[0026] The present invention will be further described in detail below in conjunction with the drawings.
[0027] Such as figure 1 As shown, the schematic diagram of the hardware configuration structure of the present invention
[0028] The invention is a method for tracking information in the production process of seamless steel pipes. The hardware part is composed of a client and a server. The server ensures data integrity through disk array technology. The working mode of the server is one work and one preparation. System software development can be done offline on the standby computer. The client computer is installed in each operating room and computer room to realize the human-computer interaction function. The system network connection adopts star connection. Each server is equipped with an Ethernet card for network communication.
[0029] Such as figure 1 As shown, the present invention is a seamless steel pipe production process information tracking method, which connects the independent first-level PLC and its upper computer of the individual equipment in each area to the server through the Ethernet, and establishes a database system in the server; Carry out equipment electrical control partition and single branch tracking partition, arrange corresponding detection and tracking acquisition devices and components in different areas, and connect with the first-level PLC of each single equipment in the area.
[0030] Such as figure 1 As shown, the present invention divides the entire production line into 4 single-branch tube tracking areas, respectively preparing a heating zone, a rolling deformation zone, a finishing zone 1, and a finishing zone 2 for the tube billet. The tube blank prepares the heating zone: the tube blank begins to be loaded and ends with the furnace roller table. Rolling deformation zone: the piercing machine starts at the front desk and ends at the exit roller table of the micro-tension sizing machine. Finishing zone 1: 1# starts from the entrance roller table of the cooling bed and ends with the exit roller table of the online flaw detector. Finishing zone 2: the beginning of the entrance roller table of the outer surface inspection table and the end of the unloading of the oiler.
[0031] The material form of a single pipe on the production line can be divided into the following types:
[0032] Tube blank: the shape of the material before perforation;
[0033] Capillary: the shape of the material after perforation;
[0034] Waste pipe: the shape of the material after the pipe is removed;
[0035] Steel pipe: the shape of the material after the sizing machine;
[0036] Sub-tube: The shape of the material after the pipe is cut.
[0037] There are four specific material forms for the mother tube, which are called blank tube, capillary tube, waste tube and steel tube in different areas in the production. The billet preparation heating zone is the billet, the rolling deformation zone is the capillary tube, the waste pipe, and the steel pipe, and the finishing zone 1 is the steel pipe and the sub-pipe. Finishing area 2 is a sub-pipe.
[0038] Under normal circumstances, there is a one-to-one relationship from the tube blank to the steel pipe (parent pipe), and a one-to-many relationship from the steel pipe (parent pipe) to the child pipe. According to the different forms of materials in each area, the present invention divides the material tracking of the entire production line into two parts: parent pipe tracking and child pipe tracking. The tracking principles are summarized as follows:
[0039] 1. The tracking principle of the parent tube, such as figure 2 Shown.
[0040] Such as figure 2 As shown, the basic principle of single pipe tracking in the billet preparation heating zone, rolling deformation zone, and finishing zone is the same: when the single pipe runs to this area, the database system automatically scans and detects, and passes the first-level PLC detection of each individual device The combined state of HMD, CMD, magnetic switch and other detection elements in different parts of this area (ON or OFF), thereby automatically distinguishing the running direction of the steel pipe and the actual running position of the steel pipe, and automatically receiving the actual production information of the PLC of different equipment in the tracking area. Generate parent tube tracking keywords and automatically store tracking data. When the tracking of a single pipe in this area ends, the tracking data table and tracking pointer table automatically move to the next tracking area.
[0041] The scope of mother pipe tracking and data management: from the single pipe entering the blank preparation area to the single pipe exiting the cooling bed area. The system manages each tube blank entering the production line (from the intermediate transportation roller table after sawing to before cutting by the pipe saw) through the mother tube data table and the mother tube tracking pointer table. Each tube blank corresponds to a mother tube data record and mother tube tracking pointer.
[0042] After the single pipe database system receives the signal of the single pipe billet on-line (the intermediate transport roller table of the pipe billet after being turned into the saw), it sets the corresponding steel pipe number for it, and establishes a parent pipe in the parent pipe data table and the parent pipe tracking pointer table. Tube data recording and parent tube tracking pointer. When the mother tube moves on the production line, the tracking pointer of the mother tube will move in the tracking pointer table to indicate the current position of the mother tube.
[0043] Definition of mother pipe number: It is composed of (batch number + rolling sequence number in batch), which can uniquely identify each steel pipe.
[0044] Mother Pipe Data Sheet: Store the calculated data of the steel pipe at this stage and the measured data obtained.
[0045] Mother tube tracking pointer table: Record the actual running position of the mother tube in the production line in real time.
[0046] The parent pipe tracking belongs to the single pipe tracking in the general case of the present invention, which is divided into two situations: tracking under normal conditions and tracking under special conditions.
[0047] Under normal circumstances, the parent pipe tracking: when a single parent pipe enters the single equipment in the next area from the single equipment in the previous area, the order of the steel pipes is "first in, first out", and the front and back position and sequence of each pipe does not change.
[0048] Mother pipe tracking under special circumstances: Ring furnace and cold sheet branch pipe tracking are special. The order of steel pipes may be "first in, last out", and the front and back position and sequence of each steel pipe may change.
[0049] When the ring furnace adopts double-row feeding, the first tube blank A 1 When entering the furnace, lean into the furnace (away from the furnace door), the second tube blank A 2 Lean into the furnace door when entering the furnace. When out of the furnace, the second tube blank A 2 First out, the first tube blank A 1 Later out.
[0050] In view of the situation that double-row feeding is sometimes used in the ring furnace, the database system establishes two single steel pipe tracking queues in the furnace and outside the furnace, and the tracking pointer of each queue is moved to realize the entry and exit of each pipe. Real-time tracking and recording of steel pipe position.
[0051] On the cooling bed, when the three steel pipes in a row of teeth are cooled and ready to exit the cooling bed, the first steel pipe B of the advanced cooling bed 1 Last out of the cooling bed, the third steel pipe B that enters the cooling bed last 3 Get out of the cooling bed first.
[0052] In view of the above situation of the cooling bed, the database system separately establishes 3 single steel pipe tracking queues in the cooling bed area, and realizes real-time tracking and recording of the position of each steel pipe entering and leaving the cooling bed by moving the tracking pointer of each queue.
[0053] 2. The tracking principle of the sub-pipe, such as image 3 Shown.
[0054] The sub-pipe tracking belongs to the single-pipe tracking in the special case of the present invention. The scope of sub-pipe tracking and data management: from the cutting of the pipe saw into the sub-pipe, until the sub-pipe is offline.
[0055] After the steel pipe is cut into sub-pipes by the pipe saw, it is realized through the sub-pipe data table and the sub-pipe tracking pointer table. Each sub-pipe corresponds to a sub-pipe data record and sub-pipe tracking pointer.
[0056] When the database system receives the sub-pipe cutting signal through the first-level PLC of the pipe saw, it establishes the corresponding pipe number, sub-pipe data record and sub-pipe tracking pointer for each sub-pipe. When the sub tube moves on the production line, the tracking pointer of the sub tube will move in the tracking pointer table to indicate the current position of the sub tube. The sub-tube data table is used to store the calculated data and the measured data obtained in each area of the production line (after the pipe saw cut).
[0057] Definition of sub-tube number: The sub-tube number is composed of (batch number + intra-batch rolling sequence number + sub-tube cutting sequence number), which can uniquely identify each sub-tube.
[0058] Sub-tube data table: store the calculated data of the sub-tube at this stage and the measured data obtained.
[0059] Sub-pipe tracking pointer table: record the actual running position of the sub-pipe in the production line in real time.
[0060] Such as image 3 As shown, the tracking process of the mother tube being sawed into multiple sub-tubes is like this. When the mother tube is cooled by the cooling bed, it is discharged by the cooling bed outlet unloading device and enters the finishing zone 1, and the database system automatically scans and detects. Detect the combined state (ON or OFF) of detection elements such as CMD and magnetic switch in different parts of the area through the first-level PLC of each single device, thereby automatically distinguishing the running direction of the steel pipe and the actual running position of the steel pipe, and automatically receiving and tracking the pipe in the area The sawing information from the saw PLC, the parent tube number is composed of the batch number + the rolling sequence number in the batch, and the sub-tube cutting sequence number is automatically filled at the end to form the sub-tube number, and the sub-tube number and sub-tube tracking keywords are automatically generated after cutting. , And automatically store the tracking data of the sub-pipes.
[0061] After the mother tube is cut into multiple daughter tubes, the original mother tube "cut head and length of cutting head" information is not recorded in the data table of each "child tube", but recorded in the data table of the "parent tube" to facilitate statistics The yield rate is used.
[0062] After the tracking of this branch is finished, the tracking data table and tracking pointer table of this branch will automatically move to the next tracking area, and the tracking result information of this branch will be automatically transmitted to the single branch quality analysis control system for analysis through the database system Processing, while preparing for automatic tracking of the next branch pipe.
[0063] 3. The principle of single branch tracking
[0064] For online materials in each area, the system tracks the head of the material, as long as the head of the material is located in which area, it will determine which area the material is located in. When there is an error between the actual material position and the position tracked by the computer, the operator must correct it through the HMI.
[0065] For the offline materials in each area, the system saves all the picking data in the picking data table in the database. For the picking with possibility of loopback, the operator should mark the number of the picking pipe on the pipe. When the processed materials are returned to the production line, the operator can select in the picking data or directly enter the tube number in the screen to put the materials into the team. The reject data is automatically deleted after being saved in the database for a period of time. As the single pipe moves on the production line, the tracking pointer will move in different areas to achieve real-time tracking of the single pipe.
[0066] Such as Figure 4 Shown is a process flow diagram of a specific embodiment of the present invention, including a production process information collection device in different areas of the production line.
[0067] The double-length tube blank is transported into the tube blank inventory, and the tube blank is hoisted to the tube blank feeding platform according to the production plan, and the tube blank is sawed to length, and the tube blank area is transported to the tube blank length measuring and weighing device for online After measuring the length and weighing, the tube blank is heated in the ring furnace, and the heated tube blank is transported to the front desk of the piercing machine through the "arc roller table", and is rolled into a capillary tube by the large-angle mushroom piercing machine, and the material is turned into a star shape. Turn the hook to the anti-oxidation station, blow nitrogen and borax inside the capillary to prevent oxidation, move the capillary to the front desk of the continuous tube mill by moving the manipulator horizontally. After the mandrel is threaded online, it is descaled by high-pressure water, and 1 overhead reducer reduces the diameter 5 stands for continuous rolling and stripping to 3 stripping machines.
[0068] The waste pipe after rolling is transported by the pipe stripper and then output by the roller table. The rotary arm moves horizontally. After being heated by the intermediate frequency induction furnace before sizing, it is rolled into the double-length steel pipe (parent pipe) by 14 micro-tension sizing mills. # Step cooling bed pre-cooling and 2 # After the main cooling of the stepping cooling bed, 2 # Discharging by the double-side discharging device of the cooling bed, feed 1 separately # And 2 # Pipe saw, cut into fixed-length steel pipes (sub-pipes), and then separately # And 2 # After the straightening machine is straightened, the finished pipes (sub-tubes) are sequentially turned into the two-in-one roller table after the straightening machine, and then transferred into the steel pipe horizontal moving table after being transported, and after the inside of the steel pipe is sucked ash, it enters the magnetic flux leakage detector Flaw detection, automatic spray labeling machine nozzle number, finished pipe after external surface inspection, manual comprehensive inspection, finished pipe length measurement and weighing, according to user needs # The finished pipe unloading position is offline.
[0069] For steel pipes that need to be inspected through the rod, after passing the rod inspection by the through rod machine, they can be # The finished pipe unloading position is offline. For steel pipes to be pressure tested, enter 1 # Or 2 # Hydraulic pressure test, the steel pipes that have passed the hydraulic test are chamfered by the chamfering machine and oiled by the oiling machine. # The finished pipe unloading position is offline.
[0070] In order to ensure the quality of seamless pipe products, combined with the possible waste situations in different processes, after the pipe blank is sawed, the bench is collected, the pipe blank length measurement and weighing waste returns to the end of the roller table, the end of the discharge roller table, the front desk of the continuous tube mill, and the The end of the exit roller table of the pipe machine, the end of the two-in-one roller table after the straightening machine, the entrance of the outer surface inspection table, the front of the finished pipe length measuring and weighing device, the end of the exit roller table of the pass-through machine, the middle roller table of the hydraulic press and the chamfering machine, Waste collection baskets are set on the exit stand of the chamfering machine. The invention can also automatically track and record waste pipe numbers and rejection information generated in different parts of the production line, and transmit them to a single petroleum pipe quality analysis control system through a database system for real-time data analysis and setting data optimization.
[0071] For example, a certain parent tube on the production line is the "A001" batch, and the rolling sequence number within the batch is the 177th. The database system of the present invention automatically generates the parent tube number as "A001-177". When the parent tube "A001-177" is cut into 3 sub-tubes by the 1# tube saw, the sub-tube numbers are automatically generated, namely "A001-177.1-1", "A001-177.2-1", and "A001-177.3-1" ". Among them, the pipe number "A001-177.1-1" represents that the parent pipe number is "A001-177", and the pipe number is 1 # The first pipe saw cut by a gang saw. The pipe number "A001-177.2-1" means that the parent pipe number is "A001-177", and the pipe is 1 # The second branch pipe cut by the gang saw.
[0072] For example, "A001-177.3-1" means that the parent tube is a batch of "A001", the rolling sequence number in the batch is the 177th, and the third branch tube cut by the 1# row tube saw. The complete tracking record should record the following production process information. The initial setting value and actual production value of the mother tube in the preparation zone, heating zone, piercing zone, continuous rolling tube zone, sizing zone, and cooling bed zone, and the mother tube being cut into The initial setting value and actual production value in the pipe saw area, straightening machine area, flaw detection area, inspection area, pass-through machine area, hydraulic press area, chamfering machine area, and oiling machine area after the sub-pipe, such as pipe The length and weight of the blank, the temperature of the blank tube, the current, speed, rolling force of the piercer, the length, temperature, outer diameter, wall thickness of the piercer outlet capillary, the amount of borax inside the capillary, the injection time, each continuous rolling tube Machine current, speed, rolling force, waste tube length, temperature, outer diameter, wall thickness after tube removal, intermediate frequency furnace inlet and outlet temperature, sizing machine current, speed, rolling force, mother tube length after sizing, temperature, Outer diameter, wall thickness, operating position and cooling time of the main pipe on the cooling bed, which pipe saw was used to cut the main pipe into sub-pipes; sub-pipe sequence number, pipe sawing head and tail length, sub-pipe Which straightening machine straightened, the straightening speed of the sub-tube, the set value of the roll gap, the straightening force, whether the sub-tube is defective after flaw detection, the defect location and type, the length and weighing results of the sub-tube, the sub-tube is connected Bar inspection results, which hydraulic press and water pressure result information for the sub-pipe, the sub-pipe chamfering result information, the sub-pipe oiling result information, the offline reason of each offline pipe, the offline location and actual rolling production information, etc. .
[0073] Such as Figure 4 As shown, in order to realize the tracking control of a single branch, the production line is divided into 14 equipment control zones. The details are as follows:
[0074] Electrical control zone of seamless pipe production line equipment
[0075] sequence
[0076] There can be one or more single devices in each control zone in the above table. The position tracking of a single steel pipe in each control zone is completed by the first-level PLC and upper computer of each single equipment in the zone.
[0077] Specifically, in each control zone, the single equipment body, its front and rear roller tables, front and rear loading and unloading platforms, rotating arm steel moving machines and material stoppers can be equipped with hot metal detectors, Various detection components such as cold metal detectors, magnetic switches, proximity switches, etc., through real-time scanning to detect the characteristic status and combination status of various detection components in the zone, and the single equipment level PLC and host computer in the zone automatically identify the location of the steel pipe The specific location in this area.
[0078] When a steel pipe in a certain batch leaves the previous area and wants to enter the next area, the single equipment level-one PLC or host computer in the previous area informs the next area single equipment through network or hard wire communication methods First-level PLC or upper computer, the server uses OPC to access the first-level PLC of the individual equipment in each area through the Ethernet, and accesses the upper computer of the individual equipment in each area by means of a database.
[0079] Such as Figure 4 As shown, in order to realize the tracking control of a single branch, based on the electrical control of all equipment on the production line, the entire production line is divided into four single branch tracking partitions, which are:
[0080] 1. Tube blank preparation heating zone: from the beginning of tube blank feeding to the end of the roller table.
[0081] 2. Rolling deformation zone: from the front desk of the piercing machine to the end of the exit roller table of the micro-tension sizing machine.
[0082] 3. Finishing zone 1: From the entrance roller table of 1# cooling bed to the end roller table of the online flaw detector.
[0083] 4. Finishing zone 2: starting from the entrance roller table of the outer surface inspection table to the end of the oiling machine unloading.
[0084] Such as Figure 4 As shown, the division of seamless pipe production line equipment electrical control zone and single pipe tracking control zone is based on the basic principles of the specific process flow of seamless pipe production, the specific equipment composition of the production line, and the need for tracking and collecting information and data throughout the entire process of single pipe production.
[0085] Such as Figure 4 As shown, in order to achieve single pipe tracking, in view of the current domestic and foreign seamless pipe production line's incomplete online tracking and collection of steel pipe production information and detection methods, the production line is equipped with a seamless steel pipe production information tracking collection device to track and collect all single pipes in real time. The production information is as follows:
[0086] 1. There is an online marking machine at the exit of the flaw detector, which can automatically track, record and spray each steel pipe number with the characteristics of "uniqueness" and "identification".
[0087] 2. There is an online steel pipe labeling machine at the exit of the manual comprehensive inspection platform, which can identify the pipe number of each steel pipe in the form of "bar code", and use the pipe number reading and identification machine (ie, bar code machine) to identify each finished product. The whole process production information of the steel pipe is read.
[0088] 3. A set of QAS (QUALITY ASSURANCE SYSTEM) device is installed after the pipe stripping machine and after the sizing machine to realize the automatic tracking and inspection record of the actual production information (such as wall thickness, length, outer diameter, temperature) of each steel pipe.
[0089] 4. Before entering the furnace, there is a tube blank measuring and weighing device, which automatically detects and records the length and weight of the tube blank into the furnace, and the unqualified tube blanks are timely removed to facilitate the statistics of the yield rate.
[0090] 5. In front of the manual comprehensive inspection station to export the through rod machine, there is a finished pipe length measuring and weighing device, which automatically detects and records the length and weight of the finished pipe, which is convenient for statistics of the yield rate.
[0091] 6. There is an on-line flaw detector after the straightening machine to realize the automatic inspection record of the inner and outer defects of the finished steel pipe.
[0092] 7. In the tube blank feeding platform, tube saw back frame, external surface inspection platform, manual comprehensive inspection platform, etc., there are inspection steel pipes at the front turning position and the rear full material position of each section of the inclined arm bench. With or without a magnetic switch (welded under the inclined arm bar), it can automatically track and detect a single steel pipe moving on the platform, which is convenient for automatically controlling the movement of the front and back turning device of the inclined arm bar.
[0093] 8. At the outlet of the ring furnace, the inlet and outlet of the piercer, the inlet and outlet of the continuous tube rolling mill, the outlet of the stripper, the inlet and outlet of the mandrel preheating furnace, the inlet and outlet of the intermediate frequency furnace before sizing, and the inlet and outlet of the sizing machine The pyrometer is used to detect the temperature of steel pipes, and cooperates with various detection elements such as hot metal detectors, cold metal detectors, and magnetic switches in each area to realize full-line tracking of a single pipe.
[0094] Such as Figure 4 As shown, in order to realize the tracking of a single pipe, a specific embodiment of the present invention uses the Visual Studio.Net programming language to access the Oracle database to track the production process information of each steel pipe. Specifically, it uses the Visual Studio.Net programming language to encapsulate all functions related to Oracle database operations (such as establishing a connection with the database, opening the database, closing the database, reading the database, creating a database set, executing SQL statements, etc.) Together, make a class library. Application programs such as single pipe tracking can realize real-time access to the "Oracle" database by calling this library.
[0095] The server uses OPC and database to access the primary PLC and upper computer of the individual equipment in each area through the industrial Ethernet, and collects and records the original process setting parameters, actual production information, and automatic Arrange to generate the tube number of each steel pipe in each batch.
[0096] Specifically, the server uses OPC to access the primary PLC of the individual equipment in each area through the industrial Ethernet, and accesses the upper computer of the individual equipment in each area through the database. Database management is mainly realized by establishing different forms of tracking data tables, tracking pointer tables, and tracking relationship tables.
