An online monitoring method for blockage of a circular shear

Abstract

An on-line monitoring method for the blockage of a circular shear, belonging to the field of monitoring. It arranges diffuse reflection photoelectric switches at the top of the bin; collects the signal of whether the circular shear is working from L1 and obtains relevant production data from L2; when the circular shear starts to work, the on-line monitoring and early warning function is activated; decides whether to start the on-line monitoring and early warning function for the edge wire width of thick high-strength steel according to whether the incoming material is thick high-strength steel; if no edge wire is detected to stay, or the edge wire stays but the staying time does not exceed the set alarm duration, it is determined that the circular shear is working normally; otherwise, it is determined that the edge wire inside the bin has been blocked, and the corresponding bin blockage alarm module outputs sound and light alarm signals; when the incoming material is thick high-strength steel, the real-time actual width is compared with the target width after shearing: if it is greater than the edge wire over-width warning value, an early warning signal is sent through the on-line monitoring software; when the edge wire over-width warning signal is sent, check the video monitoring. If there is a trend of bin blockage, deal with it immediately.

Description

Technical Field

[0001] The present invention belongs to the field of monitoring, and particularly relates to an on-line monitoring device and method for a circular shear bin blockage based on diffuse reflection photoelectric switch detection. Background Art

[0002] The circular shear is an important and indispensable equipment for cold rolling hot-dip galvanizing units, and its main function is to perform width-fixed shearing on strip steel and remove edge defects of the strip steel.

[0003] As a common process flow, during the operation of the circular shear, the edge wires cut by the circular shear first need to enter the chute, then be introduced into the bin by the chute, and finally enter the briquetting machine through the bin for briquetting treatment.

[0004] Therefore, the edge wires need to pass through the chute and the bin smoothly in order to enter the briquetting machine for waste treatment.

[0005] With the continuous improvement of product strength, the problem of bin blockage by edge wires is one of the common problems during the shearing of thick high-strength steel. The characteristics of high-strength steel are high hardness and not easy to bend. Sometimes the edge wires will be blocked in the bin channel and cannot naturally fall into the briquetting machine.

[0006] If it can be detected in time at the initial stage of the bin blockage by edge wires, it can be processed by means of manual intervention, thus avoiding downtime losses; otherwise, if it is not detected in time, the bin will be filled with edge wires, production cannot continue, and the circular shear must be shut down and withdrawn for bin cleaning operation, which not only greatly increases the downtime and repair volume, but also is time-consuming, laborious and has potential safety hazards.

[0007] With the continuous improvement of the intelligent level and speed of the unit, the shearing speed of the circular shear is getting faster and faster, and the problem of bin blockage has become a bottleneck affecting the speed increase and stable production of the unit.

[0008] How to adopt intelligent monitoring and detection means for the prevention and fault identification of circular shear bin blockage, detect and process it in time at the initial stage of the bin blockage by edge wires, so as to avoid the downtime accidents and batch product scrapping caused by untimely bin blockage treatment to the greatest extent, and ensure the stable operation of the circular shear in a good working state, is a technical problem urgently to be solved in the actual process operation and production process. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to provide an on-line monitoring method for circular shear bin blockage. By constructing an on-line monitoring software and hardware system for circular shear bin blockage based on diffuse reflection photoelectric switch detection, it realizes the real-time monitoring and timely alarm of circular shear bin blockage faults, and timely warns of the bin blockage risks caused by the width fluctuation and deviation of thick high-strength steel, so as to avoid downtime accidents and batch product scrapping caused by untimely bin blockage treatment, and ensure the stable operation of the circular shear in a good working state.

[0010] The technical solution of the present invention is: to provide an on-line monitoring method for the clogging of a circular shear bin, including setting a video monitoring system inside the bin of the circular shear to view the inside of the bin in a timely manner, and characterized in that:

[0011] 1) At least one diffuse reflection photoelectric switch is arranged in the width direction at the top of the bin to detect the residence time of the edge wire in the bin;

[0012] 2) Collect the identification signal indicating whether the circular shear is working from the on-site control computer L1 to judge in real time whether the circular shear is working; at the same time, grab the relevant production data in real time from the process control computer L2, and store all the data in the database of the remote server;

[0013] 3) When it is detected that the circular shear starts to work, the on-line monitoring and early warning function of the diffuse reflection photoelectric induction switch is started; at the same time, according to whether the incoming material is thick high-strength steel, decide whether to start the on-line monitoring and early warning function for the edge wire width of thick high-strength steel;

[0014] 4) Set a timer for cumulative timing, which is used to emit an alarm signal after delaying an alarm duration after detecting the residence of the edge wire;

[0015] 5) When the edge wire residence is not detected, or the edge wire residence is detected but the residence time does not exceed the set alarm duration, it is determined that the circular shear is working normally;

[0016] 6) When it is detected that the residence time of the edge wire exceeds the set alarm duration, it is determined that the edge wire inside the bin has been blocked and accumulated in the bin, and the corresponding bin clogging alarm module responds accordingly, outputting audible and visual alarm signals;

[0017] 7) After the on-line monitoring system issues a bin clogging alarm signal, the operator confirms it through video monitoring. If the alarm signal is confirmed to be correct, confirm it immediately; if the alarm signal is incorrect, after confirmation, correct the alarm duration;

[0018] 8) Judge according to the thickness h, strength σ s , real-time actual width w s , deviation δ of the center line of the incoming material, and target width w after shearing: When the incoming material is thick high-strength steel, that is, h≥h0, σ s ≥σ s0 , and When, it is prompted that the edge wire is too wide and there is a risk of bin clogging, and a warning signal is sent through the on-line monitoring software;

[0019] Where h0 is the critical thickness for distinguishing thick and thin materials, σ s0 is the critical strength for distinguishing high-strength steel; a is the warning value for the edge wire being too wide set by the system;

[0020] 9) After the system issues a warning signal for excessive side wire width, the operator checks the video monitoring to confirm whether there is a tendency of bin blockage. If a bin blockage tendency is found, it should be dealt with immediately.

[0021] Specifically, the relevant production data at least includes the coil number, steel grade, incoming material thickness, incoming material strength, incoming material actual width, incoming material center line deviation, and the target width after shearing.

[0022] Specifically, the light detection end of the diffuse reflection photoelectric switch is arranged towards the inside of the bin.

[0023] Furthermore, the diffuse reflection photoelectric switch is connected to the system electric control box through a multi-core wire, and the electric control box is connected to a network switch through a network cable; the network switch transmits data through the network to a remote server. The remote server is used to install and run online monitoring software to monitor and alarm for bin blockage faults.

[0024] Furthermore, in step 2), an identification signal indicating whether the circular shear is working is collected from the on-site control computer L1; when the circular shear is put into operation, the diffuse reflection photoelectric induction switch and the online monitoring and warning function for the side wire width of thick material and high-strength steel are started simultaneously.

[0025] Furthermore, in step 8), when there is incoming material deviation, the incoming material center line deviation δ is not zero; when there is no incoming material deviation, the incoming material center line deviation δ is zero.

[0026] Specifically, the incoming material deviation signal is obtained from the on-site control computer L1 or the process control computer L2.

[0027] Furthermore, when the side wire is detected to stay, the timer starts to work. When the alarm time is reached, it is considered that a bin blockage fault has occurred and an alarm is given; if the signal disappears within the alarm time, it is considered that the side wire jam has been cleared, the timer is cleared, and the timer starts to prepare for timing again.

[0028] Compared with the prior art, the advantages of the present invention are:

[0029] 1. This technical solution realizes the online monitoring of bin blockage faults during the shearing process by constructing an online monitoring system for circular shear bin blockage based on diffuse reflection photoelectric switch detection;

[0030] 2. This technical solution proposes a method for judging bin blockage faults during the shearing process of a circular shear, which can timely give early warnings and alarms for bin blockage faults, avoid shutdown accidents and batch product scrapping caused by untimely handling of bin blockage, and ensure the stable operation of the circular shear in good working condition;

[0031] 3. The entire technical solution is simple and easy to implement, and operates reliably. There is no need to modify the original equipment, which is convenient for on-site practical application. It can be further optimized during actual use to continuously improve the accuracy of alarm and early warning. Brief Description of the Drawings

[0032] Figure 1 is a schematic diagram of the online monitoring hardware system for the stock bin blockage of the disc shear of the present invention;

[0033] Figure 2 is a flowchart block diagram of the online monitoring system for the stock bin blockage of the disc shear of the present invention. Detailed Embodiment

[0034] The present invention will be further described below with reference to the drawings and embodiments.

[0035] The technical solution of the present invention proposes an online monitoring method for the stock bin blockage of the disc shear based on the detection of diffuse reflection photoelectric switches. The main principle is as follows:

[0036] A diffuse reflection photoelectric switch is a sensor that integrates a transmitter and a receiver. When a detected object passes by, the object reflects the light emitted by the photoelectric switch transmitter to the receiver, and thus the photoelectric switch generates a switching signal. When the surface of the detected object is bright or its reflectivity is extremely high, the diffuse reflection photoelectric switch is the preferred detection mode.

[0037] In this technical solution, in order to automatically monitor the stock bin blockage fault of the edge wire in the stock bin, the diffuse reflection induction principle is adopted to identify whether the edge wire is detected within a certain distance and whether it stays for more than a certain duration after the edge wire is detected. If the staying time of the edge wire exceeds the set duration, it is considered that a stock bin blockage fault has occurred and an alarm is given in a timely manner.

[0038] To implement the above principle, the monitoring mode of the present invention mainly includes the following steps:

[0039] 1. Construct an online monitoring hardware system for the stock bin blockage of the disc shear:

[0040] The online monitoring hardware system for the stock bin blockage of the disc shear is as Figure 1 shown. This system mainly includes a diffuse reflection photoelectric switch, a system electric control box, a network switch, a server, and system software.

[0041] One or more diffuse reflection photoelectric switches are arranged in the width direction at the top of the silo (to ensure the monitoring effect and, at the same time, based on keeping the number of involved detectors to a minimum, it is advisable to select 2 diffuse reflection photoelectric switches). A diffuse reflection photoelectric switch is a sensor that integrates a transmitter and a receiver. When there is a snagging of the edge wire in the silo, the snagged edge wire reflects the light emitted by the photoelectric switch transmitter to the receiver, and thus the photoelectric switch generates a switching signal. When it is sensed that the edge wire has stayed for more than the set duration, it is judged that a silo blockage fault has occurred and an alarm is given.

[0042] The diffuse reflection photoelectric switch is connected to the system electric control box through a multi-core wire, and at the same time, the AC power supply is connected to the electric control box. The electric control box is connected to the network switch beside the machine through a network cable; finally, it is transmitted to the remote server through the network, and an optical cable or a network cable can be selected for connection according to the transmission distance. The remote server is used to install and run the online monitoring software to monitor and alarm the silo blockage fault that occurs.

[0043] 2. Online monitoring method:

[0044] After the hardware system is built, develop and install the software of the silo blockage online monitoring system so that it has functions such as data acquisition, real-time analysis, alarm processing, and data storage at the same time. Its monitoring process is as Figure 2 shown below, and the specific description is as follows:

[0045] (1) Connect the external power supply, turn on the air switch and power switch of the electric control box, and set the timer to the required alarm time according to the actual situation. This set time is the cumulative timing time, and the timing length is the time length from the first sensing of the appearance of the edge wire and its continuation. When the edge wire is detected and stays, the timer starts to work. When it lasts until the alarm time, it is considered that a silo blockage fault has occurred and an alarm is given; if the signal disappears within the alarm time, it is considered that the edge wire snagging has been cleared, the timer is cleared, and it is ready to time again.

[0046] (2) Real-time capture relevant production data from the unit big data server, mainly including: coil number, steel grade, incoming material thickness, incoming material strength, incoming material actual width, incoming material center line deviation, target width after shearing, and the working identification signal of the circular shear, etc., and store all the data in the database for subsequent call and historical query.

[0047] (3) According to the collected working identification signal of the circular shear, judge in real time whether the circular shear is working. If the circular shear starts to work, enter the next step.

[0048] (4) After the circular shear starts to work, the diffuse reflection photoelectric induction switch and the online monitoring and early warning function for the width of the edge wire of thick material and high-strength steel are started simultaneously.

[0049] (5) When no edge wire stay is detected, or when the edge wire stay is detected but the stay time does not exceed the set alarm duration, it is determined that the circular shear is working normally; when the detected edge wire stay time exceeds the set alarm duration, it is determined that the edge wire inside the bin has become blocked and accumulated in the bin, and the corresponding bin blockage alarm module responds accordingly, the alarm indicator light turns red, and the alarm bell rings.

[0050] When the alarm duration is set short, the risk of bin blockage can be discovered and processed in a timely manner, but it is also possible that the accumulated edge wire drops under the action of gravity, resulting in false alarms; when the alarm duration is set long, although correct alarms can be ensured, there is also a risk that the delay in alarm time will lead to a more serious bin blockage. Therefore, the alarm duration can be set within a small range during the software debugging stage and gradually corrected according to the actual confirmation situation.

[0051] (6) After the online monitoring system issues a bin blockage alarm signal, manual confirmation is carried out through video monitoring. If the alarm signal is confirmed to be correct, it is immediately processed, and the "Alarm correct" confirmation item is clicked on the system software; if the alarm signal is incorrect, the "Alarm incorrect" confirmation item is clicked on the system software, and the software will correct the alarm duration.

[0052] (7) Considering that abnormal situations such as fluctuations in the width of the incoming strip and deviation during operation may occur during the operation of the strip steel, when the incoming material is thick, high-strength, and the edge wire width on the operation side or the drive side is too large, it is very easy to occur a bin blockage fault. Therefore, the software system automatically judges according to the thickness h, strength σ s , real-time actual width w s , incoming material center line deviation δ, and the target width w after shearing:

[0053] When the incoming material is thick high-strength steel, that is, h≥h0, σ s ≥σ s0 , and When, the system prompts that the edge wire is too wide and there is a risk of bin blockage, and issues a warning signal through the online monitoring software. Among them, when there is deviation of the incoming material, the incoming material center line deviation δ is not zero; when there is no deviation of the incoming material, the incoming material center line deviation δ is zero. h0 and σ s0 are the critical thickness and strength for distinguishing thick and thin materials and high-strength steel respectively; a is the warning value for the edge wire being too wide set by the system.

[0054] When the system issues a warning signal that the edge wire is too wide, the operator checks the video monitoring to confirm whether there is a trend of bin blockage. If a trend of bin blockage is found, it is processed immediately.

[0055] Example:

[0056] To further illustrate the application process of the related technologies of the present invention, taking the circular shear unit of a certain production line as an example, the application process of the online monitoring method for circular shear bin blocking will be described in detail below.

[0057] First, construct the online monitoring hardware system and software system for circular shear bin blocking according to the technical solution. Arrange 2 diffuse reflection photoelectric switches in the width direction at the top of the bin to collect the diffuse reflection signals at different positions in the width direction respectively.

[0058] The diffuse reflection photoelectric switches are connected to the system electric control box through multi-core wires. Connect the brown, black, and blue wires of the diffuse reflection photoelectric switches to the corresponding terminal blocks of the electric control box respectively. At the same time, connect the 220V, 50Hz AC power supply to the electric control box.

[0059] The electric control box is connected to the network switch beside the machine through a network cable, and finally transmitted to the remote server through an optical cable. The server is used to install and run the online monitoring software to monitor and alarm the bin blocking faults that occur.

[0060] Connect the external power supply, turn on the air switch and power switch of the electric control box, and set the alarm time of the timer to 120 seconds according to the actual situation. When the working identification signal Circle_shear_use of the circular shear is equal to 1, it means that the circular shear is put into work, and the diffuse reflection photoelectric induction switch and the online monitoring and early warning function of the width of the thick material high-strength steel edge wire are started at the same time.

[0061] When no edge wire stay is detected, or the edge wire stay is detected but the stay time does not exceed the set alarm duration, it is determined that there is no bin blocking fault in the circular shear and the working condition is normal. When the edge wire stay is first sensed and the duration exceeds 120 seconds, the system determines that a bin blocking fault has occurred. After that, the alarm indicator light turns red and the alarm bell rings. If the duration does not exceed 120 seconds after the edge wire stay is sensed, it means that the edge wire jam is cleared, the timer is cleared, and the timing is prepared again.

[0062] At the same time, set the early warning value of the width of the thick material high-strength steel edge wire to 23mm, distinguish the critical thickness h0 of thick and thin materials = 1.5mm, and distinguish the critical strength σ s0 = 460MPa.

[0063] When the system receives the incoming material thickness h = 1.988mm, strength σ s = 520MPa, the real-time actual width w of the strip steel s = 1245mm, the target width w after shearing = 1200mm, and the deviation δ of the center line of the incoming material = 0. At this time, is less than the early warning value of 23mm, and the system determines that the working condition is normal; when the real-time actual width w of the strip steel received by the system s = 1246mm and the incoming material is off-track, δ = 0.5mm, If it exceeds the warning value of 23 mm, the system will issue a warning signal for excessive edge wire width. The operator can confirm whether there is a tendency of bin blockage by checking the video monitoring. If a bin blockage tendency is found, it should be dealt with immediately.

[0064] The technical solution of the present invention can construct an online monitoring software and hardware system for the bin blockage of the circular shear based on the detection of diffuse reflection photoelectric switches, and can monitor and alarm the bin blockage fault of the circular shear in real time, so as to alarm and handle the bin blockage fault of the circular shear in time, and timely warn of the bin blockage risk caused by the width fluctuation and deviation of thick high-strength steel, thereby avoiding the shutdown accidents and batch product scrapping caused by untimely bin blockage handling, ensuring the stable operation of the circular shear in good working condition, and minimizing the losses caused by shutdown.

[0065] The present invention can be widely used in the field of online monitoring and warning of bin blockage faults of circular shears.

Claims

1. An on-line monitoring method for the stock bin blocking of a circular shear, including setting a video monitoring system inside the stock bin of the circular shear to view the situation inside the stock bin in a timely manner, characterized in that: 1) At least one diffuse reflection photoelectric switch is arranged in the width direction at the top of the stock bin for detecting the residence time of the edge wire inside the stock bin; 2) The identification signal indicating whether the circular shear is working is collected from the on-site control computer L1 to judge in real time whether the circular shear is working; at the same time, relevant production data is captured in real time from the process control computer L2, and all data is stored in the database of the remote server; 3) After it is detected that the circular shear starts to work, the on-line monitoring and early warning function of the diffuse reflection photoelectric induction switch is started; at the same time, according to whether the incoming material is thick high-strength steel, it is decided whether to start the on-line monitoring and early warning function for the edge wire width of thick high-strength steel; 4) A timer is set for cumulative timing, which is used to send an alarm signal after delaying an alarm duration after detecting the residence of the edge wire; 5) If the residence of the edge wire is not detected, or the residence of the edge wire is detected but the residence time does not exceed the set alarm duration, it is determined that the circular shear is working normally; 6) If the residence time of the edge wire is detected to exceed the set alarm duration, it is determined that the edge wire inside the stock bin has been blocked and accumulated in the stock bin, and the corresponding stock bin blocking alarm module responds accordingly, outputting sound and light alarm signals; 7) After the on-line monitoring system sends out a stock bin blocking alarm signal, the operator confirms it through video monitoring. If it is confirmed that the alarm signal is correct, it is immediately confirmed; if the alarm signal is incorrect, after confirmation, the alarm duration is corrected; 8) According to the thickness h and strength σ of the incoming material s , the real-time actual width w s , the deviation δ of the center line of the incoming material, and the target width w after cutting, make a judgment: When the incoming material is thick high-strength steel, that is, h ≥ h0, σ s ≥ σ s0 , and at this time, it is indicated that the side wire is too wide and there is a risk of bin blockage, and a warning signal is sent through the online monitoring software; Among them, h0 is the critical thickness for distinguishing thick and thin materials, and σ s0 is the critical strength for distinguishing high-strength steel; a is the warning value for too wide side wire set by the system; 9) After the system sends out an early warning signal for the over-wide edge wire, the operator checks the video monitoring to confirm whether there is a tendency of stock bin blocking. If a tendency of stock bin blocking is found, it is processed immediately.

2. The on-line monitoring method for the clogging bin of the circular shear according to claim 1, characterized in that The relevant production data at least includes the coil number, steel type, incoming material thickness, incoming material strength, incoming material actual width, incoming material center line deviation and the target width after shearing.

3. The on-line monitoring method for the disc shear plugging bin according to claim 1, characterized in that The light detection end of the diffuse reflection photoelectric switch is arranged facing the inside of the stock bin.

4. The on-line monitoring method for the plugging bin of the circular shear according to claim 1, characterized in that The diffuse reflection photoelectric switch is connected to the system electric control box through a multi-core wire, and the electric control box is connected to the network switch through a network cable; The network switch transmits the network to the remote server. The remote server is used to install and run on-line monitoring software to monitor and alarm the occurring stock bin blocking faults.

5. The online monitoring method for the clogging bin of the circular shear according to claim 1, characterized in that In step 2), the identification signal indicating whether the circular shear is working is collected from the on-site control computer L1; when the circular shear is put into work, the on-line monitoring and early warning functions of the diffuse reflection photoelectric induction switch and the edge wire width of thick high-strength steel are started simultaneously.

6. The online monitoring method for the clogging bin of the circular shear according to claim 1, characterized in that In step 8), when there is incoming material deviation, the incoming material center line deviation δ is not zero; when there is no incoming material deviation, the incoming material center line deviation δ is zero.

7. The on-line monitoring method for the blocking bin of the circular shear according to claim 6, characterized in that The incoming material deviation signal is taken from the on-site control computer L1 or the process control computer L2.

8. The online monitoring method for the blocking bin of the circular shear according to claim 1, characterized in that After detecting the residence of the edge wire, the timer starts to work. When it continues until the alarm time, it is considered that a stock bin blocking fault has occurred and an alarm is given; if the signal disappears within the alarm time, it is considered that the edge wire jamming is cleared, the timer is cleared, and the preparation for timing starts again.

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