A batch steel plate thickness control system and method for medium and thick plate order requirements

Abstract

The present invention discloses a batch steel plate thickness control system and method for medium and thick plate order requirements. The system comprises a first storage unit for storing user order customization requirements; a second storage unit for storing production data; and an automatic control module for connecting the first and second storage units to a computer information system. The present invention meets user customization requirements, reduces the labor intensity of production management and operators, and taps into 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 batch steel plate thickness control system and method oriented to medium and thick plate order requirements. Background Art

[0002] 1. The existing manufacturing process of medium and thick plate products involves order production, material design, rolling process, post-rolling processes, and quality inspection and dimension inspection.

[0003] Modern plate manufacturers typically use a production organization based on order contracts. Sales personnel sign supply contracts with customers and enter the contract information into the company's internal sales management system. Production organizers 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 continuous casting unit and the rolling unit are determined based on the order's final product dimensions and performance requirements. These target dimensions include target thickness, target width, and minimum length.

[0005] The production process of the rolling unit is:

[0006] Heating - rolling - cooling - hot straightening - shearing - shot blasting - heat treatment - cold straightening - quality inspection. If surface defects of the steel plate are found during quality inspection, additional grinding process will be added.

[0007] Thickness-related processes include: the rolling mill's automatic control system rolls the steel plate to the target thickness specified in the material design. After rolling, a thickness gauge measures the steel plate's thickness. If a thick plate shot blasting process is performed, the surface will be shot blasted, which will slightly reduce the plate's thickness. If a heat treatment and quenching process is performed, the tempered steel plate's thickness will vary slightly. Finally, quality inspectors measure the thickness and determine whether it meets the product order requirements. If defects appear on the steel plate's surface, manual grinding will be performed, which will reduce the plate's thickness.

[0008] 2. Multi-level computer information systems and automatic control systems involved in the sales and production of medium and thick plates.

[0009] The production and operations of modern large-scale steel conglomerates typically adopt a four-level computer information system architecture: Level 1 is basic automation (L1), Level 2 is process control system (L2), Level 3 is production line manufacturing execution system (MES L3), and Level 4 is corporate production operation system (ERP L4).

[0010] The computer or automation system functions involved in the aforementioned steps of order production organization include:

[0011] Supply contract entry: L4's sales management subsystem converts the user's order requirements such as steel type, steel plate size and tolerance range, material properties, delivery date, etc. into computer information.

[0012] 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 rolling target dimensions of the rolling unit, including target thickness, target width, and target thickness allowable deviation range.

[0013] Production Planning: Rolling L3 compiles all contract material design information and arranges the rolling production plan. Before issuing the production plan, L3 verifies the compatibility between the material design information and the actual slab dimensions, often referred to as "yield verification." The purpose of this verification is to check whether the slab size meets the material design rolling target dimensions and the dimensional requirements specified in the order, after accounting for various production losses. If the verification passes, the production plan is issued to the heating furnace L2, rolling line L2, and other departments, preparing to begin production. If the verification fails, L4 is notified to cancel the production plan and select a slab of a different size that matches the order dimensions.

[0014] Production Logistics: Steel Rolling L3 tracks and manages the production progress in the steel rolling area.

[0015] Process control of each production process of the rolling unit: For more complicated processes, the corresponding L2 / L1 divides the work and coordinates the control of the corresponding equipment, such as the heating furnace is controlled by the heating furnace L2 / L1, the rolling mill is controlled by the rolling line L2 / L1, the cooling is controlled by the cooling L2 / L1, and the heat treatment is controlled by the heat treatment L2 / L1; for some less complicated processes, the corresponding equipment is controlled by the corresponding L1, such as hot straightening, cold straightening, shearing equipment and other equipment are all controlled by their respective L1s; there are also some simple processes that are completed manually, and the corresponding process result information is entered into the steel rolling L3, such as shot blasting, grinding and other processes.

[0016] Quality Inspection: Quality inspectors measure the dimensions of finished products to be shipped using automated instruments or manual measurement, and enter the measurement results into the steel rolling L3. If the dimensions meet the order requirements, L3 will mark the dimensions as passed. If not, L3 will mark the dimensions as failed.

[0017] 3. User material usage characteristics and personalized needs, taking pipeline steel as an example.

[0018] Through user services and other channels, we can learn that different medium and thick plate users have many different ways of using steel plates. For medium and thick plate suppliers, due to the personalized characteristics of users' material usage, users' actual requirements for medium and thick plates, in addition to general dimensions and performance, also include several industry-specific individual needs. Taking pipeline steel as an example, due to the requirements of pipeline steel's pipe manufacturing process and material service conditions, in recent years, many energy industry users have proposed additional remarks for the supply of medium and thick plates for pipeline steel, such as "the average plate thickness of the delivered batch of steel plates shall not be less than the nominal thickness" in addition to conventional dimensions and tolerances. These personalized requirements written into the contract text may not be entered into the regular input interface when entering into the sales management system, and cannot be converted into computerized contract information.

[0019] 4. Blind spots in the management and control of the current four-level information system.

[0020] The current L4 / L3 / L2 information systems lack corresponding production order information that fully encompasses the stipulation that "the average thickness of the delivered batch of steel plates must not be less than the nominal thickness." Without access to the average thickness of the produced batches, the L2 / L1 automation systems and operators in the rolling process are unable to precisely adjust the rolling thickness. This presents a management blind spot within the existing information system, which already covers sales, production organization, and automated control.

[0021] Shortcomings of existing technology:

[0022] The manual corrective measures for tracking and monitoring the aforementioned contractual stipulation that "the average thickness of the delivered batch of steel plates shall not be less than the nominal thickness" have the following deficiencies:

[0023] 1) Due to incomplete data and information access rights, operators were unable to proactively obtain contract-related personalized information and could only adjust plate thickness control after being notified by manufacturing management. This manual information transmission loop was long, delayed, and unstable.

[0024] 2) Manually tracking contract progress information increases the labor intensity of repetitive work for manufacturing managers;

[0025] 3) The subsequent process control target is still incorrect. When the operator receives the current overall thickness deviation of the steel plate, the adjustment of the control target thickness is made based on operating experience. The adjustment operation may be insufficient or excessive, resulting in quality loss. Summary of the Invention

[0026] In response to the above-mentioned defects in the prior art, the present invention provides a batch steel plate thickness control system and method for medium and thick plate order requirements, which meets the user's personalized order needs, reduces the labor intensity of production management and operators, and taps the cost reduction potential of the production and operation process.

[0027] To achieve the above object, the present invention adopts the following technical solutions:

[0028] On the one hand, a batch steel plate thickness control system for medium and thick plate order requirements includes:

[0029] The first storage unit is used to store the personalized needs of user orders;

[0030] a second storage unit for storing production data;

[0031] Computer information system, including basic automation subsystem, process control subsystem, production line manufacturing execution subsystem and production operation subsystem;

[0032] The automatic control module is used to perform automatic functional control on each subsystem of the computer information system according to the personalized needs of user orders in the first storage unit and the production data of the second storage unit.

[0033] Preferably, the user order personalization requirements include:

[0034] Steel grade, customer number, contract number; and

[0035] "Is it required that the thickness of the delivered batch of steel plates should not be less than the nominal thickness?"

[0036] Preferably, the computer information system has four levels, including:

[0037] Level 1 corresponds to the rolling mill L1 of the basic automation subsystem;

[0038] The second level corresponds to the rolling mill L2 of the process control subsystem;

[0039] Level 3 corresponds to the steel rolling L3 of the production line manufacturing execution subsystem;

[0040] Level 4 corresponds to the sales management subsystem L4 and the manufacturing management subsystem L4 of the production operation subsystem.

[0041] On the other hand, a batch steel plate thickness control method for medium and thick plate order requirements:

[0042] The batch steel plate thickness control system oriented to medium and thick plate order requirements is utilized to perform automated functions of production process capability evaluation, material design information verification, and rolling target optimization according to the personalized needs of user orders.

[0043] Preferably, the personalized requirement of the user order is that the average thickness of the delivered batch of steel plates is not less than the nominal thickness of the order.

[0044] Preferably, the automation function is triggered by multiple external events with different processing flows to jointly complete the automation function.

[0045] Preferably, the external events triggering different processing processes specifically include:

[0046] Event 1: Automatically triggered at a fixed period;

[0047] The processing flow of event 1: access the basic information of the medium and thick plate contract in the sales management subsystem L4, and synchronize the contract number, user number, contract-agreed thickness dimension, contract-agreed width dimension, contract-agreed length dimension, contract-agreed thickness tolerance range, and steel plate order quantity information to the internal database of the automatic control module;

[0048] Access the basic information of the medium and heavy plate material design in the manufacturing management subsystem L4, and synchronize the contract number, design slab number, rolling target size, and rolling target upper and lower limits to the internal database of the automatic control module;

[0049] Event 2: Salesperson enters the contract;

[0050] The processing flow of event 2: the salesperson enters the steel type, user number, contract number, and "whether the thickness of the delivered steel plate is required to be no less than the nominal thickness" into the first storage unit;

[0051] Event 3: After the rolling mill is completed;

[0052] The processing flow of event 3: after the rolling mill L1 completes rolling of a steel plate, the rolling mill L2 stores the rolling production data in the second storage unit and notifies the automatic control module that the rolling mill is completed;

[0053] After receiving the notification that the rolling mill has completed rolling, the automatic control module starts to calculate the rolling thickness control level;

[0054] Event 4: After the quality inspector measures the size of the finished product;

[0055] The processing flow of event 4: the quality inspector measures the dimensions of the finished product to be shipped and inputs the measurement results to the steel rolling L3. The steel rolling L3 stores the design slab number, steel plate number, measured dimensions, and whether the dimension inspection is qualified or not of the corresponding medium and thick plate finished product in the second storage unit, and notifies the automatic control module that the finished product dimension measurement is completed;

[0056] After receiving the notification that the finished product size measurement is completed, the automatic control module starts to calculate the thickness impact of the post-rolling mill process;

[0057] Event 5: When the rolling line production plan starts;

[0058] The processing flow of event 5: when the production plan of the thick plate rolling line is completed, the steel rolling L3 will automatically trigger the rolling line production plan start event, and the steel rolling L3 inquires the automatic control module whether the automatic control module performs rolling thickness target adjustment optimization. If the automatic control module answers "no", the steel rolling L3 performs yield rate verification and subsequent original processing flow according to the original process; if the automatic control module answers "yes", it returns the adjustment optimization amount calculation result △H, and the steel rolling L3 adjusts the rolling target thickness of the steel plate, and then performs yield rate verification and subsequent original processing flow.

[0059] Preferably, in the processing flow of event 3, the rolling production data includes the thickness measured by the thickness gauge after the rolling mill, steel type, size specification, target size, and steel plate number; and / or

[0060] In the processing flow of event 3, the specific steps of the rolling thickness control level statistics are as follows:

[0061] 1) based on the steel grade and size of the rolled steel plate, extracting from the second storage unit all rolling production data of existing steel plates with the same size and steel grade, wherein the rolling production data includes the thickness measured by the thickness gauge after the rolling mill and the rolling target thickness;

[0062] 2) For all the existing steel plates taken out, calculate the rolling thickness control deviation of each existing steel plate:

[0063] Rolling thickness control deviation = thickness measured by thickness gauge after rolling mill - rolling target thickness;

[0064] 3) For all the existing steel plates taken out, the average value μ of the rolling thickness control deviation of all the existing steel plates taken out is calculated MC and standard deviation σ MC ;

[0065] 4) The statistical average value μ MC and standard deviation σ MC , with the corresponding steel type and size as index, and saved in the internal database of the automatic control module.

[0066] Preferably, in the processing flow of event 4, the specific steps of calculating the impact of the thickness of the post-rolling mill process are as follows:

[0067] 1) based on the steel type and size of the measured steel plate, retrieve from the second storage unit the production data of all existing steel plates with the same size and steel type, the production data including the thickness measured by the thickness gauge after the rolling mill and the thickness measured by the quality inspection;

[0068] 2) For all the existing steel plates taken out, calculate the thickness change of each existing steel plate after rolling process:

[0069] Thickness change after rolling process = thickness measured by thickness gauge after rolling mill - thickness measured by quality inspection;

[0070] 3) Sort all the existing steel plates taken out from smallest to largest according to the thickness change after rolling process, and obtain the median △H of the thickness change after rolling process of all the existing steel plates PV50 , △H ranked at 10% PV10 and △H sorted at the 90% position PV90 ;

[0071] 4) The median △H of the thickness change after rolling obtained by statistics PV50 , △H ranked at 10% PV10 and △H sorted at the 90% position PV90 , with the corresponding steel type and size as index, and saved in the internal database of the automatic control module.

[0072] Preferably, in the processing flow of event 5, the steel rolling L3 inquires the automatic control module, and the inquiry message includes the design slab number, design slab weight, contract number, steel type, size and / or

[0073] In the processing flow of event 5, the calculation of the rolling thickness target adjustment optimization is as follows:

[0074] Target rolling thickness = original material design target rolling thickness + △H.

[0075] Preferably, in the processing flow of event 5, the method for determining whether the automatic control module performs rolling thickness target adjustment optimization is as follows:

[0076] The automatic control module uses the contract number as an index to search the first storage unit to obtain an indication of "whether the thickness of the steel plate of the delivery batch is required to be no less than the nominal thickness";

[0077] If the indicator of "whether the thickness of the delivered batch of steel plates is required to be no less than the nominal thickness" is no, the automatic control module responds with no;

[0078] If the question "Whether the thickness of the delivered batch of steel plates is required to be no less than the nominal thickness" is marked as yes, the automatic control module calculates the rolling thickness target adjustment optimization amount. If the rolling thickness target adjustment optimization amount calculation result cannot be obtained, the automatic control module answers no; if the rolling thickness target adjustment optimization amount calculation result can be obtained, the automatic control module answers yes, and at the same time returns the rolling thickness target adjustment optimization amount calculation result to the steel rolling L3.

[0079] Preferably, the specific steps of calculating the rolling thickness target adjustment optimization amount by the automatic control module are as follows:

[0080] 1) Data preparation:

[0081] According to the design slab number and the contract number, the contract agreed thickness Hctr, the thickness corresponding to the upper limit of the contract permitted thickness tolerance HHctr, the thickness corresponding to the lower limit of the contract permitted thickness tolerance HLctr, the steel plate order quantity M, the material design rolling target thickness Hmtr, the material design rolling target thickness upper limit HHmtr, the material design rolling target thickness lower limit HLmtr, the material design rolling target width B, the material design rolling minimum length Lm, and the material design weight W are obtained from the second storage unit and the internal database of the automatic control module;

[0082] According to the steel type and size, the average value μ of the rolling thickness control deviation is obtained from the internal database of the automatic control module. MC and standard deviation σ MC , get the median △H of the thickness change after rolling process PV50 , △H ranked at 10% PV10 and △H sorted at the 90% position PV90 ;

[0083] 2) Statistics on the thickness of the steel plates produced for this order:

[0084] Using the order number as an index, obtain the quality inspection and measurement thickness of all existing steel plates corresponding to the order number and that have passed the quality inspection from the second storage unit, and obtain the number of all existing steel plates N and the overall thickness deviation ΔH of all existing steel plates by statistics. Done :

[0085]

[0086] In the above formula, Hinsp is the quality inspection measurement thickness;

[0087] 3) Calculate the target thickness adjustment amount:

[0088] First calculate the proposed adjustment amount △Hp of the finished product thickness:

[0089]

[0090] In the above formula, a1 is an adjustment parameter with a value of -0.0005 to 0.0005, unit: m;

[0091] Then calculate the preliminary adjustment amount △H1 of the rolling target thickness:

[0092] △H1=△Hp+Hctr+△HPV50 -Hmtr;

[0093] 4) Estimate the rolling thickness distribution range after the rolling target thickness is adjusted [H MCL ,H MCH ];

[0094]

[0095] 5) estimating an acceptable maximum thickness representation value and an acceptable minimum thickness representation value of thickness distribution of finished products after the rolling target adjustment and after the post-rolling process;

[0096] The acceptable maximum thickness characterization value of the finished product thickness distribution after the rolling target adjustment and the post-rolling process has two values H PV1 、H PV2 The acceptable minimum thickness characterization value of the finished product thickness distribution after the rolling target adjustment has two values H PV3 、H PV4 ;

[0097]

[0098] 6) Calculate the permissible thickness limit of finished products under multiple conditions:

[0099] The upper limit of the permissible thickness of the finished product HH is the minimum value among the three restrictions: the thickness corresponding to the upper limit of the permissible thickness tolerance in the contract HHctr, the upper limit of the material design rolling target thickness converted into the finished product thickness HHmtp, and the finished product thickness converted into the minimum length of the material design rolling; the lower limit of the permissible thickness of the finished product is the maximum value among the two restrictions: the thickness corresponding to the lower limit of the permissible thickness tolerance in the contract HLctr and the finished product thickness converted into the lower limit of the material design rolling target thickness HLmtp;

[0100]

[0101]

[0102] In the above formula, ρ is the density of steel, a2 is the adjustment parameter, ranging from 0 to 1.0, unit: m;

[0103] 7) Determine whether the thickness control process capability after the rolling target thickness is adjusted meets the permitted limit of finished product thickness:

[0104] If it is determined that the thickness control process capability after the rolling target thickness is adjusted does not meet the permitted limit of the finished product thickness, the rolling L3 is not adjusted and optimized;

[0105] If it is determined that the thickness control process capability after the rolling target thickness adjustment fully meets the permitted limit of the finished product thickness, the steel rolling L3 is adjusted and optimized, and the adjustment optimization result ΔH=ΔH1;

[0106] If it is determined that the thickness control process capability after adjusting the rolling target thickness basically meets the finished product thickness permission limit, respond to the steel rolling L3 for adjustment and optimization, and according to more specific conditions, output the adjustment and optimization result △H;

[0107] The specific condition for determining that the thickness control process capability after adjusting the rolling target thickness does not meet the finished product thickness permission limit is: min(H PV1 ,H PV2 )>HH or max(H PV3 ,H PV4 )<HL;

[0108] The specific condition for determining that the thickness control process capability after adjusting the rolling target thickness completely meets the finished product thickness permission limit is: max(H PV1 ,H PV2 )<HH or min(H PV3 ,H PV4 )>HL;

[0109] The specific condition for determining that the thickness control process capability after adjusting the rolling target thickness basically meets the finished product thickness permission limit is that one of the following two conditions is satisfied:

[0110] Condition 1: min(H PV1 ,H PV2 )≤HH and max(H PV1 ,H PV2 )≥HH;

[0111] Condition 2: min(H PV3 ,H PV3 )≤HL and max(H PV3 ,H PV4 )≥HL;

[0112] If it is determined that the thickness control process capability after adjusting the rolling target thickness basically meets the finished product thickness permission limit, respond to the steel rolling L3 for adjustment and optimization. The calculation process and more specific judgment conditions of the adjustment and optimization result are:

[0113] When the slab to be planned for startup meets both Condition 1 and Condition 2 at the same time, the adjustment and optimization result △H = △H₁;

[0114] When the slab to be planned for startup only meets Condition 1, the following steps are taken:

[0115] a1. Calculate the additional thickness adjustment amount △Ha = HH - max(H PV1 ,H PV2 );

[0116] a2. Calculate the acceptable minimum thickness characterization value H including the additional thickness adjustment PV3a 、H PV4a :

[0117]

[0118] a3、If min(H PV3a ,H PV4a )≥HL, if yes, adjust the optimization result △H=△H1+△Ha; otherwise, adjust the optimization result △H=△H1;

[0119] When the slab to be planned to start only meets condition 2, proceed as follows:

[0120] b1. Calculate the additional thickness adjustment △Hb=HL-min(H PV3 ,H PV4 );

[0121] b2. Calculate the acceptable maximum thickness representation value H including the additional thickness adjustment PV1b 、H PV2b :

[0122]

[0123] b3、If max(H PV1b ,H PV2b )≤HH, if so, adjust the optimization result △H=△H1+△Hb; otherwise, adjust the optimization result △H=△H1.

[0124] The present invention provides a batch steel plate thickness control system and method for medium and thick plate order requirements. The system adopts a fully automated approach, relies on a data platform interconnected with computer systems at all levels, integrates existing information across processes and levels, and digitizes key previously non-digitized user order individual requirements, thereby realizing an automatic control process for the overall thickness of a full batch of medium and thick plate finished products based on contract orders, and automatically adjusts the size target of the subsequent rolling of the order steel plate, thereby reducing the labor intensity of production management and operating personnel and fully tapping the cost reduction potential of the production and operation process. BRIEF DESCRIPTION OF THE DRAWINGS

[0125] Figure 1 This is a schematic diagram of the framework of a batch steel plate thickness control system for medium and thick plate order requirements of the present invention;

[0126] Figure 2 It is a schematic diagram of the processing flow of event 3 in a batch steel plate thickness control method oriented to medium and thick plate order requirements of the present invention;

[0127] Figure 3It is a schematic diagram of the processing flow of event 4 in a batch steel plate thickness control method oriented to medium and thick plate order requirements of the present invention;

[0128] Figure 4 It is a schematic diagram of the processing flow of event 5 in a batch steel plate thickness control method oriented to medium and thick plate order requirements of the present invention;

[0129] Figure 5 It is a schematic diagram of a judgment method for optimizing the rolling thickness target adjustment by an automatic control module in the processing flow of event 5 in a batch steel plate thickness control method oriented to medium and thick plate order requirements of the present invention;

[0130] Figure 6 It is a schematic diagram of the calculation of the thickness adjustment optimization amount by the automatic control module in the processing flow of event 5 in the batch steel plate thickness control method oriented to the medium and thick plate order requirements of the present invention. DETAILED DESCRIPTION

[0131] 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.

[0132] Please combine Figure 1 As shown, the present invention provides a batch steel plate thickness control system for medium and thick plate order requirements, comprising:

[0133] The first storage unit 101 is used to store user order personalization requirements;

[0134] The second storage unit 102 is used to store actual production data;

[0135] 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 .

[0136] A corresponding control module software interface framework 100 is also designed, on which automated functions such as production process capability evaluation, material design information verification, and rolling target optimization based on user requirements are implemented, and adaptive changes are required to connect to the computer information system 200.

[0137] The first storage unit 101 stores the personalized requirements of user orders. In addition to index conditions such as steel type, user number, and contract number, only one characteristic data needs to be saved: "whether the thickness of the delivered batch of steel plates is required to be no less than the nominal thickness". The salesperson enters this data into the first storage unit 101 when entering the contract.

[0138] Second storage unit 102 stores actual production data, quality inspection dimensional measurement data, and other data. This data is used to filter historical production data for all steel plates of the same steel grade and specification as the contract order. This data is used to statistically analyze the rolling thickness deviation, rolling thickness control capability, and the impact of each post-rolling process on minor changes in steel plate thickness for this steel grade and specification. These statistics on rolling thickness deviation and post-rolling thickness change are crucial parameters in the overall thickness control calculation for this contract order, contributing to the optimization of target thickness adjustments and demonstrating the power of data.

[0139] The computer information system 200 has four levels, including:

[0140] L1 level rolling mill 201;

[0141] L2 level rolling mill 202;

[0142] L3 grade rolled steel 203;

[0143] L4 level sales management subsystem 204 and manufacturing management subsystem 205.

[0144] The user's characteristic requirement is that the average thickness of the delivered batch of steel plates should not be less than the nominal thickness of the order.

[0145] The present invention also provides a batch steel plate thickness control method oriented to medium and thick plate order requirements:

[0146] The batch steel plate thickness control system for medium and thick plate orders of the present invention utilizes the automated functions of production process capability evaluation, material design information verification, and rolling target optimization for personalized user order needs, and the connected computer information system 200 needs to be adaptively modified.

[0147] The automation function is triggered by multiple external events, which trigger different processing processes to complete the automation function.

[0148] External events trigger different processing processes, including:

[0149] Event 1: Automatically triggered at a fixed period;

[0150] Processing flow of event 1: Access the basic information of the medium and thick plate contract of the L4-level sales management subsystem 204, and synchronize the contract number, user number, contract-agreed thickness dimension, contract-agreed width dimension, contract-agreed length dimension, contract-agreed thickness tolerance range, steel plate order quantity and other information to the internal database of the automatic control module 103.

[0151] Access the basic information of medium and thick plate material design of the L4 manufacturing management subsystem 205, and synchronize the contract number, design slab number, rolling target size, rolling target upper and lower limits and other information to the internal database of the automatic control module 103.

[0152] Event 2: Salesperson enters the contract;

[0153] Processing flow of event 2: The salesperson enters the steel type, user number, contract number and characteristic data "whether the thickness of the delivered batch of steel plates is required to be no less than the nominal thickness" into the first storage unit 101.

[0154] Event 3: After the rolling mill is completed;

[0155] Please combine Figure 2 As shown, the processing flow of event 3 is: after the L1-level rolling mill 201 completes the rolling of a steel plate, the L2-level rolling mill 202 stores the actual rolling production data (including the thickness measured by the thickness gauge after the rolling mill, steel type, size specifications, target size, steel plate number and other data) into the second storage unit 102 and notifies the automatic control module 103.

[0156] After receiving the notification that the rolling mill has finished rolling, the automatic control module 103 starts to calculate the rolling thickness control level. The steps of calculating the rolling thickness control level are as follows:

[0157] 1) Based on the steel type and size of the steel plate after rolling, retrieve the actual rolling production data of all existing steel plates with the same size and steel type from the second storage unit 102, wherein the actual rolling production data includes the thickness measured by the thickness gauge after the rolling mill and the rolling target thickness;

[0158] 2) For the existing steel plates taken out, calculate the rolling thickness control deviation of each existing steel plate:

[0159] Rolling thickness control deviation = thickness measured by thickness gauge after rolling mill - rolling target thickness;

[0160] 3) For the existing steel plates taken out, the average value μ of the rolling thickness control deviation of all the existing steel plates taken out is calculated. MC and standard deviation σ MC ;

[0161] 4) The statistical average value μ MC and standard deviation σ MC , with the corresponding steel type and size as index, and saved in the internal database of the automatic control module 103.

[0162] Event 4: After the quality inspector measures the size of the finished product;

[0163] Please combine Figure 3As shown, the processing flow of event 4 is: the quality inspector measures the size of the finished product to be shipped, and inputs the measurement results to the L3 level steel rolling 203. The L3 level steel rolling 203 stores the design slab number, steel plate number, measured size, size inspection pass or fail data of the corresponding medium and thick plate finished product to the second storage unit 102, and notifies the automatic control module 103.

[0164] After receiving the notification that the finished product size measurement is completed, the automatic control module 103 starts to calculate the thickness influence degree of the post-rolling mill process. The steps of calculating the thickness influence degree of the post-rolling mill process are as follows:

[0165] 1) Based on the steel type and size of the steel plate, actual production data of all existing steel plates with the same size and steel type are retrieved from the second storage unit 102, the actual production data including the thickness measured by the thickness gauge after the rolling mill and the thickness measured by the quality inspection;

[0166] 2) For the existing steel plates taken out, calculate the thickness change of each existing steel plate after rolling process:

[0167] Thickness change after rolling process = thickness measured by thickness gauge after rolling mill - thickness measured by quality inspection;

[0168] 3) Sort the existing steel plates taken out according to the thickness change after rolling from small to large, and obtain the median △H of the thickness change after rolling of all existing steel plates PV50 , △H ranked at 10% PV10 and △H sorted at the 90% position PV90 ;

[0169] 4) The median △H of the thickness change after rolling obtained by statistics PV50 , △H ranked at 10% PV10 and △H sorted at the 90% position PV90 , with the corresponding steel type and size as index, and saved in the internal database of the automatic control module 103.

[0170] Event 5: When the rolling line production plan starts;

[0171] Please combine Figure 4As shown, the processing flow of event 5: when the production plan of the thick plate rolling line is completed, the L3 level steel rolling 203 will automatically trigger the rolling line production plan start event. The L3 level steel rolling 203 does not directly perform the yield rate verification according to the original process, but first inquires the automatic control module 103 whether the automatic control module performs the rolling thickness target adjustment optimization (the inquiry message includes the design slab number, design slab weight, contract number, steel type, size specifications and other information). If the automatic control module 103 answers "no", the L3 level steel rolling 203 performs the yield rate verification and subsequent original processing flow according to the original process; if the automatic control module 103 answers "yes", it returns the adjustment optimization amount calculation result △H, the L3 level steel rolling 203 adjusts the rolling target thickness of the steel plate, and then performs the yield rate verification and subsequent original processing flow.

[0172] The calculation formula for rolling thickness target adjustment is as follows:

[0173] Target rolling thickness = original material design target rolling thickness + △H.

[0174] Please combine Figure 5 As shown, in the processing flow of event 5, the method for determining whether the automatic control module performs rolling thickness target adjustment optimization is as follows:

[0175] The automatic control module 103 uses the contract number as an index to search the first storage unit 101 and obtains the identifier of "whether the thickness of the steel plate of the delivery batch is required to be no less than the nominal thickness";

[0176] If the indicator "whether the thickness of the steel plates in the delivery batch is required to be not less than the nominal thickness" is negative, the automatic control module 103 responds with negative;

[0177] If the question "Is the thickness of the delivered batch of steel plates required to be no less than the nominal thickness" is marked as yes, the automatic control module 103 performs adjustment optimization calculation. If the adjustment optimization calculation result cannot be obtained, the automatic control module 103 answers no; if the adjustment optimization calculation result can be obtained, the automatic control module 103 answers yes and simultaneously returns the adjustment optimization calculation result to the L3 level steel rolling 203.

[0178] Please combine Figure 6 As shown, the specific steps for the automatic control module 103 to calculate the adjustment optimization amount are as follows:

[0179] 1) Data preparation:

[0180] Based on the design slab number, contract number and other information, the contract agreed thickness Hctr, the thickness corresponding to the upper limit of the contract permitted thickness tolerance HHctr, the thickness corresponding to the lower limit of the contract permitted thickness tolerance HLctr, the steel plate order quantity M, the material design rolling target thickness Hmtr, the material design rolling target thickness upper limit HHmtr, the material design rolling target thickness lower limit HLmtr, the material design rolling target width B, the material design rolling minimum length Lm, and the material design weight W are obtained from the internal database of the second storage unit 102 and the automatic control module 103;

[0181] According to the information of steel type, size and specification, the average value μ of rolling thickness control deviation is obtained from the internal database of the automatic control module 103. MC and standard deviation σ MC , get the median △H of the thickness change after rolling process PV50 , △H ranked at 10% PV10 and △H sorted at the 90% position PV90 ;

[0182] 2) Actual statistics of the thickness of the steel plates produced for this order:

[0183] Using the order number as an index, obtain the quality inspection thickness of the existing steel plate corresponding to the order number and that has passed the quality inspection from the second storage unit 102, and obtain the number of pieces N of the existing steel plate and the overall thickness deviation ΔH of the existing steel plate by statistics. Done :

[0184]

[0185] In the above formula, Hinsp is the quality inspection measurement thickness;

[0186] 3) Calculate the target thickness adjustment amount:

[0187] First calculate the proposed adjustment amount △Hp of the finished product thickness:

[0188]

[0189] In the above formula, a1 is an adjustment parameter with a value of -0.0005 to 0.0005, unit: m;

[0190] Then calculate the preliminary adjustment amount △H1 of the rolling target thickness:

[0191] △H1=△Hp+Hctr+△H PV50 -Hmtr;

[0192] 4) Estimate the rolling thickness distribution range after the rolling target thickness is adjusted [H MCL ,H MCH ];

[0193]

[0194] 5) estimating an acceptable maximum thickness representation value and an acceptable minimum thickness representation value of thickness distribution of finished products after the rolling target adjustment and after the post-rolling process;

[0195] The acceptable maximum thickness characterization value of the finished product thickness distribution after the rolling target adjustment and the post-rolling process has two values H PV1 、H PV2 The acceptable minimum thickness characterization value of the finished product thickness distribution after the rolling target adjustment has two values H PV3 、H PV4 ;

[0196]

[0197] 6) Calculate the permissible thickness limit of finished products under multiple conditions:

[0198] The upper limit of the permissible thickness of the finished product HH is the minimum value among the three restrictions: the thickness corresponding to the upper limit of the permissible thickness tolerance in the contract HHctr, the upper limit of the material design rolling target thickness converted into the finished product thickness HHmtp, and the finished product thickness converted into the minimum length of the material design rolling; the lower limit of the permissible thickness of the finished product is the maximum value among the two restrictions: the thickness corresponding to the lower limit of the permissible thickness tolerance in the contract HLctr and the finished product thickness converted into the lower limit of the material design rolling target thickness HLmtp;

[0199]

[0200]

[0201] In the above formula, ρ is the density of steel, a2 is the adjustment parameter, ranging from 0 to 1.0, unit: m;

[0202] 7) Determine whether the thickness control process capability after the rolling target thickness is adjusted meets the permitted limit of finished product thickness:

[0203] If it is determined that the thickness control process capability after the rolling target thickness adjustment does not meet the permitted limit of finished product thickness, the L3 level rolling will not be adjusted and optimized;

[0204] If it is determined that the thickness control process capability after the rolling target thickness adjustment fully meets the permitted limit of the finished product thickness, the L3 level rolling will be adjusted and optimized, and the adjustment optimization result △H=△H1;

[0205] If it is determined that the thickness control process capability after the rolling target thickness adjustment basically meets the permitted limit of the finished product thickness, the L3 level rolling will be adjusted and optimized, and the adjustment optimization result △H will be output according to more specific conditions;

[0206] The specific condition for judging that the thickness control process ability after adjusting the rolling target thickness does not meet the finished product thickness permission limit is: min(H PV1 ,H PV2 )>HH or max(H PV3 ,H PV4 )<HL;

[0207] The specific condition for judging that the thickness control process ability after adjusting the rolling target thickness fully meets the finished product thickness permission limit is: max(H PV1 ,H PV2 )<HH or min(H PV3 ,H PV4 )>HL;

[0208] The specific condition for judging that the thickness control process ability after adjusting the rolling target thickness basically meets the finished product thickness permission limit is that one of the following two conditions is met:

[0209] Condition 1: min(H PV1 ,H PV2 )≤HH and max(H PV1 ,H PV2 )≥HH;

[0210] Condition 2: min(H PV3 ,H PV3 )≤HL and max(H PV3 ,H PV4 )≥HL;

[0211] If it is judged that the thickness control process ability after adjusting the rolling target thickness basically meets the finished product thickness permission limit, the calculation process and more specific judgment conditions of the adjustment and optimization result for answering the L3-level steel rolling adjustment and optimization are:

[0212] When the slab to be planned to start meets both Condition 1 and Condition 2 at the same time, the adjustment and optimization result △H = △H1;

[0213] When the slab to be planned to start only meets Condition 1, the following step a is carried out:

[0214] a1. Calculate the additional thickness adjustment amount △Ha = HH - max(H PV1 ,H PV2 );

[0215] a2. Calculate the acceptable smaller thickness characterization values H PV3a ,H PV4a that include the additional thickness adjustment amount:

[0216]

[0217] a3. If min(H PV3a,H PV4a )≥HL, if yes, adjust the optimization result △H=△H1+△Ha; otherwise, adjust the optimization result △H=△H1;

[0218] When the slab to be planned to start only meets condition 2, proceed to step b as follows:

[0219] b1. Calculate the additional thickness adjustment △Hb=HL-min(H PV3 ,H PV4 );

[0220] b2. Calculate the acceptable maximum thickness representation value H including the additional thickness adjustment PV1b 、H PV2b :

[0221]

[0222] b3、If max(H PV1b ,H PV2b )≤HH, if so, adjust the optimization result △H=△H1+△Hb; otherwise, adjust the optimization result △H=△H1.

[0223] The statistical method for evaluating rolling thickness control deviation in the process flow for Event 3 is based on the mean and standard deviation of a normal distribution. The statistical method for evaluating thickness variation in the post-rolling process in the process flow for Event 4 is the median method, which does not assume a statistical distribution. The different methods are used because of the differences in the distribution of actual production performance data between the two. The rolling process is stable and controlled, and the deviation between the thickness measurement after the rolling mill and the rolling target clearly conforms to a normal distribution through data exploration. Therefore, the corresponding mean and standard deviation are used to evaluate rolling control deviation. The numerous post-rolling processes, including abnormal operating conditions such as grinding, result in large fluctuations and poor regularity in thickness variation in the post-rolling process. Data exploration does not reveal a clear data distribution pattern, so the corresponding median and percentage position numbers are used.

[0224] Rolling thickness control deviation and post-rolling thickness variation reflect the control capability level of each rolling line process and the control capability level of steel plates of the same steel grade and specification. Generally, regardless of the customer order for a particular steel grade and specification, the control level is approximately the same. Furthermore, the number of steel plates in a single contract order is significantly larger than the total production volume of that steel grade and specification, and the total production volume is not of the same order of magnitude. The greater the data volume, the easier it is to reflect the value of data statistics. Therefore, the classification method is not based on statistics for individual orders, but rather on statistics for rolling thickness control deviation and post-rolling thickness variation for the same steel grade and specification.

[0225] In the processing flow for Event 4, the original yield verification function of the L3 steel rolling 203 was primarily to check whether the slab size matched the material design rolling target size and the size requirements specified in the order. This algorithm is complex and produces precise results. The primary implementation measure for the batch steel plate thickness control method for medium and thick plate order requirements of the present invention is to adjust the rolling target thickness. This requires checking the size of the planned starting slab against the rolling target size (including target thickness) and the order size requirements. To avoid reimplementing this function in the automatic control module 103, inserting this function into the L3 steel rolling 203 process is both feasible and necessary.

[0226] Example

[0227] The existing sales staff received an order contract for pipeline steel, with steel type X70M, size specifications (thickness × width × length: 20mm × 3m × 15m), and order quantity 1,000 pieces. The contract was entered into the L4 sales management subsystem 204 with contract number 010, and "Whether the thickness of the delivered batch of steel plates is required to be no less than the nominal thickness" was set to yes in the first storage unit 101.

[0228] The automatic control module 103 synchronizes the basic plate contract information from the L4 sales management subsystem 204 daily, including the contract number, user number, contracted thickness, contracted width, contracted length, contracted thickness tolerance, and plate order quantity, with its internal database. The automatic control module 103 also synchronizes the basic plate material design information from the L4 manufacturing management subsystem 205 daily, including the contract number, designed slab number, target rolling size, and target upper and lower limits, with its internal database.

[0229] After the rolling mill completes rolling of a medium-thick plate (steel plate number A001), the L2-level rolling mill 202 stores the rolling production performance data, including the thickness measured by the thickness gauge after the rolling mill (0.0202m), steel type, size specifications, target size (rolling thickness target 0.0205m), steel plate number, etc., in the second storage unit 102 and notifies the automatic control module 103 that the steel type of the medium-thick plate is X70M and the size specifications are 20mm×3m×15m. After receiving the notification of the rolling completion of the rolling mill, the automatic control module 103 begins to calculate the rolling thickness control level statistics. The specific steps of the rolling thickness control level statistics are as follows:

[0230] According to the steel type and size of the rolled steel plate, all the actual rolling production data of the existing steel plates with the same size and steel type are retrieved from the second storage unit 102. The specific data are the thickness measured by the thickness gauge after the rolling mill and the rolling target thickness.

[0231] For all the steel plates taken out, calculate the rolling thickness control deviation of each steel plate:

[0232] Rolling thickness control deviation = thickness measured by thickness gauge after rolling mill - rolling target thickness;

[0233] For steel plate A001, the rolling thickness control deviation = 0.0202-0.0205=-0.0003m.

[0234] For all the steel plates taken out, the average value of the rolling thickness control deviation of this batch of steel plates is calculated. MC = 0.0005m and standard deviation σ MC =0.0001m.

[0235] The average value of the rolling thickness control deviation obtained by statistics is μ MC = 0.0005m and standard deviation σ MC =0.0001m, with the corresponding steel grade X70M and size specification 20mm×3m×15m as index, and saved in the internal database of the automatic control module 103.

[0236] After manufacturing is complete, the quality inspector measures the dimensions of the finished product to be shipped. The inspector finds steel plate A001 to be 0.02m thick and enters the measurement result into the L3 steel rolling mill 203. The L3 steel rolling mill 203 stores the corresponding medium and thick plate product's design slab number, plate number, measured dimensions, and dimensional inspection pass / fail data in the second storage unit 102 and notifies the automatic control module 103. Upon receiving notification that the finished product dimension measurement is complete, the automatic control module 103 begins calculating the impact of the thickness of the post-rolling mill process. The specific steps for calculating the impact of the thickness of the post-rolling mill process are as follows:

[0237] According to the measurement, the steel plate is of grade X70M and has dimensions of 20mm×3m×15m. All existing steel plate production performance data of the same dimensions and steel grade are retrieved from the second storage unit 102. The specific data are the thickness measured by the thickness gauge after the rolling mill and the thickness measured by the quality inspection.

[0238] For all the steel plates taken out, calculate the thickness change of each steel plate after rolling process:

[0239] Thickness change after rolling process = thickness measured by thickness gauge after rolling mill - thickness measured by quality inspection;

[0240] For steel plate A001, the thickness change after rolling = 0.0202-0.0200 = 0.0002m.

[0241] For all the steel plates taken out, sort them from small to large according to the thickness change of the post-rolling process, and get the median △H of the thickness change of this batch of steel plates after rolling process. PV50=0.0002m, △H ranked at 10% PV10 = 0.0001m and △H ranked at 90% PV90 =0.0003m.

[0242] The median △H of the thickness change after rolling obtained by statistics PV50 =0.0002m, △H ranked at 10% PV10 = 0.0001m and △H ranked at 90% PV90 =0.0003m, with the corresponding steel grade X70M and size specification 20mm×3m×15m as index, and saved in the internal database of the automatic control module 103.

[0243] When the rolling line production plan is started;

[0244] When the production plan for a batch of thick plate orders (Contract No. 010) is completed, the L3 rolling mill 203 automatically triggers a rolling line production plan start event. Instead of directly performing a yield check according to the existing process, the L3 rolling mill 203 first queries the automatic control module 103 to determine whether to adjust and optimize the rolling thickness target. The query message contains information such as the designed slab number (B001), designed slab weight (7500kg), contract number (010), steel grade (X70M), and dimensions (20mm×3m×15m). Automatic control module 103 responds with an optimization and returns an optimization result, ΔH = -0.0003m. The L3 rolling mill 203 then adjusts the target rolling thickness of the plate to (0.0205-0.0003 = 0.0202m), then performs a yield check and continues with the existing process.

[0245] The formula for adjusting the rolling target thickness of the rolling line is: rolling target thickness = original material design rolling target thickness + △H;

[0246] The automatic control module 103 determines whether the response is optimized or not by:

[0247] Automatic control module 103 uses contract number 010 as an index to search first storage unit 101 and obtains a "Yes" indicator for "Is the thickness of the delivered steel plate required to be no less than the nominal thickness?" It then calculates the optimization adjustment amount. If no result is obtained, the response to whether optimization adjustment is performed is "No." If a result is obtained, the response is "Yes" and the result is returned to L3 steel rolling mill 203. Since the optimization adjustment amount calculation result was obtained, the response is "Yes."

[0248] The specific steps of calculating the adjustment optimization amount of the automatic control module 103 are:

[0249] 1) Based on the design slab number B001, contract number 010 and other information, the contract agreed thickness Hctr = 0.020m, the thickness corresponding to the upper limit of the contract permitted thickness tolerance HHctr = 0.021m, the thickness corresponding to the lower limit of the contract permitted thickness tolerance HLctr = 0.019m, the steel plate order quantity M = 1000, the material design rolling target thickness Hmtr = 0.0205m, the material design rolling target thickness upper limit HHmtr = 0.021m, the material design rolling target thickness lower limit HLmtr = 0.019m, the material design rolling target width B = 3.2m, the material design rolling minimum length Lm = 20.5m, and the material design weight W = 11000kg are obtained from the internal database of the second storage unit 102 and the automatic control module 103.

[0250] According to the information of steel grade X70M and size specification 20mm×3m×15m, the average value μ of rolling thickness control deviation is obtained from the internal database of the automatic control module 103. MC = 0.0005m and standard deviation σ MC =0.0001m, and the median △H of the thickness change after rolling is obtained PV50 =0.0002m, △H ranked at 10% PV10 = 0.0001m and △H ranked at 90% PV90 =0.0003m.

[0251] 2) Statistics on the actual thickness of the steel plates produced for the order: using the order number as an index, obtain the quality inspection thickness of all the steel plates corresponding to the order number that have passed the quality inspection from the second storage unit 102, and obtain the number of qualified steel plates produced N = 500 and the overall thickness deviation of the qualified steel plates produced ΔH Done :

[0252]

[0253] Where Hinsp is the quality control measurement thickness.

[0254] 3) Calculate the target thickness adjustment amount;

[0255] First calculate the proposed adjustment amount △Hp of the finished product thickness, a1=0.0m:

[0256]

[0257] Then calculate the preliminary adjustment amount △H1 of the rolling target thickness:

[0258] △H1=△Hp+Hctr+△H PV50-Hmtr=0.0001+0.020+0.0002-0.0205=-0.0002m;

[0259] 4) Estimate the rolling thickness distribution range after the rolling target thickness is adjusted [H MCL ,H MCH ]:

[0260]

[0261] H MCL =0.0205-0.0002+0.0005-3×0.0001=0.0205m;

[0262] H MCH =0.0205-0.0002+0.0005+3×0.0001=0.0211m.

[0263] 5) Estimate the acceptable maximum thickness characterization value and the acceptable minimum thickness characterization value of the thickness distribution of the finished product after the rolling target is adjusted and after the rolling process.

[0264] The acceptable maximum thickness characterization value of the finished product thickness distribution after the rolling target adjustment and the post-rolling process has two values H PV1 、H PV2 The acceptable minimum thickness characterization value of the finished product thickness distribution after the rolling target adjustment has two values H PV3 、H PV4 :

[0265]

[0266] H PV1 =0.0211-0.0001=0.0210m;

[0267] H PV2 =0.0211-0.0002=0.0209m;

[0268] H PV3 =0.0205-0.0002=0.0203m;

[0269] H PV4 =0.0205-0.0003=0.0202m.

[0270] 6) Calculate the permissible thickness limit of finished products under multiple conditions:

[0271] The upper limit of the permissible thickness of the finished product HH is the minimum value among the three restrictions: the upper limit of the permissible thickness tolerance in the contract corresponds to the thickness HHctr = 0.021m, the upper limit of the material design rolling target thickness converted into the finished product thickness HHmtp, and the minimum length of the material design rolling converted into the finished product thickness HHmtl. The lower limit of the permissible thickness of the finished product is the maximum value among the two restrictions: the lower limit of the permissible thickness tolerance in the contract corresponds to the thickness HLctr = 0.019m, and the lower limit of the material design rolling target thickness converted into the finished product thickness HLmtp.

[0272]

[0273]

[0274] HHmtp=0.021-0.0001=0.0209m; HLmtp=0.019-0.0001=0.0189m;

[0275] HHmtl=11000 / (7850×3.2×20.5)=0.02136m;

[0276] HH=min(0.021,0.0209,0.02136)=0.0209m;

[0277] HL=max(0.019,0.0189)=0.019m;

[0278] In the above formula, ρ is the density of steel (7850kg / m 3 ), a2 is the adjustment parameter, set to 0.0m.

[0279] 7) Determine whether the thickness control process capability after the rolling target thickness is adjusted meets the permitted limit of finished product thickness:

[0280] If it is determined that the thickness control process capability after the rolling target thickness adjustment does not meet the permitted limit of the finished product thickness, the L3 level steel rolling 203 is not adjusted and optimized;

[0281] If it is determined that the thickness control process capability after the rolling target thickness adjustment fully meets the permitted limit of the finished product thickness, the L3 level rolling steel 203 is adjusted and optimized, and the adjustment optimization result △H=△H1;

[0282] If it is determined that the thickness control process capability after the rolling target thickness adjustment basically meets the permitted limit of the finished product thickness, the L3 level rolling steel 203 is adjusted and optimized, and the adjustment optimization result △H is output according to more specific conditions;

[0283] H PV1 =0.0210m;

[0284] H PV2= 0.0209 m;

[0285] H PV3 = 0.0203 m;

[0286] H PV4 = 0.0202 m, HH = 0.0209 m, HL = 0.0190 m;

[0287] The specific condition for determining that the thickness control process capability after adjusting the rolling target thickness does not meet the finished product thickness permission limit is: min(H PV1 , H PV2 ) > HH or max(H PV3 , H PV4 ) < HL, and it is determined that the condition is not met;

[0288] The specific condition for determining that the thickness control process capability after adjusting the rolling target thickness fully meets the finished product thickness permission limit is: max(H PV1 , H PV2 ) < HH or min(H PV3 , H PV4 ) > HL, and it is determined that the condition is not met;

[0289] The specific condition for determining that the thickness control process capability after adjusting the rolling target thickness basically meets the finished product thickness permission limit is that one of the following two conditions is met:

[0290] Condition 1: min(H PV1 , H PV2 ) ≤ HH and max(H PV1 , H PV2 ) ≥ HH, and it is determined that the condition is met;

[0291] Condition 2: min(H PV3 , H PV3 ) ≤ HL and max(H PV3 , H PV4 ) ≥ HL, and it is determined that the condition is not met;

[0292] If it is determined that the thickness control process capability after adjusting the rolling target thickness basically meets the finished product thickness permission limit, the more specific judgment condition for answering whether to adjust and optimize the steel rolling 203 at L3 level is:

[0293] When the slab to be planned to start meets both Condition 1 and Condition 2 at the same time, the adjustment and optimization result △H = △H1, which is not met in this embodiment.

[0294] When the slab to be planned to start only meets Condition 1, the following step a is carried out:

[0295] a1. Calculate the additional thickness adjustment amount △Ha = HH - max(HPV1 ,H PV2 ):

[0296] △Ha=HH-max(H PV1 ,H PV2 )=0.0209-0.0210=-0.0001m;

[0297] a2. Calculate the acceptable minimum thickness characterization value H including the additional thickness adjustment PV3a 、H PV4a :

[0298]

[0299] H PV3a =0.0203-0.0001=0.0202m;

[0300] H PV4a =0.0202-0.0001=0.0201m;

[0301] a3、If min(H PV3a ,H PV4a )≥HL, then adjust the optimization result △H=△H1+△Ha; otherwise adjust the optimization result △H=△H1. min(H PV3a ,H PV4a )=0.0201m is greater than HL, adjust △H=△H1+△Ha=-0.0002-0.0001=-0.0003m;

[0302] Returned to L3 grade rolled steel 203, the adjustment amount is -0.0003m.

[0303] The batch steel plate thickness control system and method provided by this invention, tailored to the requirements of medium and thick plate orders, offers broad applicability and ease of use. Suitable for medium and thick plate manufacturers, it fully leverages existing equipment and information systems, leverages factory-level data platforms, and maximizes the potential for process cost reduction in the era of intelligent factory upgrades. This technology is fully adaptable and has broad prospects for widespread adoption.

[0304] 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 batch steel plate thickness control method for medium and thick plate order requirements, the method is based on a batch steel plate thickness control system for medium and thick plate order requirements, characterized in that: The batch steel plate thickness control system for medium and thick plate order requirements includes: The first storage unit is used to store the personalized needs of user orders; a second storage unit for storing production data; The computer information system includes a basic automation subsystem, a process control subsystem, a production line manufacturing execution subsystem, and a production operation subsystem; an automatic control module is used to perform automatic functional control on each subsystem of the computer information system based on the personalized needs of user orders in the first storage unit and the production data in the second storage unit. The computer information system has four levels, including: Level 1 corresponds to the rolling mill L1 of the basic automation subsystem; The second level corresponds to the rolling mill L2 of the process control subsystem; Level 3 corresponds to the steel rolling L3 of the production line manufacturing execution subsystem; Level 4 corresponds to the sales management subsystem L4 and the manufacturing management subsystem L4 of the production operation subsystem; The batch steel plate thickness control method for medium and thick plate order requirements performs automated functions of production process capability evaluation, material design information verification, and rolling target optimization based on the personalized needs of user orders; The user order personalization requirements include: Steel grade, customer number, contract number; and "Is it required that the thickness of the delivered steel plate should not be less than the nominal thickness?" 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; Event 2: Salesperson enters the contract; The processing flow of event 2: the salesperson enters the steel type, user number, contract number and "whether the thickness of the delivered steel plate is required to be no less than the nominal thickness" into the first storage unit, Event 3: After the rolling mill is completed; Event 4: After the quality inspector measures the size of the finished product; Event 5: When the rolling line production plan starts; The processing flow of event 5: When the thick plate rolling line production plan is completed, the steel rolling L3 will automatically trigger the rolling line production plan start event, and the steel rolling L3 inquires the automatic control module whether the automatic control module performs rolling thickness target adjustment optimization. If the automatic control module answers "no", the steel rolling L3 performs yield rate verification and subsequent original processing flow according to the original process; if the automatic control module answers "yes", the adjustment optimization amount calculation result ΔH is returned, and the steel rolling L3 adjusts the rolling target thickness of the steel plate, and then performs yield rate verification and subsequent original processing flow. The calculation of the rolling thickness target adjustment optimization is as follows: Rolling target thickness = original material design rolling target thickness + ΔH, The specific steps of calculating the rolling thickness target adjustment optimization amount by the automatic control module are as follows: 1) Data preparation: According to the design slab number and the contract number, the contract agreed thickness Hctr, the thickness corresponding to the upper limit of the contract permitted thickness tolerance HHctr, the thickness corresponding to the lower limit of the contract permitted thickness tolerance HLctr, the steel plate order quantity M, the material design rolling target thickness Hmtr, the material design rolling target thickness upper limit HHmtr, the material design rolling target thickness lower limit HLmtr, the material design rolling target width B, the material design rolling minimum length Lm, and the material design weight W are obtained from the second storage unit and the internal database of the automatic control module; According to the steel type and size, the average value μ of the rolling thickness control deviation is obtained from the internal database of the automatic control module. MC and standard deviation σ MC , get the median ΔH of the thickness change after rolling PV50 , ΔH ranked at the 10% position PV10 and ΔH at the 90% position PV90 ; Rolling thickness control deviation = thickness measured by thickness gauge after rolling mill - rolling target thickness; Thickness change after rolling process = thickness measured by thickness gauge after rolling mill - thickness measured by quality inspection; 2) Statistics on the thickness of the steel plates produced for this order: Using the order number as an index, obtain the quality inspection and measurement thickness of all existing steel plates corresponding to the order number and that have passed the quality inspection from the second storage unit, and obtain the number N of all existing steel plates and the overall thickness deviation ΔH of all existing steel plates by statistics. Done : In the above formula, Hinsp is the quality inspection measurement thickness; 3) Calculate the target thickness adjustment amount: First calculate the proposed adjustment amount ΔHp of the finished product thickness: In the above formula, a1 is an adjustment parameter with a value of -0.0005 to 0.0005, unit: m; Then calculate the preliminary adjustment amount ΔH1 of the rolling target thickness: ΔH1=ΔHp+Hctr+ΔH PV50 -Hmtr; 4) estimating the rolling thickness distribution range after the rolling target thickness is adjusted; 5) estimating an acceptable maximum thickness representation value and an acceptable minimum thickness representation value of thickness distribution of finished products after the rolling target adjustment and after the post-rolling process; 6) Calculate the thickness limit of finished products under multiple conditions; 7) Determine whether the thickness control process capability after the rolling target thickness is adjusted meets the permitted limit of finished product thickness: If it is determined that the thickness control process capability after the target rolling thickness is adjusted does not meet the permitted limit of the finished product thickness, the L3 level rolling will not be adjusted and optimized; If it is determined that the thickness control process capability after the rolling target thickness is adjusted fully meets the permitted limit of the finished product thickness, the L3 level rolling is adjusted and optimized, and the adjustment optimization result ΔH=ΔH1; If it is determined that the thickness control process capability after the rolling target thickness is adjusted basically meets the permitted limit of the finished product thickness, the L3 level steel rolling is adjusted and optimized, and the adjustment optimization result ΔH is output according to more specific conditions.

2. The method for controlling the thickness of batch steel plates according to the requirements of medium and thick plate orders according to claim 1, characterized in that: The external events trigger different processing processes and further include: The processing flow of event 1: access the basic information of the medium and thick plate contract in the sales management subsystem L4, and synchronize the information of the contract number, user number, contract-agreed thickness dimension, contract-agreed width dimension, contract-agreed length dimension, contract-agreed thickness tolerance range, and steel plate order quantity into the internal database of the automatic control module; Access the basic information of the medium and heavy plate material design in the manufacturing management subsystem L4, and synchronize the information of the contract number, the designed slab number, the rolling target size, and the upper and lower limits of the rolling target into the internal database of the automatic control module; The processing flow of event 3: after the rolling mill L1 completes rolling of a steel plate, the rolling mill L2 stores the rolling production data in the second storage unit and notifies the automatic control module that the rolling mill is completed; After receiving the notification that the rolling mill has completed rolling, the automatic control module starts to calculate the rolling thickness control level; The processing flow of event 4: the quality inspector measures the dimensions of the finished product to be shipped and inputs the measurement results to the steel rolling L3. The steel rolling L3 stores the design slab number, steel plate number, measured dimensions, and whether the dimension inspection is qualified or not of the corresponding medium and thick plate finished product in the second storage unit, and notifies the automatic control module that the finished product dimension measurement is completed; After receiving the notification that the finished product size measurement is completed, the automatic control module starts to calculate the thickness impact of the post-rolling mill process.

3. The method for controlling the thickness of batch steel plates according to claim 2, wherein: In the processing flow of event 3, the rolling production data includes the thickness measured by the thickness gauge after the rolling mill, steel type, size specification, target size, and steel plate number; and / or In the processing flow of event 3, the specific steps of the rolling thickness control level statistics are as follows: 1) based on the steel grade and size of the rolled steel plate, extracting from the second storage unit all rolling production data of existing steel plates with the same size and steel grade, wherein the rolling production data includes the thickness measured by the thickness gauge after the rolling mill and the rolling target thickness; 2) For all the existing steel plates taken out, calculate the rolling thickness control deviation of each existing steel plate: Rolling thickness control deviation = thickness measured by thickness gauge after rolling mill - rolling target thickness; 3) For all the existing steel plates taken out, the average value μ of the rolling thickness control deviation of all the existing steel plates taken out is calculated MC and standard deviation σ MC ; 4) The statistical average value μ MC and standard deviation σ MC , with the corresponding steel type and size as index, and saved in the internal database of the automatic control module.

4. The method for controlling the thickness of batch steel plates according to claim 3, wherein: In the processing flow of event 4, the specific steps for calculating the impact of the thickness of the post-rolling mill process are as follows: 1) based on the steel type and size of the measured steel plate, retrieve from the second storage unit the production data of all existing steel plates with the same size and steel type, the production data including the thickness measured by the thickness gauge after the rolling mill and the thickness measured by the quality inspection; 2) For all the existing steel plates taken out, calculate the thickness change of each existing steel plate after rolling process: Thickness change after rolling process = thickness measured by thickness gauge after rolling mill - thickness measured by quality inspection; 3) Sort all the existing steel plates taken out from smallest to largest according to the thickness change after rolling process, and obtain the median ΔH of the thickness change after rolling process of all the existing steel plates PV50 , ΔH ranked at the 10% position PV10 and ΔH at the 90% position PV90 ; 4) The median ΔH of the thickness change after rolling obtained by statistics PV50 , ΔH ranked at the 10% position PV10 and ΔH at the 90% position PV90 , with the corresponding steel type and size as index, and saved in the internal database of the automatic control module.

5. The method for controlling the thickness of batch steel plates according to the requirements of medium and thick plate orders according to claim 3 is characterized in that: In the processing flow of event 5, the steel rolling L3 inquires the automatic control module, and the inquiry message includes the design slab number, design slab weight, contract number, steel type, and size specifications.

6. The method for controlling the thickness of batch steel plates according to the requirements of medium and thick plate orders according to claim 5, characterized in that: In the processing flow of event 5, the method for determining whether the automatic control module performs rolling thickness target adjustment optimization is as follows: The automatic control module uses the contract number as an index to search the first storage unit to obtain an indication of "whether the thickness of the steel plate of the delivery batch is required to be no less than the nominal thickness"; If the indicator of "whether the thickness of the steel plate in the delivery batch is required to be not less than the nominal thickness" is "no", the automatic control module responds with "no"; If the "whether the thickness of the delivered batch of steel plates is required to be no less than the nominal thickness" is marked as yes, the automatic control module calculates the rolling thickness target adjustment optimization amount. If the rolling thickness target adjustment optimization amount calculation result cannot be obtained, the automatic control module answers no; if the rolling thickness target adjustment optimization amount calculation result can be obtained, the automatic control module answers yes, and at the same time returns the rolling thickness target adjustment optimization amount calculation result to the steel rolling L3.

7. The method for controlling the thickness of batch steel plates according to claim 6, wherein: The specific steps of calculating the rolling thickness target adjustment optimization amount by the automatic control module also include: 4) Estimate the rolling thickness distribution range after the rolling target thickness is adjusted [H MCL ,H MCH ]; 5) estimating an acceptable maximum thickness representation value and an acceptable minimum thickness representation value of thickness distribution of finished products after the rolling target adjustment and after the post-rolling process; The acceptable maximum thickness characterization value of the finished product thickness distribution after the rolling target adjustment and the post-rolling process has two values H PV1 、H PV2 The acceptable minimum thickness characterization value of the finished product thickness distribution after the rolling target adjustment has two values H PV3 、H PV4 ; 6) Calculate the permissible thickness limit of finished products under multiple conditions: The upper limit of the permissible thickness of the finished product HH is the minimum value among the three restrictions: the thickness corresponding to the upper limit of the permissible thickness tolerance in the contract HHctr, the upper limit of the material design rolling target thickness converted into the finished product thickness HHmtp, and the finished product thickness converted into the minimum length of the material design rolling; the lower limit of the permissible thickness of the finished product is the maximum value among the two restrictions: the thickness corresponding to the lower limit of the permissible thickness tolerance in the contract HLctr and the finished product thickness converted into the lower limit of the material design rolling target thickness HLmtp; In the above formula, ρ is the density of steel, a2 is the adjustment parameter, ranging from 0 to 1.0, unit: m; 7) Determine whether the thickness control process capability after the rolling target thickness is adjusted meets the permitted limit of finished product thickness: If it is determined that the thickness control process capability after the target rolling thickness is adjusted does not meet the permitted limit of the finished product thickness, the L3 level rolling will not be adjusted and optimized; If it is determined that the thickness control process capability after the rolling target thickness is adjusted fully meets the permitted limit of the finished product thickness, the L3 level rolling is adjusted and optimized, and the adjustment optimization result ΔH=ΔH1; If it is determined that the thickness control process capability after the target rolling thickness is adjusted substantially meets the permitted limit of the finished product thickness, the L3 level rolling is adjusted and optimized, and the adjustment optimization result ΔH is output according to more specific conditions; The specific conditions for judging that the thickness control process capability after the rolling target thickness adjustment does not meet the permitted limit of finished product thickness are: min(H PV1 ,H PV2 )>HH or max(H PV3 ,H PV4 )<HL; The specific conditions for judging that the thickness control process capability after the rolling target thickness adjustment fully meets the permitted limit of finished product thickness are: max(H PV1 ,H PV2 )<HH or min(H PV3 ,H PV4 )>HL; The specific conditions for judging that the thickness control process capability after the rolling target thickness is adjusted basically meets the permissible limit of the finished product thickness are that one of the following two conditions is met: Condition 1: min(H PV1 ,H PV2 )≤HH and max(H PV1 ,H PV2 )≥HH; Condition 2: min(H PV3 ,H PV3 )≤HL and max(H PV3 ,H PV4 )≥HL; If it is determined that the thickness control process capability after the rolling target thickness is adjusted basically meets the permitted limit of the finished product thickness, the calculation process and more specific judgment conditions for the adjustment optimization result of the L3 level rolling optimization are as follows: When the slab to be started satisfies both conditions 1 and 2, the optimization result ΔH is adjusted to ΔH1; When the slab to be planned to start only meets condition 1, proceed as follows: a1. Calculate the additional thickness adjustment ΔHa = HH-max(H PV1 ,H PV2 ); a2. Calculate the acceptable minimum thickness characterization value H including the additional thickness adjustment PV3a 、H PV4a : a3、If min(H PV3a ,H PV4a )≥HL, if yes, adjust the optimization result ΔH=ΔH1+ΔHa; otherwise, adjust the optimization result ΔH=ΔH1; When the slab to be planned to start only meets condition 2, proceed as follows: b1. Calculate the additional thickness adjustment ΔHb = HL-min (H PV3 ,H PV4 ); b2. Calculate the acceptable maximum thickness representation value H including the additional thickness adjustment PV1b 、H PV2b : b3、If max(H PV1b ,H PV2b )≤HH, if so, adjust the optimization result ΔH=ΔH1+ΔHb; otherwise, adjust the optimization result ΔH=ΔH1.

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