A control method for avoiding simultaneous replacement of a multi-threaded steel production line process equipment stop station

Abstract

This invention discloses a control method to avoid simultaneous shutdowns of multiple rebar production lines due to equipment changes. It records historical data on the steel throughput of all rebar production lines within the same specification, brand, and heat transfer ratio range, constructs a steel throughput database, and calculates a baseline steel throughput. For the current rebar production line, the corresponding baseline steel throughput is found in the database. The predicted shutdown time period and predicted shutdown time nodes for the current rebar production line are calculated. The method then determines whether the predicted shutdown time nodes overlap and makes adjustments accordingly. This invention avoids losses caused by power overflow and provides stronger production control.

Description

Technical Field

[0001] This invention relates to a control method, and more particularly to a control method for avoiding simultaneous shutdowns of process equipment in multiple rebar production lines, belonging to the field of steel rolling technology. Background Technology

[0002] A newly built large-scale steel plant typically has multiple production lines and its own power plant, which supplies power to these lines. However, due to insufficient control over production, multiple lines often have to shut down simultaneously due to product quality issues, resulting in power leakage, losses, and potential disruption to other units' operations (power distribution). If simultaneous shutdowns of multiple rebar production lines could be avoided, this power leakage could be prevented. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a control method to avoid the simultaneous shutdown of process equipment in multiple rebar production lines, thereby avoiding losses caused by power leakage.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A control method for avoiding simultaneous equipment shutdowns during the replacement of multiple rebar production lines includes the following steps: S1. Record the historical data of steel throughput of all rebar production lines within the same specification, brand, and heat delivery ratio range. Construct a steel throughput database from these historical data. Then, based on all historical data of steel throughput of the same specification, brand, and heat delivery ratio range for the rebar production line, obtain the benchmark steel throughput of that rebar production line within the same specification, brand, and heat delivery ratio range. S2. For the current rebar production line, estimate the heat delivery ratio range of the corresponding rebar production line through the production plan, and then find the corresponding benchmark steel delivery volume in the steel delivery volume database based on the rebar specifications, brand and heat delivery ratio range of the current rebar production line. S3. Calculate the output per unit time of the current rebar production line based on the current operating speed of the rebar mill. S4. Calculate the ratio between the current rebar production line's benchmark steel throughput and the unit time output, and convert this ratio into the predicted replacement downtime period for the current rebar production line. S5. Record the time of the last changeover stop on each rebar production line and calculate the predicted time period for the changeover stop on each rebar production line. The predicted time node for the changeover stop on the rebar production line can be obtained by adding the time of the last changeover stop to the predicted time period. S6. After calculating the predicted time nodes for all rebar production line replacement shutdowns, calculate the difference ΔT between the predicted time nodes for all rebar production line replacement shutdowns, and determine whether ΔT is greater than or equal to the preset time difference T. m If so, no intervention is needed; otherwise, ensure the difference ΔT is less than the time difference T. m The predicted shutdown time for the replacement of one of the two rebar production lines was artificially brought forward.

[0005] Furthermore, in step S1, the steel throughput database includes rebar specification S, brand Q, hot delivery ratio range [p,q), and steel throughput M.

[0006] Further, in step S1, the median value of all historical data on the steel throughput of the rebar production line within the same specification, brand, and heat delivery ratio range is taken as the benchmark steel throughput of the rebar production line within the same specification, brand, and heat delivery ratio range.

[0007] Furthermore, in step S6, if ΔT≥T m If the time nodes of the next replacement shutdown of all rebar production lines do not overlap, then the predicted time nodes of the next replacement shutdown of all rebar production lines are the actual time nodes of the next replacement shutdown of rebar production lines.

[0008] Furthermore, in step S6, if ΔT < T m If the time nodes of the last replacement shutdown of all rebar production lines overlap, then the difference ΔT needs to be less than the time difference T. m The predicted shutdown time for the replacement of one of the two rebar production lines was artificially brought forward.

[0009] Furthermore, the predicted time points for the next replacement shutdown of all rebar production lines are arranged in ascending order. Then, the difference ΔT between two adjacent predicted time points is calculated in descending order. If the difference ΔT between two adjacent predicted time points is less than T... m Then, the smaller of the two adjacent prediction time points will be moved forward by a time T. p T p = T m -(T) q+1 -T q ), where T q+1 It is the larger of two adjacent prediction time points, T. q It is the smaller of two adjacent prediction time points.

[0010] Compared with existing technologies, this invention has the following advantages and effects: This invention provides a control method to avoid simultaneous shutdowns of multiple rebar production lines, preventing losses caused by power overflow and providing stronger production control. Besides power overflow, simultaneous shutdowns also cause problems with personnel allocation, such as for electromechanical maintenance personnel, extending maintenance time and reducing production efficiency. This invention avoids simultaneous shutdowns of multiple production lines, thus enabling more rational personnel allocation. Furthermore, this invention provides a specific database of roller consumption, reducing roller consumption to some extent. Finally, this invention offers better quality control, preventing situations where a production line delays production to ensure staggered shutdowns, thus avoiding quality problems. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the steel throughput data of the No. 1 rebar production line, which is an embodiment of a control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to the present invention.

[0012] Figure 2 This is a schematic diagram of the steel throughput data of rebar production line No. 2, which is an embodiment of the control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to the present invention.

[0013] Figure 3 This is a schematic diagram of the steel throughput data of the No. 3 rebar production line, which is an embodiment of a control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to the present invention.

[0014] Figure 4 This is a table showing the predicted downtime periods for a control method of avoiding simultaneous downtime of process equipment in multiple rebar production lines, as described in this invention.

[0015] Figure 5 This is a table showing the non-overlapping predicted shutdown times for three production lines in an embodiment of a control method for avoiding simultaneous shutdowns of process equipment on multiple rebar production lines according to the present invention.

[0016] Figure 6 This is a table showing the overlapping predicted time points for the replacement shutdowns of three production lines in an embodiment of a control method for avoiding simultaneous replacement shutdowns of process equipment on multiple rebar production lines according to the present invention. Detailed Implementation

[0017] To illustrate in detail the technical solutions adopted by the present invention to achieve the intended technical objectives, the technical solutions in 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, not all embodiments. Furthermore, the technical means or technical features in the embodiments of the present invention can be replaced without creative effort. The present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0018] The wear of the rolling mill groove is affected by the following factors: 1. Hot feed ratio: the proportion of hot billet in the cold billet. Because hot billet has better plasticity, a higher proportion of hot billet results in less groove wear and a larger steel throughput. 2. Roll brand: Currently, larger steel companies often tender for rolls from multiple manufacturers in their rolling mill units to enhance competitiveness and avoid risks. The quality of rolls from different brands varies, and the stability of steel throughput also differs; this factor needs to be considered. 3. Roll size: Different roll sizes, even with the same brand and hot feed ratio, result in different wear amounts. Smaller roll sizes, due to their higher rolling speed, longer finished product, and longer relative distance to the roll, experience greater wear and relatively less steel throughput. 4. Adjustment method. 5. Special steel grades. Factors 4 and 5 are relatively boundary conditions and have a smaller impact on normal production processes; they can be ignored here.

[0019] In this embodiment, rebar production line 1 produces 16mm specification, rebar production line 2 produces 22mm specification, and rebar production line 3 produces 28mm specification. The daily heat delivery ratio of rebar production line 1 is in the range of [30%, 40%), the daily heat delivery ratio of rebar production line 2 is in the range of [50%, 60%), and the daily heat delivery ratio of rebar production line 3 is in the range of [70%, 80%). Rebar production line 1 uses brand 1, rebar production line 2 uses brand 1, and rebar production line 3 uses brand 4.

[0020] The present invention provides a control method for avoiding simultaneous shutdowns of process equipment in multiple rebar production lines, comprising the following steps: S1. Record the historical data of steel throughput for all rebar production lines within the same specification, brand, and heat delivery ratio range. Construct a steel throughput database from this historical data. Then, based on all historical data of steel throughput for the same specification, brand, and heat delivery ratio range for the same rebar production line, obtain the benchmark steel throughput for that rebar production line within that specification, brand, and heat delivery ratio range.

[0021] The steel throughput database includes rebar specification S, brand Q, hot delivery ratio range [p,q) and steel throughput M.

[0022] In one embodiment of the present invention, such as Figure 1 , Figure 2 and Figure 3 As shown, the median value of all historical data on the steel throughput of a rebar production line within the same specification, brand, and heat delivery ratio range is taken as the benchmark steel throughput of that rebar production line within the same specification, brand, and heat delivery ratio range.

[0023] S2. For the current rebar production line, estimate the heat delivery ratio range of the corresponding rebar production line through the production plan, and then find the corresponding benchmark steel delivery volume in the steel delivery volume database based on the rebar specifications, brand and heat delivery ratio range of the current rebar production line.

[0024] S3, such as Figure 4 As shown, the output per unit time of the current rebar production line is calculated based on the current operating speed of the rebar mill.

[0025] S4. Calculate the ratio between the current benchmark steel throughput of the rebar production line and the output per unit time, and convert this ratio into the predicted downtime period for the current rebar production line replacement.

[0026] S5. Record the time of the last changeover stop on each rebar production line, and calculate the predicted time period for the changeover stop on each rebar production line. The predicted time node for the changeover stop on the rebar production line can be obtained by adding the time of the last changeover stop to the predicted time period.

[0027] S6. After calculating the predicted time nodes for all rebar production line replacement shutdowns, calculate the difference ΔT between the predicted time nodes for all rebar production line replacement shutdowns, and determine whether ΔT is greater than or equal to the preset time difference T. m If so, no intervention is needed; otherwise, ensure the difference ΔT is less than the time difference T. m The predicted shutdown time for the replacement of one of the two rebar production lines was artificially brought forward.

[0028] Specifically, such as Figure 5 As shown, if ΔT≥T m If the time nodes of the next replacement shutdown of all rebar production lines do not overlap, then the predicted time nodes of the next replacement shutdown of all rebar production lines are the actual time nodes of the next replacement shutdown of rebar production lines.

[0029] like Figure 6 As shown, if ΔT < T m If the time nodes of the last replacement shutdown of all rebar production lines overlap, then the difference ΔT needs to be less than the time difference T. m The predicted shutdown time for the replacement of one of the two rebar production lines was artificially brought forward.

[0030] Arrange the predicted time points of the next replacement shutdown of all rebar production lines in ascending order. Then, calculate the difference ΔT between any two adjacent predicted time points in descending order. If the difference ΔT < T between any two adjacent predicted time points... m Then, the smaller of the two adjacent prediction time points will be moved forward by a time T. p T p = T m -(T) q+1 -T q ), where T q+1 It is the larger of two adjacent prediction time points, T. q It is the smaller of two adjacent prediction time points.

[0031] This invention provides a control method to avoid simultaneous shutdowns of multiple rebar production lines during equipment changes, preventing losses caused by power overflow and providing stronger production control. Besides power overflow, simultaneous shutdowns also cause problems with personnel allocation, such as for mechanical and electrical maintenance staff, extending maintenance time and reducing production efficiency. This invention avoids simultaneous shutdowns of multiple production lines, allowing for more rational personnel allocation. Furthermore, this invention provides a specific database of roller consumption, reducing roller consumption to some extent. Finally, this invention offers better quality control, preventing situations where a production line delays production to ensure staggered shutdowns, thus avoiding quality issues.

[0032] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent substitutions, and improvements made to the above embodiments without departing from the scope of the present invention, based on the technical essence of the present invention and within the spirit and principles of the present invention, shall still fall within the protection scope of the present invention.

Claims

1. A control method for avoiding simultaneous equipment shutdowns during the replacement of multiple rebar production lines, characterized in that... Includes the following steps: S1. Record the historical data of steel throughput of all rebar production lines within the same specification, brand, and heat delivery ratio range. Construct a steel throughput database from these historical data. Then, based on all historical data of steel throughput of the same specification, brand, and heat delivery ratio range for the rebar production line, obtain the benchmark steel throughput of that rebar production line within the same specification, brand, and heat delivery ratio range. S2. For the current rebar production line, estimate the heat delivery ratio range of the corresponding rebar production line through the production plan, and then find the corresponding benchmark steel delivery volume in the steel delivery volume database based on the rebar specifications, brand and heat delivery ratio range of the current rebar production line. S3. Calculate the output per unit time of the current rebar production line based on the current operating speed of the rebar mill. S4. Calculate the ratio between the current rebar production line's benchmark steel throughput and the unit time output, and convert this ratio into the predicted replacement downtime period for the current rebar production line. S5. Record the time of the last changeover stop on each rebar production line and calculate the predicted time period for the changeover stop on each rebar production line. The predicted time node for the changeover stop on the rebar production line can be obtained by adding the time of the last changeover stop to the predicted time period. S6. After calculating the predicted time nodes for all rebar production line replacement shutdowns, calculate the difference ΔT between the predicted time nodes for all rebar production line replacement shutdowns, and determine whether ΔT is greater than or equal to the preset time difference T. m If so, no intervention is needed; otherwise, ensure the difference ΔT is less than the time difference T. m The predicted shutdown time for the replacement of one of the two rebar production lines was artificially brought forward.

2. The control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to claim 1, characterized in that: In step S1, the steel throughput database includes rebar specification S, brand Q, hot delivery ratio range [p,q) and steel throughput M.

3. The control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to claim 1, characterized in that: In step S1, the median value of all historical data on the steel throughput of the rebar production line within the same specification, brand, and heat delivery ratio range is taken as the benchmark steel throughput of the rebar production line within the same specification, brand, and heat delivery ratio range.

4. The control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to claim 1, characterized in that: In step S6, if ΔT≥T m If the time nodes of the next replacement shutdown of all rebar production lines do not overlap, then the predicted time nodes of the next replacement shutdown of all rebar production lines are the actual time nodes of the next replacement shutdown of rebar production lines.

5. The control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to claim 1, characterized in that: In step S6, if ΔT < T m If the time nodes of the last replacement shutdown of all rebar production lines overlap, then the difference ΔT needs to be less than the time difference T. m The predicted shutdown time for the replacement of one of the two rebar production lines was artificially brought forward.

6. The control method for avoiding simultaneous shutdown of process equipment in multiple rebar production lines according to claim 5, characterized in that: Arrange the predicted time points of the next replacement shutdown of all rebar production lines in ascending order. Then, calculate the difference ΔT between any two adjacent predicted time points in descending order. If the difference ΔT < T between any two adjacent predicted time points... m Then, the smaller of the two adjacent prediction time points will be moved forward by a time T. p T p = T m -(T) q+1 -T q ), where T q+1 It is the larger of two adjacent prediction time points, T. q It is the smaller of two adjacent prediction time points.

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