An online automatic calibration control system for vertical rollers

Abstract

The present invention relates to an online automatic calibration control system for vertical rolls. The control system includes an L3 roll management control module, an L2 roll management module, and an L1 basic automation program control module. In this system, the L3 roll management control module, the L2 roll management module, and the L1 basic automation program control module work together to realize that the L1 basic automation program automatically captures changes in roll diameter on the L2 process control system screen, automatically recalculates the control calibration offset, and sends it to the equipment in the L1 roll management control module for control. Based on changes in vertical roll diameter, a program is used to implement a control method for automatic vertical roll calibration. The calibration offset calculated by the present invention is compared with the vertical roll opening measured on site, and the error is controlled within ±1 mm. The entire control process is simple, fast, highly accurate, requires minimal personnel, is safe, does not require specialized on-site operators, and is unaffected by the external operating environment.

Description

Technical Field

[0001] The invention relates to a control system, in particular to an online automatic calibration control system for vertical rollers, and belongs to the technical field of hot rolling production. Background Art

[0002] In actual hot rolling mill production, the magnetic scales (position sensors) of the roughing rolls are generally calibrated or replaced every six months if any problems arise. The hydraulic cylinders are replaced every one or two years, depending on actual usage. Due to the physical conditions of the hot rolling mill site, such as lubricants, iron filings, and water, as well as the limited workspace and the interweaving of multiple tasks during maintenance, the on-site work environment is complex and maintenance time is prolonged. Monthly calibration of the rolls includes verticality calibration and adjustment, as well as alignment calibration. Both operations require the collaboration of at least two operators on-site: operators in the operator's office repeatedly move the rolls, while on-site operators repeatedly measure them. This roll calibration method requires numerous operators, is difficult, unsafe, and prone to misjudgment. It also requires a long calibration time, and any field anomalies require temporary roll replacement, often resulting in extended hot production downtime. With the company's advancement of intelligent manufacturing, the operating rooms corresponding to on-site equipment have been consolidated and staff reduced. This traditional method ran counter to the company's high safety, environmental protection, and labor efficiency targets.

[0003] After novelty search, patent CN201110274492, titled "A Method for Calibrating the Roll Gap of Hot-Strip Vertical Rollers," was discovered. This method is a traditional manual operation method that requires real-time coordination between the on-site operator and the operator's office. This patent is intended to replace the previously used method.

[0004] Patent: CN201910454339 Title: A vertical roller calibration method. This invention uses a slab to calibrate the mechanical gap of the vertical roller opening after the two vertical rollers are replaced. This method uses a slab to calibrate the mechanical gap, which requires the preparation of a slab and the adjustment of equipment such as a slab crane. This method still requires real-time coordination between the site and the operation room. The methods disclosed in the prior art are not ideal technical solutions. Therefore, a new solution is urgently needed to address the above technical problems. Summary of the Invention

[0005] This invention addresses the challenges of the existing technology by providing an online automatic calibration control system for vertical rollers. This technical solution automatically calibrates the vertical rollers based on their diameters. This is achieved through the L1 program: the L1 basic automation program automatically captures changes in roller diameter on the L2 screen, automatically recalculates the control calibration offset, and sends it to the L1 device for control. The calculated calibration offset is compared with the vertical roller opening measured on site, with an error control range of ±1mm. This control method is simple, fast, highly accurate, requires minimal personnel, is safe, and does not require specialized on-site personnel. It is also unaffected by the external operating environment.

[0006] In order to achieve the above-mentioned purpose, the technical solution of the present invention is as follows: an online automatic calibration control system for vertical rolls, the control system comprising an L3 roll management control module, an L2 roll management module and an L1 basic automation program control module. In this system, the L3 roll management control module, the L2 roll management module and the L1 basic automation program control module cooperate to realize that the L1 basic automation program automatically captures the changes in the roll diameter on the L2 process control system screen, automatically recalculates the control calibration OFFSET, and sends it to the equipment in the L1 roll management control module for control.

[0007] As an improvement of the present invention, the L3 roll management and control module is a roll grinding workshop that grinds rolls according to the hot rolling production plan requirements. Before changing rolls, that is, before starting a new plan, the roll plan information is sent to the L2 process control system through the L3 roll management and control module; the L3 roll management and control module includes: roll parameter information, roll pairing information, roll grinding history, roll offline history, roll changing information, and roll scrapping management.

[0008] As an improvement of the present invention, in the L2 roll management module, the L2 process control system receives the roll planning information and updates the L2 roll screen. After the L2 roll management module reads the roll screen information, it broadcasts the roll information to the public network; the L2 roll management module includes a current roll management module and a spare roll management module.

[0009] As an improvement of the present invention, the L1 basic automation program control module includes an L1 basic automation program capture module, an L1 basic automation program calculation module and an L1 basic automation program control module. The specific control process is as follows:

[0010] 1) L1 basic automation program capture module: The L1 basic automation capture program cyclically monitors the information of the public network every 5ms. Once the roll information is updated, it captures the current roll information of the public network, captures the current magnetic scale change, and updates the last magnetic scale change;

[0011] 2) L1 basic automation program calculation module first determines whether the received vertical roller diameter has changed with the last saved vertical roller diameter. If there is no change, no action is taken. If there is a change in the roller diameter, the vertical roller opening corresponding to the vertical roller maximum diameter / 2) + (vertical roller maximum diameter - vertical roller new roller diameter) / 2 is used.

[0012] The single-side calibration OFFSET is calculated, where: Since the vertical roller is composed of a group of rollers located on the transmission side and the operating side, the new roller diameter of the vertical roller is divided into the new roller diameter of the transmission side vertical roller and the new roller diameter of the operating side vertical roller; According to the single-side calibration OFFSET calculated above and the change of the magnetic scale, the formula "single-side vertical roller opening =

[0013] The "single-side vertical roller opening" can be calculated by "single-side calibration OFFSET-magnetic scale change", where the magnetic scale change is calculated according to the formula: "magnetic scale change = magnetic scale feedback position - magnetic scale zero position", and the total vertical roller opening is calculated by the sum of the transmission side vertical roller opening and the operating side vertical roller opening, that is, the total vertical roller opening = transmission side vertical roller opening + operating side vertical roller opening, where: transmission side vertical roller opening = transmission side calibration OFFSET-

[0014] (Transmission side magnetic scale feedback position - transmission side magnetic scale zero position), operation side vertical roller opening = operation side calibration

[0015] OFFSET-(operating side magnetic scale feedback position-operating side magnetic scale zero position);

[0016] The L1 basic automation program control module controls the opening of the vertical rollers on both sides of the site to a single-sided opening position of "total vertical roller opening / 2" based on the total vertical roller opening calculated by the calculation module. This solution implements an online automatic calibration control method for vertical rollers. Operators in the control room can open the vertical rollers to any position and then compare the on-site vertical roller opening with the vertical roller opening value displayed on the screen, with the error controlled within ±1mm. This method achieves online automatic calibration control of vertical rollers with simple and quick operation, completing vertical roller verticality and centering calibration in less than 5 minutes. This effectively shortens calibration time, improves vertical roller calibration efficiency, significantly shortens maintenance time for vertical roller calibration projects, and enhances vertical roller calibration control accuracy. It also eliminates the thermal downtime caused by traditional vertical roller calibration during abnormal vertical roller replacement, contributing to cost reduction and efficiency improvement for the enterprise.

[0017] Compared with the existing technology, the present invention has the following advantages: 1) After the technical solution is fully automatically implemented, the calibration time of the vertical roller is reduced from the original 30 minutes to the current 5 minutes, which greatly shortens the maintenance time. Once there is an abnormality on site and the vertical roller needs to be temporarily replaced, this method can avoid the hot downtime caused by the vertical roller calibration; 2) This method can reduce the number of operators by fully automatically realizing the online vertical roller calibration operation, which is beneficial to improving the company's labor efficiency; 3) The control accuracy of this method is ±1mm, which is greatly improved compared with the control accuracy of the original method of ±5mm; 4) This method fully automatically realizes the vertical roller calibration operation, which solves the problems of high operation difficulty, unsafety and misjudgment of the previous method; 5) This method fully automatically realizes the online calibration operation of the vertical roller, freeing up more working space for the vertical roller maintenance operation, and also avoids the problem of extended maintenance time caused by cross-operation of multiple types of work. After the method is fully automatically realized, the number of operators can be reduced, efficiency can be improved, and enterprise costs can be saved. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a flow chart of the prior art;

[0019] Figure 2 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0020] In order to deepen the understanding of the present invention, this embodiment is described in detail below with reference to the accompanying drawings.

[0021] Example 1: See Figure 2 An online automatic calibration control system for vertical rollers is provided. The control system includes an L3 roller management control module, an L2 roller management module, and an L1 basic automation program control module. In this system, the L3 roller management control module, the L2 roller management module, and the L1 basic automation program control module cooperate to realize that the L1 basic automation program automatically captures the changes in the roller diameter on the L2 process control system screen, automatically recalculates the control calibration offset, and sends it to the equipment in the L1 roller management control module for control.

[0022] The L3 roll management and control module can implement dynamic change management of roll information and standardize roll information management. The roll grinding workshop grinds rolls according to the hot rolling production plan requirements. Before changing rolls, that is, before starting a new plan, the roll plan information is sent to the L2 process control system through the L3 roll management and control module. The L3 roll management and control module includes: roll parameter information, roll pairing information, roll grinding history, roll offline history, roll changing information, and roll scrapping management. In the L2 roll management module, the L2 process control system receives the roll plan information and updates the L2 roll screen. After the L2 roll management module reads the roll screen information, it broadcasts the roll information to the public network. The L2 roll management module includes a current roll management module and a backup roll management module.

[0023] The L1 basic automation program control module includes the L1 basic automation program capture module, the L1 basic automation program calculation module, and the L1 basic automation program control module. The specific control process is as follows:

[0024] 1) L1 basic automation program capture module: The L1 basic automation capture program cyclically monitors the information of the public network every 5ms. Once the roll information is updated, it captures the current roll information of the public network, captures the current magnetic scale change, and updates the last magnetic scale change;

[0025] 2) L1 basic automation program calculation module first determines whether the received vertical roller diameter has changed with the last saved vertical roller diameter. If there is no change, no action is taken. If there is a change in the roller diameter, the vertical roller opening corresponding to the vertical roller maximum diameter / 2) + (vertical roller maximum diameter - vertical roller new roller diameter) / 2 is used.

[0026] The single-side calibration OFFSET is calculated, where: Since the vertical roller is composed of a group of rollers located on the transmission side and the operating side, the new roller diameter of the vertical roller is divided into the new roller diameter of the transmission side vertical roller and the new roller diameter of the operating side vertical roller; According to the single-side calibration OFFSET calculated above and the change of the magnetic scale, the formula "single-side vertical roller opening =

[0027] The "single-side vertical roller opening" can be calculated by "single-side calibration OFFSET-magnetic scale change", where the magnetic scale change is calculated according to the formula: "magnetic scale change = magnetic scale feedback position - magnetic scale zero position", and the total vertical roller opening is calculated by the sum of the transmission side vertical roller opening and the operating side vertical roller opening, that is, the total vertical roller opening = transmission side vertical roller opening + operating side vertical roller opening, where: transmission side vertical roller opening = transmission side calibration OFFSET-

[0028] (Transmission side magnetic scale feedback position - transmission side magnetic scale zero position), operation side vertical roller opening = operation side calibration

[0029] OFFSET-(operating side magnetic scale feedback position-operating side magnetic scale zero position); L1 basic automation program control module, according to the total opening of the vertical roller calculated by the calculation module, controls the vertical rollers on both sides of the site to open to the opening position of one side: "total opening of the vertical roller / 2".

[0030] Specific embodiment: refer to Figure 2 Taking the Meishan Iron and Steel 1422 hot rolling production line as an example, an online automatic calibration control system for vertical rolls is proposed. The control system includes an L3 roll management control module (including: roll parameter information, roll pairing information, roll grinding history, roll offline history, roll change information, roll scrapping management, etc.), an L2 roll management module (including the current roll management module and the spare roll management module) and an L1 basic automation program control module (including L1 basic automation program capture, L1 basic automation program calculation and L1 basic automation program control). In this system, the L3 roll management control module, the L2 roll management module and the L1 basic automation program control module cooperate to realize that the L1 basic automation program automatically captures the changes in the roll diameter of the L2 process control system screen, automatically recalculates the control calibration OFFSET, and sends it to the equipment in the L1 roll management control module for control. The control implementation steps are as follows:

[0031] (1) L3 Roller Management Control Module

[0032] The roller grinding workshop grinds rollers according to the hot rolling production plan requirements and sends the roller plan information to the L2 process control system through the L3 roller management control module before changing the rollers.

[0033] (2) L2 Roller Management Module

[0034] The L2 process control system receives the roll planning information and updates the L2 roll screen. After the L2 roll management module reads the roll screen information, it broadcasts the roll information to the public network.

[0035] (3) L1 basic automation program control module

[0036] a) L1 basic automation program capture module

[0037] The L1 basic automation capture program monitors the public network information every 5ms. Once the roll information is updated, it captures the current roll information on the public network, captures the current magnetic scale change, and updates the previous magnetic scale change.

[0038] b) L1 basic automation program calculation module

[0039] i.L1 basic automation program calculation module first determines whether the received vertical roller diameter has changed with the last saved vertical roller diameter. If there is no change, no action will be taken.

[0040] ii. If the roller diameters are different, then the vertical roller opening corresponding to the maximum roller diameter should be calculated.

[0041] / 2) + (maximum roll diameter of vertical roll - new roll diameter of vertical roll) / 2" to calculate the single-side calibration OFFSET. The maximum roll diameter allowed by the vertical roll of Meishan Iron and Steel's 1422 hot rolling production line is 1100mm, and the vertical roll opening corresponding to the maximum roll diameter is 1800mm. Taking the new vertical roll replaced on May 13, 2020 as an example, the roll diameters of the vertical rolls are 1016.2mm (drive side) and 1016.4mm (operation side). Therefore, the following formula can be used to calculate:

[0042] Transmission side calibration OFFSET = (verter roller opening corresponding to the maximum roller diameter / 2) + (verter roller maximum roller diameter - transmission side roller diameter)

[0043] / 2=(1800 / 2)+(1100-1016.2) / 2=941.9

[0044] Operation side calibration OFFSET = (verter roll opening corresponding to the maximum roll diameter of the vertical roll / 2) + (verter roll maximum roll diameter - operation side vertical roll diameter)

[0045] / 2=(1800 / 2)+(1100-1016.4) / 2=941.8

[0046] iii. Based on the above calculated single-side calibration offset and magnetic scale variation, the single-side vertical roller opening can be calculated by "single-side calibration offset - magnetic scale variation". Among them, "magnetic scale variation = magnetic scale feedback position - magnetic scale zero position"

[0047] Transmission side vertical roller opening = transmission side calibration OFFSET - (transmission side magnetic scale feedback position - transmission side magnetic scale zero position) = 941.9 - (350-58) = 649.9

[0048] Operating side vertical roller opening = operating side calibration OFFSET - (operating side magnetic scale feedback position - operating side magnetic scale zero position) = 941.8 - (352.5 - 60.2) = 649.5

[0049] Therefore, the total opening of the vertical roller = the opening of the transmission side vertical roller + the opening of the operating side vertical roller

[0050] =649.9+649.5=1299.4mmc)L1 basic automation program control module

[0051] The L1 basic automation control module controls the vertical rollers on both sides of the site to open to an opening position of 649.7mm on one side according to the set vertical roller opening of 1299.4mm.

[0052] Through the above steps, a method for online automatic calibration control of vertical rollers is implemented. Operators in the operating room can open the vertical rollers to any position and then compare the on-site vertical roller opening with the vertical roller opening value displayed on the screen. The error is controlled within ±1mm. This method realizes online automatic calibration control of vertical rollers. The operation is simple and fast. The vertical roller verticality and centering calibration operation can be completed in less than 5 minutes, effectively shortening the calibration time, improving the efficiency of vertical roller calibration work, greatly shortening the maintenance time of vertical roller calibration projects, and improving the control accuracy of vertical roller calibration operations. It also eliminates the thermal downtime caused by traditional vertical roller calibration when abnormal vertical roller replacement occurs.

[0053] It should be noted that the above embodiments are not intended to limit the scope of protection of the present invention, and equivalent changes or substitutions made on the basis of the above technical solutions fall within the scope of protection of the claims of the present invention.

Claims

1. An online automatic calibration control system for vertical rollers, characterized in that: The control system includes an L3 roll management control module, an L2 roll management module and an L1 basic automation program control module. In this system, the L3 roll management control module, the L2 roll management module and the L1 basic automation program control module cooperate to realize that the L1 basic automation program automatically captures the changes in the roll diameter of the L2 process control system screen, automatically recalculates the control calibration OFFSET, and sends it to the equipment in the L1 roll management control module for control. The L3 roll management control module includes: roll parameter information, roll pairing information, roll grinding history, roll offline history, roll change information, roll scrapping management, the L3 roll management control module, grinding The roll shop grinds rolls according to the hot rolling production plan. Before changing rolls, that is, before starting a new plan, the roll plan information is sent to the L2 process control system through the L3 roll management control module. The L2 roll management module includes the current roll management module and the spare roll management module. In the L2 roll management module, the L2 process control system receives the roll plan information and updates the L2 roll screen. After reading the roll screen information, the L2 roll management module broadcasts the roll information to the public network. The L1 basic automation program control module includes the L1 basic automation program capture module, the L1 basic automation program calculation module, and the L1 basic automation program control module. The specific control process is as follows: 1) L1 basic automation program capture module: The L1 basic automation capture program cyclically monitors the information of the public network every 5ms. Once the roll information is updated, it captures the current roll information of the public network, captures the current magnetic scale change, and updates the last magnetic scale change; 2) L1 basic automation program calculation module first determines whether the received vertical roller diameter has changed with the last saved vertical roller diameter. If there is no change, no action is taken. If there is a change in the roller diameter comparison, the single-side calibration OFFSET is calculated based on "(verter roller opening corresponding to the maximum vertical roller diameter / 2) + (verter roller maximum diameter - vertical roller new roller diameter) / 2". Among them: Since the vertical roller is composed of a group of rollers located on the transmission side and the operating side respectively, the new vertical roller diameter is divided into the new roller diameter of the transmission side vertical roller and the new roller diameter of the operating side vertical roller; Based on the single-side calibration offset and magnetic scale variation calculated above, the "single-side vertical roller opening" can be calculated using the formula "single-side vertical roller opening = single-side calibration offset - magnetic scale variation". The magnetic scale variation is calculated according to the formula: "magnetic scale variation = magnetic scale feedback position - magnetic scale zero position". The total vertical roller opening is calculated by the sum of the transmission side vertical roller opening and the operating side vertical roller opening, that is, the total vertical roller opening = transmission side vertical roller opening + operating side vertical roller opening, where: transmission side vertical roller opening = transmission side calibration offset - (transmission side magnetic scale feedback position - transmission side magnetic scale zero position), and operating side vertical roller opening = operating side calibration offset - (operation side magnetic scale feedback position - operation side magnetic scale zero position). The L1 basic automation program control module controls the vertical rollers on both sides of the site to open to the opening position on one side: "total vertical roller opening / 2" based on the total vertical roller opening calculated by the calculation module.

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