System and method for slab size calibration and automatic adjustment of rolling targets for medium and heavy plates

Abstract

This invention discloses a system and method for calibrating slab dimensions and automatically adjusting rolling targets for medium and heavy plate production. The system comprises: a first storage unit for storing user-defined material usage requirements; a second storage unit for storing internal production process requirements; a computer information system for performing basic automation control, process control, production line manufacturing execution control, and production operation control; and an automatic control module for connecting the first and second storage units with the computer information system. For modern medium and heavy plate production enterprises, this invention can reduce the labor intensity of frontline operators and fully tap the cost-reduction potential of the production and operation process.

Description

Technical Field

[0001] The present invention relates to an automatic control technology for a medium and thick plate production line, and more particularly to a system and method for automatically adjusting the slab size and rolling target of a medium and thick plate. Background Art

[0002] 1. Order production, material design, hot charging and delivery, and slab weighing in the existing medium and thick plate product manufacturing process.

[0003] In modern plate production, order-based production is typically organized based on contract orders. Sales personnel sign supply contracts with customers and enter the contract information into the company's internal sales management system. Production personnel then schedule production for steelmaking, rolling, and other production units based on the contract information. These units then execute specific production tasks and deliver qualified plate products to the corresponding customers.

[0004] Material Design: During the production organization process, target dimensions for the steelmaking unit's continuous casting and rolling units' rolling targets are determined based on the order's final product dimensions and performance requirements. This is called material design. The target dimensions for continuous casting in the steelmaking unit primarily refer to the width and length of the continuously cast slabs, which can be divided into several width levels based on the equipment's design capabilities. The target dimensions for rolling units include target thickness, target width, and minimum length.

[0005] The brief production process of medium and thick plates mainly includes steelmaking-continuous casting-heating-rolling.

[0006] Hot charging and hot delivery: Hot charging and hot delivery refers to the direct transportation of high-temperature continuously cast slabs produced during the continuous casting process to the reheating furnace, without cooling them in the slab storage. When the slab temperature exceeds 300°C, they are loaded into the reheating furnace for subsequent heating and rolling. The advantage of hot charging and hot delivery is energy conservation. However, some steel grades with unique material structures, such as mold steel, are prone to quality defects such as cracking at the edges or corners after cooling to a cold slab if hot charging and hot delivery is not implemented.

[0007] Slab weighing: Slab weighing is a dimensional verification step before the slab enters the reheating furnace. A weighing machine is installed at the furnace entry roller table to compare the weighed slab weight with the target weight converted from the target rolling dimensions. If the weight deviation is large, it indicates an anomaly in the material design or continuous casting process. The slab will then be removed from the production line for subsequent manual processing.

[0008] There are several reasons for abnormal slab weight. First, when the continuous casting machine for continuous casting production changes the slab width specifications, it is bound to cause inconsistent widths at the head and tail of the slab produced at that time; second, the continuous casting machine produces continuously, but the molten steel comes from the converter of the entire furnace production. The slab cast by the last molten steel in the last furnace of continuous casting often cannot reach the target slab length; third, the material design or weighing machine is abnormal.

[0009] 2. Multi-level computer information systems and automatic control systems involved in the sales and production of medium and thick plates.

[0010] The production operations of modern large-scale steel joint ventures usually adopt a four-level computer information system architecture, including the first level for basic automation (L1), the second level for process control system (L2), the third level for production line manufacturing execution system (MES L3), and the fourth level for company production operation system (ERP L4).

[0011] The computer or automation system functions involved in the aforementioned steps of order production organization include:

[0012] Supply contract entry: L4's sales management subsystem converts the user's order requirements such as steel type, steel plate size, material properties, delivery date, etc. into computer information.

[0013] Material design: L4's manufacturing management subsystem reads in the informatized contract information such as steel type and size, and designs reasonable process target dimensions for the production unit, including the width and length of the continuous casting slab, and the rolling target dimensions of the rolling unit, including target thickness, target width, and minimum length.

[0014] Production plan: Steelmaking L3 summarizes the material design information of all contracts and arranges the steelmaking production plan; steel rolling L3 summarizes the material design information of all contracts and arranges the rolling production plan.

[0015] Production logistics: Steelmaking L3 tracks and manages the production progress of the steelmaking area; Steel rolling L3 tracks and manages the production progress of the steel rolling area.

[0016] Hot charging and hot delivery: The slab logistics information transmission is completed by the steelmaking L3 and rolling L3, the automatic control of the transport roller is completed by the heating furnace area L1, and the automatic furnace entry process is automatically completed by the heating furnace L2 operating the heating furnace steel loader L1.

[0017] Slab weighing: The weighing machine outputs weight information, and the heating furnace L2 compares the weight deviation. If the weight is normal, the automatic furnace entry process is started. If the weight is abnormal, the rolling mill L3 is notified to refuse the slab from entering the furnace.

[0018] The crane lifts the slab off the production line: Steel Rolling L3 notifies the crane operator to complete the operation.

[0019] Slab rolling: Rolling mill L2 receives the rolling target size forwarded by rolling mill L3 and coordinates with rolling mill L1 to control the rolling process.

[0020] 3. User material usage characteristics and user personalized needs, taking mold steel as an example.

[0021] Through customer service and other channels, we've learned that different medium and heavy plate users have diverse ways of using steel. For example, some weld whole plates, such as pipeline steel users; some cut and then splice, such as shipbuilding steel users; and still others process them into several smaller components, such as mold steel users. For medium and heavy plate suppliers, due to the individual characteristics of user material usage, their actual requirements for medium and heavy plate range from standard dimensions and performance to specific industry requirements. For mold steel, for example, because users cut the steel into small pieces for processing, their requirements for width and length vary widely, ranging from wide to narrow, and from long to short within a certain range. Some of these individual material requirements are reflected in the contract, while others may not. Even if these individual requirements are included in the contract, they may not be input into the standardized input interface of the sales management system and thus fail to be converted into computerized contract information.

[0022] 4. Special process requirements for steel plates in internal production.

[0023] Due to the characteristics of the materials, some steel grades have certain special process requirements in the continuous casting, heating, rolling and other links. For example, after the continuous casting billets of mold steel are cooled to room temperature by natural air, they are very prone to cracking defects at the edges or corners. The product development personnel stipulated that the mold steel slabs must be hot-charged and hot-delivered, and the slabs are not allowed to be shipped off the line. The common heating furnace temperature, warm rolling temperature, cooling rate, etc. in the steel production process are all stored in the L4 process design subsystem. However, these special process requirements in internal production are not included in L4. Instead, they are retained in the relevant production units in the form of official documents and are not actually digitized.

[0024] 5. Problems existing in the slab weighing process.

[0025] During slab weighing, the heating furnace's L2 computer compares the weighed slab weight with the target weight, converted from the target rolling dimensions. If the weight deviation is significant, the slab is removed from the production line. This processing logic, viewed as a single step, appears to be flawless. However, when considered within the overall production, marketing, and research process for medium and heavy plate products, there are still areas for improvement.

[0026] Take the mold steel business process as an example. Sales personnel and users sign orders with wide tolerances on width and length. However, during the material design phase, conventional rolling target dimensions are still specified. When the slab width specification changes during the continuous casting process, or when the last slab is cast at the end of a continuous casting cycle, the actual slab weight differs significantly from the target weight calculated based on the rolling target dimension. For these variable width slabs or the final slab, heating furnace L2 automatically performs offline processing according to the aforementioned rules. These mold steel slabs are very likely to crack at the edges and corners, forcing them to be scrapped.

[0027] Existing technical solutions for these types of information systems, which ignore personalized user needs and specialized internal production process requirements, primarily rely on manual correction. Regarding the aforementioned issues with slab weighing, production units often document that operators must switch to manual weighing and loading for certain steel grades, ignoring weight verification information.

[0028] Shortcomings of existing technology:

[0029] Manual corrective measures for the aforementioned weighing process:

[0030] 1) Due to the labor intensity and information access restrictions of operators, it is not possible to formulate more detailed manual verification rules. As a result, the rules for exempting slab verification are too broad, potentially masking errors in weighing machines and material design. Furthermore, steel grade classification is not reliable. For example, for mold steel, there is no guarantee that every user who purchases mold steel will not care about the length of the steel plate.

[0031] 2) The switch to manual operation increases the labor intensity of the operators;

[0032] 3) The reliability of corrective measures is not high. If the production guidance documents are neglected and forgotten, the corresponding steel slabs may have quality defects after the production line is automatically shut down.

[0033] 4) The control targets of the subsequent processes are still incorrect. The actual object and the information judged in the weighing link are indeed inconsistent and are not transferred to the subsequent processes. The rolling process still uses unattainable length and width targets, which will reduce the stability of the subsequent processes and increase the frequent manual operation intervention of the subsequent processes. Summary of the Invention

[0034] In response to the above-mentioned defects in the prior art, the present invention provides a system and method for calibrating the slab size and automatically adjusting the rolling target of medium and thick plates. For modern medium and thick plate production enterprises, the purpose is to reduce the labor intensity of front-line operators and fully tap the cost reduction potential of the production and operation process.

[0035] To achieve the above object, the present invention adopts the following technical solutions:

[0036] In one aspect, a system for calibrating slab dimensions and automatically adjusting rolling targets for medium and heavy plates comprises:

[0037] The first storage unit is used to store the user's personalized material usage requirements;

[0038] The second storage unit is used to store internal production process requirements;

[0039] Computer information systems for basic automation control, process control, production line manufacturing execution control, and production operation control;

[0040] The automatic control module is used to connect the first storage unit, the second storage unit and the computer information system.

[0041] Preferably, the user material uses personalized needs, including:

[0042] Steel grade, customer number, contract number; and

[0043] "Is it allowed that the actual width deviates greatly?", "Is it allowed that the actual length deviates greatly?"

[0044] Preferably, the internal production process requirements include:

[0045] Steel grade, process design number; and

[0046] "Is it only allowed to use hot loading and hot delivery process?"

[0047] Preferably, the computer information system has four levels, including:

[0048] L1-level weighing machines, heating furnace steel loading machines, and rolling mills;

[0049] L2 level heating furnace and rolling mill;

[0050] L3 level steelmaking and steel rolling;

[0051] L4 sales management subsystem and manufacturing management subsystem.

[0052] On the other hand, a method for automatically adjusting the slab size and rolling target of medium and heavy plates is provided:

[0053] In order to utilize the automated functions of the system for identification, weight verification, and rolling target adjustment control of continuous casting slabs, adaptive changes need to be made to the computer information system connected thereto.

[0054] Preferably, the continuous casting slab needs to meet the following requirements:

[0055] 1) The maximum permissible short length deviation of the continuous casting slab is: -10 meters to +10 meters;

[0056] 2) The maximum permissible short length of the width deviation of the continuous casting slab is: -1 meter to +1 meter;

[0057] 3) The continuous casting slab is only allowed to adopt the hot charging and hot delivery process, and is not allowed to be taken off the line;

[0058] 4) The continuous casting slab is the slab cast when the slab width specification of the continuous casting machine is converted, or when the last molten steel is cast at the end of the continuous casting.

[0059] Preferably, the automation function is triggered by multiple external events to trigger different processing flows, which together complete the automation function.

[0060] Preferably, the external events triggering different processing processes specifically include:

[0061] Event 1: Automatically triggered at a fixed period;

[0062] The processing flow of event 1: access the basic information of the medium and heavy plate contract in the L4 sales management subsystem, and synchronize the contract number, user number, contract-agreed thickness dimension, contract-agreed width dimension, contract-agreed length dimension, contract-allowed width tolerance range, and contract-allowed length tolerance range information to the internal database of the automatic control module;

[0063] Event 2: Salesperson enters the contract;

[0064] The processing flow of event 2: the salesperson enters the steel type, user number, contract number, "whether a large deviation in the actual width is allowed", and "whether a large deviation in the actual length is allowed" into the first storage unit;

[0065] Event 3: After product R&D personnel complete the production process design;

[0066] The processing flow of event 3: the product R&D personnel enters the steel type, process design number, and "whether only hot charging and hot delivery processes are allowed" into the second storage unit;

[0067] Event 4: After the continuous casting machine casts the slab;

[0068] The processing flow of event 4: the L3 steelmaking generates two identifiers based on actual production information: "whether the production is during the continuous casting machine slab width specification conversion" and "whether the slab is the last molten steel cast in the last heat of continuous casting". The slab number and the two identifiers are automatically sent to the automatic control module, and the automatic control module stores the received information in its internal database;

[0069] Event 5: When the rolling line production plan starts;

[0070] The processing flow of event 5: When the production plan of the thick plate rolling line is completed, the L3 level rolling mill will automatically trigger the rolling line production plan start event. The L3 level rolling mill will send the slab number, contract number, user number, steel grade, process design number, and "hot charging and hot delivery" flag corresponding to the steel plate to be produced to the automatic control module, and the automatic control module will start the pre-processing process of automatic slab weight verification;

[0071] Event 6: After the slab weighing is completed;

[0072] The processing flow of event 6: After the slab weighing is completed, the L2-level heating furnace receives the slab measurement weight sent by the L1-level weighing machine, and the L2-level heating furnace first inquires the automatic control module whether the automatic control module takes over the weight deviation calibration of the slab. If so, the automatic control module takes over the weight deviation calibration of the slab, and uses the slab weight deviation rule to determine whether it is allowed to be loaded into the heating furnace. Otherwise, the weight deviation calibration of the slab is not taken over, and the L2-level heating furnace continues to execute the original slab calibration process.

[0073] Preferably, in the processing flow of event 5, the pre-processing flow is specifically as follows:

[0074] For the steel plate to be produced, the information of "whether hot loading and hot delivery" is obtained from the information sent by the L3 grade rolled steel in the event 5;

[0075] For the steel plate to be produced, using the steel type, user number, and contract number as indexes, obtain "whether a large deviation in the actual width is allowed" and "whether a large deviation in the actual length is allowed" from the first storage unit;

[0076] For the steel plate to be produced, using the steel type and process design number as indexes, obtain "whether only hot charging and hot delivery processes are allowed" from the second storage unit;

[0077] For the steel plate to be produced, using the slab number as an index, obtain from the internal database of the automatic control module whether "the production is during the slab width specification conversion of the continuous casting machine" and "whether it is the last slab casted by molten steel in the last heat of continuous casting";

[0078] If and only if the "whether large deviation of actual width is allowed" is yes, the "whether large deviation of actual length is allowed" is yes, the "whether only hot charging and hot delivery process is allowed" is yes, the "whether hot charging and hot delivery" is yes, and at least one of the two identifications "whether it is produced when the slab width specification of the continuous casting machine is converted" or "whether it is the last slab cast by molten steel in the last furnace of continuous casting" is yes, the preprocessing conclusion is obtained, and the steel plate to be produced meets the specific characteristics of automatic weight verification, and finally the slab number and the identification of "whether it meets the specific characteristics of automatic weight verification" are saved in the internal database of the automatic control module.

[0079] Preferably, in the processing flow of event 6, the L2-level heating furnace first inquires the automatic control module about the inquiry message including the slab number, the measured weight of the slab, and the rolling size target.

[0080] Preferably, in the processing flow of event 6, the slab weight deviation rule is used to determine whether it is allowed to be loaded into the heating furnace. If so, the L2-level heating furnace is responded to and the weight deviation check of the slab is taken over. If the weight deviation check result is that the slab is allowed to be loaded into the furnace, if the slab weight deviation rule gives a new rolling target width and rolling minimum length, the L2-level rolling mill is notified at the same time, and the rolling target size of the steel plate to be produced is changed to the new rolling target width and rolling minimum length; after receiving the response result that the slab weight check is taken over and the check is that the slab is allowed to be loaded into the furnace, the L2-level heating furnace does not execute the original slab check process, but directly and automatically controls the L1-level heating furnace steel loading machine to start the automatic steel loading process; after receiving the notification of the rolling target change, the L2-level rolling mill updates the internally saved rolling target information. When steel rolling starts, the L1-level rolling mill and the L2-level rolling mill perform the rolling process according to the new target size information;

[0081] If the response is otherwise, the L2-level heating furnace will take over the weight deviation calibration of the slab, and the weight deviation calibration result is that the slab is not allowed to enter the furnace. After receiving the response result that the weight calibration of the slab is taken over and the calibration result is that the slab is not allowed to enter the furnace, the L2-level heating furnace will not execute the original slab calibration process, and directly start the weight exception processing, and refuse the slab from entering the furnace through the L3-level steel rolling.

[0082] Preferably, in the processing flow of event 6, the specific steps of checking the weight deviation of the slab are as follows:

[0083] 1) Calculate the minimum weight permitted by the contract Wmin:

[0084] Wmin = rolling target thickness × (minimum width of contractually permitted tolerance + △b0) × (minimum length of contractually permitted tolerance + △L0);

[0085] In the above formula, △b0 is between 0 and 0.5m, and △L0 is between 0 and 1.0m;

[0086] 2) Check whether the slab measurement weight is ≤ Wmin;

[0087] If yes, the result of the entry into the L2 level heating furnace is “not allowed to enter the furnace”, the weight deviation check of the slab is completed, and the subsequent steps are not executed;

[0088] If the result of the L2-level heating furnace entry is "OK", the subsequent steps are executed;

[0089] 3) Calculate the material design slab weight Wdgn:

[0090] Wdgn = target rolling thickness × target rolling width × minimum rolling length × steel density;

[0091] 4) Compare the measured slab weight with Wdgn and execute the same judgment logic as the L2 level heating furnace:

[0092] If the result is passed, there is no need to adjust the rolling target size, the slab weight deviation check is completed, and the subsequent steps are not executed;

[0093] If the result of the judgment is not passed, the rolling target size needs to be adjusted and the process goes to step 5);

[0094] 5) Adjust the calculation process of the rolling target size. The required quantities are the width change △b and the length change △L. The commonly used nonlinear optimization algorithm is used to determine these two required quantities.

[0095] The objective function to be optimized is:

[0096] In the above formula, W meas is the measured weight of the slab, b tgt is the existing rolling target width;

[0097] Calculate the new rolling target width b new and the new minimum rolling length L new :

[0098]

[0099] 7) The calculated new rolling target width b new and the new minimum rolling length L new Sent to the L2 level rolling mill as a specific data item for changing the rolling target size.

[0100] Preferably, in step 4), the judgment logic is as follows:

[0101] Whether (measured slab weight / Wdgn) is between 0.9 and 1.1, if so, it is judged as passed, otherwise it is failed.

[0102] Preferably, in formula (1) of step 5), the calculation formula of W is as follows:

[0103] W=h×(b tgt +△b0+△b)×(L tgt +△L0+△L)×ρ formula (3);

[0104] In the above formula, h is the target rolling thickness, Ltgt is the existing minimum rolling length, and ρ is the density of steel.

[0105] The present invention provides a system and method for calibrating the size of medium and thick plate slabs and automatically adjusting the rolling targets. Relying on a data platform interconnected with computer systems at all levels, it integrates existing information across processes and levels, and digitizes key information such as user material usage individual needs, internal production special process requirements, etc. that were previously not digitized. Ultimately, it achieves automatic calibration of the refined weight of the slabs and automatically adjusts the size targets of subsequent rolling processes accordingly, thereby reducing the labor intensity of operators and fully tapping the cost reduction potential of the production and operation process. BRIEF DESCRIPTION OF THE DRAWINGS

[0106] Figure 1 This is a schematic diagram of the framework of a system for slab size verification and automatic rolling target adjustment of medium and thick plates according to the present invention;

[0107] Figure 2 It is a schematic diagram of the pre-processing process of the processing flow of event 5 in the method for slab size verification and automatic adjustment of rolling targets of medium and thick plates of the present invention;

[0108] Figure 3 It is a schematic diagram of the processing flow of event 6 in a method for slab size verification and automatic adjustment of rolling targets for medium and thick plates according to the present invention;

[0109] Figure 4 It is a schematic diagram of slab weight deviation verification in the processing flow of event 6 in a method for slab size verification and automatic adjustment of rolling targets for medium and thick plates of the present invention. DETAILED DESCRIPTION

[0110] In order to better understand the above technical solutions of the present invention, the technical solutions of the present invention are further described below with reference to the accompanying drawings and embodiments.

[0111] Please combine Figure 1 As shown, the present invention provides a system for calibrating the slab size and automatically adjusting the rolling target of a medium and thick plate, comprising:

[0112] The first storage unit 101 is used to store user material usage personalization requirements;

[0113] The second storage unit 102 is used to store internal production process requirements;

[0114] Computer information system 200, used for basic automation control, process control, production line manufacturing execution control and production operation control;

[0115] The automatic control module 103 is used to connect the first storage unit 101 , the second storage unit 102 and the computer information system 200 .

[0116] A corresponding control module software interface framework 100 is also designed, on which automated functions such as identification, weight verification, and rolling target adjustment control of continuous casting slabs with specific characteristics are implemented, and adaptive changes are required to connect to the computer information system 200.

[0117] The first storage unit 101 stores the user's personalized material usage requirements. In addition to index conditions such as steel type, user number, and contract number, only two characteristic data need to be saved: "Whether large deviation in physical width is allowed" and "Whether large deviation in physical length is allowed". The sales staff enters these into the first storage unit 101 when entering the contract.

[0118] The second storage unit 102 stores internal production process requirements. In addition to index conditions such as steel type and process design number, it only needs to save one characteristic data: "Whether only hot charging and hot delivery processes are allowed". The R&D personnel enter this into the second storage unit 102 after the product process design.

[0119] The computer information system 200 has four levels, specifically including:

[0120] L1 level weighing machine 201, heating furnace steel loading machine 202, rolling mill 203;

[0121] L2 level heating furnace 204, rolling mill 205;

[0122] L3 level steelmaking 206, steel rolling 207;

[0123] L4 sales management subsystem 208 and manufacturing management subsystem 209.

[0124] The continuous casting slab with specific characteristics mainly includes the following specific characteristics:

[0125] 1) Based on the user's personalized material usage requirements, there is a large allowable range for the length deviation of the continuous casting slab (maximum allowable short length: -10 meters to +10 meters);

[0126] 2) Based on the user's personalized material usage requirements, there is a large allowable range for the width deviation of the continuous casting slab (maximum allowable short length: -1 meter to +1 meter);

[0127] 3) Adopt hot loading and hot delivery technology;

[0128] 4) Due to the special requirements of the internal production process, the continuous casting slab is only allowed to adopt the hot charging and hot delivery process, and it is not allowed to run off the line;

[0129] 5) The continuous casting slab is the slab cast when the slab width specification of the continuous casting machine is converted, or when the last molten steel is cast at the end of the continuous casting.

[0130] The present invention also provides a method for automatically adjusting the slab size and rolling target of medium and thick plates:

[0131] In order to utilize the automated functions of the system of the present invention for the identification, weight verification, and rolling target adjustment control of the continuous casting slab, the computer information system 200 needs to be adaptively modified.

[0132] The automation function is triggered by multiple external events, which trigger different processing processes to complete the automation function.

[0133] The specific external events and corresponding processing procedures are as follows:

[0134] Event 1: Automatically triggered at a fixed period;

[0135] Processing flow of event 1: Access the basic information of the medium and thick plate contract of the L4-level sales management subsystem 208, and synchronize the contract number, user number, contract-agreed thickness dimension, contract-agreed width dimension, contract-agreed length dimension, contract-agreed width tolerance range, contract-agreed length tolerance range and other information to the internal database of the automatic control module 103.

[0136] Event 2: Salesperson enters the contract;

[0137] Processing flow of event 2: The salesperson enters the steel type, user number, contract number and two characteristic data of the user's material usage personalized requirements, "whether large deviation in actual width is allowed" and "whether large deviation in actual length is allowed" into the first storage unit 101.

[0138] Event 3: After product R&D personnel complete the production process design;

[0139] Processing flow of event 3: The product development personnel enter the steel type, process design number and a characteristic data of the internal production process requirement “whether only hot charging and hot delivery process is allowed” into the second storage unit 102 .

[0140] Event 4: After the continuous casting machine casts the slab;

[0141] Processing flow of event 4: L3 level steelmaking 206 generates two identifiers, "whether the production is during the continuous casting machine slab width specification conversion" and "whether it is the last slab cast by molten steel in the last furnace of continuous casting" based on actual production information, and automatically sends the slab number and the two identifiers to the automatic control module 103. The automatic control module 103 saves the received information in its internal database.

[0142] Event 5: When the rolling line production plan starts;

[0143] Processing flow of event 5: When the thick plate rolling line production plan is completed, the L3 level rolling mill 207 automatically triggers the rolling line production plan start event. The L3 level rolling mill 207 sends the slab number, contract number, customer number, steel grade, process design number, "hot loading and hot delivery" flag and other information corresponding to the steel plate to be produced to the automatic control module 103. The automatic control module 103 starts the pre-processing process of automatic slab weight verification.

[0144] Please combine Figure 2 As shown, the automatic control module 103 starts the pre-processing process of automatic slab weight verification as follows:

[0145] For the steel plate to be produced, the information "whether hot loading and hot delivery" is obtained from the information sent by the L3 level rolling mill 207 in event 5;

[0146] For the steel plate to be produced, the steel type, user number, and contract number are used as indexes to obtain "whether a large deviation in the actual width is allowed" and "whether a large deviation in the actual length is allowed" from the first storage unit 101;

[0147] For the steel plate to be produced, the steel type and process design number are used as indexes to obtain "whether only hot charging and hot delivery processes are allowed" from the second storage unit 102;

[0148] For the steel plate to be produced, the slab number is used as an index to obtain information from the internal database of the automatic control module 103, such as "whether the production is during the slab width specification conversion of the continuous casting machine" and "whether it is the last slab casted by molten steel in the last heat of continuous casting".

[0149] If and only if "Is large deviation of actual width allowed" is yes, "Is large deviation of actual length allowed" is yes, "Is only hot charging and hot delivery process allowed" is yes, "Is hot charging and hot delivery" is yes, and at least one of the two identifications "Is it produced when the slab width specification of the continuous casting machine is converted" or "Is it the last slab cast by molten steel in the last furnace of continuous casting" is yes, the preprocessing conclusion is obtained, and the steel plate to be produced meets the specific characteristics of automatic weight verification. Finally, the slab number and the identification of "whether it meets the specific characteristics of automatic weight verification" are saved in the internal database of the automatic control module 103.

[0150] Event 6: After the slab weighing is completed;

[0151] Please combine Figure 3As shown, the processing flow of event 6: after the slab weighing is completed, the L2-level heating furnace 204 receives the slab measurement weight sent by the L1-level weighing machine 201. The L2-level heating furnace 204 does not directly judge the slab weight deviation according to the original process, but first inquires the automatic control module 103 whether the automatic control module 103 takes over the weight deviation calibration of the slab. The inquiry message includes information such as the slab number, the slab measurement weight, and the rolling size target.

[0152] After receiving the query from the L2 heating furnace 204, the automatic control module 103 searches its internal database using the slab number as an index. If the result indicates "does it meet the specific characteristics for automatic weight verification?", the automatic control module 103 notifies the L2 heating furnace 204 that it will not take over the weight deviation verification for the slab. Upon receiving the "not taking over" response, the L2 heating furnace 204 continues the original slab verification process.

[0153] After receiving the inquiry from the L2 level heating furnace 204, the automatic control module 103 searches the internal database with the slab number as the index. If the result of "whether it meets the specific characteristics of automatic weight verification" is yes, the new slab weight deviation rule is first used to determine whether it is allowed to be loaded into the heating furnace.

[0154] If the new slab weight deviation rule determines that the slab can be loaded into the heating furnace, the L2-level heating furnace 204 will be notified to take over the weight deviation check of the slab. The weight deviation check result is that the slab can be loaded into the furnace. If the new slab weight deviation rule gives a new rolling target width and minimum rolling length, the L2-level rolling mill 205 will be notified at the same time that the rolling target size of the steel plate to be produced is changed to the new rolling target width and minimum rolling length. After receiving the response result that the slab weight check has been taken over and the check is that the slab can be loaded into the furnace, the L2-level heating furnace 204 will not execute the original slab check process, but will directly and automatically control the L1-level heating furnace steel loader 202 to start the automatic steel loading process. After receiving the notification of the rolling target change, the L2-level heating furnace 204 will update the internally saved rolling target information. At the start of steel rolling, the L1-level rolling mill 203 and the L2-level rolling mill 205 will carry out the rolling process according to the new target size information.

[0155] If the new slab weight deviation rule determines that it is not allowed to be loaded into the heating furnace, the L2-level heating furnace 204 will take over the weight deviation calibration of the slab, and the weight deviation calibration result will be that it is not allowed to enter the furnace. After receiving the response result of taking over the weight calibration of the slab and the calibration result being that it is not allowed to enter the furnace, the L2-level heating furnace 204 will not execute the original slab calibration process, but directly start the weight exception processing, and refuse to let the slab into the furnace through the L3-level steel rolling 207.

[0156] Please combine Figure 4 As shown, the specific steps for the new slab weight deviation verification are as follows:

[0157] 1) Calculate the minimum weight permitted by the contract Wmin:

[0158] Wmin = rolling target thickness × (minimum width of contractually permitted tolerance + △b0) × (minimum length of contractually permitted tolerance + △L0);

[0159] In the above formula, the value of △b0 is between 0 and 0.5m, and the value of △L0 is between 0 and 1.0m, which is determined by the production process control capability of the rolling line;

[0160] 2) Check whether the slab measurement weight is ≤ Wmin;

[0161] If yes, the result of the entry into the heating furnace 204 of level L2 is “not allowed to enter the furnace”, the weight deviation check of the slab is completed, and the subsequent steps are not executed;

[0162] If the result of the heating furnace 204 at level L2 is "OK", the subsequent steps are executed;

[0163] 3) Calculate the material design slab weight Wdgn:

[0164] Wdgn = target rolling thickness × target rolling width × minimum rolling length × steel density;

[0165] 4) Compare the measured slab weight with Wdgn and execute the same judgment logic as the L2 level heating furnace:

[0166] If the result is passed, there is no need to adjust the rolling target size, the slab weight deviation check is completed, and the subsequent steps are not executed;

[0167] If the result of the judgment is not passed, the rolling target size needs to be adjusted and the process goes to step 5);

[0168] The judgment logic is as follows:

[0169] Is (measured slab weight / Wdgn) between 0.9 and 1.1? If yes, it is considered passed; otherwise, it is considered failed.

[0170] 5) Adjust the calculation process of the rolling target size. The required quantities are the width change △b and the length change △L. The commonly used nonlinear optimization algorithm is used to determine these two required quantities.

[0171] The objective function to be optimized is:

[0172] In the above formula, W meas is the measured weight of the slab, b tgt is the existing rolling target width;

[0173] The objective function is set up with two factors in mind: first, the new target size matches the measured weight, and second, the minimum rolling length in the rolling size target is adjusted first. In the above formula, the calculation formula for W is as follows:

[0174] W=h×(b tgt +△b0+△b)×(L tgt +△L0+△L)×ρ formula (3);

[0175] In the above formula, h is the target rolling thickness, L tgt is the existing minimum rolling length, and ρ is the density of steel.

[0176] The optimization algorithm gives the width change △b and length change △L after optimization calculation, and calculates the new rolling target width b new and the new minimum rolling length L new :

[0177]

[0178] 7) The calculated new rolling target width b new and the new minimum rolling length L new Sent to the L2 level rolling mill 205 as a specific data item for changing the rolling target size.

[0179] In summary, existing technologies primarily rely on manual management and human intervention. This invention, however, employs a fully automated approach, relying on a data platform interconnected with computer systems at all levels. This integrates existing information across processes and levels, and digitizes key, previously undigitized information such as individual user material requirements and internal production process requirements. This ultimately enables automated verification of slab weight and corresponding adjustments to target dimensions in subsequent rolling steps, reducing operator workload and fully tapping the potential for cost reduction in the production and operation process.

[0180] Example

[0181] The existing salesperson receives a mold steel sales contract and enters the contract into the L4 sales management subsystem 208, and establishes a first storage unit 101, setting "whether large deviation in physical width is allowed" and "whether large deviation in physical length is allowed" to yes.

[0182] The product development personnel have entered the steel type of the mold steel, the process design number, and the "only hot charging and hot delivery process is allowed" into the second storage unit 102 .

[0183] The automatic control module 103 synchronizes the basic information of the medium and thick plate contract with the L4-level sales management subsystem 208 on a daily basis, and synchronizes the contract number, user number, contract-agreed thickness dimension, contract-agreed width dimension, contract-agreed length dimension, contract-allowed width tolerance range, contract-allowed length tolerance range and other information of this mold steel sales contract to the internal database of the automatic control module 103.

[0184] After the sales contract begins production within the enterprise and the continuous casting machine completes casting of the corresponding steel grade slab, L3 steelmaking 206 generates, based on actual production information, an indicator indicating whether the production occurred during a slab width change on the continuous casting machine and whether the slab is the last slab cast in the last heat of continuous casting. It then automatically sends the slab number and corresponding identifier for each steel plate to automatic control module 103, which stores the received information in its internal database. In this embodiment, the slab number is 099, and the "Is this the last slab cast in the last heat of continuous casting?" indicator is yes.

[0185] When a slab with slab number 099 is transported to the heavy plate rolling mill using the hot charging and hot delivery process, the L3 steel rolling mill 207 begins scheduling the heavy plate rolling line production plan. This automatically triggers the rolling line production plan start event and sends information such as the slab number 099, contract number, customer number, steel grade, process design number, and "hot charging and hot delivery" flag corresponding to the steel plate to be produced to the automatic control module 103. The automatic control module 103 then begins the preprocessing process for automatically checking the slab weight.

[0186] The preprocessing process is as follows:

[0187] For the steel plate to be produced, using the steel type, user number, and contract number as indexes, obtain from the first storage unit 101 whether "large deviation of actual width is allowed" is yes and "large deviation of actual length is allowed is yes";

[0188] For the steel plate to be produced, using the steel type and process design number as indexes, the first storage unit 102 is used to obtain whether "only hot charging and hot delivery process is allowed" is yes;

[0189] For the steel plate to be produced, using the slab number as an index, the internal database of the automatic control module 103 is used to obtain whether "is it produced when the slab width specification of the continuous casting machine is changed?" is no, and "is it the last slab casted by molten steel in the last heat of continuous casting?" is yes;

[0190] For the steel plate to be produced, from the information sent by the L3 level rolling mill 207 in event 5, it is obtained that "whether hot charging and hot delivery" is yes;

[0191] Based on the above pre-processing conclusion, the steel plate to be produced meets the specific characteristics of automatic weight verification, and the slab number 099 and the identifier of "meeting the specific characteristics of automatic weight verification" are saved in the internal database of the automatic control module 103.

[0192] After the slab with slab number 099 is transported to the medium and thick plate workshop, it is directly transported to the roller conveyor in front of the heating furnace for weighing on the weighing machine due to the hot loading and hot delivery process. When the weighing is completed, the L2-level heating furnace 204 receives the slab measured weight of 13 tons sent by the L1-level weighing machine 201. The L2-level heating furnace 204 first inquires the automatic control module 103 whether the automatic control module 103 should take over the weight deviation calibration of the slab. The inquiry message contains information such as the slab number 099, the slab measured weight of 13 tons, and the rolling size target.

[0193] After the automatic control module 103 receives the inquiry from the L2-level heating furnace 204 about "whether the newly designed automatic control module will take over the slab weight deviation verification", it queries the internal database of the automatic control module 103 with the slab number 099 as the index. If the result is "whether it meets the specific characteristics of automatic weight verification", the new slab weight deviation verification rules are used to determine whether it is allowed to be loaded into the heating furnace.

[0194] The new slab weight deviation verification rule judgment process is as follows:

[0195] 1) Calculate the minimum weight permitted by the contract Wmin:

[0196] Wmin = rolling target thickness × (minimum width of contractually permitted tolerance + △b0) × (minimum length of contractually permitted tolerance + △L0);

[0197] Select △b0=0, △L0=0, and calculate Wmin=11 tons;

[0198] 2) The measured weight of the slab is 13 tons, which is greater than Wmin, which is 11 tons;

[0199] The result of the heating furnace 204 at level L2 is "OK", and the subsequent steps are continued;

[0200] 3) Calculate the material design slab weight Wdgn:

[0201] Wdgn = target rolling thickness × target rolling width × minimum rolling length × steel density;

[0202] The calculation results show that Wdgn = 15 tons;

[0203] 4) Compare the measured slab weight with Wdgn and execute the same judgment logic as the heating furnace 204 at level L2;

[0204] The judgment logic of the heating furnace 204 at level L2 is: if (measured slab weight / Wdgn) is between 0.9 and 1.1, it is judged as passed, otherwise it is failed. In this case, (measured slab weight / Wdgn) = 0.867 < 0.9, which is judged as failed;

[0205] 5) Because the comparison between the measured slab weight and Wdgn is judged as failed, the calculation process for adjusting the rolling target is started;

[0206] 6) The calculation process for adjusting the rolling target is as follows: the required quantities are the width change △b and the length change △L, and the commonly used nonlinear optimization algorithm is used to determine these two required quantities;

[0207] The optimized objective function is:

[0208] Current rolling target width b tgt =3.0m, target thickness h = 0.02m, target minimum length = 20m, then the optimization target used is:

[0209]

[0210] W=0.02×(3.0+△b)×(20.0+△L)×ρ;

[0211] In the above formula, ρ is the density of steel.

[0212] The optimization algorithm gives the optimized width change △b=0.0m and length change △L=-2.67m, and calculates the new rolling target width b new =3.0m and the new minimum rolling length L new =17.33m.

[0213] Because the new slab weight deviation check rule determines that the slab can be put into the furnace, the heating furnace 204 of the response L2 level takes over the weight deviation check of the slab, and the weight deviation check result is that the slab is allowed to be put into the furnace.

[0214] Because the new slab weight deviation verification rule gives a new rolling target width and rolling minimum length, the L2 level rolling mill 205 is notified that the rolling target size of the steel plate to be produced is changed to the new rolling target width of 3.0m and the rolling minimum length of 17.33m.

[0215] After receiving the response result that the slab weight check has been taken over and the check is allowed to enter the furnace, the L2-level heating furnace 204 does not execute the original slab check process, but directly and automatically controls the L1-level heating furnace steel loading machine to start the automatic steel loading process.

[0216] After receiving the notification of the change in rolling target size, the L2-level rolling mill 205 updates the internally saved rolling target information. When steel rolling begins, the L1-level rolling mill 203 and the L2-level rolling mill 205 will perform the rolling process according to the new target size information.

[0217] This invention has a wide range of applications and is easy to use, making it suitable for medium and heavy plate manufacturers. It fully utilizes existing equipment and information systems, leverages factory floor-level data platforms, and maximizes the potential for reducing process costs in the context of intelligent factory upgrades. This technology is fully adaptable and has broad prospects for widespread adoption.

[0218] Those skilled in the art should recognize that the above embodiments are merely intended to illustrate the present invention and are not intended to limit the present invention. As long as they are within the spirit of the present invention, any changes or modifications to the above embodiments will fall within the scope of the claims of the present invention.

Claims

1. A method for calibrating the size of medium and heavy plate slabs and automatically adjusting the rolling target, using a system for calibrating the size of medium and heavy plate slabs and automatically adjusting the rolling target, characterized in that: The medium and heavy plate slab size verification and rolling target automatic adjustment system includes: The first storage unit is used to store the user's personalized material usage requirements; The second storage unit is used to store internal production process requirements; Computer information systems for basic automation control, process control, production line manufacturing execution control, and production operation control; an automatic control module, for connecting the first storage unit, the second storage unit and the computer information system; The computer information system has four levels, including: L1-level weighing machines, heating furnace steel loading machines, and rolling mills; L2 level heating furnace and rolling mill; L3 level steelmaking and steel rolling; L4 sales management subsystem and manufacturing management subsystem, The method for automatically adjusting the size of medium and heavy plate slabs and rolling targets has the automated functions of identifying, weight checking, and adjusting the rolling targets of continuous casting slabs, and the computer information system needs to be adaptively modified. The automation function is triggered by multiple external events with different processing flows, which together complete the automation function. The external events trigger different processing processes, specifically including: Event 1: Automatically triggered at a fixed period; The processing flow of event 1: access the basic information of the medium and heavy plate contract in the L4 sales management subsystem, and synchronize the contract number, user number, contract-agreed thickness dimension, contract-agreed width dimension, contract-agreed length dimension, contract-allowed width tolerance range, and contract-allowed length tolerance range information to the internal database of the automatic control module; Event 2: Salesperson enters the contract; The processing flow of event 2: the salesperson enters the steel type, user number, contract number, "whether large deviation in actual width is allowed", and "whether large deviation in actual length is allowed" into the first storage unit; Event 3: After product R&D personnel complete the production process design; The processing flow of event 3: the product development personnel enters the steel type, process design number, and "whether only hot charging and hot delivery processes are allowed" into the second storage unit; Event 4: After the continuous casting machine casts the slab; The processing flow of event 4: the L3 steelmaking generates two identifiers based on actual production information: "whether the production is during the continuous casting machine slab width specification conversion" and "whether the slab is the last molten steel cast in the last heat of continuous casting". The slab number and the two identifiers are automatically sent to the automatic control module, and the automatic control module stores the received information in its internal database; Event 5: When the rolling line production plan starts; The processing flow of event 5: When the production plan of the thick plate rolling line is completed, the L3 level rolling mill will automatically trigger the rolling line production plan start event. The L3 level rolling mill will send the slab number, contract number, user number, steel type, process design number, and "hot charging and hot delivery" flag corresponding to the steel plate to be produced to the automatic control module. The automatic control module will start the pre-processing process of automatic slab weight verification. In the processing flow of event 5, the pre-processing process is as follows: For the steel plate to be produced, "whether hot loading and hot delivery" is obtained from the information sent by the L3 level rolled steel in the event 5; For the steel plate to be produced, using the steel type, user number, and contract number as indexes, obtain "whether a large deviation in the actual width is allowed" and "whether a large deviation in the actual length is allowed" from the first storage unit; For the steel plate to be produced, using the steel type and process design number as indexes, obtain "whether only hot charging and hot delivery processes are allowed" from the second storage unit; For the steel plate to be produced, using the slab number as an index, obtain from the internal database of the automatic control module whether "the production is during the slab width specification conversion of the continuous casting machine" and "whether it is the last slab casted by molten steel in the last heat of continuous casting"; If and only if the question "whether large deviation of actual width is allowed" is yes, the question "whether large deviation of actual length is allowed" is yes, the question "whether only hot charging and hot delivery process is allowed" is yes, the question "whether hot charging and hot delivery is allowed" is yes, and at least one of the two flags "whether production is carried out when slab width specification is changed during continuous casting machine" or "whether it is the last slab casted by molten steel in the last heat of continuous casting" is yes, a pre-processing conclusion is obtained that the steel plate to be produced meets the specific characteristics of automatic weight verification, and finally the slab number and the flag "whether it meets the specific characteristics of automatic weight verification" are saved in the internal database of the automatic control module; Event 6: After the slab weighing is completed; The processing flow of event 6: After the slab weighing is completed, the L2-level heating furnace receives the slab measurement weight sent by the L1-level weighing machine. The L2-level heating furnace first inquires the automatic control module whether the automatic control module takes over the weight deviation calibration of the slab. If so, the automatic control module takes over the weight deviation calibration of the slab and uses the slab weight deviation rule to determine whether it is allowed to be loaded into the heating furnace. Otherwise, the slab weight deviation calibration is not taken over, and the L2-level heating furnace continues to execute the original slab calibration process. In the processing flow of event 6, the specific steps for checking the weight deviation of the slab are as follows: 1) Calculate the minimum weight permitted by the contract Wmin: Wmin = rolling target thickness × (minimum width of contractual tolerance + △b0) × (minimum length of contractual tolerance + △L0) × steel density; In the above formula, △b0 is between 0 and 0.5m, and △L0 is between 0 and 1.0m; 2) Check whether the slab measurement weight is ≤ Wmin; If yes, the result of the entry into the L2 level heating furnace is "not allowed to enter the furnace", the weight deviation check of the slab is completed, and the subsequent steps are not executed; If the result of the L2-level heating furnace entry is "OK", proceed to the subsequent steps; 3) Calculate the material design slab weight Wdgn: Wdgn=rolling target thickness × rolling target width × rolling minimum length × steel density; 4) Compare the measured slab weight with Wdgn and execute the same judgment logic as the L2 level heating furnace: If the result is passed, there is no need to adjust the rolling target size, the slab weight deviation check is completed, and the subsequent steps are not executed; If the result of the judgment is failure, the rolling target size needs to be adjusted and go to step 5); 5) Adjust the calculation process of the rolling target size. The required quantities are the width change △b and the length change △L. A nonlinear optimization algorithm is used to determine these two required quantities. The objective function to be optimized is: Formula (1); In the above formula, W meas is the measured weight of the slab, b tgt is the existing rolling target width; Calculate the new rolling target width b new and the new minimum rolling length L new : Formula (2); 6) The calculated new rolling target width b new and the new minimum rolling length L new Sent to the L2 level rolling mill as a specific data item for changing the rolling target size.

2. The method for calibrating slab size and automatically adjusting rolling targets for medium and thick plates according to claim 1, characterized in that: In the processing flow of event 6, the L2-level heating furnace first queries the automatic control module with an inquiry message including the slab number, the measured weight of the slab, and the rolling size target.

3. The method for calibrating slab size and automatically adjusting rolling targets for medium and thick plates according to claim 1, characterized in that: In the processing flow of event 6, the slab weight deviation rule is used to determine whether it is allowed to be loaded into the heating furnace. If so, the L2-level heating furnace is notified to take over the weight deviation verification of the slab. The weight deviation verification result is that the slab is allowed to enter the furnace. If the slab weight deviation rule gives a new rolling target width and minimum rolling length, the L2-level rolling mill is notified at the same time, and the rolling target size of the steel plate to be produced is changed to the new rolling target width and minimum rolling length. After receiving the response result that the slab weight verification is taken over and the verification is that the slab is allowed to enter the furnace, the L2-level heating furnace does not execute the original slab verification process, but directly and automatically controls the L1-level heating furnace steel loading machine to start the automatic steel loading process. After receiving the notification of the rolling target change, the L2-level rolling mill updates the internally saved rolling target information. When steel rolling starts, the L1-level rolling mill and the L2-level rolling mill perform the rolling process according to the new target size information. If the response is otherwise, the L2-level heating furnace will take over the weight deviation calibration of the slab, and the weight deviation calibration result is that the slab is not allowed to enter the furnace. After receiving the response result that the weight calibration of the slab is taken over and the calibration result is that the slab is not allowed to enter the furnace, the L2-level heating furnace will not execute the original slab calibration process, and directly start the weight exception processing, and refuse the slab from entering the furnace through the L3-level steel rolling.

4. The method for calibrating slab size and automatically adjusting rolling targets for medium and thick plates according to claim 1, characterized in that: In step 4), the judgment logic is as follows: Whether the ratio of the measured slab weight to Wdgn is between 0.9 and 1.1, if so, it is judged as passed, otherwise it is failed.

5. The method for calibrating slab size and automatically adjusting rolling targets for medium and thick plates according to claim 1, characterized in that: In the formula (1) of step 5), the calculation formula of W is as follows: Formula (3); In the above formula, h is the target rolling thickness, L tgt is the existing minimum rolling length and is the density of the steel.

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