A method for automatic switching of fault redundancy of a high-speed counting module of a vibration table position

Abstract

The present application relates to a kind of vibration table position high-speed counting module fault redundancy automatic switching method, including hydraulic cylinder, servo valve, module rack, power module, controller module, I0Module, position sensor and high-speed counting module, the power module, controller module, I0Module and high-speed counting module are sequentially arranged on the module rack, the position sensor is connected high-speed counting module, servo valve connects I0Module, servo valve drives hydraulic cylinder, hydraulic cylinder is set in crystallizer vibration table both sides, it is characterized in that, it further includes relay, spare position sensor and spare high-speed counting module, the spare high-speed counting module is set in the spare slot of module rack, and relay is respectively installed between high-speed counter, spare high-speed counter and the signal line of position sensor;Realize the automatic switching of high-speed counting module, ensure stable operation, simple transformation, low cost, greatly save economic cost.

Description

Technical Field

[0001] This invention relates to the field of continuous casting technology, and in particular to a method for automatic switching of fault redundancy in a high-speed position counting module of a vibration table. Background Technology

[0002] The purpose of crystallizer vibration is to prevent the billet from sticking to the copper plate during solidification, which could lead to hanging, cracking, or leakage accidents. To ensure smooth billet pulling, the up-and-down vibration of the crystallizer periodically changes the relative position of the liquid surface and the crystallizer wall, facilitating the penetration of protective slag into the crystallizer wall, improving lubrication, reducing frictional resistance and the possibility of sticking during billet pulling, and ensuring smooth pulling. An external position sensor detects the target position, and the longitudinal movement of the hydraulic cylinder generates vibrations of a certain frequency, stroke, and waveform in the crystallizer. A hydraulic station provides hydraulic power. In the entire vibration system, any failure in the cables, sensors, servo valves, hydraulic components, mechanical components, etc., can easily cause production stoppages. Based on field experience, the high-speed counter FM452 position detection module may fail to calculate data under certain electromagnetic interference environments, directly leading to the inability to identify the actual vibration position, causing vibration position closed-loop control system failures, resulting in vibration stoppages and production stoppages. Existing redundant switching equipment is costly, complex to modify, and involves a large amount of switching data. Summary of the Invention

[0003] This invention provides a method for automatic switching of redundancy in high-speed counting modules at vibration table positions. It adds a relay switching circuit to the existing corresponding high-speed counting module to achieve automatic switching. By utilizing delay, host speed reduction, and manual / automatic switching, stable production operation is ensured. Therefore, it solves the problem of interrupted casting due to high-speed counting module failure without the ability to perform emergency switching or quickly replace and restore the module. The automatic control process is safe, convenient, and stable, avoiding equipment damage accidents, reducing economic costs, and improving production line efficiency. It also features a simple structure, low hardware cost, and low maintenance costs.

[0004] To achieve the above objectives, the present invention employs the following technical solution:

[0005] A method for automatic failover switching of a high-speed counter module for a vibration table position includes a hydraulic cylinder, a servo valve, a module frame, a power supply module, a controller module, an I / O module, a position sensor, a high-speed counter module, and an HMI (Human-Machine Interface). The power supply module, controller module, I / O module, and high-speed counter module are sequentially mounted on the module frame. The position sensor is connected to the high-speed counter module, the servo valve is connected to the I / O module, and the servo valve drives the hydraulic cylinder. The hydraulic cylinder is located on both sides of the crystallizer vibration table. The controller module is connected to the HMI via a communication line. The method also includes relays and a backup high-speed counter module. The backup high-speed counter module is located in a spare slot on the module frame. Relays are installed between the high-speed counter and the position sensor, and between the backup high-speed counter and the position sensor, respectively. The method includes the following steps:

[0006] (1) Configure the module, perform field wiring for the backup high-speed counting module and relay, and configure the module;

[0007] (2) Configure module address and position sensor accuracy;

[0008] (3) Copy the high-speed counting module program for the vibration table position, and use the backup high-speed counting module to receive the position sensor data as the newly added vibration position signal in the copied program;

[0009] (4) Connect the fault signal to the IO module, connect the IO module to the relay coil, connect the normally closed contact of the relay to the input terminal of the high-speed counting module, and connect the normally open contact of the relay to the input terminal of the spare high-speed counting module.

[0010] (5) After a fault occurs, set a fault delay of 3 to 5 seconds;

[0011] (6) After the fault delay, the relay coils in front of the high-speed counter and the backup high-speed counter are both energized, the normally closed contact of the corresponding relay is opened, and the normally open contact is closed, switching from the high-speed counter to the backup high-speed counter, and synchronously transmitting the position sensor data to the backup high-speed counter.

[0012] (7) If a fault occurs but the high-speed counting module cannot activate the fault delay, switch to manual mode operation;

[0013] (8) During the redundancy switching process, the vibration frequency of the vibration table is reduced to 38-42 Hz, the casting speed is reduced to 0.3-0.7 m / min, and the speed reduction ramp is 5-7 m / min².

[0014] (9) During the redundancy switching process, control the vibration position closed-loop accuracy, and adjust the PID adjustment parameters of the position closed-loop control as follows:

[0015] PQW%=T△POS*Kp+ΣKi+Sp*Kff (1)

[0016] Wherein, PQW% is the total servo valve output reference value, in % .

[0017] T△POS is the deviation between the target position and the actual position of the vibration table, in mm;

[0018] Kp is the proportional coefficient for vibration closed-loop control;

[0019] T△POS*Kp is the total output of the proportional section of the vibration closed-loop control, in percentage (%).

[0020] ΣKi represents the total output of the integral part of the vibration closed-loop control, in percentage (%).

[0021] ΣKi=T△POS*Ki (2)

[0022] Where Ki is the integral coefficient of the vibration closed-loop control;

[0023] Sp represents the casting machine speed, measured in m / min.

[0024] Kff is the feedforward coefficient for the vibration closed-loop control, in mm / s;

[0025] Sp*Kff is the total output of the feedforward section of the vibration closed-loop control, in units of %.

[0026] Furthermore, the HMI (Human Machine Interface) adds vibration start ramp, stop ramp, vibration amplitude offset, vibration amplitude ramp, vibration frequency ramp, maximum and minimum vibration position closed-loop control gain, proportional coefficient, integral coefficient, feedforward coefficient, manual switch to the original high-speed counting module button, display of position sensor values ​​read by the backup high-speed counting module, and a newly added manual switch to the backup high-speed counting module button.

[0027] Furthermore, the number of backup high-speed counters is matched with the number of position sensors.

[0028] Furthermore, the input terminal of the servo valve is connected to the analog output module in the IO module, and the output terminal of the servo valve is connected to the hydraulic cylinder.

[0029] Furthermore, the address parameters of the backup high-speed counting module are configured as PIW516~PIW518.

[0030] Furthermore, the position sensor is a linear high-precision displacement sensor.

[0031] Compared with the prior art, the beneficial effects of the present invention are:

[0032] 1) Add a relay switching circuit to the existing corresponding high-speed counting module to achieve automatic switching, thus solving the problem of interruption of casting due to high-speed counting module failure but inability to perform emergency switching or quick replacement and recovery;

[0033] 2) Stable production operation is ensured by utilizing delay, main machine speed reduction, and manual / automatic switching;

[0034] 3) The automatic control process is safe, convenient, and stable, with automatic equipment switching and synchronous data transmission;

[0035] 4) Avoid equipment damage accidents, reduce economic costs, improve production line efficiency, have a simple structure, low hardware costs, and low maintenance costs. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the structure of the present invention.

[0037] Figure 2 This is a circuit diagram of a high-speed counting module redundancy switching circuit as described in this invention.

[0038] Figure 3 It is a curve of the vibration position during redundant switching. Detailed Implementation

[0039] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings:

[0040] See Figure 1 This is a structural schematic diagram of the present invention. The present invention provides a method for automatic switching of redundancy in the high-speed position counting module of a vibration table, comprising a hydraulic cylinder, a servo valve, a module frame, a power supply module, a controller module, an I / O module, a position sensor, and a high-speed counting module. The power supply module, controller module, I / O module, and high-speed counting module are sequentially arranged on the module frame. The position sensor is connected to the high-speed counting module, the servo valve is connected to the I / O module, and the servo valve drives the hydraulic cylinder. The hydraulic cylinder is located on both sides of the crystallizer vibration table. The invention also includes relays, a backup position sensor, and a backup high-speed counting module. The backup high-speed counting module is located in a backup slot on the module frame. The relays are respectively installed between the signal lines of the high-speed counter, the backup high-speed counter, and the position sensor.

[0041] See Figure 2The module rack and controller module adopt the S7400 series. Two new spare high-speed counters are added, model FM452 452-1AH00-0AE0. Four new relays are added, model 3RT1016-1AN21. The position sensor is a linear high-precision displacement sensor, model RHM0075MP021S2G61. The 24V and 0V terminals of the position sensor are connected to the input power supply. The two existing high-speed counters correspond to two relays, and the two spare high-speed counters correspond to two relays. The D+, D-, C+, and C- terminals of the position sensor are connected to the normally closed contact of relay K01 and the normally open contact of relay K02. The normally closed contact of relay K01 is then connected to the DATA+, DATA-, CLOCK+, and CLOCK- terminals of high-speed counter AI06. The normally open contact of relay K02 is then connected to the DATA+, DATA-, CLOCK+, and CLOCK- terminals of spare high-speed counter AI07. The connection method of the other set of spare high-speed counters is the same as above.

[0042] The method includes the following steps:

[0043] (1) Configure the module, install the power module, controller module, IO module and two high-speed counters in sequence on the module rack, install two spare high-speed counters in the spare slot, connect the terminals of the two spare high-speed counters to the newly added spare position sensor in the field, connect the wiring coils of the four relays to the original high-speed counter, position sensor, spare high-speed counter and spare position sensor, and then configure the ste7 software terminal to the system according to the serial number;

[0044] (2) Configure the address of the high-speed counting module. Configure the address of the two newly added backup high-speed counting modules as PIW516 and PIW518.

[0045] (3) Copy the high-speed counting module program for the vibration table position, and use the backup high-speed counting module to receive the position sensor data as the newly added vibration position signal in the copied program;

[0046] (4) Connect the fault signal to the wiring coil connected to the relay, connect the normally closed contact of the relay before the high-speed counting module, and connect the normally open contact of the relay before the spare high-speed counting module;

[0047] (5) After the fault occurs, due to the factors of the high-speed counting module, the position sensor reading will experience a special pulse fault in actual production, which lasts for 50 to 500 ms. Then the high-speed counting module fault will automatically recover. If the redundant program is switched during this special pulse fault time, the host will also need to automatically reduce the speed, which will cause instability to the production. Therefore, a delay of 3 to 5 seconds is required to trigger the redundancy switch.

[0048] (6) After the fault delay, the relay coils before the high-speed counter and the backup high-speed counter are both energized. The normally closed contact of the corresponding relay is opened and the normally open contact is closed. Then, the digital output module in the S7400 IO module outputs a signal to the newly added relay to energize it, disconnecting the original high-speed counting module from the position sensor. At the same time, it will automatically switch to the newly added backup high-speed counting module.

[0049] (7) A fault occurs, but the high-speed counting module has a dead zone, causing the position sensor reading to be a fixed dead number. The fault delay cannot be activated, so the redundant program cannot be switched, resulting in the left and right sides of the vibration table being out of sync and polarized. In severe cases, it can cause steel leakage accidents. Therefore, the fault delay cannot be activated and it is necessary to switch to manual mode operation.

[0050] (8) During the redundancy switching process, the vibration frequency of the vibration table is reduced to 40Hz, the casting speed is reduced to 0.5m / min, and the speed reduction ramp is 7m / min².

[0051] (10) During the redundancy switching process, control the vibration position closed-loop accuracy, and adjust the PID adjustment parameters of the position closed-loop control as follows:

[0052] PQW%=T△POS*Kp+ΣKi+Sp*Kff (3)

[0053] Wherein, PQW% is the total servo valve output reference value, in % .

[0054] T△POS is the deviation between the target position and the actual position of the vibration table, in mm;

[0055] Kp is the proportional coefficient for vibration closed-loop control;

[0056] T△POS*Kp is the total output of the proportional section of the vibration closed-loop control, in percentage (%).

[0057] ΣKi represents the total output of the integral part of the vibration closed-loop control, in percentage (%).

[0058] ΣKi=T△POS*Ki (4)

[0059] Where Ki is the integral coefficient of the vibration closed-loop control;

[0060] Sp represents the casting machine speed, measured in m / min.

[0061] Kff is the feedforward coefficient for the vibration closed-loop control, in mm / s;

[0062] Sp*Kff represents the total output of the feedforward section of the vibration closed-loop control, in percentage terms.

[0063] The vibration position closed-loop accuracy was controlled using PID control. During the actual switching, when T△POS=2, Kp=2.2, ΣKi=6, Ki=3.0, Sp=0.4, Kff=10, and PQW%=14.4 was calculated. During the actual switching, when T△POS=0.1, Kp=2.2, ΣKi=0.3, Ki=3.0, Sp=0.4, Kff=10, and PQW%=4.52 was calculated. The time taken during this period was 2 seconds. (See...) Figure 3 The left and right deviations and the deviations from the target position meet the requirements of the vibration system, so the positional accuracy meets production requirements.

[0064] After the improvement, the high-speed counting module can automatically switch to the backup high-speed counting module after a failure, and the interruption of pouring will not occur due to the loss of position caused by vibration. Based on 2 machines and 3 flow, there will be about 3 failures per year. Each failure will cause a downtime of 1 to 3 hours, affecting 1 to 3 furnaces. Each furnace has a production of 180 to 540 tons of 180 tons. With one intermediate batch, the direct economic loss will be saved by about 300,000 to 900,000 yuan.

[0065] The above embodiments are implemented based on the technical solution of the present invention, providing detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the above embodiments. Unless otherwise specified, the methods used in the above embodiments are conventional methods.

Claims

1. A method for automatic fault redundancy switching of a high-speed counting module for a vibration table, comprising a hydraulic cylinder, a servo valve, a module frame, a power supply module, a controller module, an I / O module, a position sensor, a high-speed counting module, and an HMI (Human-Machine Interface), wherein the power supply module, controller module, I / O module, and high-speed counting module are sequentially arranged on the module frame; the position sensor is connected to the high-speed counting module; the servo valve is connected to the I / O module; the servo valve drives the hydraulic cylinder; the hydraulic cylinder is disposed on both sides of the crystallizer vibration table; and the controller module is connected to the HMI via a communication line. The method is characterized in that... It also includes relays and a backup high-speed counting module. The backup high-speed counting module is installed in a spare slot in the module rack. The relays are respectively installed between the high-speed counter and the position sensor, and between the backup high-speed counter and the position sensor. The method includes the following steps: (1) Configure the module, perform field wiring for the backup high-speed counting module and relay, and configure the module; (2) Configure module address and position sensor accuracy; (3) Copy the high-speed counting module program for the vibration table position, and use the backup high-speed counting module to receive the position sensor data as the newly added vibration position signal in the copied program; (4) Connect the fault signal to the IO module, connect the IO module to the relay coil, connect the normally closed contact of the relay to the input terminal of the high-speed counting module, and connect the normally open contact of the relay to the input terminal of the spare high-speed counting module. (5) After a fault occurs, set a fault delay of 3 to 5 seconds; (6) After the fault delay, the relay coils in front of the high-speed counter and the backup high-speed counter are both energized, the normally closed contact of the corresponding relay is opened, and the normally open contact is closed, switching from the high-speed counter to the backup high-speed counter, and synchronously transmitting the position sensor data to the backup high-speed counter. (7) If a fault occurs but the high-speed counting module cannot activate the fault delay, switch to manual mode operation; (8) During the redundancy switching process, the vibration frequency of the vibration table is reduced to 38-42 Hz, the casting speed is reduced to 0.3-0.7 m / min, and the speed reduction ramp is 5-7 m / min². (9) During the redundancy switching process, control the vibration position closed-loop accuracy, and adjust the PID adjustment parameters of the position closed-loop control as follows: PQW%=T△POS*Kp+ΣKi+Sp*Kff (1) Wherein, PQW% is the total servo valve output reference value, in % . T△POS is the deviation between the target position and the actual position of the vibration table, in mm; Kp is the proportional coefficient for vibration closed-loop control; T△POS*Kp is the total output of the proportional section of the vibration closed-loop control, in percentage (%). ΣKi represents the total output of the integral part of the vibration closed-loop control, in percentage (%). ΣKi=T△POS*Ki (2) Where Ki is the integral coefficient of the vibration closed-loop control; Sp is the casting speed of the casting machine, in m / min; Kff is the feedforward coefficient for the vibration closed-loop control, in mm / s; Sp*Kff is the total output of the feedforward section of the vibration closed-loop control, in units of %.

2. The method for automatic switching of fault redundancy in a high-speed vibration table position counting module according to claim 1, characterized in that, The HMI now includes vibration start ramp, stop ramp, vibration amplitude offset, vibration amplitude ramp, vibration frequency ramp, maximum and minimum vibration position closed-loop control gain, proportional coefficient, integral coefficient, feedforward coefficient, manual switch to the original high-speed counting module button, display of position sensor values ​​from the backup high-speed counting module, and a newly added manual switch to the backup high-speed counting module button.

3. The method for automatic switching of fault redundancy in a high-speed position counting module of a vibration table according to claim 1, characterized in that, The number of backup high-speed counters is matched with the number of position sensors.

4. The method for automatic switching of fault redundancy in a high-speed position counting module of a vibration table according to claim 1, characterized in that, The input end of the servo valve is connected to the analog output module in the IO module, and the output end of the servo valve is connected to the hydraulic cylinder.

5. The method for automatic switching of fault redundancy in a high-speed position counting module of a vibration table according to claim 1, characterized in that, The address parameters of the backup high-speed counting module are configured as PIW516~PIW518.

6. The method for automatic fault redundancy switching of a high-speed position counting module for a vibration table according to claim 1, characterized in that, The position sensor is a linear high-precision displacement sensor.

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