JP4876556B2 - Operation instruction device for continuous equipment and method for manufacturing steel sheet - Google Patents

Description

The present invention relates to a continuous facility operation instruction apparatus and a steel plate manufacturing method including a continuous line in which a plurality of facilities are arranged in series and process a group of materials sequentially connected at a leading facility.

As for this type of continuous equipment, for example, for the purpose of optimal design of continuous integrated process lines, line specifications, operating conditions, production plan line stoppage information of processed materials are input, and optimal design is performed by dynamic simulation. There has been proposed one in which the specifications according to the above are modified as appropriate (see, for example, Patent Document 1).
Japanese Patent Laid-Open No. 7-246407 ("Continuous Integration Process Line Design Method")

  The above prior art (Patent Document 1) relates to a design method for a new continuous line, and has a problem that it cannot be applied as it is to an efficient operation of existing equipment. The reason will be described below.

  The continuous equipment is given a speed pattern for each material and equipment. For example, as shown in Table 1, the pickling line consists of three equipment (inlet, center, outlet), and there is a looper between the instruments. (Variable length buffer device: absorbs the speed difference between the upstream and downstream of the looper to increase or decrease the coil accumulation amount).

  The problem here is the central minimum speed constraint. As an example, consider the case where the exit side stops. FIG. 6 shows an example of the operation. The remaining length to the cutting machine is monitored based on the tracking information of the exit side cutting point (entrance side welding position or coil split position), and the exit side deceleration starts at point A. Until then, since the outgoing speed MAX> the central speed MAX, the outgoing looper decreased, but after point A, the speed is reversed and the looper starts accumulating. The exit looper position (accumulated amount) reaches the synchronization position at the point C ′. This is the point to match the speed before and after the looper when the remaining looper length decreases, but in this example, the center has the lowest speed constraint for the stop on the exit side, so in practice the speed synchronization The central speed will drop to MIN. Still, looper accumulation does not stop, so accumulation proceeds in proportion to the exit stop time. The exit process ends at point E and acceleration starts. As a result, the exit looper position also starts to decrease, and the central speed returns to MAX. This example can be handled by the dynamic simulation proposed in the above [Patent Document 1].

  Next, consider the case where the exit side is also stopped. FIG. 7 shows an example of the operation. The difference from FIG. 6 is the setting of the synchronization start point, which in this example is point C, which is closer to the equipment limit than point C ′. As in the example of FIG. 6, the exit looper reaches the synchronization position at point C. However, in this example, the exit looper reaches the emergency stop point D, and the center makes an emergency stop. If there is such an emergency stop, the coil in the pickling tank becomes an abnormal material (defective product). This is due to inappropriate management of the outgoing looper length with respect to the remaining stop time on the outgoing side. This example is difficult to cope with in the dynamic simulation proposed in the above [Patent Document 1].

The present invention has been made in order to solve the above-described problems, and is a continuous facility operation instruction device capable of pursuing high efficiency while satisfying severe restrictions such as a central minimum speed restriction. , and an object thereof to provide a steel manufacturing method using the operation instruction device of the continuous equipment.

The operation instruction device for continuous equipment according to the present invention includes a welding machine disposed on the entry side, a pickling tank disposed on the center, an inspection room disposed on the exit side, and an entry looper between the entry side and the center. Is an operation instruction device for continuous equipment comprising a pickling line for processing a group of materials sequentially connected by a welding machine on the entry side, wherein an exit side looper is arranged between the center and the exit side. First storage means for storing plan data, second storage means for storing operation result data, third storage means for storing equipment specifications, and fourth for storing operation conditions A storage means, a continuous line operation simulator for performing an operation simulation of a continuous line based on the production plan data, the operation performance data, the equipment specifications and the operation conditions, and a result evaluation means for evaluating a result of the simulation; The stain Comprising a operational condition changing means for changing operating conditions based on the results evaluation of configuration, and operation instruction means for performing the operation instruction facilities based on the changed operating conditions, the result evaluation unit, the simulation of exit side stop Using time and central deceleration start time, simulation central emergency stop time, and remaining stop time information indicating how many seconds the coil that is stopped on the outgoing side continues from the production plan data and operating condition data. If there is no upper limit on the exit looper length, calculate how many meters the center has traveled during the remaining stop time on the exit side, and set this progress length as the looper shortage length. Is to correct the central deceleration start time so that the looper shortage length becomes zero or a negative value.
Moreover, the manufacturing method of the steel plate which concerns on this invention operates an installation according to the driving | operation instruction | indication of the driving | operation instruction | indication apparatus of said continuous equipment, and manufactures a steel plate.

  In the present invention, the operation simulation of the continuous equipment is performed based on the production plan data, the equipment specifications, and the operating conditions, the simulation is evaluated, the operating conditions are changed based on the result evaluation, and the predetermined evaluation is satisfied. Since the operation of the facility is instructed, it is possible to operate in pursuit of high efficiency while satisfying severe constraint conditions such as the central minimum speed constraint.

Embodiment 1. FIG.
FIG. 1 is an equipment configuration diagram of a pickling line to which the present invention is applied, and FIG. 2 is a conceptual diagram thereof. The pickling line consists of three facilities and two loopers. The entry side 10 includes a payoff reel 11 and a welding machine 12 for winding the rolled coil, and continuously feeds the coil into the facility. There is a pickling tank (for removing surface iron oxide with hydrochloric acid) 21 at the center 20 for pickling the material while keeping a predetermined plate speed range. If the material stops in the pickling tank 21, it becomes an abnormal material. Therefore, the operation is performed with care so as not to make it smaller than the central speed MIN. On the exit side 30, there are a trimmer (width reduction cutter) 31, a surface inspection room (visual or sensor) 32, a cutter (shear) 33, and a tension reel 34, and the predetermined surface inspection is completed after finishing the width. Cut later and rewind. An entrance looper 15 is disposed between the entry side 10 and the center 20, and an exit side looper 25 is disposed between the center 20 and the exit side 30. The entry-side looper 15 and the exit-side looper 25 absorb the speed difference between the upstream and downstream coils and increase or decrease the coil accumulation amount.

  FIG. 3 is a block diagram showing a configuration of the continuous facility operation instruction device according to the first embodiment of the present invention. This driving instruction device is composed of a computer (electronic computer) 40 and a storage device (for example, a database) 50. The function of the computer 40 includes a data input processing unit 41, a continuous line operation simulator 42, a result evaluation unit 43, an operation condition changing unit 44, and an operation instruction unit 45. The storage device 50 includes a production plan data storage unit 51, an operation result data storage unit 52, an equipment specification storage unit 53, an operation condition storage unit 54, and a simulation progress / result storage unit 55.

  The production plan data stored in the production plan data storage unit 51 includes an output side coil as a unit, and some of the coils are divided into an input side 1 coil and an output side N coil. Examples of production plan data include those shown in Table 2, for example.

  The actual operation data stored in the production plan data storage unit 51 includes, for example, the speeds and accelerations (decelerations) on the input side, the center and the output side, the positions of the input side looper and the output side looper, etc. Sent from a managed computer and updated.

  The equipment specifications stored in the equipment specification storage unit 53 include, for example, equipment length, looper length (MAX, MIN), equipment speed (MAX, MIN), and equipment acceleration. Examples of the equipment specifications include those shown in Table 3, for example.

  The operation conditions stored in the operation condition storage unit 54 include, for example, a stop time on the entry side and the exit side and a deceleration pattern for exit side inspection. Table 4 shows examples of stop times on the entry side and the exit side. Moreover, the example of the deceleration pattern for an exit side inspection is shown in FIG. This deceleration pattern decelerates for visual (or sensor) inspection at the tip, center, and tail according to the coil attribute, and the deceleration distance and deceleration speed are registered as a pattern. The simulation progress / result stored in the simulation progress / result storage unit 55 includes the progress and result of the simulator by the continuous line operation simulator 42.

  In the operation instruction device of FIG. 3, the data input processing unit 41, the continuous line operation simulator 42, the result evaluation unit 43, the operation condition changing unit 44, and the operation instruction unit 45 operate periodically (for example, about 10 seconds). First, the data input processing unit 41 takes in the data of the production plan data storage unit 51 and the operation result data storage unit 52, grasps information on coils to be put into the line in the future, collects the latest operation result data, Understand the current operation status of continuous lines. The continuous line operation simulator 42 takes in the data from the data input processing unit 41 and the data in the facility specification storage unit 53 and the operation condition storage unit 54 and simulates the continuous line operation. It is stored in the storage unit 55. The continuous line operation simulator 42 is intended for a short period from the present to a few minutes ahead, and is intended to automatically operate the line directly or to sequentially issue appropriate operation instructions to the operator. It is said. Specifically, a simulation is performed to scrutinize future possibilities, signs of potential errors are detected at an early stage, operational conditions that can be avoided are searched, verified, and presented to the operator. The result evaluation unit 43 evaluates the result of the simulation, and the operation condition changing unit 44 changes the operation condition as necessary and gives the changed operation condition to the continuous line operation simulator 42 to perform the simulation. When the evaluation by the result evaluation unit 43 is appropriate, the operation instruction unit 45 instructs an operation condition. The driving instruction to the operator by the driving instruction unit 45 is in the same position as the driving guidance of the car navigation system in the drive. In other words, since it is too late to prompt the current action for the instruction, the next action is notified in advance several seconds or more than 10 seconds, and the final decision is left to the operator.

FIG. 5 is a flowchart showing details of processing of the continuous line operation simulator 42.
The continuous line operation simulator 42 is activated every monitoring cycle (for example, 1 second cycle) and performs the following processing (S10). In addition, the meaning of the variable used for the following numerical formulas is as follows.
(Explanation of variables)
Subscript i = 1 Input side, 2 Center, 3 Output side
j = 1 input side, 2 output side
Simulation calculation period ΔT (sec)
Current speed Vc (i) (m / sec)
Target speed Va (i) (m / sec)
Minimum speed Vmin (i) (m / sec)
Acceleration α (i) (m / sec ² )
Acceleration / deceleration mode A_mode (i)
Plate travel length L (i) (m)
Looper length Lp (j) (m)
Stop time Dn (i) (sec)
Cumulative stop time results Dn_Ji (i) (sec)
Coil remaining length Lc (j) (m)
Deceleration start length Ld (j) (m)
Looper long end side synchronization position L_lng_sync (i) (m)

(S11) Current speed calculation
When A_mode (i) = 1 (acceleration) or A_mode (i) = -1 (deceleration)
Vc (i) = Vc (i) + A_mode (i) × α (i) × ΔT
When A_mode (i) = 10 (constant speed) or A_mode (i) = 0 (stop)
Vc (i) = Vc (i)
(S12) Plate travel length calculation
When A_mode (i) = 1 (acceleration) or A_mode (i) = -1 (deceleration)
L (i) = L (i) + 0.5 × α (i) × (ΔT) ²
When A_mode (i) = 10 (constant speed) or A_mode (i) = 0 (stop)
L (i) = L (i) + Vc (i) × ΔT

(S13) Looper length calculation
Lp (1) = Lp (1) + L (1)-L (2)
Lp (2) = Lp (2) + L (2)-L (3)
(S14) Update stop time
When A_mode (i) = 0 (stop)
Dn_Ji (i) = Dn_Ji (i) + ΔT

(S15) Remaining coil length calculation Incoming coil remaining length
Lc (1) = Incoming coil length-ΣL (1)
Note that Σ means the total length of plate travel after welding is completed.
Remaining length until starting coil deceleration
Ld (2) = 0.5 × Vc (3) ² / α (3)
Note that Σ means the total plate length after cutting is completed.
Outgoing coil remaining length
Lc (2) = Outgoing coil length-ΣL (2)

(S16) Event generation check (S17) Target speed change The presence / absence of an event (for example, deceleration, acceleration, stop, etc.) is checked and the target speed is changed accordingly.
(Example 1): The input coil approaches the end, and is stopped at the tail end of the coil for welding with the next coil.
Remaining length until start of input side coil deceleration
Ld (1) = 0.5 × Vc (1) ² / α (1)
Decelerate if Lc (1) ≤ Ld (1).
Va (1) = 0 (stop)

(Example 2): When the outgoing looper reaches the long-end synchronization position, the central speed is synchronized with the outgoing speed.
Decelerate if Lp (2) ≧ L_lng_sync (i).
Va (2) = Max (Va (3), Vmin (2))

(S18) Change of display information Display information is changed based on the calculation result.

  When the continuous line operation simulator 42 finishes the above processing (S11) to (S18), it is next determined whether any of welding, inspection, or cutting is performed (S20), and the corresponding processing is performed. In some cases, any one of coil connection, inspection, and disconnection is performed (S30). Then, the result of the above processing is stored in the simulation progress / result storage 55 (S40).

  Table 5 shows an example of the progress of the simulation, and stores the target speed changing operation on the entry side, the center, and the exit side. This information is used for verification of simulation results and investigation of the cause when a simulation error occurs.

Table 6 shows an example of the result of the simulation, and for example, efficiency calculation can be performed based on this content and the above simulation progress.
Efficiency calculation Example: Input side efficiency = input side coil weight / (input side pass completion time of the coil-input side charging time)

  The result evaluation unit 43 evaluates the progress / result of the above simulation, and outputs it when an error occurs during the simulation according to the operating conditions, for example. Table 7 shows examples of simulation errors.

  When the result evaluation unit 43 obtains an evaluation result “no error has occurred”, the operation can be continued without changing the operation conditions, and the result evaluation unit 43 obtains an evaluation result “an error has occurred”. If the operation condition is changed, the operation condition changing unit 44 goes back to the past in the simulation and changes the operation condition so that an error can be avoided.

As an example of the operation change by the operation condition changing unit 44, the case of FIGS. 6 and 7 will be described.
(A) In the simulation process,
Point B in Fig. 7 (Exit stop time)
Same point C (Central deceleration start time)
The time remains.
(B) For simulation errors,
Same point D (central emergency stop)
The time remains.
(C) From the production plan data and the operation condition data, there is information on the remaining stop time indicating how many seconds the coil stopped on the outgoing side continues to stop after that.
From the above data, if there is no upper limit on the outgoing looper length, it can be calculated how many meters the center has traveled during the remaining stop time on the outgoing side. This distance is called “looper shortage”. If the outgoing looper 25 can accumulate the looper shortage length, it means that an emergency stop has not taken place. The synchronization start position for determining the point C (center deceleration start time) may be corrected to the position C ′ in FIG. 6 so that the looper shortage length becomes 0 m or negative. At this time, it is also possible to add a numerical value to the looper shortage length in consideration of variations due to fluctuations. This corresponds to a change in operating conditions.

  After changing the operating conditions, it is also possible to perform a simulation again by the continuous line operation simulator 42 to confirm error elimination. It is possible to select whether the operating condition change is permanent (learning), temporary, or valid for a certain period of time.

  As described above, in the present embodiment, a process of performing an operation simulation of a continuous facility based on production plan data, facility specifications, and operation conditions, evaluating the simulation, and changing the operation conditions based on the result evaluation. The operation state after a predetermined time is predicted and the operation of the equipment that satisfies the predetermined evaluation is instructed. For example, high efficiency is pursued while satisfying severe constraint conditions such as the central minimum speed constraint. Can be operated.

It is an equipment block diagram of a pickling line to which an embodiment of the present invention is applied. It is a conceptual diagram of the pickling line of FIG. It is the block diagram which showed the structure of the operation instruction | indication apparatus of the continuous installation which concerns on Embodiment 1 of this invention. It is the figure which showed the example of the speed pattern for an exit side test | inspection. It is the flowchart which showed the detail of the process of a continuous line operation simulator. It is the timing chart (the 1) which showed the operation example. It is the timing chart (the 2) which showed the operation example.

Explanation of symbols

10 entry side, 11 payoff reel, 12 welding machine, 15 entry side looper, 20 center, 21 pickling tank, 25 exit side looper, 30 exit side, 34 tension reel, 40 computer (electronic computer), 41 data input processing section 42 continuous line operation simulator, 43 result evaluation unit, 44 operation condition change unit, 45 operation instruction unit, 51 production plan data storage unit, 52 operation result data storage unit, 53 equipment specification storage unit, 54 operation condition storage unit, 55 Simulation progress / result storage unit.

Claims (2)

A welding machine is placed on the entrance side, a pickling tank is placed in the center, an inspection room is placed on the exit side, an entrance looper is placed between the entrance side and the center, and between the center and the exit side An operation instruction device for continuous equipment consisting of a pickling line in which an exit side looper is arranged and a group of materials sequentially connected by an entrance side welding machine,
First storage means for storing production plan data;
A second storage means for storing operation result data;
Third storage means for storing equipment specifications;
A fourth storage means for storing operating conditions;
A continuous line operation simulator that performs an operation simulation of a continuous line based on the production plan data, the operation result data, the facility specifications, and the operation conditions;
A result evaluation means for evaluating the result of the simulation;
An operation condition changing means for changing the operation condition based on the result evaluation of the simulation;
An operation instruction means for instructing operation of the equipment based on the changed operation condition,
The result evaluation means includes
The exit stop time and central deceleration start time of the simulation,
Central emergency stop time of simulation,
Information on the remaining stop time, such as how many seconds after the coil that is stopped on the exit side, obtained from the production plan data and operation condition data,
If there is no upper limit on the exit side looper length, calculate how many meters the center has traveled during the remaining stop time on the exit side, and let this progress length be the looper shortage length.
The operation condition changing means corrects the central deceleration start time so that the looper shortage length becomes 0 or a negative value, and the operation instruction device for continuous equipment is characterized in that:   A method for producing a steel sheet, comprising: operating a facility according to an operation instruction of an operation instruction device for a continuous facility according to claim 1 to manufacture a steel plate.

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