Method and device for detecting abnormal conditions of a segment roller by friction

Abstract

This invention relates to a method and apparatus for detecting abnormal conditions of a sector-shaped roller using friction, belonging to the technical field of continuous casting machine monitoring methods and devices. The technical solution of this invention is as follows: a friction wheel device with motor reduction drive is fabricated and placed on a repaired sector-shaped roller. Parameters are input into a detection model, which calculates the theoretical current driven by the motor. The friction wheel device rotates, generating an actual current. The real-time current of the motor is collected, and the actual current is compared with the theoretical current according to the detection model algorithm to determine the abnormal condition of the sector-shaped roller. The beneficial effects of this invention are: by using the friction wheel device to drive the detection current on the repaired sector-shaped roller to determine its abnormal condition, potential assembly problems can be predicted in advance, thereby improving the service life of the online sector-shaped roller, reducing unplanned downtime, ensuring continuous and stable production, and avoiding uncertainties that could affect the quality of the cast billet.

Description

Technical Field

[0001] This invention relates to a method and apparatus for detecting abnormal conditions of sector-shaped rollers by friction, belonging to the technical field of continuous casting machine monitoring methods and apparatus. Background Technology

[0002] The condition of the sector section rollers after maintenance will affect the service life of the sector section line, ensuring continuous and stable production, reducing unplanned downtime, and avoiding uncertainties in billet quality.

[0003] The slab continuous casting machine is designed with fan-shaped sections of different roller diameters and closely spaced rollers to form the slab guide zone and shape the slab. Currently, after the offline position adjustment of the fan-shaped rollers is qualified, there is no means to detect abnormal conditions of the fan-shaped rollers. This allows some abnormal rollers to be put online. In the high-temperature, heavy-load, and humid environment of the continuous casting machine, they cannot reach their intended service life, which seriously hinders the high-yield and high-efficiency production of continuous casting slabs and causes significant economic losses. Summary of the Invention

[0004] The purpose of this invention is to provide a method and apparatus for detecting abnormal conditions of sector-shaped rollers by friction. By using a friction wheel device to drive a detection current on the repaired sector-shaped rollers, the abnormal conditions of the sector-shaped rollers can be determined, and potential problems in roller assembly can be predicted in advance. This can improve the service life of the online sector-shaped rollers, reduce unplanned downtime, ensure continuous and stable production, avoid uncertainties in the quality of cast billets, and effectively solve the above-mentioned problems in the background art.

[0005] The technical solution of the present invention is: a method for detecting abnormal conditions of a sector-shaped roller by friction, comprising the following steps:

[0006] (1) Use a friction wheel device with motor reduction drive, place it on the repaired sector section roller, input the parameters into the detection model, and the model calculates the theoretical current of motor drive;

[0007] (2) The friction wheel rotates, and the fan-shaped roller rotates by friction, generating actual current;

[0008] (3) Collect the actual current of the motor at this time, and compare the actual current with the theoretical current according to the detection model algorithm to determine the abnormal state of the sector roller.

[0009] In step (1), the specific steps are as follows: record the friction wheel device using motor reduction transmission, place it on the repaired sector section roller, input the parameters into the detection model, and the model calculates the theoretical current of motor drive.

[0010] The formula for determining the theoretical current of a motor is:

[0011]

[0012] In the formula: ----The theoretical current (A) for the friction wheel to rotate the sector-shaped roller.

[0013] ----Friction wheel idle current, A

[0014] The current generated by the friction between the friction wheel and the sector-shaped roller, A

[0015]

[0016] in ----Resistance torque generated by the weight of the sector-shaped roller, Nm

[0017] G----The weight of the sector-shaped roller itself, N

[0018] ----The friction coefficient of the sector-shaped roller bearing is taken as 0.02, while the friction coefficient of the rolling bearing is taken as 0.02.

[0019] ----The average diameter of the sector-shaped roller bearing, in meters, is taken as the rolling bearing.

[0020]

[0021]

[0022] in ----The resistance torque generated by the frictional rotation of the friction wheel and roller, Nm

[0023] Q----The force exerted by the friction wheel on the roller, N

[0024] The coefficient of friction between the friction wheel and the roller is typically 0.4-0.6.

[0025] D----Diameter of the sector-shaped roller, in meters

[0026]

[0027] in ----Static torque required for the rotation of the sector-shaped roller

[0028]

[0029] in ----Friction wheel motor current, A

[0030] K----A safety factor considering factors such as installation accuracy and grease condition, typically 1.3-1.5.

[0031] ----Roller speed, r / min

[0032] η----Mechanical efficiency, taken as 0.85

[0033] U----Motor power, 380V

[0034] In step (2), the specific steps are as follows: the friction wheel device rotates, and the fan-shaped roller rotates by friction, generating actual current, which is then connected to the control server for data interaction via an RS485 to USB data transmission cable.

[0035] In step (3), the actual current of the motor is collected at this time. According to the detection model algorithm, the actual current is compared with the theoretical current. The deviation is not allowed to exceed 10% in order to determine the abnormal state of the fan-shaped roller.

[0036] A device for detecting abnormal conditions of a sector roller by friction includes a power supply cabinet for the friction wheel device, a monitoring unit, an alarm device, and a friction wheel device. The power supply cabinet for the friction wheel device is connected to the monitoring unit, the alarm device, and the friction wheel device. The alarm device is installed on the monitoring unit, and the friction wheel device is placed on the repaired sector roller.

[0037] The friction wheel device is driven by a motor with a speed reduction mechanism.

[0038] The friction wheel device is connected to the control server for data exchange via an RS485 to USB data transmission cable.

[0039] The beneficial effects of this invention are: by using a friction wheel device to drive the detection current on the repaired sector section rollers, abnormal conditions of the sector section rollers can be determined, and potential problems in roller assembly can be predicted in advance, so as to improve the service life of the online sector section, reduce unplanned downtime, enable continuous and stable production, and avoid uncertain risks to the quality of the cast billet. Attached Figure Description

[0040] Figure 1 This is a flowchart of the process of this invention;

[0041] Figure 2 This is a schematic diagram of the structure of the present invention;

[0042] In the diagram: 1. Power supply cabinet for friction wheel device; 2. Monitoring unit; 3. Alarm device; 4. Friction wheel device. Detailed Implementation

[0043] To make the purpose, technical solutions, and advantages of the invention's embodiments clearer, 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 embodiments described are only a small part of the embodiments of the present invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0044] A method for detecting abnormal conditions of a sector-shaped roller by friction includes the following steps:

[0045] (1) Use a friction wheel device with motor reduction drive, place it on the repaired sector section roller, input the parameters into the detection model, and the model calculates the theoretical current of motor drive;

[0046] (2) The friction wheel rotates, and the fan-shaped roller rotates by friction, generating actual current;

[0047] (3) Collect the actual current of the motor at this time, and compare the actual current with the theoretical current according to the detection model algorithm to determine the abnormal state of the sector roller.

[0048] In step (1), the specific steps are as follows: record the friction wheel device using motor reduction transmission, place it on the repaired sector section roller, input the parameters into the detection model, and the model calculates the theoretical current of motor drive.

[0049] The formula for determining the theoretical current of a motor is:

[0050]

[0051] In the formula: ----The theoretical current (A) for the friction wheel to rotate the sector-shaped roller.

[0052] ----Friction wheel idle current, A

[0053] The current generated by the friction between the friction wheel and the sector-shaped roller, A

[0054]

[0055] in ----Resistance torque generated by the weight of the sector-shaped roller, Nm

[0056] G----The weight of the sector-shaped roller itself, N

[0057] ----The friction coefficient of the sector-shaped roller bearing is taken as 0.02, while the friction coefficient of the rolling bearing is taken as 0.02.

[0058] ----The average diameter of the sector-shaped roller bearing, in meters, is taken as the rolling bearing.

[0059]

[0060]

[0061] in ----The resistance torque generated by the frictional rotation of the friction wheel and roller, Nm

[0062] Q----The force exerted by the friction wheel on the roller, N

[0063] The coefficient of friction between the friction wheel and the roller is typically 0.4-0.6.

[0064] D----Diameter of the sector-shaped roller, in meters

[0065]

[0066] in ----Static torque required for the rotation of the sector-shaped roller

[0067]

[0068] in ----Friction wheel motor current, A

[0069] K----A safety factor considering factors such as installation accuracy and grease condition, typically 1.3-1.5.

[0070] ----Roller speed, r / min

[0071] η----Mechanical efficiency, taken as 0.85

[0072] U----Motor power, 380V

[0073] In step (2), the specific steps are as follows: the friction wheel device rotates, and the fan-shaped roller rotates by friction, generating actual current, which is then connected to the control server for data interaction via an RS485 to USB data transmission cable.

[0074] In step (3), the actual current of the motor is collected at this time. According to the detection model algorithm, the actual current is compared with the theoretical current. The deviation is not allowed to exceed 10% in order to determine the abnormal state of the fan-shaped roller.

[0075] A device for detecting abnormal conditions of a sector roller by friction includes a friction wheel device power supply cabinet 1, a monitoring unit 2, an alarm device 3, and a friction wheel device 4. The friction wheel device power supply cabinet 1 is connected to the monitoring unit 2, the alarm device 3, and the friction wheel device 4 respectively. The alarm device 3 is installed on the monitoring unit 2, and the friction wheel device 4 is placed on the repaired sector roller.

[0076] The friction wheel device 4 is driven by a motor with a speed reduction.

[0077] The friction wheel device 4 is connected to the control server for data exchange via an RS485 to USB data transmission cable.

[0078] Example:

[0079] A certain factory's 230*1900mm slab continuous casting machine has an arc radius of 9.5 meters, one curved section, and 14 sector sections. After on-site repairs to the outer arc of the horizontal sector sections, a friction wheel device was used to inspect them. The relevant parameters were input into the inspection system. The specific parameters are as follows:

[0080] The horizontal fan-shaped section has 7 rows of rollers, each with a diameter of 300mm and a spacing of 340mm between rollers. The friction wheel assembly weighs 1614N, the rollers weigh 12744N, the bearing outer diameter is 240mm, the bearing inner diameter is 160mm, the friction wheel diameter is 375mm, the reducer input speed is 1360r / min, and the speed ratio is 180.6.

[0081] Substitute into the formula

[0082]

[0083] in ----Resistance torque generated by the roller's own weight, Nm

[0084] G----The weight of the roller itself, N

[0085] ----The coefficient of friction for roller bearings is taken as 0.02; the coefficient of friction for rolling bearings is taken as 0.02.

[0086] ----The average diameter of the bearing, in meters (m), is taken as...

[0087]

[0088]

[0089]

[0090] in ----The resistance torque generated by the frictional rotation of the friction wheel and roller, Nm

[0091] Q----The force exerted by the friction wheel on the roller, N

[0092] The coefficient of friction between the friction wheel and the roller is typically 0.4-0.6.

[0093] D----Roller diameter, m

[0094]

[0095]

[0096] in ----Static torque required for roller rotation

[0097]

[0098] Where I represents the friction wheel motor current, in A.

[0099] K----A safety factor considering factors such as installation accuracy and grease condition, typically 1.3-1.5.

[0100] ----Roller speed, r / min

[0101] η----Mechanical efficiency, taken as 0.85

[0102] U----Motor power, 380V

[0103]

[0104] The on-site test data for the unloaded motor is as follows:

[0105] =1.3A

[0106]

[0107] After the friction wheel device was placed on the sector section roller, the actual current was detected to be 1.79A, with a deviation of 7.3%, indicating that the sector section roller was in normal condition.

[0108] The online application of this invention uses a friction wheel device to drive a detection current on the repaired sector section rollers to determine abnormal conditions of the sector section rollers, predict potential problems in roller assembly in advance, thereby improving the service life of the online sector section, reducing unplanned downtime, ensuring continuous and stable production, and avoiding uncertainties in billet quality.

Claims

1. A method for detecting abnormal conditions of a sector-shaped roller by friction, characterized in that... Includes the following steps: S1. Record the friction wheel device using motor reduction transmission, place it on the repaired sector roller, input the parameters into the detection model, and the model calculates the theoretical current for the friction wheel to rotate the sector roller; the formula for determining the theoretical current for the friction wheel to rotate the sector roller is: , In the formula: ----The theoretical current (A) for the friction wheel to rotate the sector-shaped roller. ----Friction wheel idle current, A The current generated by the friction between the friction wheel and the sector-shaped roller, A , in ----The resistance torque generated by the weight of the sector-shaped roller, Nm G----The weight of the sector-shaped roller itself, N ----The friction coefficient of the sector-shaped roller bearing is taken as 0.02, while the friction coefficient of the rolling bearing is taken as 0.

02. ----The average diameter of the sector-shaped roller bearing, in meters, is taken as the rolling bearing. , , in ----The resistance torque generated by the frictional rotation of the friction wheel and roller, in Nm Q----The force exerted by the friction wheel on the roller, N The coefficient of friction between the friction wheel and the roller is taken as 0.4-0.

6. D----Diameter of the sector-shaped roller, in meters , in ----Static torque required for the rotation of the sector-shaped roller , Where k is a safety factor considering installation accuracy and grease condition, taken as 1.3-1.

5. ----Roller speed, r / min η----Mechanical efficiency, taken as 0.85 U----Motor power, 380V; S2. The friction wheel device rotates, and the sector-shaped roller rotates by friction, generating actual current; S3. Collect the actual current of the motor at this time, and compare the actual current with the theoretical current according to the detection model algorithm to determine the abnormal state of the sector roller.

2. The method for detecting abnormal conditions of a sector-shaped roller by friction according to claim 1, characterized in that: In step S2, the friction wheel device rotates, and the fan-shaped roller rotates by friction, generating an actual current. The current is then transmitted to the control server via an RS485 to USB data transmission cable for data interaction.

3. The method for detecting abnormal conditions of a sector-shaped roller by friction according to claim 1, characterized in that: In step S3, the actual current of the motor is collected at this time. According to the detection model algorithm, the actual current is compared with the theoretical current. The deviation is not allowed to exceed 10% in order to determine the abnormal state of the fan-shaped roller.

4. An apparatus for detecting abnormal conditions of a sector-shaped roller by friction, used in a method for detecting abnormal conditions of a sector-shaped roller by friction according to claim 1, 2, or 3, characterized in that: The device includes a power supply cabinet (1) for the friction wheel device, a monitoring unit (2), an alarm device (3) and a friction wheel device (4). The power supply cabinet (1) for the friction wheel device is connected to the monitoring unit (2), the alarm device (3) and the friction wheel device (4) respectively. The alarm device (3) is set on the monitoring unit (2) and the friction wheel device (4) is placed on the repaired fan-shaped roller.

5. The device for detecting abnormal conditions of a sector-shaped roller by friction according to claim 4, characterized in that: The friction wheel device (4) is driven by a motor speed reduction.

6. The device for detecting abnormal conditions of a sector-shaped roller by friction according to claim 4, characterized in that: The friction wheel device (4) is connected to the control server for data interaction via an RS485 to USB data transmission cable.

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