A horizontal loop rope wheel diameter automatic control method, system, device and medium

Abstract

The application discloses a horizontal loop rope wheel diameter automatic control method, system, equipment and medium, which comprises the following steps: based on statistical rope wheel wear data, the wear amount of the rope wheel bushing in a unit time is calculated according to the motion speed of the corresponding rope wheel; the wear amount of the bushing is monitored in real time, and when the wear amount of the bushing exceeds a preset threshold, an alarm is prompted to check and replace the rope wheel bushing. The application can effectively reduce the labor intensity of workers and avoid the equipment failure shutdown caused by unreliable manual operation.

Description

Technical Field

[0001] This invention relates to the field of looper tension control technology in cold rolling and pickling, and particularly to a method, system, equipment and medium for automatic control of the diameter of a horizontal looper pulley. Background Technology

[0002] To ensure a balanced production rhythm across all processes in a cold rolling and pickling line, loopers are installed between the processes to store steel strip. Pickling line loopers typically include inlet loopers, outlet loopers, and connecting loopers, with essentially the same structure and function. Tension matching between processes is a prerequisite for normal production, and maintaining stable looper tension is particularly important. Its transmission... Figure 4 As shown, the main components include: rope pulley motors (3 units), wire rope, telescopic cylinder, slipway trolley, swing door, and correction device. The wire rope is the connecting mechanism between the slipway trolley and the rope pulley; one end is fixed, and the rope is... Figure 5 As shown, after bypassing the looper and sheave, the other end is connected to a hydraulic cylinder (the specific wire rope routing sequence is: motor #1, motor #2, motor #3; r is the inner diameter of the sheave; d is the sheave liner length; R is the outer diameter of the sheave). The hydraulic cylinder is set to a pressure of approximately 100 bar to maintain the tension of the wire rope. The three sheave motors are the main drive mechanisms for the inlet looper, used to drive the looper during punching and releasing and to ensure constant tension within the looper during punching and releasing, as well as during static conditions. This is similar to the tension roller group, using static friction between the wire rope and the sheave to prevent slippage and ensure control accuracy. Liners are installed on the sheaves to increase the static friction coefficient and protect the sheave body. As the unit operates, the linings wear down continuously, requiring replacement when they wear down to approximately 50%. The looper uses closed-loop tension control; the tension setpoint is compared with the actual tension value measured by the tension gauge, and then adjusted by a PI controller, with the output serving as an additional setpoint for the sheave motor speed. In other words, the stability of the inlet looper tension is ensured by adjusting the speed of the sheave motor. The speed setting of the sheave motor consists of two parts: the main speed setting is the speed difference between the looper's inlet and outlet; the auxiliary speed setting is mainly composed of the tension controller's additional value and strip weight compensation.

[0003] The problem is that during the operation of the unit, due to the wear of the liner, the diameter of the rope pulley continuously decreases. The actual diameter of the rope pulley is smaller than the preset diameter value in the program, which causes the actual speed to deviate from the calculated speed. This causes tension fluctuations during the high-speed charging and discharging of the looper, which in turn leads to the unit stopping. Summary of the Invention

[0004] This application provides an automatic control method, system, device, and medium for the diameter of a horizontal looper sheave, which at least partially solves the technical problem in the prior art where the actual diameter of the looper is smaller than the preset diameter value in the program due to the continuous reduction of the looper diameter, causing the unit to stop. It achieves the technical effect of avoiding looper tension fluctuations caused by wear of the looper liner, which could lead to malfunctions and shutdowns.

[0005] Firstly, to solve the above-mentioned technical problems, embodiments of the present invention provide the following technical solutions:

[0006] A method for automatically controlling the diameter of a horizontal slipknot pulley includes:

[0007] Based on statistical data on sheave wear, the wear amount of the sheave liner per unit time is calculated according to the movement speed of the corresponding sheave.

[0008] The wear of the aforementioned liner blocks is monitored in real time. When the wear of the aforementioned liner blocks exceeds a preset threshold, an alarm is triggered to prompt the inspection and replacement of the sheave liner blocks.

[0009] Optionally, the above-mentioned step of real-time monitoring of the wear of the liner further includes:

[0010] A high-level pulse signal is triggered by a signal generator and sent to the trigger.

[0011] The aforementioned trigger sends a working signal to the timer, which starts working when the speed of the aforementioned pulley is not equal to 0, and sends a feedback signal to the aforementioned trigger;

[0012] After receiving the feedback signal, the trigger sends an inverted signal to the selector switch.

[0013] When the speed of the aforementioned pulley is equal to 0, the aforementioned selector switch defines the wear amount as 0 and sends it to the subtractor;

[0014] When the speed of the aforementioned pulley is not equal to 0, the aforementioned selection switch selects to send the current amount of wear to the subtractor;

[0015] After receiving the wear amount, the subtractor subtracts the wear amount from the initial diameter of the sheave to obtain the new diameter of the sheave at this moment.

[0016] The change in the diameter of the rope pulley is obtained by subtracting the new diameter from the initial diameter.

[0017] When the diameter change exceeds 50% of the liner thickness, an alarm will be triggered to check and replace the sheave liner.

[0018] Optionally, the step of obtaining the new diameter of the sheave at this moment further includes:

[0019] The new diameter value is returned to the subtractor to replace the original diameter value, and used as the initial diameter in the next calculation cycle.

[0020] Optionally, the step of sending an inverted signal to the selector switch as described above further includes:

[0021] The trigger simultaneously sends the aforementioned inverted signal to the signal transmitter and triggers a new high-level pulse signal.

[0022] Optionally, before sending the feedback signal to the trigger, the method further includes:

[0023] Set a delay time, and after the above delay time, send a feedback signal to the above trigger.

[0024] Optionally, before sending a high-level pulse signal to the trigger via a signal generator, the above method may include:

[0025] The above signal generator is triggered by a button or / and a preset internal signal.

[0026] Optionally, the above steps for calculating the wear of the sheave pad per unit time include:

[0027] The diameter of the above-mentioned pulley after the new liner was replaced was measured to obtain the initial diameter;

[0028] Based on historical and experimental data, the running time when the speed of the rope pulley is not equal to 0 and the corresponding wear of the aforementioned liner are statistically analyzed.

[0029] Based on the above operating time and wear amount, calculate the wear amount of the sheave pad per unit time.

[0030] Secondly, an automatic control system for the diameter of a horizontal slipknot pulley is provided, the system comprising:

[0031] The trigger module is used to send a high-level pulse signal to the trigger via a signal generator;

[0032] The trigger module is used to send a working signal to the timer, the timer starts working when the speed of the rope wheel is not equal to 0, and sends a feedback signal to the trigger; after receiving the feedback signal, the trigger sends an inverted signal to the selection switch.

[0033] The selection module is used to define the wear amount as 0 and send it to the subtractor when the speed of the above-mentioned rope wheel is equal to 0; when the speed of the above-mentioned rope wheel is not equal to 0, the selection switch selects to send the wear amount at this moment to the subtractor.

[0034] The calculation module is used to subtract the wear amount from the initial diameter of the rope wheel after the subtractor receives the wear amount, so as to obtain the new diameter of the rope wheel at this moment.

[0035] The prompting module is used to obtain the diameter change value of the rope wheel by subtracting the new diameter from the initial diameter; when the diameter change value exceeds 50% of the liner thickness, an alarm prompts to check and replace the rope wheel liner.

[0036] Thirdly, an electronic device is provided, comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to perform the steps corresponding to the method described in the first aspect.

[0037] Fourthly, a computer-readable storage medium is provided having a computer program stored thereon, which, when executed by a processor, performs the steps corresponding to the method described in the first aspect.

[0038] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0039] By using historical and experimental data, the wear amount of the sheave liner per unit time is obtained. A program is then set to calculate the liner wear based on the sheave time, thus achieving real-time monitoring of liner wear. A wear threshold is set to prompt an alarm for checking and replacing the sheave liner. This effectively reduces manual labor intensity and avoids equipment malfunctions and downtime caused by unreliable manual operation. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 A flowchart of an automatic control method for the diameter of a horizontal slipknot pulley provided in this application;

[0042] Figure 2 A schematic diagram of the structure of an automatic control system for the diameter of a horizontal slipknot pulley provided in this application;

[0043] Figure 3 A schematic diagram of the structure of an electronic device provided in this application;

[0044] Figure 4 A schematic diagram of the horizontal looper pulley transmission structure provided in this application;

[0045] Figure 5A schematic diagram of the connection structure between the wire rope, the looper, and the sheave provided in this application. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0047] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0048] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0049] It should be understood that the embodiments of the present invention and the specific features in the embodiments are detailed descriptions of the technical solutions of this application, rather than limitations on the technical solutions of this application. Unless otherwise specified, the embodiments of the present application and the technical features in the embodiments can be combined with each other.

[0050] Furthermore, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.

[0051] The technical solution of this application embodiment is to solve the above-mentioned technical problems, and the general idea is as follows:

[0052] By using historical and experimental data, the wear amount of the sheave liner per unit time is obtained. A program is then set to calculate the liner wear based on the sheave time, thus achieving real-time monitoring of liner wear. A wear threshold is set to prompt an alarm for checking and replacing the sheave liner. This effectively reduces manual labor intensity and avoids equipment malfunctions and downtime caused by unreliable manual operation.

[0053] In the embodiments of this application, the following are provided: Figure 1The method shown is an automatic control method for the diameter of a horizontal slipknot pulley. The method includes: calculating the wear amount of the pulley liner per unit time based on statistical pulley wear data and the movement speed of the corresponding pulley; monitoring the wear amount of the liner in real time; and prompting an alarm to check and replace the pulley liner when the wear amount of the liner exceeds a preset threshold.

[0054] It should be noted that the statistical data on sheave wear is mainly based on historical or experimental data. Furthermore, because the bushings installed on the sheaves serve two purposes: increasing the static friction coefficient and protecting the sheave itself, the wear on the sheave and other components in contact with the bushings, due to their material properties, is relatively stable during wear. Therefore, only the wear of the bushings needs to be monitored. However, the bushings cannot be directly measured, and since they interact with the sheave, the wear rate per unit time can be calculated based on the sheave's speed and operating time. When the bushings wear to a certain extent during real-time monitoring, an alarm will be triggered to check and replace the sheave bushings.

[0055] Furthermore, such as Figure 1 As shown, the above-mentioned step of real-time monitoring of the wear of the liner further includes:

[0056] Step S101: A high-level pulse signal is sent to the trigger via a signal generator;

[0057] It should be noted that the signal generator is mainly used to trigger the high-level pulse generator, and in order to send different signals to the selector switch and timer later, a trigger is used for processing. Therefore, a high-level pulse signal is used to trigger the trigger here.

[0058] In step S102, the trigger sends a working signal to the timer, and the timer starts working when the speed of the rope wheel is not equal to 0, and sends a feedback signal to the trigger.

[0059] It should be noted that when the pulley is not moving, it indicates that the liner has not worn, and therefore timing is not required. However, when the pulley speed is not zero, it means the pulley is in operation, i.e., wearing against the liner; the recorded time is the actual time when the liner wears out, improving the accuracy of the calculation. Specifically, this embodiment uses a RE trigger, and the timer receives the high-level output signal Q from the RE trigger. The timer feedback signal is fed back to the RESET port of the RE trigger.

[0060] Step S103: After receiving the feedback signal, the trigger sends an inverted signal to the selection switch.

[0061] It should be noted that sending the feedback signal to the trigger is used to generate a new signal to activate the selection switch. The purpose of using the selection switch is to judge or select based on preset conditions.

[0062] Step S104: When the speed of the aforementioned pulley is equal to 0, the aforementioned selection switch defines the wear amount as 0 and sends it to the subtractor; when the speed of the aforementioned pulley is not equal to 0, the aforementioned selection switch selects to send the wear amount at this moment to the subtractor.

[0063] It should be noted that the speed of the rope wheel is still used as the criterion. Essentially, it determines whether the rope wheel has started rotating, and thus selects the corresponding output value. When the rope wheel speed is 0, the wear is also 0, and the output value is also 0. When the rope wheel speed is not 0, the wear is calculated by multiplying the running time by the wear per unit time, and this result is sent to the subtractor.

[0064] Step S105: After receiving the wear amount, the subtractor subtracts the wear amount from the initial diameter of the sheave to obtain the new diameter of the sheave at this moment.

[0065] It should be noted that if the received wear amount is 0, the diameter will not change, and the output new diameter will be equal to the original diameter, which is consistent with the case when the sheave is not moving. If the received wear amount is the current wear amount, the new diameter of the sheave at this moment is obtained by subtracting the wear amount from the initial diameter of the sheave.

[0066] Step S106: Obtain the diameter change value of the rope wheel by subtracting the new diameter from the initial diameter; when the diameter change value exceeds 50% of the liner thickness, prompt an alarm to check and replace the rope wheel liner.

[0067] It should be noted that the diameter change value here is the same as the change value of the liner thickness. Since the liner needs to be replaced when it wears down to about 50%, 50% is used as the threshold. This achieves the goal of real-time automated monitoring of the liner thickness, effectively reducing the labor intensity of manual operations and avoiding equipment failures and downtime caused by unreliable manual execution.

[0068] Furthermore, the step of obtaining the new diameter of the rope pulley at this moment also includes: returning the new diameter value to the subtractor, replacing the original diameter value, and using it as the initial diameter in the calculation of the next operation cycle.

[0069] It should be noted that by using the new diameter calculated in the previous operation in the next operation cycle, the entire monitoring process only requires measuring the initial diameter once, which further effectively reduces the labor intensity.

[0070] Furthermore, the step of sending an inverted signal to the selection switch further includes: the trigger simultaneously sending the inverted signal to the signal transmitter and triggering a new high-level pulse signal.

[0071] It should be noted that in order to enable continuous real-time monitoring over a period of time, the program is set to monitor automatically in a loop. That is, the trigger sends a signal to the signal transmitter at the same time as the selector switch sends a signal to the selector switch.

[0072] Furthermore, before sending the feedback signal to the trigger, the method further includes: setting a delay time, and after the delay time, sending the feedback signal to the trigger.

[0073] It should be noted that different factories have different process requirements for cold rolling and pickling line units, resulting in different required inspection time cycles. Therefore, a delay time is set before sending the feedback signal to the trigger, i.e., the interval between two inspection cycles is set. The specific delay time can be set according to needs. Since this embodiment requires high-frequency inspection, a delay time of 1 second is used.

[0074] Furthermore, before sending a high-level pulse signal to the trigger via the signal generator, the above method may include: triggering the signal generator via a button or / and a preset internal signal.

[0075] It should be noted that, depending on different practical needs, manual activation can be achieved by setting a button; alternatively, it can be linked with other equipment in the cold rolling and pickling unit, for example, using the unit's equipment activation as an internal signal to further achieve automated detection.

[0076] In addition, the change in the liner plate will cause a change in the diameter of the rope pulley. The newly calculated diameter will then be used in other PLC units that require the rope pulley diameter, thereby making the adjustment of the loop tension more precise.

[0077] Furthermore, the step of calculating the wear amount of the sheave liner per unit time includes: measuring the diameter of the sheave after replacing the liner to obtain the initial diameter; calculating the running time when the sheave speed is not equal to 0 and the corresponding wear amount of the liner based on historical data and experimental data; and calculating the wear amount of the sheave liner per unit time based on the running time and the wear amount.

[0078] For example: record the monthly wear amount h (unit: mm) of the rope sheave liner; the general rope sheave replacement cycle is 3 months, and the wear amounts are recorded as h1, h2, and h3 respectively; the running time of the loop sheave with speed ≠ 0 is t1, t2, and t3, then the wear amount per unit time is Δd:

[0079]

[0080] Based on the same inventive concept, embodiments of this application provide an automatic control system for the diameter of a horizontal slipknot pulley, such as... Figure 2 As shown, it includes:

[0081] Trigger module 201 is used to trigger a high-level pulse signal to be sent to the trigger via a signal generator;

[0082] The trigger module 202 is used to send a working signal to the timer, the timer starts working when the speed of the rope wheel is not equal to 0, and sends a feedback signal to the trigger; after receiving the feedback signal, the trigger sends an inverted signal to the selection switch.

[0083] The selection module 203 is used to define the wear amount as 0 and send it to the subtractor when the speed of the above-mentioned rope wheel is equal to 0; when the speed of the above-mentioned rope wheel is not equal to 0, the selection switch selects to send the wear amount at this moment to the subtractor.

[0084] The calculation module 204 is used to subtract the wear amount from the initial diameter of the rope wheel after the subtractor receives the wear amount to obtain the new diameter of the rope wheel at this moment.

[0085] The prompt module 205 is used to obtain the diameter change value of the rope wheel by subtracting the new diameter from the initial diameter; when the diameter change value exceeds 50% of the thickness of the liner, an alarm prompts to check and replace the rope wheel liner.

[0086] Based on the same inventive concept, embodiments of this application provide an electronic device, such as... Figure 3 As shown, it includes: a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements an automatic control method for the diameter of a horizontal looper.

[0087] Based on the same inventive concept, this embodiment provides a computer-readable storage medium storing a computer program, characterized in that the program, when executed by a processor, implements an automatic control method for the diameter of a horizontal slipknot pulley.

[0088] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0089] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0090] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0091] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for automatically controlling the diameter of a horizontal slipknot pulley, characterized in that, The method includes: Based on statistical data on sheave wear, the wear amount of the sheave liner per unit time is calculated according to the movement speed of the corresponding sheave. The wear of the liner is monitored in real time. When the wear of the liner exceeds a preset threshold, an alarm is triggered to check and replace the sheave liner. The step of real-time monitoring of the wear of the liner also includes: A high-level pulse signal is triggered by a signal generator and sent to the trigger. The trigger sends a working signal to the timer, which starts working when the speed of the rope wheel is not equal to 0, and sends a feedback signal to the trigger. After receiving the feedback signal, the trigger sends an inverted signal to the selection switch; When the speed of the pulley is equal to 0, the selection switch defines the wear amount as 0 and sends it to the subtractor; When the speed of the pulley is not equal to 0, the selection switch selects to send the current amount of wear to the subtractor; After receiving the wear amount, the subtractor subtracts the wear amount from the initial diameter of the rope wheel to obtain the new diameter of the rope wheel at this moment. The change in the diameter of the rope pulley is obtained by subtracting the new diameter from the initial diameter; When the diameter change exceeds 50% of the liner thickness, an alarm will be triggered to check and replace the sheave liner. The step of calculating the wear of the sheave pad per unit time includes: The diameter of the sheave after the new liner was replaced was measured to obtain the initial diameter; Based on historical and experimental data, the running time when the speed of the rope pulley is not equal to 0 and the corresponding wear of the liner are statistically analyzed. Based on the running time and the wear amount, calculate the wear amount of the sheave pad per unit time.

2. The method as described in claim 1, characterized in that, The step of obtaining the new diameter of the sheave at this moment further includes: The new diameter value is returned to the subtractor, replacing the original diameter value, and used as the initial diameter in the calculation of the next operation cycle.

3. The method as described in claim 2, characterized in that, The step of sending an inverted signal to the selection switch further includes: The trigger simultaneously sends the inverted signal to the signal transmitter and triggers a new high-level pulse signal.

4. The method as described in claim 3, characterized in that, Before sending the feedback signal to the trigger, the method further includes: Set a delay time, and after the delay time, send a feedback signal to the trigger.

5. The method as described in claim 1, characterized in that, Before sending a high-level pulse signal to the trigger via a signal generator, the method further includes: The signal generator is triggered by a button or / and a preset internal signal.

6. An automatic control system for the diameter of a horizontal slipknot pulley, characterized in that, The system includes: The trigger module is used to send a high-level pulse signal to the trigger via a signal generator; A trigger module is used to send a working signal to a timer, the timer starts working when the speed of the rope wheel is not equal to 0, and sends a feedback signal to the trigger; after receiving the feedback signal, the trigger sends an inverted signal to a selection switch. The selection module is used to define the wear amount as 0 and send it to the subtractor when the speed of the rope wheel is equal to 0; when the speed of the rope wheel is not equal to 0, the selection switch selects to send the wear amount at this moment to the subtractor. The calculation module is used by the subtractor to subtract the wear amount from the initial diameter of the rope pulley after receiving the wear amount, so as to obtain the new diameter of the rope pulley at this moment. The prompting module is used to obtain the diameter change value of the rope pulley by subtracting the new diameter from the initial diameter; when the diameter change value exceeds 50% of the liner thickness, an alarm is triggered to check and replace the rope pulley liner.

7. An electronic device, characterized in that, The electronic device includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps corresponding to the method of any one of claims 1 to 5.

8. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the program is executed by the processor, it implements the steps corresponding to the method as described in any one of claims 1 to 5.

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