A control method to prevent tilting during the transport of rebar rollers

Abstract

This invention discloses a control method to prevent tilting during the conveyor transport of rebar. By setting different attributes affecting blade life for rebar of different specifications and grades, and then calculating the ratio relationship between different attributes based on historical data, the total steel throughput of one attribute is calculated as a benchmark value. During production, all rebar attributes are converted to the attributes corresponding to the benchmark value, and the total steel throughput is calculated relative to the benchmark value to determine the blade replacement cycle. By establishing a mathematical model, a more accurate blade replacement cycle is predicted, improving the quality of the rebar production process, avoiding uneven shearing surfaces caused by overuse of blades, which leads to tilting and a series of subsequent quality problems, thus enhancing the competitiveness of the enterprise.

Description

Technical Field

[0001] This invention relates to a control method, and more particularly to a control method for preventing tilting during the transport of rebar rollers, belonging to the field of steel rolling technology. Background Technology

[0002] Newly constructed steel mills currently have the following characteristics: large output and operation of dual cooling beds for finishing. Therefore, the corresponding roller conveyor lines are long. During the roller conveyor transport of rebar, wear on the rollers is unavoidable. Due to factors such as equipment installation precision, roller wear is usually uneven. Therefore, if the dwell time is too long during the alignment process, the rebar will tilt to one side under the friction of the rollers. This will cause twisting and interlocking during subsequent chain sorting and bundling by the rebar-turning machine, resulting in bending or loose bundling. Furthermore, the shearing flatness of the rebar ends is also an important influencing factor. As the cold shear blades wear, the sheared section will gradually become uneven, even developing defects such as triangular heads or bends. Such rebar cannot be aligned by straight ramming plates; its inherent defects cause tilting. Therefore, controlling the steel throughput standard of the cold shear blades and avoiding roller idling that causes rebar tilting are two methods to ensure the straightness of the rebar during transport.

[0003] The steel throughput of cutting blades is significantly affected by different specifications and steel grades. A production line typically produces multiple specifications, with larger specifications having a lower throughput than smaller specifications. Larger specifications have larger diameters and experience greater shearing forces. Steel throughput can be defined here as the tonnage of rebar produced from the time it enters the production line until a small batch of uneven shearing or bends occurs. The challenge lies in accurately predicting the blade's replacement time when there are many order volumes (multiple specifications), allowing for early replacement and preventing uneven rebar end faces that could cause tilting. For example, the single-sided steel throughput of a cutting blade is approximately 30,000 tons. A production line's daily output is 4,500-5,000 tons. This 30,000-ton throughput would last for nearly a week. During this week, different specifications and steel grades are produced. Certain special steel grades, such as British Standard and Hong Kong Standard, have lower temperatures and higher finished product strength. Although the order volume is small, these grades significantly impact the blade's lifespan, shortening its lifespan. Therefore, determining the factors influencing the blade's lifespan for each specification and steel grade is crucial for accurately predicting the next blade replacement time. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a control method to avoid tilting during the transport of rebar on roller conveyors, thereby solving the technical problem of rebar tilting in the prior art.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] A method for controlling tilting during the transport of rebar on roller conveyors includes the following steps:

[0007] S1. Determine the quantity n of the specifications of rebar produced by the rebar production line, and then determine the quantity m of the steel grade of each specification of rebar. Then there are a total of n*m different attributes that affect the blade life of the rebar production line.

[0008] S2. Calculate the total output of rebar with different properties from the time the blades of the rebar production line are put on the line to the time they are taken off the line, and compile a corresponding steel throughput table.

[0009] S3. Let the different attributes affecting the blade life be A1, A2, ..., A n*m In a set of steel throughput tables, the steel throughput corresponding to attribute A1 is S1, the steel throughput corresponding to attribute A2 is S2, ..., attribute A n*m The corresponding steel throughput is S n*m The total steel throughput corresponding to all attributes is S. all The equations are as follows:

[0010] S1*A1+S2*A2+··+S n*m *A n*m =S all ;

[0011] S4. Select a sufficient number of sets of steel throughput data, and combine the equations to obtain a series of polynomial equations.

[0012] S5. Solving the series of polynomials, we get A2 = P1 * A1, A3 = P2 * A2, ..., A n*m =P n*m-1 *A n*m-1 ;

[0013] S6. Let attribute A1 be the base attribute. Assume that all steel grades with attribute A1 are rolled during the period from the entry to the exit of the rebar production line blades. Substituting the result of step S5 into the equation of step S3, the total steel throughput S when rolling all steel grades with attribute A1 can be obtained. all1 The total steel throughput S when rolling all steel grades with A1 rolling properties all1 Set as the standard for steel throughput D;

[0014] S7. Based on the steel passage amount benchmark D, convert all attributes into the steel passage amount corresponding to the specification of attribute A1 to deduce the replacement time.

[0015] Furthermore, in step S1, if different steel grades under the same specification have the same performance requirements, they are considered as the same steel grade. These different steel grades are then merged to reduce the final total number of attributes.

[0016] Furthermore, in step S3, if the steel throughput of the corresponding attribute in the steel throughput table is 0, that is, no rebar of the corresponding attribute is produced during the period from the on-line to the off-line of the corresponding blade, then the corresponding attribute is omitted in the equation.

[0017] Further, step S7 specifically includes:

[0018] In actual production, the order in which different properties correspond to different specifications of rebar is not the same;

[0019] Taking the moment when the rebar production line blades are put into service as the starting time t0, for the first type of rebar, let its attribute be B1, and attribute B1 correspond to attributes A1, A2, ..., A n*m One of them, we can get B1=Q1*A1. Let the current steel throughput of the first production specification of rebar be M1. Determine whether B1*M1= Q1*A1*M1 is greater than or equal to the steel throughput reference D. If it is, replace the cutting tool. Otherwise, proceed to the next step.

[0020] When the production of rebar with attribute B1 is completed, let the steel throughput of attribute B1 be N1. At this point, the production of a second type of rebar, with attribute B2, is initiated. Attribute B2 corresponds to attributes A1, A2, ..., A... n*m One of them, we can get B2=Q2*A1. Let the current steel throughput of the second type of rebar be M2. Determine whether B1*N1+B2*M2= Q1*A1*N1+ Q2*A1*M2 is greater than or equal to the steel throughput benchmark D. If it is, replace the cutting tool; otherwise, proceed to the next step.

[0021] When the production of rebar with attribute B2 is completed, let the steel throughput of attribute B2 be N2. At this point, a third type of rebar is produced, with attribute B3. Attribute B3 corresponds to attributes A1, A2, ..., A... n*m One of them, we can get B3=Q3*A1. Let the current steel throughput of the second type of rebar be M3. Determine whether B1*N1+B2*N2+B3*M3= Q1*A1*N1+ Q2*A1*N2+ Q3*A1*M3 is greater than or equal to the steel throughput benchmark D. If yes, replace the cutting tool. Otherwise, proceed to the next step.

[0022] This process continues until the total amount of rebar of different properties produced is converted to property A1 and is greater than or equal to the steel quantity reference D, at which point the blade replacement is complete.

[0023] Furthermore, a pressure sensor is installed on the alignment plate of the roller conveyor, and the current signal of the pressure sensor is linked to the control system of the roller conveyor.

[0024] Furthermore, when the pressure sensor detects that a rebar has struck its impact plate, the pressure sensor sends a current signal to the roller conveyor control system, and the roller conveyor control system has a delay time t. m The roller conveyor in the rebar alignment area is then stopped.

[0025] Furthermore, the time t m It takes 600ms.

[0026] Compared with the prior art, the present invention has the following advantages and effects: By establishing a mathematical model, the present invention predicts a more accurate blade replacement cycle, improves the quality in the rebar production process, avoids uneven shearing end face caused by excessive use of blades, resulting in tilting and a series of subsequent quality problems, and enhances the competitiveness of enterprises; and controls the tilting of rebar during roller conveyor transport through automation. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the steel throughput table, representing an embodiment of a control method for preventing tilting during the transport of rebar rollers according to the present invention.

[0028] Figure 2 This is a schematic diagram of the alignment plate structure of an embodiment of a control method for preventing tilting during the transport of rebar rollers according to the present invention. Detailed Implementation

[0029] 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.

[0030] This invention discloses a control method to prevent tilting during the transport of rebar on roller conveyors, comprising the following steps:

[0031] S1. Determine the quantity n of the rebar specifications produced by the rebar production line, and then determine the quantity m of the steel grade for each specification of rebar. Then, there are a total of n*m different attributes that affect the blade life of the rebar production line.

[0032] In step S1, different steel grades under the same specification have the same performance requirements for some steel grades, which are then considered as the same steel grade. These different steel grades are then merged to reduce the final total number of properties.

[0033] S2. Calculate the total output of rebar of different properties from the time the blades of the rebar production line are put on the line to the time they are taken off the line, and formulate a corresponding steel throughput table.

[0034] S3. Let the different attributes affecting the blade life be A1, A2, ..., A n*m In a set of steel throughput tables, the steel throughput corresponding to attribute A1 is S1, the steel throughput corresponding to attribute A2 is S2, ..., attribute A n*m The corresponding steel throughput is S n*m The total steel throughput corresponding to all attributes is S. all The equations are as follows:

[0035] S1*A1+S2*A2+··+S n*m *A n*m =S all .

[0036] In step S3, if the steel throughput of the corresponding attribute in the steel throughput table is 0, that is, no rebar of the corresponding attribute is produced during the period from the upper to the lower end of the corresponding blade, then the corresponding attribute is omitted in the equation.

[0037] S4. Select a sufficient number of steel quantity table data sets and combine the equations to obtain a series of polynomial equations.

[0038] S5. Solving the series of polynomials, we get A2 = P1 * A1, A3 = P2 * A2, ..., A n*m =P n*m-1 *A n*m-1 .

[0039] S6. Let attribute A1 be the base attribute. Assume that all steel grades with attribute A1 are rolled during the period from the entry to the exit of the rebar production line blades. Substituting the result of step S5 into the equation of step S3, the total steel throughput S when rolling all steel grades with attribute A1 can be obtained. all1 The total steel throughput S when rolling all steel grades with A1 rolling properties all1 The standard for steel throughput is set as D.

[0040] S7. Based on the steel passage amount benchmark D, convert all attributes into the steel passage amount corresponding to the specification of attribute A1 to deduce the replacement time.

[0041] Step S7 is as follows:

[0042] In actual production, the order in which different properties correspond to different specifications of rebar is not the same.

[0043] Taking the moment when the rebar production line blades are put into service as the starting time t0, for the first type of rebar, let its attribute be B1, and attribute B1 correspond to attributes A1, A2, ..., A n*mOne of the options is to obtain B1=Q1*A1. Let the current steel throughput of the first type of rebar be M1. Determine whether B1*M1= Q1*A1*M1 is greater than or equal to the steel throughput reference D. If yes, replace the cutting tool; otherwise, proceed to the next step.

[0044] When the production of rebar with attribute B1 is completed, let the steel throughput of attribute B1 be N1. At this point, the production of a second type of rebar, with attribute B2, is initiated. Attribute B2 corresponds to attributes A1, A2, ..., A... n*m One of the options is to obtain B2=Q2*A1. Let the current steel throughput of the second type of rebar be M2. Determine whether B1*N1+B2*M2= Q1*A1*N1+ Q2*A1*M2 is greater than or equal to the steel throughput reference D. If yes, replace the cutting tool; otherwise, proceed to the next step.

[0045] When the production of rebar with attribute B2 is completed, let the steel throughput of attribute B2 be N2. At this point, a third type of rebar is produced, with attribute B3. Attribute B3 corresponds to attributes A1, A2, ..., A... n*m One of the options is to obtain B3=Q3*A1. Let the current steel throughput of the second type of rebar be M3. Determine whether B1*N1+B2*N2+B3*M3= Q1*A1*N1+ Q2*A1*N2+ Q3*A1*M3 is greater than or equal to the steel throughput reference D. If yes, replace the cutting tool; otherwise, proceed to the next step.

[0046] This process continues until the total amount of rebar of different properties produced is converted to property A1 and is greater than or equal to the steel quantity reference D, at which point the blade replacement is complete.

[0047] like Figure 2 As shown, a pressure sensor is installed on the alignment plate of the roller conveyor, and the current signal of the pressure sensor is linked to the control system of the roller conveyor.

[0048] When the pressure sensor detects that a rebar has struck its impact plate, it sends a current signal to the roller conveyor's control system. The roller conveyor control system then delays for a period of time t. m The roller conveyor in the rebar alignment area then stops operating. Time t m The optimal time is 600ms. After the rebar is aligned, some of it may move backward due to elasticity. If the pressure signal stops immediately, it may cause unevenness at the ends and lose the original function of the impact plate. Therefore, a certain delay is required.

[0049] This invention uses mathematical models to predict the blade replacement cycle more accurately, improving the quality of rebar production and avoiding uneven shearing surfaces caused by overuse of blades, which can lead to tilting and a series of subsequent quality problems, thus enhancing the competitiveness of enterprises. Furthermore, it uses automation to control the tilting of rebar during roller conveyor transport.

[0050] The present invention will be further described below through specific embodiments.

[0051] The rebar wire is produced in two specifications, 16 and 18 mm. Each specification is rolled with four steel grades: HRB400, HRB400E, HRB500E, and B500B. HRB400 and HRB400E have the same performance requirements and can therefore be considered the same steel grade for current calculations. This is because, for this production line, with two specifications and three steel grades, there are a total of six properties that have different impacts on blade life.

[0052] like Figure 1 The table shows the steel throughput of various specifications of rebar rolled during the process from the time the blades are loaded onto the production line to the time they are unloaded.

[0053] The six different attributes are set as A1, A2, A3, A4, A5, and A6, respectively, corresponding to 16-size HRB400(E), 16-size HRB500E, 16-size B500B, 18-size HRB400(E), 18-size HRB500E, and 18-size B500B.

[0054] The equations are as follows:

[0055] (1) 11500 A1+500 A2+14000 A4+800 A6=26800

[0056] (2) 12000 A1+800 A3+13500 A4+500 A5=28800

[0057] (3) 13000 A1+500 A2+1000 A3+11000 A4+500 A5=26000

[0058] (4) 13000 A1+2000 A3+9000 A4+1000 A5=25000

[0059] …

[0060] The results were calculated as follows: A2=1.85A1, A3=2.6A1, A4=1.1A1, A5=2.2A1, A6=3.05A1.

[0061] If all steel grades corresponding to A1 are rolled, the final steel throughput can reach approximately 30,000. We take 30,000 as the steel throughput baseline D.

[0062] Based on this value D, the replacement time can be deduced by converting all specifications into the steel throughput corresponding to A1.

[0063] 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 tilting during the transport of threaded steel on roller tables, characterized in that Comprise the following steps: S1, determine the number n of specifications of threaded steel produced by the threaded steel production line, then determine the number m of steel grades of each specification of threaded steel, then the threaded steel production line has n m attributes that affect the service life of the blade. S2, statistics thread steel production line blade on-line to off-line during different properties of the total production of thread steel and make the corresponding steel quantity table; S3, set the different attributes of the impact on the life of the blade for A1, A2,..., A n m , for a set of steel quantity table, the attribute A1 corresponding to the steel quantity is S1, the attribute A2 corresponding to the steel quantity is S2,..., the attribute A n m corresponding to the steel quantity is S n m , the total steel quantity corresponding to all attributes is S all , the equation is as follows: S1 A1+S2 A2+···+S n m A n m =S all ; S4, select enough number of steel quantity table data, and the equation is listed to get the polynomial equation; S5, solve the resulting polynomial chain equation, A2 = P1 A1, A3 = P2 A2,..., A n m = P n m-1 A n m-1 ; S6, assuming that the thread steel production line blade is on line to off line during all rolling property A1 steel grade, the results of step S5 are substituted into the equation of step S3 to obtain the total over steel amount S when all rolling property A1 steel grade all1 , the total over steel amount S when all rolling property A1 steel grade is set as the over steel amount reference D all1 ​ S7, according to the steel quantity reference D, all attributes are converted into attribute A1 corresponding specification steel quantity, that is, the replacement time can be deduced; The step S7 is specifically: In actual production process, the order of thread steel corresponding to different properties of different specifications is not the same; With the moment when the blade of the thread steel production line is put on line as the starting moment t0, for the first production specification of thread steel, set its attribute as B1, the attribute B1 corresponds to attributes A1, A2, ···, A n m Among one kind, B1=Q1 A1, set the current steel quantity of the first production specification of thread steel as M1, judge B1 M1=Q1 A1 Whether M1 is greater than or equal to the steel quantity reference D, if yes, replace the blade, if not, proceed to the next step; When the threaded steel of attribute B1 is finished, let the over-steel quantity of attribute B1 be N1, at this time the second specification threaded steel is produced, let its attribute be B2, attribute B2 corresponds to attributes A1, A2, ···, A n m Among them, B2 = Q2 A1, let the current over-steel quantity of the second specification threaded steel be M2, judge B1 N1 + B2 M2 = Q1 A1 N1 + Q2 A1 M2 whether is greater than or equal to the steel quantity reference D, if yes, replace the blade, if not, proceed to the next step; When the threaded steel of attribute B2 is finished, let the over-steel quantity of attribute B2 be N2, at this time the threaded steel of the third specification is produced, let its attribute be B3, attribute B3 corresponds to attributes A1, A2, ···, A n m Among them, B3=Q3 A1, let the current over-steel quantity of the threaded steel of the third specification be M3, judge B1 N1+B2 N2+B3 M3= Q1 A1 N1+ Q2 A1 N2+ Q3 A1 M3 whether greater than or equal to the steel quantity reference D, if yes, replace the blade, if not, proceed to the next step; By analogy, until the sum of the thread steel corresponding to different properties of attribute A1 is greater than or equal to the steel quantity reference D, the blade replacement is completed.

2. The control method for avoiding tilting of a thread steel roller table during transportation according to claim 1, characterized in that: In the step S1, different steel grades under the same specification, the performance requirements of some steel grades are the same, which is regarded as the same steel grade, so these different steel grades are combined to reduce the number of final total attributes.

3. The control method for avoiding tilting of a thread steel roller table during transportation according to claim 1, characterized in that: In the step S3, if the steel quantity corresponding to the attribute in the steel quantity table is 0, that is, the corresponding attribute is not produced during the on-line to off-line period of the corresponding blade, the corresponding attribute is omitted in the equation.

4. The control method for avoiding tilting of a thread steel roller table during transportation according to claim 1, characterized in that: The pressure sensor is installed on the roller alignment bump plate, and the current signal of the pressure sensor is linked with the control system of the roller.

5. The control method for avoiding tilting of a threaded steel roller bed during transportation according to claim 4, characterized in that: When the pressure sensor detects that the threaded steel hits the alignment baffle, the pressure sensor sends a current signal to the control system of the roller bed, and the roller bed control system delays for a time t m The roller bed controlling the alignment area of the threaded steel stops working.

6. The control method for avoiding tilting of a threaded steel roller bed during transportation according to claim 5, characterized in that: The time t m is 600 ms.

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