A multi-stage early warning method based on reasonable prediction of cold-rolled product plan volume division

Abstract

The application discloses a multi-stage early warning method based on cold-rolled product plan sub-volume rationality prediction, according to the upper limit and lower limit of the target sub-volume single weight of the cold-rolled product, automatically calculates the sub-volume number, judges whether the sub-volume is qualified according to the sub-volume unqualified risk coefficient, and establishes a sub-volume rationality prediction model. The model is suitable for the sub-volume rationality prediction before the production plan is executed in each process related to the cold-rolled product production. For the production plan that can be qualified sub-volume, the sub-volume number based on different sub-volume strategies is given. For the production plan that cannot be qualified sub-volume, the system gives a mark warning, so that the producer can take measures in advance, avoids the situation that the product cannot be reasonably sub-volume after being produced, and reduces the generation of the weight unqualified defect rejudgment volume.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of cold rolling, and particularly relates to a multi-stage early warning method based on cold rolling product plan volume division rationality pre-judgment. BACKGROUND

[0002] The production process of cold-rolled sheet is long, from the steel billet to the final product, involving hot rolling, pickling, cold rolling, continuous annealing / galvanizing, rewinding and other processes. The steel billet will have a yield loss when passing through each process, resulting in a continuous decrease in the weight of the billet.

[0003] Due to the limitation of user deep processing equipment conditions, the users of cold-rolled products generally have requirements for the weight of the received steel coil, and usually set an upper limit and a lower limit for the weight of a single coil, so as to ensure that the steel coil does not exceed the equipment load during user processing, such as the maximum lifting weight of the crane, the maximum unwinding weight of the uncoiler, etc.

[0004] The slitting operation of the cold-rolled finished product process is the process of dividing a mother coil into several child coils according to the upper limit and lower limit of the weight of a single coil required by the user. In order to ensure that the weight of the steel coil produced after multiple slitting meets the contract requirements, different algorithms are used in each cold rolling process continuous production unit to calculate the most perfect weight slitting result.

[0005] A common problem is that after the mother coil is slitted into 1 to 2 child coils that meet the upper limit and lower limit of the weight of a single coil required by the user, the last child coil cannot meet the requirements, i.e., the weight of the steel coil does not meet the logic. When this happens, most units have to temporarily change to manual calculation of slitting or directly produce the coil without slitting, which seriously affects the production rhythm and increases unnecessary resource waste. The child coil that does not meet the weight requirements can only be closed for processing, and even be judged as unqualified.

[0006] The patent with the authorized publication number CN109909304B, a cold-rolled steel coil weight slitting algorithm with supplementary logic, discloses a cold-rolled steel coil weight slitting algorithm with supplementary logic. The application uses the idea of average slitting to make the weight of each slitting output as uniform as possible. The pre-calculation method is used to abandon the real-time dynamic calculation method, and the raw material production information data is fully utilized to complete the preliminary calculation of the slitting algorithm after the inlet steel coil is loaded. It can ensure that the weight of each coil is approximately the same.

[0007] The pre-calculation method actually simulates the conventional dividing process, and the core is to iteratively calculate the average divided weight corresponding to different divided numbers from the first divided number 1, and to judge whether it is between the upper and lower limits of the single weight. And the pre-calculation method is applied after the loading of the inlet steel coil, even if the divided logic is found to be inconsistent, a divided way still needs to be selected to produce down, which will inevitably cause the problem that the divided result does not meet the user's requirements. In addition, the solution given after the divided logic is inconsistent is to divide and cut the sub-coil as much as possible to meet the requirements, and then the smallest sub-coil is left to be judged as unqualified products.

[0008] The application adopts a completely different divided rationality judgment logic from the prior art, and a multi-level early warning method based on cold-rolled product plan divided rationality pre-judgment. SUMMARY

[0009] The application aims to provide a multi-level early warning method based on cold-rolled product plan divided rationality pre-judgment.

[0010] The technical scheme adopted by the application to solve the technical problems is: a multi-level early warning method based on cold-rolled product plan divided rationality pre-judgment, comprising a divided rationality pre-judgment model, the divided rationality pre-judgment model comprising the following steps:

[0011] 1) Obtain order line basic information;

[0012] 2) According to the upper limit of single weight W1 and the lower limit of single weight W2, the average single weight Wa=(W1+W2) / 2 is calculated; the single weight range tolerance Wt=(W1-W2) / 2 is calculated;

[0013] 3) According to the current process raw material coil weight W0 and the upper limit of single weight W1, the minimum divided number C1=ROUNDUP(W0*mu / W1,0) is budgeted, and the material yield from the current process to the finished product is denoted as mu; according to the current process raw material coil weight W0 and the lower limit of single weight W2, the minimum divided number C2=ROUNDOWN(W0*mu / W2,0) is budgeted; the budgeted median divided number C3=ROUNDOWN((C1+C2) / 2,0) is budgeted, wherein the ROUNDUP function is a rounding up function, and the ROUNDOWN function is a rounding down function;

[0014] 4) According to the C1, C2, and C3 divided numbers, the budgeted unqualified divided risk coefficients f1=ABS(W0*mu / C1-Wa) / Wt, f2=ABS(W0*mu / C2-Wa) / Wt, and f3=ABS(W0*mu / C3-Wa) / Wt are calculated, and at least one of f1, f2, and f3 is less than a preset value f0, that is, it is judged as a qualified divided, and the system is marked as "OK", otherwise it is judged as an inconsistent divided, and the system is marked as "NG";

[0015] 5) In the production manufacturing execution system, the coil rationality prediction model is embedded in each process plan, if the raw material coil is judged as unqualified budget coil, the system is reminded and closed for waiting, the order is re-set, and the upper and lower limits are re-set until the qualified coil condition is met, and then the coil production plan is transferred to the next process, so that the on-line steel coil is qualified.

[0016] Specifically, the specific steps in step 5) are:

[0017] 1) In the production manufacturing execution system, the coil rationality prediction model is embedded in each process plan, if the raw material coil is judged as unqualified budget coil, the system is reminded and closed for waiting, the order is re-set, and the upper and lower limits are re-set until the qualified coil condition is met, and then the coil production plan is transferred to the next process, so that the on-line steel coil is qualified.

[0018] 2) In the production manufacturing execution system, the coil rationality prediction model is embedded in each process plan, if the raw material coil is judged as unqualified budget coil, the system is reminded and closed for waiting, the order is re-set, and the upper and lower limits are re-set until the qualified coil condition is met, and then the coil production plan is transferred to the next process, so that the on-line steel coil is qualified.

[0019] 3) In the production manufacturing execution system, the coil rationality prediction model is embedded in each process plan, if the raw material coil is judged as unqualified budget coil, the system is reminded and closed for waiting, the order is re-set, and the upper and lower limits are re-set until the qualified coil condition is met, and then the coil production plan is transferred to the next process, so that the on-line steel coil is qualified.

[0020] 4) In the production manufacturing execution system, the coil rationality prediction model is embedded in each process plan, if the raw material coil is judged as unqualified budget coil, the system is reminded and closed for waiting, the order is re-set, and the upper and lower limits are re-set until the qualified coil condition is met, and then the coil production plan is transferred to the next process, so that the on-line steel coil is qualified.

[0021] 5) Before each process production, the plan row marked as "NG" is screened out when the current process production plan is viewed, and is closed for processing, and the single weight upper and lower limits are re-set until the qualified coil is transferred into the normal production procedure.

[0022] The present application has the following beneficial effects:

[0023] 1) The unqualified budget coil risk coefficient is used to quantitatively judge the coil rationality, which is fast and more accurate;

[0024] 2) The coil rationality prediction model is embedded in the production plan system of each process in the whole process of cold-rolled product production, and the coil rationality of each coil is automatically judged. For the production plan that can be qualified for coil, the number of coils based on different coil strategies is given; for the production plan that cannot be qualified for coil, the system is marked and warned to avoid the situation that the steel coil is on-line without reasonable cutting scheme and is not qualified for cutting or whole coil production, and resource waste is avoided.

[0025] 3) Implementing multi-level early warning before steel coil production begins allows sufficient response time for producers and users to negotiate and revise the upper and lower limits of single coil weight, creating conditions for collaborative optimization of the production process by production, sales, and R&D, and achieving a win-win situation for both user needs and production efficiency. Attached Figure Description

[0026] Fig. 1 Flowchart for the model to predict the rationality of volume division.

[0027] Fig. 2 This is a flowchart of the multi-level early warning process. Detailed Implementation

[0028] The invention will now be described in further detail with reference to the accompanying drawings.

[0029] like Figs. 1-2 This paper presents a multi-level early warning method based on the prediction of the rationality of coiling in cold-rolled product planning. It estimates the reasonable number of coils by using upper and lower limits of the single coil weight, then estimates the weight of sub-coils based on the number of coils, and introduces a risk coefficient for non-compliance in coiling to quantify the rationality of coiling. For production plans that can achieve acceptable coiling, it provides the number of coils based on different coiling strategies; for production plans that cannot achieve acceptable coiling, it marks and warns in the system. Furthermore, this prediction model is applied to continuous casting, hot rolling, pickling, and continuous annealing / galvanizing processes. Before raw materials are delivered to the next production process, it predicts the rationality of coiling in advance, providing multi-level early warnings and allowing sufficient response time for producers and users to negotiate and revise the upper and lower limits of the single coil weight, ensuring that acceptable coiling can be achieved when production begins.

[0030] Volume Segmentation Rationality Prediction Model:

[0031] 1) Calculate the average unit weight based on the upper limit W1 and the lower limit W2: Wa = (W1 + W2) / 2; Unit weight range tolerance: Wt = (W1 - W2) / 2;

[0032] 2) Based on the current process raw material roll weight W0 and the single weight limit W1, estimate the minimum number of rolls: C1 = ROUNDUP(W0*μ / W1, 0); denot the yield rate from the current process to the finished product as μ; Based on the current process raw material roll weight W0 and the single weight limit W2, estimate the minimum number of rolls: C2 = ROUNDOWN(W0*μ / W2, 0); Estimate the median number of rolls: C3 = ROUNDOWN((C1+C2) / 2, 0), where the ROUNDUP function rounds up and the ROUNDOWN function rounds down;

[0033] 3) Divide the volume into C1, C2, and C3 volumes respectively. Risk factor for volume division that does not meet budget requirements: f1 = ABS(W0*μ / C1-Wa) / Wt;

[0034] f2=ABS(W0*μ / C2-Wa) / Wt;f3=ABS(W0*μ / C3-Wa) / Wt, f1, f2, f3 three sub-volume unqualified risk factor, as long as one is less than the preset value f0, that is, the qualified sub-volume is determined, and the system is marked as "OK"; otherwise, the unqualified sub-volume is determined, and the system is marked as "NG", generally f0=90%.

[0035] In the production manufacturing execution system (MES), the model is embedded in each process plan, if the raw material coil is determined to be unqualified, the system warns the producer and closes the waiting producer to negotiate with the customer with the sub-volume unqualified risk factor less than f0, and the order is re-set to the upper and lower limits until the qualified sub-volume condition is met, and then the coil production plan is transferred to the next process, so that the on-line steel coil can be qualified. The specific steps are as follows:

[0036] 1) The hot rolling production plan interface of the production manufacturing execution system (MES) is set with a field in each billet production plan row, which displays the sub-volume rationality prediction result "OK" or "NG" according to the above-mentioned sub-volume rationality prediction model;

[0037] 2) The acid rolling production plan interface of the production manufacturing execution system (MES) is set with a field in each raw material production plan row, which displays the sub-volume rationality prediction result "OK" or "NG" according to the above-mentioned sub-volume rationality prediction model;

[0038] 3) The continuous annealing production plan interface of the production manufacturing execution system (MES) is set with a field in each raw material production plan row, which displays the sub-volume rationality prediction result "OK" or "NG" according to the above-mentioned sub-volume rationality prediction model;

[0039] 4) The hot galvanizing production plan interface of the production manufacturing execution system (MES) is set with a field in each raw material production plan row, which displays the sub-volume rationality prediction result "OK" or "NG" according to the above-mentioned sub-volume rationality prediction model;

[0040] Before each process production, the current process production plan is checked, the plan row marked as "NG" is screened out, closed for processing, transferred to the business personnel to contact the user to negotiate the new upper and lower limits of the order, and then transferred into the normal production procedure until the qualified sub-volume.

[0041] The present application is not limited to the above-mentioned embodiments, and any person should know that the structural changes made under the inspiration of the present application, any technical solution with the same or similar to the present application, falls within the protection scope of the present application.

[0042] The technologies, shapes and structures not described in detail in the present application are all known technologies.

Claims

1. A multi-level early warning method based on the prediction of the rationality of cold-rolled product planning and coiling, characterized in that, This includes a volume splitting rationality prediction model, which comprises the following steps: 1) Obtain basic order line information; 2) Calculate the average unit weight based on the upper limit W1 and the lower limit W2: Wa = (W1 + W2) / 2; Unit weight range tolerance: Wt = (W1 - W2) / 2; 3) Based on the current process raw material roll weight W0 and the upper limit of single weight W1, estimate the minimum number of rolls: C1 = ROUNDUP(W0*μ / W1, 0), and record the yield rate from the current process to the finished product as μ; Based on the current process raw material roll weight W0 and the lower limit of single weight W2, estimate the minimum number of rolls: C2 = ROUNDOWN(W0*μ / W2, 0); Estimate the median number of rolls: C3 = ROUNDOWN((C1+C2) / 2, 0), where the ROUNDUP function rounds up and the ROUNDOWN function rounds down; 4) Divide the volume into C1, C2, and C3 volumes respectively. The risk coefficient for unqualified volumes is calculated as follows: f1 = ABS(W0*μ / C1-Wa) / Wt; f2 = ABS(W0*μ / C2-Wa) / Wt; f3 = ABS(W0*μ / C3-Wa) / Wt. If at least one of the three unqualified volumes (f1, f2, f3) is less than the preset value f0, the volume is considered qualified and marked as "OK" by the system. Otherwise, the volume is considered unqualified and marked as "NG" by the system. 5) In the manufacturing execution system, the reasonableness prediction model of the coil is embedded in each process plan. If the raw material coil is judged to be unqualified for budgeted coiling, a warning will be issued in the system and the system will be closed and wait. The upper and lower limits of the single weight will be revised until the qualified coiling conditions are met. Then the production plan of the coil will be transferred to the next process to ensure that all the steel coils on the line are qualified coils.

2. The multi-level early warning method based on the prediction of the rationality of cold-rolled product planning and coiling as described in claim 1, characterized in that, The specific steps in step 5) are as follows: 1) In the manufacturing execution system, set the display of the coil rationality prediction result "OK" or "NG" in the production plan line of each billet in the hot rolling production plan; 2) In the manufacturing execution system, set the display of the roll reasonableness prediction result "OK" or "NG" in the production plan row of each roll of raw material in the pickling and rolling production plan; 3) In the manufacturing execution system, set the display of the roll reasonableness prediction result "OK" or "NG" in the production plan line of each roll of raw materials in the continuous annealing production plan; 4) In the manufacturing execution system, set the display of the coil rationality prediction result "OK" or "NG" in the production plan row of each coil of raw materials in the hot-dip galvanizing production plan; 5) Before each process begins production, when reviewing the production plan for the current process, filter out the planned rows marked "NG", close them for processing, reset the upper and lower limits of single weight, and continue until the rolls can be successfully split before entering the normal production process.

Images