temperature sensor is used for penetrating into the outer ring of the bearing, the temperature state of the roller transmission bearing can be monitored in time, then a temperature signal is connected into a PLC (Programmable Logic Controller, a programmable logic controller), and temperature abnormality alarm information is pushed through a iba company PDA (process data acquisition process data acquisition). Fig. 9A and 9B are schematic diagrams for monitoring the assembly temperature of the drum drive bearing seat, wherein fig. 9A is a front view and fig. 9B is a side view. As shown, reference numeral 21 is a platinum-hot resistance temperature sensor; reference numeral 22 is a spool bearing cap; 23 is a reel sleeve; 24 is a bearing; 25 is a spool bearing block.

In some cases, the transmission shaft temperature online monitoring subsystem 20 can build a special 5G online intelligent monitoring platform, can check the temperature rise condition of each transmission shaft cross package in real time through a mobile phone APP, and push the transmission shaft cross package in real time by exceeding a set threshold value, so that abnormal first time is pushed to management staff at a speed of 5G, equipment abnormality is found in time, and effective measures are taken to eliminate fault hidden danger; the platform also has the functions of trend analysis, historical data tracing and the like, and the basic principle is that the technologies of image compiling algorithm, wireless remote transmission, sensors, data integration, data visualization and the like are used for realizing the multi-element centralized control of temperature data, and the platform has the advantages of real-time monitoring of point-surface temperature, partition temperature measurement, long historical storage time, multiple communication, multi-level hierarchical processing of events, multiple convergence sensors and the like, and real on-line diagnosis equipment degradation trend can be predicted, prevented and maintained in time, and the controllable operation of coiling machine equipment is ensured.

The on-line monitoring subsystem 30 for lubrication state of bearings and gears of the reel speed reducer, the pinch roll speed reducer, and the auxiliary roll speed reducer is configured to perform on-line monitoring on lubrication state, and includes: a thermal flow switch arranged on the oil inlet main pipe; a pressure transmitter arranged on the oil inlet main pipe; and the oil flow annunciator is arranged on the speed reducer bearing and used for monitoring the state of oil flow break. Therefore, lubrication of each bearing is ensured, intelligent diagnosis is realized, and the problem that the lubrication of the bearing needs manpower for inspection is thoroughly solved.

Specifically, the lubrication state of bearings and gears of the speed reducers is an important parameter, a thermal flow switch is designed on an oil inlet main pipe of each speed reducer to monitor, when a medium flows, heat received by a heat sensing sensor changes along with the change of the flow velocity of the medium, the heat sensing sensor converts a temperature difference signal into an electric signal, when the flow velocity reaches a certain set point, the thermal flow switch outputs a switching value signal, an output alarm signal is triggered to be transmitted to a unit, and corresponding control logic intelligent diagnosis can be made after a system obtains the signal.

The pressure transmitter is arranged for the pressure of the lubricating manifold of the bearings and gears of the speed reducer, the most advanced diffusion silicon sensor and the manufacturing process thereof are adopted, the optimal performance and long-term stability are ensured, the zero point can be adjusted on site through the free on-site configuration of three keys, the full-range zero point can be shifted, the range can be adjusted, when the pressure abnormal signal is monitored, the output alarm signal is triggered and transmitted to the unit, the corresponding control logic can be made after the system obtains the signal, and the intelligent diagnosis of the pressure deficiency of the unit is prevented.

After guaranteeing lubricated pressure and flow of coiling machine speed reducer house steward, all set up the oil flow annunciator at every bearing of all speed reducers, carried out the oil flow to every bearing and constantly monitored, adopted the oil flow annunciator that has proximity switch of a tape flap, the oil feed is accessed from appointed one end, when oil passes through the oil flow annunciator, promote the baffle, make the baffle get into proximity switch's signaling area, the switch sends the signal and monitors whether oil passes through, ensure that lubrication of every bearing obtains guaranteeing to realize intelligent diagnosis, thoroughly liberated the problem that bearing lubrication needs the manpower to carry out the inspection.

Fig. 10 is a schematic diagram of intelligent lubrication of thin oil in the drum speed reducer, wherein (1) indicates an oil flow annunciator, (2) indicates a pressure transmitter, (3) indicates a thermal flow switch, and all 10 lubrication points of the drum speed reducer in fig. 10 are monitored on line in a lubrication state. Fig. 11 is a schematic diagram of two-layer thin oil intelligent lubrication of a wrapper roller speed reducer, wherein (1) indicates a top-layer intelligent lubrication design, and (2) indicates a two-layer intelligent lubrication design, and the oil quantity is given to each point accurately, so that bearing flushing lubrication is performed in place, the optimal environment operation of the bearing without abrasive dust is maintained, and the original bearing splash lubrication mechanism is changed. The two-layer design of the monitoring element is realized for the auxiliary winding roller speed reducer, and the layout space of the element is increased. FIG. 12 is a schematic diagram of intelligent lubrication of pinch roll reducer with thin oil, wherein (1) indicates a pressure transducer and (2) indicates an oil flow annunciator.

The hydraulic lubrication control system and electric transmission operation integrated information on-line monitoring subsystem 40 comprises a hydraulic system pump station on-line monitoring and intelligent diagnosis module and a gear lubrication system pump station on-line monitoring and intelligent diagnosis module. The hydraulic system pump station on-line monitoring and intelligent diagnosis module is configured to monitor abnormal parameters of the hydraulic system, and the intelligent diagnosis system is abnormal and performs abnormality alarm. The gear lubrication system pump station on-line monitoring and intelligent diagnosis module is configured to monitor abnormal parameters of the gear lubrication system, and the intelligent diagnosis system is abnormal and performs abnormality alarm.

In some embodiments, 1 set of hydraulic lubrication equipment on-line monitoring OCMS system (as shown in fig. 13) can be arranged, an on-line cloud monitoring system is realized, physical quantity abnormal parameters such as vibration, oil product, flow, pressure difference, motor, on-line cleanliness, on-line moisture, pressure, temperature, liquid level, motor power consumption and the like of the hydraulic lubrication equipment are mainly monitored, the faults and power consumption of a main pump of the intelligent diagnosis system are abnormal, the abnormal physical quantity such as the oil liquid cleanliness, pressure difference signals, liquid level, cleanliness, moisture, pressure temperature flow and the like are timely early-warned, the running state of the main pump is timely optimized by innovative MCC monitoring analysis, invalid running and abrasion are reduced, the service life of the hydraulic main pump is prolonged, and the equipment state of a system pump station is intelligently judged.

The hydraulic lubrication control system and electric drive operation integrated information on-line monitoring subsystem 40 includes: the thermal detection monitoring and analyzing module is configured to comprehensively analyze the thermal detection monitoring quality through the thermal detection signal and the rolling line strip steel tracking signal so as to realize the early warning of the strip steel tracking state; the servo valve monitoring and analyzing module is configured to correlate a servo valve setting signal, a feedback signal, a zero drift signal and an equipment action instruction, comprehensively evaluate the state of the servo valve in the rolling process and realize the early warning of the state of the servo valve; the transient analog sensor monitoring and analyzing module is configured to analyze fluctuation conditions, maximum values, minimum values and average values of data in the rolling process by correlating transient analog sensor signals with production rolling states, and realize sensor overrun and jump alarming reminding through configuration rules; the button monitoring and analyzing module is configured to assist in analyzing the operation strategy and the coiling state of an operator by counting the operation times and the operation time of the buttons; the servo oil cylinder monitoring and analyzing module is configured to analyze impact characteristics, control performance and production state characteristics of the servo oil cylinder by transmitting displacement, pressure, servo valve and steel biting signal information of the servo oil cylinder into the servo oil cylinder monitoring model, so as to realize servo oil cylinder state early warning and intelligent diagnosis; and the electric transmission monitoring and analyzing module is configured to extract transmission impact, current amplitude limiting, torque amplitude limiting and speed difference characteristics by analyzing the speed, current and torque of the transmission device and the biting steel production signals, timely feed back abnormal production conditions and realize early warning and intelligent diagnosis of the transmission characteristics of the transmission device. The on-line monitoring system of the platform is used for innovatively realizing on-line monitoring and early warning on key equipment of the coiling machine, such as thermal detection, servo valves, various transient analog quantity sensors, servo oil cylinders, electric transmission and the like

In some embodiments, quantitative analysis and early warning of the state is realized on the coiling machine, and beneficial guarantee is provided for equipment and production. Specifically, through the online monitoring system of platform, all realize online monitoring early warning to coiling machine key equipment heat examine, servo valve, various instantaneous analog quantity sensor, servo cylinder, electric drive etc. and divide into 6 parts specifically:

1. the heat detection monitoring analysis realizes the early warning of the tracking state of the strip steel, and reduces the scrap steel accidents

And comprehensively analyzing the monitoring quality of the thermal inspection, such as abnormal alarms of flash, flash off, large fluctuation of a monitoring interval and the like through the thermal inspection signal and the rolling line belt steel tracking signal. Model parameter configuration: the physical position of the heat detecting device and the cold and hot detecting data points. Model function: thermal inspection monitoring statistics: the number of times and the time of detection.

Detecting a distance interval: and (3) collecting strip steel tracking displacement signals during each thermal detection, providing action conditions of a coiling machine, and matching with alarm rules. And (3) flashing to give an alarm: the detection time is less than 100ms. And (5) flash alarm: the detection time is less than 100ms, so that intelligent diagnosis is realized.

2. The servo valve monitoring analysis realizes state early warning, improves equipment stability, and reduces equipment production accidents

By associating information systems such as servo valve setting signals, feedback signals, zero drift signals, equipment action instructions and the like, comprehensively evaluating the servo valve state in the rolling process, alarming abnormal states such as equipment refusal action, oil cylinder blocking, zero drift and the like, assisting equipment personnel in making related pre-maintenance strategies efficiently and improving production stability. Model parameter configuration: zero drift alarm threshold value, servo valve abnormal opening degree threshold value, servo valve set opening degree, feedback opening degree, servo valve zero drift and steel biting signal. Model function: and the intelligent diagnosis is realized by state analysis, numerical analysis and zero drift alarm with alarm rules.

3. The instantaneous analog quantity sensor monitors and analyzes to improve the stability of the precision of the equipment and reduce the scrap steel

Analog quantity sensor monitoring: by associating the sensor signals with the production rolling state, the information of fluctuation conditions, maximum values, minimum values, average values and the like of data in the rolling process is analyzed, and alarm reminding such as overrun and jump of the sensor is realized through configuration rules, so that the process and equipment personnel are assisted in analyzing the equipment state, and a formulated efficient production and maintenance strategy is formulated.

Model parameter configuration: the jump threshold value, the maximum threshold value and the minimum threshold value are configured with analog signal values and steel biting signals. Model function: state analysis, numerical analysis: and analyzing the original time sequence data of the sensor, matching an alarm rule, carrying out overrun alarm, carrying out sensor jump alarm and carrying out disconnection alarm to realize intelligent diagnosis.

4. Button monitoring analysis optimizes operator operation strategy and reeling state

And the operation strategy and rolling state of operators are assisted to be analyzed by counting the times and time of the buttons.

Model data configuration: a button signal. Model function: operation statistics (button operation times, operation time)

5. Servo cylinder monitoring analysis realizing state early warning and improving product plate shape quality precision

By transmitting the displacement, pressure, servo valve, biting steel signals and other information of the servo oil cylinder into a monitoring servo oil cylinder monitoring model, the impact characteristics, control performance, production state characteristics and other information of the oil cylinder are analyzed, auxiliary equipment personnel comprehensively and deeply master the operation state of the servo oil cylinder, the abnormality of the oil cylinder is obtained in advance, a maintenance strategy is formulated, and intelligent diagnosis is realized.

Model parameter configuration: overshoot alarm threshold, impact time alarm threshold, inlet and outlet displacement deviation alarm threshold, double cylinder, displacement impact alarm threshold, displacement deviation range threshold, oil cylinder speed alarm threshold, displacement set value, feedback value, PT force and steel biting signal. Model function: impact characteristics, control performance (displacement variation, overshoot, response time); analysis of cylinder speed (maximum cylinder speed, maximum servo valve opening).

6. Electrical transmission monitoring, analyzing and early warning transmission characteristics, and improving production stability

By analyzing production signals of speed, current, torque, biting steel and the like of the transmission device, characteristics of transmission impact, current amplitude limiting, torque amplitude limiting, speed difference and the like are extracted, abnormal production conditions are fed back in time, and intelligent diagnosis of the transmission device is realized.

Model parameter configuration: impact alarm threshold, model data configuration, transmission speed set value, feedback value, current, torque and steel biting signals. Model function: curve analysis, speed, torque and current data query; impact analysis, namely, the speed impact quantity and impact time of each steel biting; and (5) matching an alarm rule and giving an impact alarm.

The fat lubrication on-line monitoring and intelligent diagnostic subsystem 50 is configured for on-line monitoring and intelligent diagnosis of fat lubrication of critical equipment of the rolls, the auxiliary rolls, and the pinch roll trains. The on-line monitoring and intelligent diagnosing subsystem 50 comprises an on-line monitoring and intelligent diagnosing module for the oil lubrication of the key equipment of the winding drum, and is configured to automatically switch the lubrication mode of the winding drum to continuous oiling of the winding drum when the winding drum is unreeled, and to recover normal oiling after the winding drum is cooled for a period of time after unreeled. That is, the online monitoring and intelligent diagnosis module for the grease lubrication of the key equipment of the winding drum is used for realizing the automatic oil feeding design of abnormal winding drum coil unloading. When the abnormal steel-piling high-temperature steel coil of the coiling machine cannot be timely uncoiled, the high-temperature steel coil stays on the coiling block for a long time, and the coiling block can be continuously heated, so that lubrication is failed for a short time. When the abnormality occurs, the interlocking production information of the winding drum oil feeding lubrication station is automatically switched to continuously oil feeding for the winding drum in a lubrication mode, and the normal oil feeding is performed after the winding drum is continuously cooled for 15 minutes after the winding drum is unwound, so that the failure caused by the carbonization of oil in an oil hole of a main transmission shaft of a main shaft and the overhigh temperature rise of a spring in a column wedge is avoided.

The grease lubrication on-line monitoring and intelligent diagnosing subsystem 50 comprises a key equipment grease lubrication on-line monitoring and intelligent diagnosing module of the auxiliary roll and the pinch roll, and is configured to sense the blockage and oil leakage conditions and send out alarm signals through a flow sensor. Specifically, the bearing grease of the high-speed running of the coiling unit roller system is lubricated intelligently, a flow sensor is arranged at each oil feeding point, in the oil feeding process, blockage and oil leakage occur, and the flow sensor sends out an alarm signal to realize on-line monitoring and intelligent diagnosis.

According to a second aspect of the present invention, there is provided a state monitoring intelligent diagnosis method for a coiler, which comprehensively collects physical quantities of coiler equipment, comprehensively determines characteristics according to fault information and time domain trend, fuses professional data of machinery, electricity, hydraulic pressure and operation, and determines coiler state by rules, and specifically includes: monitoring and intelligently diagnosing the vibration state of the rolling mill roller system bearing through the bearing vibration state monitoring subsystem 10; the temperature state is automatically monitored on the whole life cycle of the coiling machine transmission shaft (torsion weak point) through the transmission shaft temperature on-line monitoring subsystem 20; the lubrication state of the bearing gear of the coiling machine is monitored on line and intelligently diagnosed through the lubrication state on-line monitoring subsystem 30 of the speed reducer; the hydraulic lubrication pump station and the control system (cold and hot detection, servo valve, sensor, button, servo oil cylinder and electric transmission) of the coiling machine are monitored and diagnosed on line through the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem 40; the grease lubrication of each device of the coiling machine is monitored on line and intelligently diagnosed through the grease lubrication on-line monitoring and intelligent diagnosis subsystem 50.

In summary, the intelligent diagnosis system and the intelligent diagnosis method for monitoring the state of the coiling machine can effectively realize maintenance-free management of equipment, improve the operation function precision of the hot rolling coiling machine equipment and predict the preventive maintenance management level, ensure the high-quality stable operation of the coiling machine and the coil quality of hot rolling products, ensure the service life of the equipment, reduce the abnormal shutdown time and the maintenance cost, avoid the potential safety hazard of on-site manual maintenance spot inspection, and truly realize the safe and environment-friendly production of modern enterprises.

The system and the method provided by the invention belong to a management means adopted by advanced enterprises, the defect of manual spot inspection experience judgment is reduced, the full life cycle management of coiling equipment is developed and perfected from the technical progress aspect, the intelligent state monitoring diagnosis is realized, the safe and environment-friendly operation environment of the coiling machine is improved, the equipment operation and production process requirements can be met, and the system and the method are suitable for popularization and use.

The preferred embodiments of the present invention have been described in detail hereinabove, but the present invention is not limited to the specific details of the above embodiments, and various simple modifications can be made to the technical solutions of the present invention within the scope of the technical concept of the present invention, and these simple modifications all fall within the scope of the present invention.

In addition, the specific features described in the above embodiments may be combined in any suitable manner, and in order to avoid unnecessary repetition, various possible combinations are not described further.

Moreover, any combination of the various embodiments of the invention can be made without departing from the spirit of the invention, which should also be considered as disclosed herein.

Claims (10)

1. A coiler condition monitoring intelligent diagnostic system, comprising:

the bearing vibration state monitoring subsystem is configured for monitoring and intelligently diagnosing the vibration state of the coiling machine bearing;

the transmission shaft temperature on-line monitoring subsystem is configured for automatically monitoring and early warning the temperature state of the transmission shaft of the coiling machine;

the on-line monitoring subsystem for the lubrication state of the speed reducer is configured to perform on-line monitoring and intelligent diagnosis on the lubrication state of the speed reducer of the coiling machine;

the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem are configured to carry out on-line monitoring and intelligent diagnosis on a hydraulic lubrication pump station and a control system of the coiling machine;

And the fat lubrication on-line monitoring and intelligent diagnosis subsystem is configured for on-line monitoring and intelligent diagnosis of the fat lubrication of each device of the coiling machine.

2. The system of claim 1, wherein the bearing vibration condition monitoring subsystem comprises:

the auxiliary roll roller assembly state monitoring module is configured to carry out online monitoring and intelligent diagnosis on the auxiliary roll roller assembly state, and is used for carrying out integrated online monitoring of temperature vibration through a Wen Zhen sensor arranged on an auxiliary roll roller bearing seat;

a spool head bearing vibration state monitoring module configured to monitor a spool head bearing vibration state, the spool head bearing vibration state monitoring module performing vibration monitoring via a vibration sensor mounted to a spool head bearing mount, the vibration sensor being equipped with a high temperature protection structure;

the auxiliary roll and pinch roll motor speed reducer five-in-one vibration state monitoring module is configured to monitor temperature and vibration of the auxiliary roll and the pinch roll motor, the speed reducer, the rear bearing of the transmission shaft, the middle bearing and the head bearing on line;

the pinch roll roller assembly state monitoring module is configured to carry out on-line monitoring and intelligent diagnosis on the pinch roll roller assembly state, and the pinch roll roller assembly state monitoring module carries out integrated on-line monitoring of temperature vibration through a Wen Zhen sensor arranged on a pinch roll bearing seat.

3. The system of claim 2, wherein the high temperature protection structure comprises:

a sensor high temperature protection cable connected with the main body sensing part of the vibration sensor;

the sensor high-temperature-preventing protection tube is arranged outside the sensor high-temperature-preventing protection cable;

a sensor high temperature prevention shield at least partially shielding the body sensing portion and connected with the sensor high temperature prevention shield;

a sensor guard water supply line connected to the sensor guard for supplying cooling water thereto.

4. The system according to claim 1, wherein the transmission shaft temperature on-line monitoring subsystem is a transmission shaft infrared imaging temperature on-line monitoring subsystem, and is configured to perform cross package infrared imaging temperature on-line monitoring on a pinch roll and a wrapper roll transmission shaft, and infrared automatically captures temperature change conditions caused by cross package lubrication and abrasion, and timely pushes early warning information.

5. The system of claim 1, wherein the drive shaft temperature on-line monitoring subsystem is configured to monitor the temperature of the spool drive support shaft bearing via a platinum-thermal-resistance temperature sensor extending into the bearing outer race, a deep hole is provided in the bearing housing for grease-added heat transfer, and the platinum-thermal-resistance temperature sensor extends into the bearing outer race via the deep hole.

6. The system of claim 1, wherein the speed reducer lubrication state online monitoring subsystem is configured to online monitor lubrication states of bearings and gears of a spool speed reducer, a pinch roll speed reducer, a wrapper roll speed reducer, comprising:

a thermal flow switch arranged on the oil inlet main pipe;

a pressure transmitter arranged on the oil inlet main pipe;

and the oil flow annunciator is arranged on the speed reducer bearing and used for monitoring the state of oil flow break.

7. The system of claim 1, wherein the hydraulic lubrication control system and electric drive operation integrated information on-line monitoring subsystem comprises:

the hydraulic system pump station online monitoring and intelligent diagnosis module is configured to monitor abnormal parameters of the hydraulic system, and is used for intelligently diagnosing system abnormality and giving an abnormality alarm;

and the gear lubrication system pump station on-line monitoring and intelligent diagnosis module is configured to monitor abnormal parameters of the gear lubrication system, and perform intelligent diagnosis system abnormality and abnormal alarm.

8. The system of claim 1, wherein the hydraulic lubrication control system and electric drive operation integrated information on-line monitoring subsystem comprises:

The thermal detection monitoring and analyzing module is configured to comprehensively analyze the thermal detection monitoring quality through the thermal detection signal and the rolling line strip steel tracking signal so as to realize the early warning of the strip steel tracking state;

the servo valve monitoring and analyzing module is configured to correlate a servo valve setting signal, a feedback signal, a zero drift signal and an equipment action instruction, comprehensively evaluate the state of the servo valve in the rolling process and realize the early warning of the state of the servo valve;

the transient analog sensor monitoring and analyzing module is configured to analyze fluctuation conditions, maximum values, minimum values and average values of data in the rolling process by correlating transient analog sensor signals with production rolling states, and realize sensor overrun and jump alarming reminding through configuration rules;

the button monitoring and analyzing module is configured to assist in analyzing the operation strategy and the coiling state of an operator by counting the operation times and the operation time of the buttons;

the servo oil cylinder monitoring and analyzing module is configured to analyze impact characteristics, control performance and production state characteristics of the servo oil cylinder by transmitting displacement, pressure, servo valve and steel biting signal information of the servo oil cylinder into the servo oil cylinder monitoring model, so as to realize servo oil cylinder state early warning and intelligent diagnosis;

And the electric transmission monitoring and analyzing module is configured to extract transmission impact, current amplitude limiting, torque amplitude limiting and speed difference characteristics by analyzing the speed, current and torque of the transmission device and the biting steel production signals, timely feed back abnormal production conditions and realize early warning and intelligent diagnosis of the transmission characteristics of the transmission device.

9. The system of claim 1, wherein the fat lubrication online monitoring and intelligent diagnostic subsystem comprises:

the roll key equipment grease lubrication on-line monitoring and intelligent diagnosis module is configured to automatically switch a roll lubrication mode into continuous oiling of the roll when the roll is unreeled, and recover normal oiling after cooling for a period of time after the roll is unreeled;

and the auxiliary roll and pinch roll key equipment grease lubrication on-line monitoring and intelligent diagnosis module is configured to sense blockage and oil leakage conditions and send alarm signals through the flow sensor.

10. The intelligent diagnosis method for monitoring the state of the coiling machine is characterized by comprising the following steps of:

monitoring and intelligently diagnosing the vibration state of the rolling mill roller system bearing through a bearing vibration state monitoring subsystem;

the temperature state of the whole life cycle of the transmission shaft of the coiling machine is automatically monitored through the transmission shaft temperature on-line monitoring subsystem;

The lubrication state of the bearing gear of the coiling machine is monitored on line and intelligently diagnosed through a lubrication state on-line monitoring subsystem of the speed reducer;

the hydraulic lubrication pump station and the control system of the coiling machine are monitored and diagnosed intelligently on line through the hydraulic lubrication control system and the electric transmission operation integrated information on-line monitoring subsystem;

and the on-line monitoring and intelligent diagnosis of the grease lubrication of each device of the coiling machine are carried out through the on-line monitoring and intelligent diagnosis subsystem of the grease lubrication.