WO2022009576A1 - 鋼管の真円度予測方法、鋼管の真円度制御方法、鋼管の製造方法、鋼管の真円度予測モデルの生成方法、及び鋼管の真円度予測装置 - Google Patents
鋼管の真円度予測方法、鋼管の真円度制御方法、鋼管の製造方法、鋼管の真円度予測モデルの生成方法、及び鋼管の真円度予測装置 Download PDFInfo
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- WO2022009576A1 WO2022009576A1 PCT/JP2021/021416 JP2021021416W WO2022009576A1 WO 2022009576 A1 WO2022009576 A1 WO 2022009576A1 JP 2021021416 W JP2021021416 W JP 2021021416W WO 2022009576 A1 WO2022009576 A1 WO 2022009576A1
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- roundness
- steel pipe
- pipe
- press
- steel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/08—Tube expanders
- B21D39/20—Tube expanders with mandrels, e.g. expandable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/01—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/02—Seam welding; Backing means; Inserts
- B23K9/025—Seam welding; Backing means; Inserts for rectilinear seams
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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
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06N—COMPUTING ARRANGEMENTS BASED ON SPECIFIC COMPUTATIONAL MODELS
- G06N20/00—Machine learning
Definitions
- the present invention relates to a method for predicting the roundness of a steel pipe, a method for controlling the roundness of a steel pipe, a method for manufacturing a steel pipe, and a method for predicting the roundness of a steel pipe after a pipe expansion process in a steel pipe manufacturing process using the press bend method. It relates to a method of generating a roundness prediction model and a roundness prediction device for steel pipes.
- a steel plate having a predetermined length, width, and plate thickness is press-processed into a U-shape and then press-formed into an O-shape. Then, a manufacturing technique of a steel pipe (so-called UOE steel pipe) in which the butt portion is welded to form a steel pipe and the diameter thereof is further expanded (so-called expanded pipe) to increase the roundness is widely used.
- UOE steel pipe steel pipe
- expanded pipe expanded pipe
- U It is sometimes called a character-shaped molded body
- the butt part is welded to make a steel pipe, and finally the pipe is formed.
- a technique of inserting a pipe expanding device inside a steel pipe to expand the inner diameter of the steel pipe has been put into practical use.
- the pipe expansion device is provided with a plurality of pipe expansion tools having a curved surface obtained by dividing an arc into a plurality of pipes, and the curved surface of the pipe expansion tool is brought into contact with the inner surface of the steel pipe to expand the steel pipe and adjust the shape of the steel pipe. Used.
- the number of 3-point bending presses is increased, the roundness of the steel pipe after the pipe expansion process is improved, but it takes a long time to form the steel pipe into a U-shaped cross section.
- the number of three-point bending presses is reduced, the cross-sectional shape of the steel pipe becomes close to a polygonal shape, and there is a problem that it is difficult to form a circular shape. Therefore, the number of three-point bending presses (for example, 5 to 13 times for a steel pipe having a diameter of 1200 mm) is empirically determined according to the dimensions of the steel pipe for operation. Many proposals have been made on the setting method of the operating conditions of the press bend process for improving the roundness of the steel pipe after the pipe expansion process.
- Patent Document 1 is a method for performing a three-point bending press as few times as possible, and a plurality of tube expansion tools arranged in the circumferential direction of the tube expansion device are deformed by the three-point bending press. A method of expanding the tube by contacting it with an undeformed portion is described.
- the radius of curvature of the outer peripheral surface of the punch used for the three-point bending press and the radius of curvature of the outer peripheral surface of the pipe expansion tool satisfy a predetermined relational expression, so that the steel pipe after the pipe expansion step can be used. It describes how to improve the roundness.
- Patent Document 3 describes at least a part of a steel sheet when performing a three-point bending press as a manufacturing method capable of efficiently manufacturing a steel pipe having a high roundness without requiring an excessive pressing force in the press bend process. Describes a method of providing a lightly machined portion having a very slight curvature as compared with other regions, or providing an unprocessed portion in which bending is omitted. Further, according to Patent Document 3, in the seam gap reducing step, a pressing force is applied to a portion separated by a predetermined distance from the center of the lightly machined portion or the unprocessed portion without restraining the lightly machined portion or the unprocessed portion. It is stated that it should be done. Normally, an O-press device is used in the seam gap reducing step performed after the press bend step.
- Patent Document 4 after forming a non-circular preform (a molded body having a U-shaped cross section) by a three-point bending press, a non-circular preform is used instead of the normal O-press process.
- a method of reducing the seam gap by applying a pressing force from the outside of the non-circular preform by a pressing tool arranged at the top so as to face the lower supporting roll while being supported by two lower supporting rolls. (Hereinafter referred to as "closing press method”) is described.
- a pressing force is applied from the outside of the non-circular preform by a pressing tool, so that the device configuration is simplified and it is necessary to prepare a die according to the outer diameter of the steel pipe like an O-press device.
- Patent Document 4 intentionally imparts a relatively slightly formed region to a part of the three-point bending press, and forms a U-shaped cross section in the closing press method used in the seam gap reducing step. It describes how to apply a pressing force to that area of the body.
- the method described in Patent Document 1 is a method of improving the roundness of a steel pipe after a pipe expanding process by associating the pressing position of a three-point bending press with the pressing position of a pipe expanding tool.
- the steel pipe manufacturing process includes at least a press bend process, a seam gap reduction process, a welding process, and a pipe expansion process. Therefore, in the method described in Patent Document 1, since the influence of the operating conditions in other processes on the roundness of the steel pipe after the pipe expansion process is not taken into consideration, the roundness of the steel pipe after the pipe expansion process is not necessarily improved. It may not be possible to make it.
- Patent Document 2 is the same as the method described in Patent Document 1, and is the radius of curvature of the outer peripheral surface of the punch used for the three-point bending press, which is the operating condition of the press bend process, and the pipe expanding tool, which is the operating condition of the pipe expanding process.
- This is a method of improving the roundness of a steel pipe after a pipe expansion step by making the radius of curvature of the outer peripheral surface satisfy a predetermined relational expression.
- the method described in Patent Document 2 has a problem that, like the method described in Patent Document 1, the influence of processes other than the press bend process such as the seam gap reducing process cannot be considered.
- the method described in Patent Document 3 changes the processing conditions of the three-point bending press in the press bend process according to the position of the steel sheet and makes the conditions related to the forming conditions in the seam gap reduction process, thereby expanding the pipe. This is a method for improving the roundness of the steel pipe later.
- the method described in Patent Document 3 has a problem that the roundness of the steel pipe after the pipe expansion process varies even under the same forming conditions when the plate thickness and the material of the steel plate as the material vary.
- Patent Document 4 is also a steel pipe after the pipe expansion step by setting the conditions for forming the U-shaped cross section into the molded body in the press bend process and the forming conditions in the seam gap reducing step. It is a method to improve the roundness of. However, even with the method described in Patent Document 4, there is a problem that the roundness of the steel pipe after the pipe expansion process varies even under the same forming conditions when the plate thickness and the material of the steel plate as the material vary.
- the present invention has been made to solve the above problems, and predicts the roundness of a steel pipe that can accurately predict the roundness of the steel pipe after the pipe expansion process in the manufacturing process of the steel pipe composed of a plurality of steps.
- the purpose is to provide a method and a roundness prediction device.
- Another object of the present invention is to provide a method for controlling the roundness of a steel pipe, which can accurately control the roundness of the steel pipe after the pipe expansion step in the manufacturing process of the steel pipe composed of a plurality of steps. ..
- Another object of the present invention is to provide a method for manufacturing a steel pipe capable of manufacturing a steel pipe having a desired roundness with a high yield.
- another object of the present invention is the roundness of a steel pipe capable of generating a roundness prediction model that accurately predicts the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process composed of a plurality of steps.
- the purpose is to provide a method for generating a prediction model.
- the method for predicting the roundness of a steel pipe according to the present invention is a press bend step of processing a steel plate into a U-shaped cross-section molded body by pressing a plurality of times with a punch, and reducing the seam gap portion of the U-shaped cross-section molded body.
- the pipe expansion step in the steel pipe manufacturing process including a seam gap reduction step of forming an open pipe, a welding step of joining the ends of the open pipe to each other, and a pipe expansion step of expanding the inner diameter of the steel pipe to which the ends are joined.
- a method for predicting the roundness of a steel pipe afterwards which is a method for predicting the roundness of a steel pipe, wherein one or two or more parameters are selected from the attribute information of the steel plate, and one or two or more are selected from the operation parameters of the press bend process. And one or more parameters selected from the operation parameters of the seam gap reduction process are included as input data, and the roundness information of the steel pipe after the pipe expansion process is used as output data, which was learned by machine learning.
- the roundness prediction model includes a step of predicting the roundness of the steel pipe after the pipe expansion step.
- the roundness prediction model may include one or more operation parameters selected from the operation parameters of the pipe expansion process as the input data.
- the attribute information of the steel plate may include one or two or more parameters of the yield stress, the representative plate thickness, and the plate thickness distribution information of the steel plate.
- the operation parameters of the press bend process may include the press position information on which the punch used in the press bend process presses the steel sheet and the press reduction amount, as well as the number of presses performed through the press bend process.
- the manufacturing process of the steel pipe includes an end bending step of imparting a bend to the widthwise end portion of the steel sheet prior to the press bend step, and the roundness prediction model uses the end bending step as the input data. It is preferable to include one or more parameters selected from the operation parameters.
- the method for controlling the roundness of a steel pipe according to the first aspect of the present invention uses the method for predicting the roundness of a steel pipe according to the present invention, and is a performance parameter of the attribute information of the steel plate before the start of the press bend process. And the set value of the operation parameter in the downstream process including the press bend process, the roundness of the steel pipe after the pipe expansion process is predicted, and the press bend is made so that the roundness of the steel pipe after the pipe expansion process becomes small. Includes steps to reset the operating parameters of the process.
- the method for controlling the roundness of a steel pipe according to the second aspect of the present invention uses the method for predicting the roundness of a steel pipe according to the present invention after the press bend step is completed and before the start of the seam gap reducing step.
- the true of the steel pipe after the pipe expansion process uses the actual data of the attribute information of the steel plate, the actual data of the operation parameters of the press bend process, and the set values of the operation parameters in the downstream process including the seam gap reduction process. It includes a step of predicting the roundness and resetting the operation parameters of the seam gap reduction step so that the roundness of the steel pipe after the pipe expansion step becomes small.
- the method for controlling the roundness of a steel pipe according to the third aspect of the present invention uses the method for predicting the roundness of a steel pipe according to the present invention, such as an end bending step, a press bend step, and a seam that constitute the manufacturing process of the steel pipe.
- the roundness information of the steel pipe after the pipe expansion process is predicted, and at least based on the predicted roundness information of the steel pipe.
- One or two or more operation parameters selected from the operation parameters of the reset target process, or one or two or more operations selected from the operation parameters of the molding process downstream from the reset target process. Includes steps to reset parameters.
- the method for manufacturing a steel pipe according to the present invention includes a step of manufacturing a steel pipe using the method for controlling the roundness of the steel pipe according to the present invention.
- the method for generating the roundness prediction model of the steel pipe according to the present invention is a press bend step of processing a steel plate into a U-shaped cross-section molded body by pressing a plurality of times with a punch, and a seam gap of the U-shaped cross-section molded body.
- a steel pipe manufacturing process including a seam gap reduction step of reducing portions to make an open pipe, a welding step of joining the ends of the open pipe to each other, and a pipe expanding step of expanding the inner diameter of the steel pipe to which the ends are joined.
- a method for generating a roundness prediction model for a steel pipe that generates a roundness prediction model for predicting the roundness of the steel pipe after the pipe expansion step, and is one or more actual data selected from the attribute information of the steel plate.
- 1 or 2 or more performance data selected from the operation performance data of the press bend process, and 1 or 2 or more performance data selected from the operation performance data of the seam gap reduction process are input performance data, and the input performance data is input.
- machine learning it is preferable to use machine learning selected from neural networks, decision tree learning, random forest, and support vector regression.
- the roundness prediction device for a steel pipe reduces the seam gap portion of the U-shaped cross-section molded body in the press bend step of processing the steel plate into a U-shaped cross-sectional molded body by pressing the steel tube a plurality of times with a punch.
- the pipe expansion step in the steel pipe manufacturing process including a seam gap reduction step of forming an open pipe, a welding step of joining the ends of the open pipe, and a pipe expansion step of expanding the inner diameter of the steel pipe to which the ends are joined.
- a steel pipe roundness predictor that predicts the roundness of the steel pipe afterwards, and has one or more parameters selected from the attribute information of the steel plate, and one or two or more selected from the operation parameters of the press bend process.
- Operation parameter acquisition unit that acquires one or two or more operation parameters selected from the operation parameters of the seam gap reduction step, and one or two or more parameters selected from the attribute information of the steel plate, the press bend.
- the roundness of the steel pipe after the pipe expansion process includes one or more operation parameters selected from the operation parameters of the process and one or two or more operation parameters selected from the operation parameters of the seam gap reduction process as input data.
- the operation parameter acquisition unit includes a terminal device having an input unit for acquiring input information based on a user's operation and a display unit for displaying the roundness information, and the operation parameter acquisition unit is based on the input information acquired by the input unit. It is preferable to update a part or all of the operation parameters acquired in the above-mentioned, and the display unit may display the roundness information of the steel pipe predicted by the roundness prediction unit using the updated operation parameters.
- the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process composed of a plurality of steps can be accurately predicted. ..
- the method for controlling the roundness of a steel pipe according to the present invention it is possible to accurately control the roundness of the steel pipe after the pipe expansion step in the manufacturing process of the steel pipe composed of a plurality of steps.
- a steel pipe having a desired roundness can be manufactured with a high yield.
- the roundness of the steel pipe that accurately predicts the roundness of the steel pipe after the pipe expansion step in the manufacturing process of the steel pipe composed of a plurality of steps.
- a degree prediction model can be generated.
- FIG. 1 is a diagram showing a manufacturing process of a steel pipe according to an embodiment of the present invention.
- FIG. 2 is a diagram showing an example of a process of molding a U-shaped cross-section molded body using a press bend device.
- FIG. 3 is a diagram showing an example of a process of molding a U-shaped cross-section molded body using a press bend device.
- FIG. 4 is a diagram showing a configuration example of the O-press device.
- FIG. 5 is a diagram showing a configuration example of a closing press device.
- FIG. 6 is a diagram showing a configuration example of a pipe expansion device.
- FIG. 7 is a diagram showing a configuration example of a device for measuring the outer diameter shape of a steel pipe.
- FIG. 1 is a diagram showing a manufacturing process of a steel pipe according to an embodiment of the present invention.
- FIG. 2 is a diagram showing an example of a process of molding a U-shaped cross-section molded body using a press bend device
- FIG. 8 is a diagram showing a method of generating a roundness prediction model according to an embodiment of the present invention.
- FIG. 9 is a diagram showing an example of a change in the relationship between the press working amount and the roundness of the steel pipe after the pipe expansion process due to the change in the operating conditions of the press bend process.
- FIG. 10 is a diagram showing an example of a press reduction position and a press reduction amount for each reduction frequency.
- FIG. 11 is a diagram showing a flow of a roundness control method according to an embodiment of the present invention.
- FIG. 12 is a perspective view showing the overall configuration of the C press device.
- FIG. 13 is a cross-sectional view showing the configuration of the press mechanism.
- FIG. 14 is a diagram showing a method of generating a roundness prediction model according to another embodiment of the present invention.
- FIG. 15 is a diagram showing a method for controlling the roundness of a steel pipe according to an embodiment of the present invention.
- FIG. 16 is a diagram showing a configuration of a steel pipe roundness prediction device according to an embodiment of the present invention.
- FIG. 1 is a diagram showing a manufacturing process of a steel pipe according to an embodiment of the present invention.
- a thick steel plate manufactured by a thick plate rolling process which is a pre-process of the steel pipe manufacturing process, is used as a steel sheet as a raw material.
- typical thick steel sheets have a yield stress of 245 to 1050 MPa, a tensile strength of 415 to 1145 MPa, a plate thickness of 6.4 to 50.8 mm, a plate width of 1200 to 4500 mm, and a length of 10 to 18 m.
- the widthwise end portion of the thick steel plate is pre-ground into a chamfered shape called a groove. This is to prevent overheating of the outer surface corner portion of the widthwise end portion and stabilize the welding strength in the subsequent welding process. Further, since the width of the thick steel plate affects the outer diameter after being formed into the steel pipe, it is adjusted to a predetermined range in consideration of the deformation history in the later process.
- an end bending process for bending the widthwise end of the steel sheet may be performed.
- the edge bending step is performed by a C press device, and edge bending processing (also referred to as crimping processing) is performed on the widthwise end portion of the steel sheet.
- the C press device includes a pair of upper and lower dies and a pair of upper and lower clamps for holding the central portion of the steel plate in the width direction. Since the length of the mold is shorter than the length of the steel plate, the end bending process is repeated while sequentially feeding the steel plate in the longitudinal direction. Such edge bending is performed on both ends of the steel sheet in the width direction.
- the operating parameters for specifying the machining conditions are the edge bending width, which is the length at which the die contacts the steel sheet from the widthwise end to the widthwise center, and the gripping force of the clamp. Examples thereof include the feed amount, feed direction, and number of feeds of the mold when the edge bending process is repeated in the longitudinal direction of the steel sheet.
- the subsequent press bend process is a process of processing a steel sheet into a U-shaped cross-section molded body by performing a three-point bending press by punching a plurality of times with a press bend device.
- the subsequent seam gap reducing step is a step of reducing the seam gap portion of the U-shaped cross-section molded body into an open pipe by using an O-press device.
- the closing press method described in Patent Document 4 may be used instead of the O-press device.
- the subsequent welding step is a step of restraining the seam gap portion formed at the end of the open pipe so that the ends are in contact with each other and joining the ends. As a result, the molded body becomes a steel pipe in which the ends are joined to each other.
- the subsequent pipe expansion step is a step of expanding the steel pipe by bringing the curved surface of the pipe expansion tool into contact with the inner surface of the steel pipe by using a pipe expansion device equipped with a plurality of pipe expansion tools having a curved surface obtained by dividing the arc into a plurality of sections. ..
- the steel pipe manufactured in this way is determined whether or not the quality such as material, appearance, and dimensions satisfies the predetermined specifications, and then the steel pipe is shipped as a product.
- the inspection step includes a roundness measuring step of measuring the roundness of the steel pipe.
- a forming process in a series of manufacturing processes in which a steel plate is formed into an open pipe and a pipe expansion process is performed after welding, an end bending process, a press bend process, a seam gap reduction process, and a pipe expansion process are referred to as a "forming process". Called. These steps are common as a step of applying plastic deformation to a steel sheet to control the dimensions and shape of a steel pipe.
- a step of applying plastic deformation to a steel sheet to control the dimensions and shape of a steel pipe.
- FIG. 12 is a perspective view showing the overall configuration of the C press device.
- the C press device 30 has a transport mechanism 31 for transporting the steel plate S in a direction along the longitudinal direction thereof, and one widthwise end portion with the downstream side in the transport direction of the steel plate S as the front.
- a press mechanism 32A that bends Sc to a predetermined curvature
- a press mechanism 32B that bends the other widthwise end Sd to a predetermined curvature
- the transfer mechanism 11 includes an interval adjusting mechanism (not shown) that adjusts the interval between the mechanisms 32A and 32B.
- the transfer mechanism 11 includes a plurality of rotationally driven transfer rolls 31a arranged in front of and behind the press mechanisms 32A and 32B, respectively.
- the reference numeral Sa in the drawing indicates the tip end portion (longitudinal front end portion) of the steel plate S.
- FIG. 13A shows a cross section in the width direction of the press mechanism 32A for bending one end Sc of the steel plate S in the width direction from the upstream side in the transport direction to the downstream side in the transport direction of the steel plate S.
- the press mechanism 32A and the press mechanism 32B are symmetrical and have the same configuration.
- the press mechanisms 32A and 32B push up the upper die 33 and the lower die 34 as a pair of dies arranged so as to face each other in the vertical direction and the lower die 34 together with the tool holder 35 (direction close to the upper die 33). It is provided with a hydraulic cylinder 36 as a mold moving means for mold clamping with a predetermined pressing force.
- the press mechanisms 32A and 32B may include a clamp mechanism 37 that grips the steel plate S inside the upper die 33 and the lower die 34 in the width direction.
- the length of the steel plate S of the upper mold 33 and the lower mold 34 in the longitudinal direction is usually shorter than the length of the steel plate S. In that case, the end bending process is performed a plurality of times while intermittently feeding the steel sheet S in the longitudinal direction by the transport mechanism 31 (see FIG. 12).
- the lower mold 34 in contact with the surface of the width direction ends Sc and Sd of the steel plate S to be end bent, which is outside in the bending direction, has a pressing surface 34a facing the upper mold 33.
- the upper mold 33 has a convex curved surface 33a facing the pressing surface 34a and having a radius of curvature corresponding to the inner diameter of the steel pipe to be manufactured.
- the pressing surface 34a has a concave curved surface shape that approaches the upper mold 33 toward the outside in the width direction.
- the pressing surface 34a of the lower mold 34 may be an inclined flat surface as long as it is a surface that approaches the upper mold 33 toward the outside in the width direction.
- those having an appropriate shape according to the thickness, outer diameter, etc. of the steel plate S may be designed and appropriately selected and used according to the target material. ..
- FIG. 13 (b) is a cross section in the width direction of the press mechanism 32A at the same position as in FIG. 13 (a), but shows a state in which the lower die 34 is pushed up by the hydraulic cylinder 36 and molded.
- the lower mold 34 is pushed up by the hydraulic cylinder 36, and the widthwise end Sc of the steel plate S is bent into a shape along the arcuate forming surface 33a of the upper mold 33.
- the width at which edge bending is performed (edge bending width) varies depending on the width of the steel sheet S, but is generally about 100 to 400 mm.
- FIG. 2 is a diagram showing an example of a process of molding a U-shaped cross-section molded body using a press bend device.
- reference numeral 1 indicates a die arranged in the transport path of the steel plate S.
- the die 1 is composed of a pair of left and right rod-shaped members 1a and 1b that support the steel plate S at two points along the transport direction, and the interval ⁇ D can be changed according to the size of the steel pipe to be formed.
- reference numeral 2 indicates a punch that can move in the direction of approaching and separating from the die 1.
- the punch 2 is connected to a punch tip portion 2a having a downwardly convex machined surface that is in direct contact with the steel plate S and presses the steel plate S in a concave shape, and a punch support that is connected to the back surface of the punch tip portion 2a and supports the punch tip portion 2a. It has a body 2b and. Normally, the maximum width of the punch tip portion 2a and the width (thickness) of the punch support 2b are equal to each other.
- FIG. 3 shows the steel plate S which has been subjected to the edge bending process in advance from the top to the bottom in the left column (first half (a) to (e) of the process) and then from the top to the bottom in the center column (second half of the process).
- FIG. 3 is a view illustrating a step of molding the molded body S 1 as shown in the right column diagram ((j)) by carrying out the (f) ⁇ (i)) and the bending feed processing and steel S.
- the arrows attached to the steel plate S and the punch 2 indicate the moving directions of the steel plate S and the punch 2 in each step.
- the molded article S 1 of the U-shaped cross section after processing in accordance with the present process the gap between the end portion is referred to as a "seam gap".
- examples of the operating parameters that determine the operating conditions in the press bend process include the number of presses, press position information, press reduction amount, lower die interval, punch curvature, and the like.
- the number of presses is the total number of times the steel sheet is pressed in the width direction with a 3-point bending press. As the number of presses increases, the molded body having a U-shaped cross section has a smooth curved shape, and the roundness of the steel pipe after the pipe expansion process is improved.
- Press position information refers to the position in the width direction of the steel plate that is pressed by the punch. Specifically, it can be specified by the distance from one end of the steel sheet in the width direction or the distance with respect to the center of the steel sheet in the width direction. It is preferable to handle the press position information as data associated with the number of presses (the order from the first press to the Nth press).
- the press reduction amount refers to the push amount of the punch 2 at each pressing position.
- the press reduction amount is defined as an amount in which the lower end surface of the punch tip portion 2a protrudes downward from the line connecting the points on the uppermost surface of the die 1 shown in FIG.
- the operating conditions in the press bend process are specified by 1 to N data sets, where the number of presses is N, the number of presses, the press position information, and the press reduction amount are set as a set of data sets.
- the lower die spacing is the spacing between the pair of left and right rod-shaped members 1a and 1b shown in FIG. 2, and is a parameter represented by ⁇ D in the figure.
- ⁇ D the curvature of the steel sheet changes locally even with the same press reduction amount, which affects the roundness of the steel pipe after the pipe expansion process. Therefore, it is preferable to use the lower die interval set according to the size of the steel pipe to be formed as an operation parameter in the press bend process. Further, when the lower die interval is changed each time the punch is pushed in, the data associated with the number of presses may be used as the operation parameter.
- the punch curvature is the curvature of the tip of the punch that presses. As the punch curvature increases, the local curvature applied to the steel sheet during the three-point bending press increases, which affects the roundness of the steel pipe after the pipe expansion process. However, it is difficult to change the punch curvature for each press when forming a single steel sheet, and it is recommended to use the punch curvature set according to the size of the steel pipe to be formed as the operation parameter in the press bend process. preferable.
- the seam gap reducing step is a step of reducing the seam gap of the U-shaped cross-section molded body formed by the press bend step, and bending force and compression so that the ends of the U-shaped cross-section molded body are close to each other. It gives power.
- a bending force or a compressive force is applied to the molded body having a U-shaped cross section, the seam gap is widened due to the springback at the time of unloading. Therefore, in anticipation of the occurrence of springback, a strong bending force and a compressive force are applied, and the molded body having a U-shaped cross section is deformed so as to be crushed in the vertical direction as a whole.
- FIG. 4 shows the configuration of an O-press device generally used as a seam gap reduction step.
- O press apparatus is for imparting compressive deformation in the longitudinal direction of the molded body S 1 of U-shaped cross-section with upper mold 3 and the lower mold 4.
- the surface in contact with the molded body S 1 of the U-shaped cross section of the upper die 3 and the lower mold 4 is processed into a curved surface shape, by approaching the upper die 3 and the lower mold 4, U the lower part of the molded body S 1-shape cross-section is constrained along the curved surface of the lower mold 4.
- the upper portion of the molded body S 1 including the end portion receives the bending force and the compressive force by the upper mold 3, so that the ends are close to each other along the curved surface of the upper mold 3. This temporarily reduces the seam gap between the ends facing each other in the circumferential direction. Then, by opening the pushing with a die, the seam gaps are expanded by the spring back, the opening amount of the final seam gap G of the open pipe S 2 shown in FIG. 4 (b) is determined.
- the O-press reduction amount is a steel pipe whose target is the distance between the highest point of the inscribed surface of the upper die 3 and the lowest point of the inscribed surface of the lower die 4 when the die is pushed in. It is the value subtracted from the outer diameter of. In addition, these ratios may be referred to as an O-press reduction rate.
- examples of the operating parameters for specifying the operating conditions in the seam gap reducing process include the O-press reducing amount, the O-press pressing position, the O-press die R, and the like.
- O and press pressing position means an angle between a line and the vertical line connecting the end portion and the center position in the width direction of the seam gap of the forming body S 1 having a U-shaped cross section.
- the O press die R refers to the curvature of the abutting region formed body S 1 in the upper mold 3 and the lower mold 4.
- O press reduction ratio of O pressing device increases, 3 o'clock section and the curvature in the vicinity at section 9 of the compact S 1 is the final roundness of the steel pipe is reduced by increasing.
- closing the press device As an apparatus for forming an open pipe S 2 from the molded body S 1, closing the press device is used as shown in FIG.
- the closing press device has lower tools 10a and 10b.
- the lower tools 10a and 10b are provided at intervals from each other, and each has a drive mechanism capable of reversing the rotation direction. Further, the lower tools 10a and 10b are supported via spring means 11a, 11b and the like.
- An upper tool 13 having a punch 12 is arranged so as to face the lower tools 10a and 10b. Force pushing through the punch 12 is applied to the molded body S 1 of U-shaped cross-section from the outside.
- the molded body S 1 of the U-shaped cross section is formed into an open pipe S 2 through two steps.
- a first step the molded body S 1, as shown schematically by the dashed line through the rotatable lower tool 10a, 10b, the area R1 to be applied bending deformation located on the right side of the seam gap G
- the press position is positioned so that is around 3 o'clock in the clock.
- a pressing force is applied by the punch 12, and after the pressing force is applied, the punch 12 is unloaded.
- the press position is set so that the region R2 located on the left side of the seam gap portion G to which bending deformation is to be applied is around 9 o'clock in the clock.
- a pressing force by the punch 12 is applied, unloading of the punch 12 after applying a pressing force is formed into an open pipe S 2 by being made.
- the press position in the first and second steps means the angle of the line connecting the center of the seam gap portion G and the center position in the width direction of the steel sheet (the angle formed by the alternate long and short dash line in FIG. 5). Further, the pressing force in the first and second step refers to pressing force applied to the molded body S 1 by punch 12.
- the open pipe S 2 abuts the end faces of the seam gap portions against each other and is welded by a welding machine (joining means) to form a steel pipe.
- a welding machine for example, a welding machine composed of three types of welding machines, a temporary welding machine, an inner surface welding machine, and an outer surface welding machine, is applied.
- the temporary welding machine continuously brings the surfaces abutted by the cage roll into close contact with each other in an appropriate positional relationship, and welds the close contact portion over the entire length in the pipe axial direction.
- the temporarily attached pipe is welded from the inner surface of the butt portion by the inner surface welder (submerged arc welding), and further welded from the outer surface of the butt portion by the outer surface welder (submerged arc welding).
- FIGS. 6 (b) and 6 (c) are views showing a configuration example of a tube expansion device.
- the tube expanding device includes a plurality of tube expanding dies 16 having a curved surface obtained by dividing an arc into a plurality of parts along the circumferential direction of the tapered outer peripheral surface 17.
- the first pipe expansion process is performed by retracting the pull rod 18 from the pipe expansion start position.
- each of the expansion dies 16 sliding in contact with the tapered outer peripheral surface 17 is displaced in the radial direction due to the wedge action, and the steel pipe P is expanded.
- the unevenness of the cross-sectional shape of the steel pipe P becomes small, and the cross-sectional shape of the steel pipe P becomes close to a perfect circular shape.
- the pull rod 18 is advanced to the pipe expansion start position, the pipe expansion die 16 is returned to the inside in the axial vertical direction by the release mechanism, and then the steel pipe P is increased by the amount corresponding to the pitch (axial length) of the pipe expansion die 16. To move further.
- the above operation is repeated.
- the first pipe expansion treatment can be performed over the entire length of the steel pipe P for each pitch of the pipe expansion die 16.
- the operating parameters that determine the operating conditions of the pipe expansion process include the pipe expansion rate, the number of pipe expansion dies, the diameter of the pipe expansion dies, and the like.
- the pipe expansion rate is the ratio of the difference between the outer diameter after pipe expansion and the outer diameter before pipe expansion to the outer diameter before pipe expansion.
- the outer diameter before and after the expansion of the pipe can be calculated by measuring the circumference of the steel pipe.
- the tube expansion ratio can be adjusted by the stroke amount when the tube expansion die is expanded in the radial direction.
- the number of pipe expansion dies means the number of portions that come into contact with the steel pipes arranged in the circumferential direction when the pipes are expanded.
- the diameter of the expansion die means the curvature of the portion of each expansion die that abuts on the steel pipe.
- the operation parameter that can easily adjust the roundness after the pipe expansion process is the pipe expansion rate.
- the tube expansion rate increases, the curvature of the region in contact with the tube expansion die over the entire circumference is evenly applied according to the tube expansion die R, so that the roundness is improved.
- the fluctuation of the local curvature in the circumferential direction of the steel pipe can be suppressed, so that the roundness of the steel pipe after the pipe expansion step becomes better.
- the pipe expansion ratio is too large, the compressive yield strength of the steel pipe product may decrease due to the Bauschinger effect.
- the pipe expansion rate is set so that the roundness of the steel pipe falls within a predetermined value at a pipe expansion rate smaller than the preset upper limit value of the pipe expansion rate.
- ⁇ Roundness measurement process> In the final inspection process of the steel pipe manufacturing process, the quality inspection of the steel pipe is performed and the roundness of the steel pipe is measured.
- the roundness measured in the roundness measuring step is an index showing the degree of deviation from the roundness of the outer diameter shape of the steel pipe. Normally, the closer the roundness is to zero, the closer the cross-sectional shape of the steel pipe is to a perfect circle.
- the roundness is calculated based on the outer diameter information of the steel pipe measured by the roundness measuring machine. For example, if the outer diameters of the pipes are equally divided in the circumferential direction at an arbitrary pipe length position and the outer diameters are measured at the opposite positions, and the maximum and minimum diameters are Dmax and Dmin, respectively, the roundness is Dmax-.
- the longitudinal position of the steel pipe for measuring roundness can be arbitrarily selected.
- the roundness in the vicinity of the longitudinal end of the steel pipe may be measured, or the roundness in the central portion of the steel pipe in the longitudinal direction may be measured.
- the roundness does not necessarily have to be due to the difference between the maximum diameter and the minimum diameter.
- An equivalent temporary perfect circle (diameter) having the same area as the inner area of the curve is calculated from the figure showing the outer diameter shape of the steel pipe in a continuous diagram, and the steel pipe is based on the temporary perfect circle.
- the area deviated from the outer diameter shape may be defined as an image.
- the following method can be used.
- an arm 20 that can rotate 360 degrees around the substantially central axis of the steel pipe P, displacement meters 21a and 21b attached to the tip of the arm 20, and rotation of the arm 20.
- the rotation center of the arm 20 and the outer periphery of the steel pipe P are used by the displacement meters 21a and 21b for each minute angle unit of the rotation of the arm 20. The distance from the measurement point is measured, and the outer diameter shape of the steel pipe P is specified based on this measured value.
- FIG. 7 (b) As shown in FIG. 7 (b), a rotary arm 25 that rotates around the central axis of the steel pipe P and a pedestal (not shown) provided on the end side of the rotary arm 25 so as to be movable in the radial direction of the steel pipe P.
- a pair of pressing rollers 26a and 26b that abut on the outer and inner surfaces of the ends of the steel pipe P and rotate with the rotation of the rotary arm 25, and a pedestal that presses the pressing rollers 26a and 26b against the outer and inner surfaces of the steel pipe P.
- the outer diameter of the steel pipe is based on the amount of radial movement of the gantry and the pressing positions of the pressing rollers 26a and 26b by each pressing air cylinder. Identify the shape.
- the prediction accuracy of the roundness prediction result by the roundness prediction model described later is verified by comparing with the measured value of the roundness obtained in the above inspection step. be able to. Therefore, it is possible to improve the prediction accuracy by adding the actual value of the prediction error to the prediction result of the roundness prediction model, which will be described later, in addition to the prediction result of the roundness prediction model.
- FIG. 8 is a diagram showing a method of generating a roundness prediction model according to an embodiment of the present invention.
- the roundness prediction model generation unit 100 in the figure includes actual data of attribute information of the steel plate as a material, operation actual data of the press bend process, operation actual data of the seam gap reduction process, and perfect circle of the steel pipe after the pipe expansion process. It collects the actual data of the degree and generates the roundness prediction model M by machine learning.
- the actual data of the attribute information of the steel plate is sent from the host computer 110 to the roundness prediction model generation unit 100.
- data may be sent to the roundness prediction model generation unit 100 by measuring the attribute information of the steel sheet before starting molding in the press bend process and inputting the result from a terminal or the like.
- the operation record data of the press bend process, the operation record data of the seam gap reduction process, and the roundness record data after the pipe expansion process are sent to the roundness prediction model generation unit 100, respectively, and the serial number and the product number are sent. It is linked as data for each target material specified by the above, and is stored in the database 100a. Further, the operation record data of the pipe expansion process may be added to the database 100a.
- the operation record data stored in the database 100a various data that can be collected as the record data can be adopted. Even if the information is not used for the actual data when the roundness prediction model M is generated by machine learning, it can be used later when the roundness prediction model M is regenerated, and there is no need to accumulate the data again. Because.
- FIG. 14 is a diagram showing another embodiment of the method for generating the roundness prediction model. This is to acquire the operation record data of each manufacturing process for the manufacturing process including the end bending process before the press bend process as the forming process of the steel pipe, and store it in the database of the roundness prediction model generation unit. This is an example of the case.
- the number of actual data accumulated in the database 100a is preferably at least 10 or more, preferably 100 or more, and more preferably 1000 or more. This is because the larger the number of data that forms the basis of the machine learning model, the better the accuracy of predicting the roundness after the tube expansion process.
- the machine learning unit 100b uses the database 100a created in this way, selects from at least one or two or more actual data selected from the attribute information of the steel plate and the operation actual data of the press bend process. Input actual data of 1 or 2 or more actual data selected from 1 or 2 or more actual data and operation actual data of the seam gap reduction process, and the steel pipe after the pipe expansion process in the steel pipe manufacturing process using the input actual data.
- the roundness prediction model M is generated by machine learning using the roundness actual data as the output actual data. Further, if necessary, one or more actual data selected from the operation actual data of the pipe expansion process may be added to the input actual data. Further, when the end bending process is performed before the press bend process, one or more actual data selected from the operation actual data of the end bending process may be added to the input actual data.
- a known learning method may be applied.
- Machine learning uses a known machine learning method such as a neural network. Examples of other methods include decision tree learning, random forest, and support vector regression. Further, an ensemble model in which a plurality of models are combined may be used.
- the roundness prediction model M it is determined whether or not the roundness is within the allowable range of the roundness, not the value of the roundness, and the result is binarized as pass / fail.
- a machine learning model may be generated using the data as output actual data. At that time, a classification model such as the k-nearest neighbor method or logistic regression can be used.
- the database 100a can accumulate operation record data at any time and update the roundness prediction model M periodically (for example, once a month). As a result, the prediction accuracy of the roundness prediction model M is improved.
- the roundness prediction model M of the steel pipe after the pipe expansion process generated as described above has the following features. That is, as the attribute information of the steel sheet, for example, the yield stress, the sheet thickness, etc., have a certain variation when manufacturing the steel sheet as the raw material, and the curvature of the steel sheet at the time of punching in the three-point bending press in the press bend process. And affects the curvature after unloading. Therefore, by using the attribute information of these steel plates as the input parameter of the roundness prediction model M of the steel pipe after the pipe expansion process, it is possible to consider the influence on the roundness due to the yield stress, the plate thickness, and the like.
- the seam gap reduction process is also a process of applying bending force and compressive force using a mold, etc., and since the curvature of the steel plate after unloading is changed by the yield stress, plate thickness, etc., these are perfect circles. It is used as an input parameter of the degree prediction model M.
- the press bend process is a process of performing discontinuous curvature imparting processing multiple times along the width direction of the steel sheet, a local curvature distribution occurs in the steel sheet along the width direction.
- the bending moment acting on the so-called "bent beam” is applied in the press bend process in the same way as the bending moment depends on the curvature of the beam.
- the bending moment applied in the seam gap reducing step is locally distributed according to the local curvature distribution of the steel plate.
- the operating conditions of the press bend process affect the curvature distribution along the width direction of the steel sheet after the seam gap reduction process.
- FIG. 9 shows the O-press reduction rate of an O-press device as a seam gap reduction process under the condition that the number of presses is 9 in the press bend process when manufacturing a steel pipe having an outer diameter of 30 inches and a pipe thickness of 44.5 mm. This is the result of measuring the roundness of the steel pipe after the pipe expansion process (setting the operating conditions of the same pipe expansion process).
- FIG. 9 shows the result of changing the reduction amount (final pass reduction amount) at the time of the final (9th) pressing by three levels while keeping other operating conditions in the press bend process constant.
- the press working amount in the seam gap reduction process there is an optimum value for making the roundness of the steel pipe after the pipe expansion process close to zero, and the optimum value depends on the operating conditions of the press bend process. different. That is, in order to reduce the roundness of the steel pipe after the pipe expansion process, it is necessary to change the operating conditions of the seam gap reduction process according to the operating conditions of the press bend process, and the press bend process and the seam gap reduction process. It can be seen that it is not possible to set appropriate operating conditions simply by focusing on the fact that each operating condition affects the roundness of the steel pipe after the pipe expansion process as an independent parameter. The parameters used for machine learning will be described below.
- the attribute information of the steel sheet used as the material includes the yield stress of the steel sheet, the tensile strength, the Young's modulus, the plate thickness, the plate thickness distribution in the plate surface, the distribution of the yield stress in the plate thickness direction of the steel plate, and the degree of the bow singer effect. And any parameters that affect the roundness of the steel pipe after the pipe expansion process, such as surface roughness, can be used. In particular, factors that affect the deformation state and springback of the steel sheet due to the three-point bending press in the press bend process, and factors that affect the deformation state and springback of the steel sheet due to compression and bending in the seam gap reduction process are used as indicators. It is preferable to do so.
- the distribution of the yield stress of the steel plate, the yield stress in the plate thickness direction of the steel plate, and the plate thickness directly affect the stress and strain states in the 3-point bending press.
- Tensile strength affects the stress state during bending deformation as a parameter that reflects the state of work hardening in bending.
- the Bauschinger effect affects the yield stress when the load due to bending deformation is reversed and the subsequent work hardening behavior, and affects the stress state at the time of bending deformation.
- the Young's modulus of the steel sheet affects the springback behavior after bending.
- the plate thickness distribution in the plate surface causes the distribution of bending curvature in the press bend process, and the surface roughness affects the friction state between the mold and the steel plate in the seam gap reduction process, so that the steel pipe after the pipe expansion process Affects the roundness of.
- the yield stress, the representative plate thickness, the plate thickness distribution information, and the representative plate width are the information measured in the quality inspection process of the thick plate rolling process, which is the manufacturing process of the steel sheet used as the raw material, and affect the deformation behavior in the press bend process and the seam gap reduction process. This is because it affects the roundness. In addition, this is because the attribute information varies depending on the steel sheet used as the material.
- the yield stress is information that can be obtained from a tensile test of a small test piece for quality accuracy collected from a thick steel plate as a material, and can be used as a representative value in the plane of the steel plate as a material.
- the representative plate thickness is a plate thickness that represents the in-plane plate thickness of the steel plate as a material, and when the plate thickness at the center of the width direction of the steel plate at an arbitrary position in the longitudinal direction of the steel plate is used or in the longitudinal direction. You may use the average value of the plate thickness of. Further, the average value of the plate thickness in the entire in-plane of the steel plate may be obtained and used as the representative plate thickness. Further, the plate thickness distribution information refers to information representing the plate thickness distribution in the width direction of the steel sheet.
- a typical example is a steel plate crown.
- the crown represents the difference between the center portion in the width direction of the steel sheet and the plate thickness at a position separated from the end portion in the width direction of the steel plate by a predetermined distance (for example, 100 mm, 150 mm, etc. are used).
- the plate thickness distribution information is not limited to this, and the coefficient of the approximate expression obtained by approximating the plate thickness distribution in the width direction with a function of quadratic or higher may be used as the plate thickness distribution information.
- Such representative plate thickness and plate thickness distribution information may be acquired from data measured by a plate thickness gauge during rolling in a plate rolling process, or may be data measured in a thick steel plate inspection process.
- the representative plate width is a representative value for the width of the steel plate used as the material.
- the width of the thick steel sheet used as the material may vary, or the width of the steel sheet may vary when the end is ground by groove processing, which affects the variation in the outer diameter accuracy of the steel pipe used as the product.
- the value of the representative width the width at an arbitrary position in the longitudinal direction of the steel sheet can be used, and the average value of the widths in the longitudinal direction may be used. At that time, it is preferable to actually measure the width of the steel sheet before the press bend process and use the value.
- edge bending width width to perform edge bending molding
- the feed amount of the steel plate the feed direction, the number of feeds, the pushing force (C press force), and the gripping force by the clamp mechanism 37 are used as operating parameters. You may. This is because these are factors that can affect the deformation of the widthwise end portion of the steel sheet in the edge bending process.
- an arc having a plurality of radii of curvature may be given as a continuous shape, or may be given by an involute curve or the like, and has a geometrical cross section.
- Parameters for specifying the shape can be used.
- the cross-sectional shape when the cross-sectional shape is constructed by the parabolic shape, the cross-sectional shape can be specified by using the coefficients of the primary term and the quadratic term of the quadratic equation representing the parabola passing through the origin. It can be an operating parameter of the bending process.
- the mold control number for specifying the mold used in the end bending process may be used as an operation parameter of the end bending process.
- the operation parameters of the press bend process are used for inputting the roundness prediction model.
- the operating parameters of the press bend process include the local bending curvature of the steel sheet, such as the number of presses of the three-point bending press described above, press position information, press reduction amount, lower die spacing, and punch curvature, and those steel sheets.
- Various parameters can be used that affect the distribution in the width direction of.
- the method shown in FIG. 10 can be exemplified as including all of this information.
- the press reduction position is information indicating the distance from the end portion in the width direction as a reference of the steel sheet, and this is used as the press reduction position information.
- the press reduction amount is described corresponding to each press reduction position, and such "reduction frequency", "press reduction position", and “press reduction amount” can be used as a set of data.
- the operation parameters of the press bend process are specified by the data of 16 sets and 10 sets, respectively, when the number of presses is 16 and 10.
- such a data set is used as an input of a roundness prediction model in the following form.
- the press reduction position and the press reduction amount when the press reduction is performed at the position closest to the end at one end of the steel sheet, and the press reduction at the other end of the steel sheet are the most. It is possible to use the press reduction position and the press reduction amount when the press reduction is performed at a position close to the end portion.
- the press reduction amount at one end of the steel sheet is increased, the curvature at the portion corresponding to approximately 1 o'clock and the portion corresponding to approximately 11 o'clock in the steel pipe shown in FIG.
- the U As a molded body having a character-shaped cross section, it has a horizontally long shape as a whole. Further, the closer the press reduction position is to the end portion of the steel sheet, the lower the position of the seam gap portion is, and the molded body having a U-shaped cross section has a horizontally long shape as a whole.
- the steel pipe formed into an open pipe and after undergoing the welding process and the pipe expansion process also has a horizontally long shape as a whole, which affects the roundness. Further, the punch curvature at the time of pressing down, the total number of times of pressing down, and the distance between the lower dies at the time of pressing down also affect the roundness after the steel pipe is formed.
- the prediction accuracy of the roundness prediction model can be further improved.
- data on the press reduction position and the press reduction amount are stored according to the number of reductions.
- the press reduction position and the press reduction amount in the subsequent press working without reduction are set to zero.
- the maximum number of presses assumed is 16 and the number of presses is 10
- the data of the 11th to 16th presses is assumed to be zero. , It becomes the input of the roundness prediction model.
- the operation record data in the press bend process the number of presses, the press reduction position, and the press reduction amount are information necessary for controlling the press bend device, so the set values set by the host computer are used. be able to. However, if a measuring device for measuring the reduction position and the reduction amount of the punch is provided, the measurement result may be used as the operation record data.
- the operation parameters of the seam gap reduction process are used for inputting the roundness prediction model.
- the O-press device is used as the seam gap reducing step
- the O-press reduction amount, the O-press reduction position, and the O-press die R can be used.
- the closing press method is used, the closing press pressing position and the closing press pressing force in each of the above-mentioned steps are used.
- the O-press reduction amount, the O-press reduction position, and the O-press die R are the information necessary for controlling the O-press device as the operation record data in the seam gap reduction process, and are set by the host computer.
- the set value can be used.
- the measurement result may be used as the operation record data.
- the pipe expansion rate can be used as the operation parameters of the pipe expansion process.
- the larger the pipe expansion ratio the better the roundness of the steel pipe after the pipe expansion process, but since the upper limit of the pipe expansion ratio is limited from the viewpoint of the compressive yield strength as a steel pipe product, a value within that range is used.
- the pipe expansion ratio is information necessary for controlling the pipe expansion device, and the set value set by the host computer can be used.
- the average outer diameter of the entire circumference is measured by a measuring device such as a shape dimension meter, and the average pipe expansion rate calculated by the amount of change from the outer diameter calculated from the width of the steel plate before processing is operated. It may be used as actual data. Further, in the pipe expansion step, if a pipe expansion rate measuring device is provided, the measurement result may be used as operation record data. In addition to the pipe expansion rate, the number of pipe expansion dies and the diameter of the pipe expansion dies may be used as the operation parameters of the pipe expansion process.
- the roundness prediction method for steel pipes after the pipe expansion process using the roundness prediction model generated as described above is used as follows. That is, by using this method, a press bend step of processing a U-shaped cross-section molded body by pressing it multiple times with a punch, and a seam that reduces the seam gap portion of the U-shaped cross-section molded body to form an open pipe.
- the steel pipe manufacturing process including the gap reduction process the welding process of joining the ends of the open pipe to each other, and the pipe expanding process of expanding the inner diameter of the steel pipe to which the ends are joined, the manufacturing conditions in each process are different. It is possible to verify whether it is appropriate.
- the operating conditions of the press bend process and the seam gap reduction process have a complex effect on the roundness of the steel pipe after the pipe expansion process, and the variation in the attribute information of the steel sheet in the upstream process affects these factors. Will be able to quantitatively evaluate the effect on the roundness of the product.
- the roundness prediction model M is used online to predict the roundness of the steel pipe after the pipe expansion process. Then, when the predicted roundness (predicted roundness value) and the target roundness (roundness target value) are compared and the predicted roundness is smaller than the roundness target value, Manufactures steel pipes without changing the set values of operating conditions for the press bend process, seam gap reduction process, and pipe expansion process. On the other hand, if the predicted roundness is larger than the roundness target value, the operating conditions of the press bend process are reset. Specifically, the number of presses in the press bend process is increased once or twice or more, and the interval between the press reduction positions is reset to be short. This improves the roundness of the steel pipe after the pipe expansion process.
- the roundness is predicted again by using the set values of the operating conditions of the press bend process reset in this way as the input data of the roundness prediction model, and the predicted roundness is the roundness.
- the reset value of the operating conditions of the press bend process may be determined by confirming whether or not the value is smaller than the target value. Then, the reset operating conditions of the press bend process are sent to the operating condition control unit of the press bend process, and the operating conditions of the press bend process are determined.
- the roundness target value is set small
- the operating conditions of the appropriate press bend process can be set. A steel pipe with good roundness can be manufactured.
- the operating conditions to be reset as described above are not necessarily limited to the press bend process.
- the operating conditions of the seam gap reducing process and the operating conditions of the pipe expansion process may be reset, or the operating conditions of the plurality of processes may be combined and reset.
- the operating conditions of the press bend process are reset.
- the actual data of the attribute information of the steel sheet is sent to the upper computer 110, and even if the roundness of the steel pipe after the pipe expansion process is predicted after the press bend process is completed and before the seam gap reduction process. good.
- the operation record data is sent to the operation condition resetting unit 120 as the operation condition of the press bend process, and the preset value as the operation condition of the seam gap reduction process and, in some cases, the operation condition of the pipe expansion process.
- the set value of each process including the set value set in advance is sent to the operating condition resetting unit 120.
- the actual data of the attribute information of the collected steel sheet and the roundness target value preset as the target roundness of the steel pipe after the pipe expansion process are set in the operating condition resetting unit. Sent to 120.
- the roundness prediction model is used online to predict the roundness of the steel pipe after the pipe expansion process.
- the predicted roundness and the roundness target value are compared, and if the predicted roundness falls within the roundness target value, the steel pipe is used without changing the set value of the seam gap reduction process. To manufacture.
- the operating conditions of the seam gap reduction process are reset. Specifically, a plurality of O-press reduction amount conditions are input to the roundness prediction model created as the seam gap reduction step, and the other conditions are constant conditions, and the O-press reduction that gives the best roundness can be obtained. Set to quantity. In this way, the operating conditions of the seam gap reducing process that have been reset are sent to the operating condition control unit of the seam gap reducing process, and the operating conditions of the seam gap reducing process are determined.
- the operating conditions of the press bend process are reset by the above-mentioned roundness control before the press bend process, and after the press bend process, the seam gap reduction process is performed by using the actual values of the operating conditions of the press bend process. You may adopt the method of resetting.
- the roundness control method of the present embodiment the variation in the attribute information of the steel sheet and the influence on the roundness due to the interaction between the press bend process and the seam gap reduction process are simultaneously considered. Since the roundness prediction model is used, it is possible to set appropriate operating conditions for improving the roundness of the steel pipe after the pipe expansion process, and it is possible to manufacture a steel pipe having a high roundness.
- the reset target process is selected from a plurality of forming processes constituting the steel pipe manufacturing process. Then, before the start of the reset target process, the roundness prediction model M is used to predict the roundness of the steel pipe after the pipe expansion step. Subsequently, one or more operation parameters selected from at least the operation parameters of the reset target process, or molding on the downstream side of the reset target process so that the roundness of the steel pipe after the pipe expansion process becomes small. Reset one or more operating parameters selected from the operating parameters of the machining process.
- the plurality of forming processes constituting the steel pipe manufacturing process include an end bending process, a press bend process, a seam gap reduction process, and a pipe expansion process in which the steel pipe is subjected to plastic deformation to process the steel pipe into a predetermined shape.
- any process is selected from these molding processes.
- the roundness prediction model M of the steel pipe is used to predict the roundness of the steel pipe after the pipe expansion step.
- the forming process of the steel sheet has been completed for the forming process on the upstream side of the process to be reset, when the operation parameters of the forming process on the upstream side are used, the actual data is rounded.
- the prediction model M It can be used as an input for the prediction model M.
- the set value set in advance in the host computer or the like is used for inputting the roundness prediction model M of the steel pipe. In this way, the roundness of the steel pipe after the pipe expansion process for the target material can be predicted.
- the roundness predicted as the roundness of the steel pipe after the pipe expansion process falls within the roundness allowed as a product.
- the operation parameter to be reset may be an operation parameter in the reset target process or an operation parameter in the molding process downstream of the reset target process.
- the operating parameters of the forming process suitable for changing the roundness of the steel pipe after the pipe expansion step may be selected.
- both the operation parameters in the reset target process and the operation parameters in any molding process downstream from the reset target process may be reset. This is because when the difference between the predicted roundness and the roundness allowed as a product is large, the roundness of the steel pipe after the pipe expansion process can be effectively changed.
- Table 1 specifically shows the cases of the molding process selected as the process to be reset and the molding process in which the operation parameters can be reset correspondingly.
- the end bending process is selected as the reset target process in the steel pipe manufacturing process including the end bending process.
- the roundness of the steel pipe after the pipe expansion process is predicted by using the set values of the operation parameters in the forming process including the press bend process and the seam gap reduction process. If the predicted roundness is large, any operating parameters in each forming process of the edge bending process, the press bend process, the seam gap reduction process, and the pipe expansion process can be reset.
- the operation parameters to be reset may be not only the operation parameters of the edge bending process but also the operation parameters of other molding processing processes.
- case 2 and case 3 the process to be reset can be selected and the operation parameter to be reset can be selected in the same way as in case 1.
- case 4 is a case where the pipe expansion process is set as the reset target process.
- the roundness of the steel pipe after the pipe expansion process is predicted by using the roundness prediction model M before the start of the pipe expansion process.
- at least the operation performance data in the press bend process and the seam gap reduction process can be used as the input of the roundness prediction model M.
- the actual data of the attribute information of the steel sheet and the operation actual data in the edge bending process may be used.
- the roundness of the steel pipe after the predicted pipe expansion process is compared with the roundness allowed as a product, and if the roundness is to be reduced, the operation parameters in the pipe expansion process are re-established.
- Set. It is preferable to use the pipe expansion rate as the operation parameter of the pipe expansion process to be reset.
- the amount of change from the initial setting value of the pipe expansion rate to be reset may be set based on the knowledge obtained from experience. However, if the input of the roundness prediction model M includes the pipe expansion rate of the pipe expansion process, the value of the reset pipe expansion rate is used as the input of the roundness prediction model M, and the steel pipe after the pipe expansion process is again used. You may predict the roundness and judge the suitability of the condition to be reset.
- the example shown in FIG. 15 is a case where the seam gap reduction step is selected as the reset target step, the press bend step is completed, and the U-shaped molded product is transferred for the seam gap reduction step.
- the operation record data in the press bend process is sent to the operation condition resetting unit 120.
- the operation performance data may be sent via a network from a control computer provided in each process that controls each molding process. However, it may be sent from the control computer of each forming process to the host computer 110 that controls the manufacturing process of the steel pipe, and then sent from the host computer 110 to the operating condition resetting unit 120.
- actual data regarding the attribute information of the steel sheet is sent from the host computer 110 to the operating condition resetting unit 120. Further, if necessary, operation record data in the end bending process may be sent.
- the set values are reset from the control computer of each process. It is sent to the unit 120. However, when the set values of the operation parameters of the seam gap reduction step and the pipe expansion step are stored in the upper computer 110, they may be sent from the upper computer 110 to the operation condition resetting unit 120.
- the high-level computer 110 sends a roundness target value determined according to the specifications of the steel pipe to be a product to the operating condition resetting unit 120.
- the operating condition resetting unit 120 predicts the roundness of the steel pipe after the pipe expansion process from the information using the roundness prediction model M online, and obtains the predicted roundness (roundness predicted value). Compare with the target roundness (roundness target value). When the roundness predicted value is smaller than the roundness target value, the operating condition resetting unit 120 does not change the set values of the operating conditions of the press bend process, the seam gap reduction process, and the pipe expansion process. Determine the operating conditions of the remaining forming process and manufacture steel pipes. On the other hand, when the predicted roundness is larger than the roundness target value, the operating condition resetting unit 120 resets at least the operating conditions of the seam gap reducing step or the operating conditions of the pipe expansion step. Specifically, the O-press reduction amount in the seam gap reduction step can be reset. In addition, the pipe expansion rate in the pipe expansion process can be reset. Furthermore, both the O-press reduction amount and the tube expansion rate can be reset.
- the operation condition resetting unit 120 uses the operation parameters reset in this way as the input data of the roundness prediction model M to predict the roundness again, and the predicted roundness is true. It may be confirmed whether or not it becomes smaller than the circularity target value, and the reset value of the operating conditions of the seam gap reduction step and the pipe expansion step may be determined.
- the operating conditions of the seam gap reduction process and the pipe expansion process that have been reset are sent to the respective control computers, and become the operating conditions of the seam gap reduction process and the pipe expansion process.
- the pipe expansion process is performed again for the steel pipe formed and welded into the open pipe.
- the roundness control of the steel pipe after the pipe expansion process in which is the target process for resetting may be executed. This is because the operation record data of the seam gap reduction process is obtained, and the accuracy of predicting the roundness of the steel pipe is further improved.
- the roundness in consideration of the influence on the roundness due to the interaction between the press bend step and the seam gap reducing step is taken into consideration. Since the prediction model M is used, it is possible to set appropriate operating conditions for improving the roundness of the steel pipe after the pipe expansion process, and it is possible to manufacture a steel pipe having a high roundness. In addition, it is possible to realize highly accurate roundness control that reflects variations in the attribute information of the steel sheet used as the material.
- FIG. 16 is a diagram showing a configuration of a steel pipe roundness prediction device according to an embodiment of the present invention.
- the steel pipe roundness prediction device 160 according to the embodiment of the present invention includes an operation parameter acquisition unit 161, a storage unit 162, a roundness prediction unit 163, and an output unit 164. ..
- the operation parameter acquisition unit 161 is provided with an arbitrary interface that can acquire, for example, the roundness prediction model M generated by the machine learning unit from the roundness prediction model generation unit 100.
- the operation parameter acquisition unit 161 may include a communication interface for acquiring the roundness prediction model M from the roundness prediction model generation unit 100.
- the operation parameter acquisition unit 161 may receive the roundness prediction model M from the machine learning unit 100b using a predetermined communication protocol.
- the operation parameter acquisition unit 161 acquires the operation conditions of the molding processing equipment (equipment for executing the molding processing process) from, for example, a control computer or a higher-level computer provided in the equipment used in each molding processing process.
- the operation parameter acquisition unit 161 may include a communication interface for acquiring operation conditions.
- the operation parameter acquisition unit 161 may acquire input information based on the user's operation.
- the roundness predictor 160 of the steel pipe further includes an input unit including one or more input interfaces for detecting the user input and acquiring the input information based on the user's operation.
- the input unit include, but are not limited to, a physical key, a capacitance key, a touch screen provided integrally with the display of the output unit, a microphone that accepts voice input, and the like.
- the input unit receives input of operation conditions for the roundness prediction model M acquired from the roundness prediction model generation unit 100 by the operation parameter acquisition unit 161.
- the storage unit 162 includes at least one semiconductor memory, at least one magnetic memory, at least one optical memory, or a combination of at least two of them.
- the storage unit 162 functions as, for example, a main storage device, an auxiliary storage device, or a cache memory.
- the storage unit 162 stores arbitrary information used for the operation of the roundness prediction device 160 of the steel pipe.
- the storage unit 162 may include, for example, the roundness prediction model M acquired from the roundness prediction model generation unit 100 by the operation parameter acquisition unit 161, the operation conditions acquired from the host computer by the operation parameter acquisition unit 161, and the trueness of the steel pipe.
- the roundness information predicted by the roundness predictor 160 is stored.
- the storage unit 162 may store a system program, an application program, and the like.
- the roundness prediction unit 163 includes one or more processors.
- the processor is a general-purpose processor or a dedicated processor specialized for a specific process, but is not limited thereto.
- the roundness prediction unit 163 is communicably connected to each component constituting the roundness prediction device 160 of the steel pipe, and controls the operation of the entire roundness prediction device 160 of the steel pipe.
- the roundness prediction unit 163 can be any general-purpose electronic device such as a PC (Personal Computer) or a smartphone.
- the roundness prediction unit 163 is not limited to these, and may be one or a plurality of server devices capable of communicating with each other, or may be another electronic device dedicated to the roundness prediction device 160 for steel pipes. good.
- the roundness prediction unit 163 uses the operating conditions acquired via the operation parameter acquisition unit 161 and the roundness prediction model M acquired from the roundness prediction model generation unit 100 to predict the roundness information of the steel pipe. Is calculated.
- the output unit 164 outputs the predicted value of the roundness information of the steel pipe calculated by the roundness prediction unit 163 to the device for setting the operating conditions of the forming processing equipment.
- the output unit 164 may include one or more output interfaces that output information and notify the user.
- the output interface is, for example, a display.
- the display is, for example, an LCD or an organic EL display.
- the output unit 164 outputs the data obtained by the operation of the roundness prediction device 160 of the steel pipe.
- the output unit 164 may be connected to the roundness prediction device 160 of the steel pipe as an external output device instead of being provided in the roundness prediction device 160 of the steel pipe.
- any method such as USB, HDMI (registered trademark), or Bluetooth (registered trademark) can be used.
- the output unit 164 may include, but is not limited to, a display that outputs information as a video, a speaker that outputs information as audio, and the like.
- the output unit 164 presents the predicted value of the roundness information calculated by the roundness prediction unit 163 to the user. The user can appropriately set the operating conditions of the molding processing equipment based on the predicted value of the roundness presented by the output unit 164.
- a more preferable form of the steel pipe roundness prediction device 160 after the pipe expansion step as described above is the roundness calculated by the input unit 165 for acquiring input information based on the user's operation and the roundness prediction unit 163. It is a terminal device such as a tablet terminal having a display unit 166 that displays a predicted value of information. This acquires input information based on the user's operation from the input unit 165, and updates a part or all of the operation parameters of the forming process equipment already input to the roundness prediction device 160 of the steel pipe by the acquired input information. It is something to do.
- the operation person in charge has already used the terminal device to acquire the operation parameter acquisition unit. It accepts an operation of modifying a part of the operation parameters of the forming processing equipment input to 161.
- the operation parameter acquisition unit 161 retains the initial input data for the operation parameters for which the correction input is not made from the terminal device among the operation parameters of the molding processing equipment, and changes only the operation parameters for which the correction input has been made. do.
- the operation parameter acquisition unit 161 generates new input data of the roundness prediction model M, and the roundness prediction unit 163 calculates the predicted value of the roundness information based on the input data.
- the calculated predicted value of the roundness information is displayed on the display unit 166 of the terminal device through the output unit 164.
- the person in charge of operation of the molding equipment or the person in charge of the factory can immediately confirm the predicted value of the roundness information when the operation parameter of the molding equipment is changed, and quickly change to the appropriate operation conditions. Can be done.
- a steel pipe for line pipes (API grade X60) having a plate thickness of 38.0 to 38.4 mm and a plate width of 2700 to 2720 mm is used, and a steel pipe having a diameter of 36 inches after the pipe expansion process is pressed by a press bend process and a seam gap.
- a press bend process Manufactured through a reduction process, a welding process, and a pipe expansion process.
- the operating conditions of the press bend process and the seam gap reduction process were arbitrarily changed (finely adjusted) to obtain steel pipes having various roundness.
- the average plate thickness in the plane of the steel plate was used as the representative plate thickness, and the test data of the yield stress obtained in the inspection process of the thick plate rolling process was used.
- the number of presses was fixed at 9 times, and the press position was set at a pitch of 224 mm in the width direction of the steel sheet, with the position 1120 mm away from the central portion in the width direction of the steel sheet as the first pressing position. .. At that time, the press reduction amount at each position was finely adjusted (range of 55.0 to 60.0 mm) for each steel sheet based on 15.8 mm.
- the molded body having a U-shaped cross section is held in a U-shaped posture so that the open portion faces upward by using an O-press device, and the radius R: 457.2 mm, the central angle ⁇ c:
- a mold using an upper mold having an arc surface of 60 ° and having a flat surface connected to the arc surface at an angle ⁇ d: 30 ° and a lower mold having a concave arc surface having a radius R: 502.9 mm is used.
- the distance between the apexes of the R part of the mold (the apex of the R part is the top of the arc surface for the upper mold and the bottom of the arc surface for the lower mold) is 1.0 to 3.
- the operating conditions were arbitrarily set (fine-tuned) within the range of 0%. From the actual data obtained as described above, a roundness prediction model was generated at the stage when 100 pieces were accumulated in the database.
- the roundness prediction model generated in this way was installed in the system shown in FIG. 11 as an online model.
- the press bend process was set as the process to be reset.
- the roundness target value of the steel pipe is set to 10 mm
- the roundness of the steel pipe after the pipe expansion process is predicted before the reset target process, and the predicted roundness is larger than the roundness target value.
- the average value of the roundness when manufacturing 10 pieces was 11.2 mm, and the pass rate was 80%, but in the invention example, the average value was reduced to 6.0 mm. It was confirmed that the pass rate was 90%.
- a method for predicting the roundness of a steel pipe and a device for predicting the roundness of the steel pipe which can accurately predict the roundness of the steel pipe after the pipe expansion step in the manufacturing process of the steel pipe composed of a plurality of steps. Can be done. Further, according to the present invention, it is possible to provide a method for controlling the roundness of a steel pipe, which can accurately control the roundness of the steel pipe after the pipe expansion step in the manufacturing process of the steel pipe composed of a plurality of steps. Further, according to the present invention, it is possible to provide a method for manufacturing a steel pipe capable of manufacturing a steel pipe having a desired roundness with a high yield.
- a roundness prediction model for a steel pipe capable of generating a roundness prediction model for accurately predicting the roundness of a steel pipe after a pipe expansion process in a steel pipe manufacturing process composed of a plurality of steps.
- a roundness prediction model for a steel pipe capable of generating a roundness prediction model for accurately predicting the roundness of a steel pipe after a pipe expansion process in a steel pipe manufacturing process composed of a plurality of steps.
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Abstract
Description
図1は、本発明の一実施形態である鋼管の製造工程を示す図である。図1に示すように、本発明の一実施形態である鋼管の製造工程では、素材となる鋼板として、鋼管の製造工程の前工程である厚板圧延工程によって製造される厚鋼板が用いられる。ここで、厚鋼板は、降伏応力245~1050MPa、引張強度415~1145MPa、板厚6.4~50.8mm、板幅1200~4500mm、及び長さ10~18mのものが代表的である。また、厚鋼板の幅方向端部は開先と呼ばれる面取り状の形状に予め研削される。これは、後の溶接工程において、幅方向端部の外面コーナー部の過加熱を防止して溶接強度を安定化させるためである。また、厚鋼板の幅は、鋼管に成形された後の外径に影響するため、後の工程における変形履歴を考慮して所定範囲に調整される。
端曲げ加工を行うCプレス装置について、図12,図13を用いて詳細に説明する。図12は、Cプレス装置の全体構成を示す斜視図である。図12に示すように、Cプレス装置30は、鋼板Sをその長手方向に沿う方向を搬送方向として搬送する搬送機構31と、鋼板Sの搬送方向下流側を前方として、一方の幅方向端部Scを所定の曲率に曲げ加工するプレス機構32Aと、他方の幅方向端部Sdを所定の曲率に曲げ加工するプレス機構32Bと、端曲げ加工を施す鋼板Sの幅に応じて、左右のプレス機構32A,32B間の間隔を調整する図示しない間隔調整機構と、を備えている。搬送機構11は、プレス機構32A、32Bの前後にそれぞれ配置された複数の回転駆動される搬送ロール31aからなる。なお、図中の符号Saは鋼板Sの先端部(長手方向前方端部)を示している。
図2は、プレスベンド装置を用いてU字状断面の成形体を成形する工程の一例を示す図である。図中、符号1は、鋼板Sの搬送経路内に配置されたダイを示している。ダイ1は、鋼板Sをその搬送方向に沿って2箇所で支持する左右一対の棒状部材1a,1bから構成されており、成形すべき鋼管のサイズに応じてその間隔ΔDが変更できるようになっている。また、符号2は、ダイ1に近接及び離隔する向きに移動可能なパンチを示している。パンチ2は、鋼板Sに直接接して鋼板Sを凹形状に押圧する下向き凸状の加工面を有するパンチ先端部2aと、パンチ先端部2aの背面に繋がり、パンチ先端部2aを支持するパンチ支持体2bと、を備えている。なお、通常、パンチ先端部2aの最大幅とパンチ支持体2bの幅(厚さ)とは等しくなっている。
シームギャップ低減工程は、プレスベンド工程により成形されたU字状断面の成形体のシームギャップを低減する工程であり、U字状断面の成形体の端部同士が近接するように曲げ力及び圧縮力を付与するものである。このとき、U字状断面の成形体に曲げ力や圧縮力を加えても、除荷する際のスプリングバックによってシームギャップが広がってしまう。このため、スプリングバックの発生を予め見越して、強い曲げ力や圧縮力を付与し、U字状断面の成形体が全体として縦方向につぶれるような変形を付与する。
オープン管S2は、その後、シームギャップ部の端面を相互に突合せ、溶接機(接合手段)により溶接して鋼管とする。溶接機(接合手段)としては、例えば仮付溶接機、内面溶接機、及び外面溶接機という3種類の溶接機で構成されるものを適用する。これらの溶接機において、仮付け溶接機は、ケージロールにより突き合せた面を適切な位置関係で連続的に密着させ、密着部をその管軸方向全長にわたって溶接する。次に、仮付けされた管は、内面溶接機により突き合せ部の内面から溶接(サブマージアーク溶接)され、さらに、外面溶接機により突き合せ部の外面から溶接(サブマージアーク溶接)される。
シームギャップ部を溶接された鋼管については、鋼管の内部に拡管装置を挿入して鋼管の直径を拡大(いわゆる拡管)する。図6(a)~(c)は、拡管装置の構成例を示す図である。図6(a)に示すように、拡管装置は、円弧を複数に分割した曲面を有する複数個の拡管ダイス16をテーパー外周面17の周方向に沿って備えている。拡管装置を利用して鋼管を拡管する際には、図6(b),(c)に示すように、まず、鋼管移動装置を用いて鋼管Pを移動することにより拡管ダイス16を拡管開始位置に合わせ、プルロッド18を拡管開始位置から後退させることによって1回目の拡管処理を行う。これにより、楔作用によってテーパー外周面17に摺接した拡管ダイス16のそれぞれが放射方向に変位し、鋼管Pが拡管される。そして、鋼管Pの断面形状の凹凸が小さくなり、鋼管Pの断面形状は真円形状に近くなる。次に、プルロッド18を拡管開始位置まで前進させ、リリース機構によって拡管ダイス16を軸垂直方向の内側に復帰させてから、拡管ダイス16のピッチ(軸方向の長さ)に応じた量だけ鋼管Pを更に移動させる。そして、拡管ダイス16を新たな拡管位置に合わせてから前記の動作を繰り返し行う。これにより、拡管ダイス16のピッチ分ずつ1回目の拡管処理を鋼管Pの全長にわたって行うことができる。
鋼管の製造工程の最後となる検査工程では、鋼管の品質検査が行われ、鋼管の真円度が測定される。真円度測定工程において測定される真円度とは、鋼管の外径形状について、真円からのズレの程度を表す指標である。通常は、真円度がゼロに近いほど、鋼管の断面形状が完全な円に近い形状であることを示す。真円度は、真円度測定機によって計測された鋼管の外直径情報に基づいて算出される。例えば任意の管長位置で管を周方向に等分して対向する位置での外直径を計測し、それらのうちの最大径と最少径をそれぞれDmax、Dminとした場合、真円度はDmax-Dminで定義することができる。このとき、等分する数が多いほど、拡管工程後の鋼管における小さな凹凸も数値化した指標となり好ましい。具体的には4~36000等分した情報を用いるのが良い。より好ましくは360等分以上である。
図8は、本発明の一実施形態である真円度予測モデルの生成方法を示す図である。図中の真円度予測モデル生成部100は、素材となる鋼板の属性情報の実績データ、プレスベンド工程の操業実績データ、シームギャップ低減工程の操業実績データ、及び拡管工程後の鋼管の真円度の実績データを収集し、機械学習により真円度予測モデルMを生成するものである。
素材となる鋼板の属性情報としては、鋼板の降伏応力、引張強度、縦弾性係数、板厚、板面内の板厚分布、鋼板の板厚方向の降伏応力の分布、バウシンガー効果の程度、及び表面粗さ等、拡管工程後の鋼管の真円度に影響を及ぼす任意のパラメータを用いることができる。特に、プレスベンド工程における3点曲げプレスによる鋼板の変形状態やスプリングバックに影響を与える因子や、シームギャップ低減工程における圧縮・曲げ加工による鋼板の変形状態やスプリングバックに影響を与える因子を指標とするのが好適である。
端曲げ工程の操業パラメータを真円度予測モデルの入力に用いる場合には、Cプレス装置30で使用する上金型33の成形面33aがなす形状や下金型34の押圧面34aがなす形状を特定するパラメータを操業パラメータとして用いることができる。また、端曲げ工程における端曲げ加工幅(端曲げ成形を施す幅)、鋼板の送り量、送り方向、及び送り回数、押し上げ力(Cプレス力)、クランプ機構37による把持力を操業パラメータとして用いてもよい。これらは、端曲げ工程における鋼板の幅方向端部の変形に影響を与え得る因子だからである。
本実施形態では、プレスベンド工程の操業パラメータを真円度予測モデルの入力に用いる。プレスベンド工程の操業パラメータとしては、上記に記載した3点曲げプレスのプレス回数、プレス位置情報、プレス圧下量、下ダイ間隔、及びパンチ曲率等、鋼板の局所的な曲げ曲率と、それらの鋼板の幅方向の分布に影響を与える各種パラメータを用いることができる。特に、パンチが鋼板を押圧するプレス位置情報とプレス圧下量、プレスベンド工程を通じて行うプレス回数の全てを含む情報を用いるのが好ましい。これらの情報を全て含むとは、図10に示す方法が例示できる。図10(a),(b)はそれぞれ、同一の幅の鋼板に対してプレス回数16回と10回としてパンチの押圧行った場合のプレス圧下位置とプレス圧下量の例を示している。このとき、プレス圧下位置は、鋼板の基準とする幅方向端部からの距離を表す情報であり、これをプレス圧下位置情報として用いる。一方、各プレス圧下位置に対応して、プレス圧下量が記載されており、このような「圧下回数」、「プレス圧下位置」、「プレス圧下量」が一組のデータとすることができる。図10(a),(b)に示す例では、プレス回数16回と10回で、それぞれ16組、10組のデータにより、プレスベンド工程の操業パラメータが特定される。
本実施形態では、シームギャップ低減工程の操業パラメータを真円度予測モデルの入力に用いる。シームギャップ低減工程として、Oプレス装置を用いる場合には、Oプレス圧下量、Oプレス圧下位置、及びOプレスダイスRを用いることができる。一方、クロージングプレス法を用いる場合には、上述した各ステップにおけるクロージングプレス圧下位置及びクロージングプレス押し付け力を用いる。特に、Oプレス装置を用いる場合には、Oプレス圧下量を用いるのが好適である。これは、Oプレス圧下量を大きくすると、上金型より拘束・押圧力を受ける点と下金型によって拘束される点の間の領域、主に鋼管の3時部及び9時部付近は拘束がなく、曲げ及び圧縮の変形が集中するため、その領域の曲率が増加することにより、最終的な真円度に影響を与えるからである。このとき、シームギャップ低減工程における操業実績データとして、Oプレス圧下量、Oプレス圧下位置、及びOプレスダイスRは、Oプレス装置を制御するために必要な情報であり、上位計算機で設定された設定値を用いることができる。但し、Oプレス圧下量やOプレス圧下位置を測定する計測装置(レーザー式距離計等)を備えている場合には、その測定結果を操業実績データとしてもよい。
上述した操業パラメータの他、拡管工程の操業パラメータを真円度予測モデルの入力に用いる場合には、拡管率を拡管工程の操業パラメータとして用いることができる。拡管率が大きいほど、拡管工程後の鋼管の真円度は向上するが、鋼管製品としての圧縮降伏強度の観点から拡管率の上限値が制限されるため、その範囲内での値を用いる。このとき、拡管率は、拡管装置を制御するために必要な情報であり、上位計算機で設定された設定値を用いることができる。また、拡管を行った後に形状寸法計等の測定装置によって全周の平均外径を測定し、加工前の鋼板の幅から計算される外径との変化量によって計算される平均拡管率を操業実績データとしてもよい。さらに、拡管工程において、拡管率の計測装置を備えている場合には、その測定結果を操業実績データとしてもよい。なお、拡管工程の操業パラメータとしては、拡管率の他、拡管ダイス枚数、拡管ダイス径を用いてもよい。
以上のようにして生成した真円度予測モデルを用いた拡管工程後の鋼管の真円度予測方法は以下のように用いられる。すなわち、この方法を用いることにより、パンチによる複数回の押圧によりU字状断面の成形体に加工するプレスベンド工程と、U字状断面の成形体のシームギャップ部を減少させオープン管とするシームギャップ低減工程と、オープン管の端部同士を接合する溶接工程と、端部同士が接合された鋼管の内径を拡大する拡管工程と、を含む鋼管の製造工程において、それぞれの工程における製造条件が適正かどうかの検証を行うことができる。プレスベンド工程やシームギャップ低減工程の操業条件は、拡管工程後の鋼管の真円度に対して複雑に影響するものであり、上流工程における鋼板の属性情報のばらつきが影響するため、それらの要因が製品の真円度に対する影響を定量的に評価できることになる。これにより、素材となる鋼板の属性情報のばらつきの実態を踏まえて、鋼管製品の真円度のばらつきを予測することができ、そのような素材のばらつきを考慮したプレスベンド工程やシームギャップ低減工程の操業条件の変更を行うことができる。すなわち、素材の属性情報に一定のばらつきがあっても、鋼管製品の真円度が所定の範囲内に収まるようにプレスベンド工程やシームギャップ低減工程の操業条件の適正化を事前に行うことができる。
次に、上記のようにして生成した真円度予測モデルを用いた拡管工程後の鋼管の真円度制御方法について説明する。多数の工程を経て製造される鋼管の製造工程の途中段階において、現時点よりも上流側の工程における操業実績と、下流側の工程において予め設定されている操業条件の設定値を用いて、拡管工程後の鋼管の真円度を予測することにより、予測される鋼管の真円度が、製品として許容される真円度に収まるか否かを判断することができる。これにより、必要に応じて、現時点よりも下流側の工程における操業条件を再設定することができる。このような実施形態を図11に例示する。図11に示すように、本実施形態は、鋼管の製造工程において、素材となる鋼板の属性情報に関する実績データが上位計算機110から送られ、プレスベンド工程の前に拡管工程後の鋼管の真円度予測を行う例である。このとき、プレスベンド工程の操業条件として予め設定された設定値、シームギャップ低減工程の操業条件として予め設定された設定値、及び必要に応じて拡管工程の操業条件として予め設定された設定値を含む、各工程の設定値が操業条件再設定部120に送られる。また、上位計算機110からは収集された鋼板の属性情報の実績データ及び拡管工程後の鋼管の目標とする真円度として予め設定された真円度目標値が操業条件再設定部120に送られる。
次に、図16を参照して、本発明の一実施形態である鋼管の真円度予測装置について説明する。
1a,1b 棒状部材
2 パンチ
2a パンチ先端部
2b パンチ支持体
3 上金型
4 下金型
10a,10b 下側工具
11a,11b バネ手段
12 パンチ
13 上側工具
16 拡管ダイス
17 テーパー外周面
18 プルロッド
20 アーム
21a,21b 変位計
22 回転角度検出器
25 回転アーム
26a,26b 押圧ローラ
30 Cプレス装置
31 搬送機構
31a 搬送ロール
32A,32B プレス機構
33 上金型
33a 成形面
34 下金型
34a 押圧面
36 油圧シリンダ
37 クランプ機構
100 真円度予測モデル生成部
100a データベース
100b 機械学習部
110 上位計算機
120 操業条件再設定部
160 鋼管の真円度予測装置
161 操業パラメータ取得部
162 記憶部
163 真円度予測部
164 出力部
165 入力部
166 表示部
G シームギャップ部
M 真円度予測モデル
P 鋼管
R1,R2 領域
S 鋼板
S1 成形体
S2 オープン管
Claims (13)
- パンチによる複数回の押圧により鋼板をU字状断面の成形体に加工するプレスベンド工程、前記U字状断面の成形体のシームギャップ部を減少させオープン管とするシームギャップ低減工程、前記オープン管の端部同士を接合する溶接工程、及び端部同士が接合された鋼管の内径を拡大する拡管工程を含む鋼管の製造工程における、前記拡管工程後の鋼管の真円度を予測する鋼管の真円度予測方法であって、
前記鋼板の属性情報から選択した1又は2以上のパラメータ、前記プレスベンド工程の操業パラメータから選択した1又は2以上のパラメータ、及び前記シームギャップ低減工程の操業パラメータから選択した1又は2以上のパラメータを入力データとして含み、前記拡管工程後の鋼管の真円度情報を出力データとする、機械学習により学習された真円度予測モデルを用いて、前記拡管工程後の鋼管の真円度を予測するステップを含む、鋼管の真円度予測方法。 - 前記真円度予測モデルは、前記入力データとして、前記拡管工程の操業パラメータから選択した1又は2以上の操業パラメータを含む、請求項1に記載の鋼管の真円度予測方法。
- 前記鋼板の属性情報は、前記鋼板の降伏応力、代表板厚、及び板厚分布情報のうちの1又は2以上のパラメータを含む、請求項1又は2に記載の鋼管の真円度予測方法。
- 前記プレスベンド工程の操業パラメータは、前記プレスベンド工程に用いるパンチが鋼板を押圧するプレス位置情報及びプレス圧下量と共に、前記プレスベンド工程を通じて行うプレス回数を含む、請求項1~3のうち、いずれか1項に記載の鋼管の真円度予測方法。
- 前記鋼管の製造工程は、前記プレスベンド工程に先立って前記鋼板の幅方向端部に曲げを付与する端曲げ工程を含み、前記真円度予測モデルは、前記入力データとして、前記端曲げ工程の操業パラメータの中から選択した1又は2以上のパラメータを含む、請求項1~4のうち、いずれか1項に記載の鋼管の真円度予測方法。
- 請求項1~5のうち、いずれか1項に記載の鋼管の真円度予測方法を用いて、前記プレスベンド工程の開始前に、前記鋼板の属性情報の実績パラメータと前記プレスベンド工程を含む下流工程における操業パラメータの設定値とを用いて前記拡管工程後の鋼管の真円度を予測し、拡管工程後の鋼管の真円度が小さくなるように前記プレスベンド工程の操業パラメータを再設定するステップを含む、鋼管の真円度制御方法。
- 請求項1~5のうち、いずれか1項に記載の鋼管の真円度予測方法を用いて、前記プレスベンド工程が終了した後、前記シームギャップ低減工程の開始前に、前記鋼板の属性情報の実績データ、前記プレスベンド工程の操業パラメータの実績データ、及び前記シームギャップ低減工程を含む下流工程における操業パラメータの設定値を用いて、前記拡管工程後の鋼管の真円度を予測し、拡管工程後の鋼管の真円度が小さくなるように、前記シームギャップ低減工程の操業パラメータを再設定するステップを含むことを特徴とする鋼管の真円度制御方法。
- 請求項1~5のうち、いずれか1項に記載の鋼管の真円度予測方法を用いて、前記鋼管の製造工程を構成する端曲げ工程、プレスベンド工程、シームギャップ低減工程、及び拡管工程の中から選択した再設定対象工程の開始前に、前記拡管工程後の鋼管の真円度情報を予測し、予測された鋼管の真円度情報に基づいて、少なくとも前記再設定対象工程の操業パラメータの中から選択した1又は2以上の操業パラメータ、又は、前記再設定対象工程よりも下流側の成形加工工程の操業パラメータの中から選択した1又は2以上の操業パラメータを再設定するステップを含む、鋼管の真円度制御方法。
- 請求項6~8のうち、いずれか1項に記載の鋼管の真円度制御方法を用いて鋼管を製造するステップを含む、鋼管の製造方法。
- パンチによる複数回の押圧により鋼板をU字状断面の成形体に加工するプレスベンド工程、前記U字状断面の成形体のシームギャップ部を減少させオープン管とするシームギャップ低減工程、前記オープン管の端部同士を接合する溶接工程、及び端部同士が接合された鋼管の内径を拡大する拡管工程を含む鋼管の製造工程における、前記拡管工程後の鋼管の真円度を予測する真円度予測モデルを生成する鋼管の真円度予測モデルの生成方法であって、
前記鋼板の属性情報から選択した1又は2以上の実績データ、前記プレスベンド工程の操業実績データから選択した1又は2以上の実績データ、及び前記シームギャップ低減工程の操業実績データから選択した1又は2以上の実績データを入力実績データ、該入力実績データを用いた鋼管の製造工程での前記拡管工程後の鋼管の真円度の実績データを出力実績データとした、複数の学習用データを取得し、取得した複数の学習用データを用いた機械学習によって真円度予測モデルを生成するステップを含む、鋼管の真円度予測モデルの生成方法。 - 前記機械学習として、ニューラルネットワーク、決定木学習、ランダムフォレスト、及びサポートベクター回帰から選択した機械学習を用いる、請求項10に記載した鋼管の真円度予測モデルの生成方法。
- パンチによる複数回の押圧により鋼板をU字状断面の成形体に加工するプレスベンド工程、前記U字状断面の成形体のシームギャップ部を減少させオープン管とするシームギャップ低減工程、前記オープン管の端部同士を接合する溶接工程、及び端部同士が接合された鋼管の内径を拡大する拡管工程を含む鋼管の製造工程における、前記拡管工程後の鋼管の真円度を予測する鋼管の真円度予測装置であって、
前記鋼板の属性情報から選択した1又は2以上のパラメータ、前記プレスベンド工程の操業パラメータから選択した1又は2以上の操業パラメータ、及び前記シームギャップ低減工程の操業パラメータから選択した1又は2以上の操業パラメータを取得する操業パラメータ取得部と、
前記鋼板の属性情報から選択した1又は2以上のパラメータ、前記プレスベンド工程の操業パラメータから選択した1又は2以上の操業パラメータ、及び前記シームギャップ低減工程の操業パラメータから選択した1又は2以上の操業パラメータを入力データとして含み、前記拡管工程後の鋼管の真円度情報を出力データとする、機械学習により学習された真円度予測モデルに対して、前記操業パラメータ取得部が取得した操業パラメータを入力することにより、前記拡管工程後の鋼管の真円度情報を予測する真円度予測部と、
を備える、鋼管の真円度予測装置。 - ユーザの操作に基づく入力情報を取得する入力部と、前記真円度情報を表示する表示部と、を有する端末装置を備え、
前記操業パラメータ取得部は、前記入力部が取得した入力情報に基づいて、取得した操業パラメータの一部又は全部を更新し、
前記表示部は、前記更新された操業パラメータを用いて前記真円度予測部が予測した前記鋼管の真円度情報を表示する、請求項12に記載の鋼管の真円度予測装置。
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