A heating furnace chain hoist intelligent positioning method, system, device and storage medium
By learning and memorizing the automatic operation cycle time of the chain hoist, intelligent positioning control is achieved, which solves the problems of easy sensor damage and system complexity, and improves system stability and motor life.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- YANGCHUN NEW STEEL CO LTD
- Filing Date
- 2024-01-31
- Publication Date
- 2026-07-14
AI Technical Summary
Existing automatic control methods for chain elevators are prone to sensor damage in high-temperature environments, the systems are complex, the motors have short lifespans, and it is difficult to achieve stable positioning.
By learning and memorizing the automatic operation cycle time of the hoisting chain, and using intelligent positioning methods and systems for control, the hoisting machine can be intelligently positioned without relying on sensors and encoders.
This improved system stability, reduced potential failure points, extended motor lifespan, and prevented damage to sensors from high-temperature environments.
Smart Images
Figure CN118004701B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of chain elevator control technology, and more specifically, to an intelligent positioning method, system, device, and storage medium for a heating furnace chain elevator. Background Technology
[0002] Chain elevators are the main equipment for charging hot billets in the heating furnace of steel rolling mills. They are driven by a motor to generate vertical transmission force through a hooked chain, which moves the steel billet from the low-level hot conveying roller table to the high-level furnace entry roller table.
[0003] Currently, there are three main types of automatic control for chain hoists: First, by installing proximity switches, photoelectric switches, or hot metal detection switches at specific positions (usually the bottom of the chain) within the chain's movement trajectory space, positioning control is achieved by detecting when the chain hook passes the bottom position. Second, by installing an encoder on the motor shaft, positioning control of the hoist chain is achieved by calibrating the 0 position and tracking the process position. Third, by obtaining empirical time for one revolution of the hoist (one rotation of the chain) through experimental observation, and by using forced methods to ensure that the hoist returns to its original position after each revolution, a fixed running time is set based on the empirical time to achieve positioning control.
[0004] The main defects and shortcomings are:
[0005] 1. The switch signal sensor needs to be installed close to the hook of the hoisting chain to obtain a stable and effective signal. Since the steel billets transported by the hoisting chain are all high-temperature hot billets, the sensor operates in a very high temperature environment and is easily damaged. Using the switch signal sensor to position and control the hoisting machine, the high temperature environment increases the maintenance difficulty of the switch signal sensor and the system is prone to failure.
[0006] 2. Using encoders for positioning control of the lifting chain involves numerous encoder wires and complex configurations, which complicates the control system, increases the number of potential failure points, and makes the system unstable.
[0007] 3. Using fixed-time positioning control, the lifting chain needs to be forced to return to its original position every time it runs. This requires canceling the lifting machine's brake function and using the weight of the billet to bring the chain back to its original position. This causes the motor to frequently generate electricity, reducing the motor's lifespan and making it unsuitable for long-term use. Summary of the Invention
[0008] The technical problem to be solved by the present invention is to address the above-mentioned shortcomings of the prior art. The purpose of the present invention is to provide an intelligent positioning method for a chain elevator of a heating furnace.
[0009] The second objective of this invention is to provide an intelligent positioning system for a chain elevator in a heating furnace.
[0010] The third objective of this invention is to provide a computer device.
[0011] The fourth objective of this invention is to provide a computer storage medium.
[0012] To achieve the above objective, this invention provides an intelligent positioning method for a chain elevator in a heating furnace. By learning and memorizing the automatic operation cycle time of a large number of elevator chains, the normal state control of the elevator chain is replicated and reproduced based on the memorized operation cycle time, and the elevator chain is intelligently positioned and controlled based on the replicated operation cycle time.
[0013] As a further improvement, the following steps are included:
[0014] Step 1. Obtain the cycle time of a large number of single runs of the chain hoist under normal working conditions, remove abnormal running times, and save the cycle time of each single run in sequence;
[0015] Step 2. Read the single-run cycle time saved in Step 1 one by one. After each hoist chain starts running, start counting and accumulating its running time. Compare the accumulated value with the read single-run cycle time. When the accumulated value is greater than the read single-run cycle time, issue a stop command to control the hoist chain to stop, thereby realizing intelligent positioning control.
[0016] Step 3. When the chain elevator malfunctions and the saved single-run cycle time is used for positioning, it may result in inaccurate or excessive positioning. Manual intervention is required to correct this. After forcing the chain elevator back to its original position, the chain elevator is positioned and controlled according to a fixed time. Once the chain elevator returns to normal, switch back to the intelligent positioning control in Step 2.
[0017] Step 4. When the single-run cycle time of the chain hoist changes under normal operating conditions, it needs to be run in learning mode. In learning mode, a switch signal sensor needs to be temporarily installed to locate the hoist chain. The cycle time of a large number of single runs of the hoist chain under normal operating conditions is reacquired. After eliminating abnormal running times, the reacquired single-run cycle times are saved in sequence, and the system switches back to intelligent positioning control in step 2.
[0018] Further, in step 1, obtaining the single operation cycle time specifically involves obtaining the cycle time of one cycle of the hoisting chain in the original switch sensor positioning or encoder positioning control mode of the chain hoist, and storing it in a single-update storage unit A.
[0019] Furthermore, a storage area B is created. After each week of operation, the data in A is transferred to B[X] for sequential saving to complete the memory learning process. B[X] represents the Xth storage unit in storage area B.
[0020] Furthermore, the runtime for eliminating anomalies is specifically as follows:
[0021] In automatic operation mode, the time difference of three consecutive operation cycles within 100ms is considered to be the normal operation cycle time.
[0022] The latest single-run cycle time needs to be referenced from the previous two run cycle times. After determining that it is a normal cycle time, a normal signal F is generated. The rising edge of F triggers the data in A to be transferred to the storage area B, and the storage area pointer is incremented by 1 to point to the storage for the next single-run cycle time.
[0023] If no F signal is generated during a cycle of the lifting chain, the cycle time is considered invalid, and the memory pointer remains unchanged to ensure that the data in each memory area B is continuous and valid.
[0024] Furthermore, the normal operating condition of a chain hoist means that the chain hook can automatically run from low to high position for one cycle in a stable manner; according to equipment maintenance experience data, the failure rate of the electromechanical parts in the chain hoist is very low, and the number of failures will not exceed 3 within 5 years.
[0025] Furthermore, in step 2, the single-run cycle time of the storage area B is read one by one through pointer addressing. When the lifting chain finishes each automatic run, the next single-run cycle time is transmitted to the control parameter storage unit C to complete the update of the single-run cycle time in C.
[0026] After the lifting chain starts running, it begins to count and accumulate its running time. The accumulated value is compared with the single running cycle time in C. When the accumulated value is greater than the single running cycle time in C, a stop command is issued. Intelligent positioning control of the lifting chain's automatic operation mode is completed without relying on the positioning of switch quantity sensors or encoders.
[0027] To achieve the second objective mentioned above, the present invention provides an intelligent positioning system for a chain elevator in a heating furnace, comprising:
[0028] The acquisition module is used to acquire the cycle time of a large number of single runs of the chain hoist under normal working conditions, remove abnormal running times, and save the cycle time of each single run in sequence.
[0029] The intelligent positioning module is used to read and save the single running cycle time one by one. After each lifting chain starts running, it starts to count and accumulate its running time, compares the accumulated value with the read single running cycle time, and issues a stop command when the accumulated value is greater than the read single running cycle time to control the lifting chain to stop, thereby realizing intelligent positioning control.
[0030] The manual intervention module is used when the chain elevator malfunctions and the positioning is not accurate or is over-positioned when the saved single operation cycle time is used for positioning. Manual intervention is required to correct the situation and force the chain elevator back to its original position. The chain elevator is then positioned and controlled according to a fixed time. Once the chain elevator returns to normal, it switches back to intelligent positioning control.
[0031] The learning mode module is used when the single-run cycle time of the chain hoist changes under normal operating conditions. In learning mode, a switch signal sensor needs to be temporarily installed to locate the hoist chain. The learning mode reacquires the cycle time of a large number of single runs of the hoist chain under normal operating conditions. After eliminating abnormal running times, the reacquired single-run cycle times are saved in sequence, and the system switches back to intelligent positioning control.
[0032] To achieve the above-mentioned objective three, the present invention provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the above-mentioned intelligent positioning method for a heating furnace chain elevator.
[0033] To achieve the fourth objective mentioned above, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the above-mentioned intelligent positioning method for a heating furnace chain elevator.
[0034] Beneficial effects
[0035] Compared with the prior art, the advantages of this invention are as follows:
[0036] 1. This invention enables the positioning of the hoist to be independent of a fixedly installed position signal detection sensor, avoiding the influence of harsh environments such as high temperature and dust on the sensor and improving the stability of the system.
[0037] 2. This invention can achieve position tracking without an encoder, simplifying the hardware structure of the positioning control system, reducing system complexity and failure points, and improving system stability.
[0038] 3. This invention achieves normal state reproducibility control of the booster chain by intelligently learning a large number of cycle running times. It does not require setting a fixed running time, avoids the motor from frequently generating power due to forced return to the origin, and improves the service life of the motor. Attached Figure Description
[0039] Figure 1 This is a flowchart of the method in this invention. Detailed Implementation
[0040] The present invention will be further described below with reference to specific embodiments shown in the accompanying drawings.
[0041] See Figure 1 A method for intelligent positioning of a chain elevator in a heating furnace is proposed. This method is based on a process PLC and learns and memorizes the automatic operation cycle time of a large number of elevator chains. Based on the memorized operation cycle time, the normal state control of the elevator chain is replicated and reproduced. Based on the replicated operation cycle time, the elevator chain is intelligently positioned and controlled.
[0042] The intelligent positioning of the chain elevator for the heating furnace includes the following steps:
[0043] Step 1. Obtain the cycle time of a large number of single runs of the chain hoist under normal working conditions, remove abnormal running times, and save the cycle time of each single run in sequence;
[0044] Step 2. Read the single-run cycle time saved in Step 1 one by one. After each hoist chain starts running, start counting and accumulating its running time. Compare the accumulated value with the read single-run cycle time. When the accumulated value is greater than the read single-run cycle time, issue a stop command to control the hoist chain to stop, thereby realizing intelligent positioning control.
[0045] Step 3. When the chain elevator malfunctions and the saved single-run cycle time is used for positioning, it may result in inaccurate or excessive positioning. Manual intervention is required to correct this. After forcing the chain elevator back to its original position, the chain elevator is positioned and controlled according to a fixed time. Once the chain elevator returns to normal, switch back to the intelligent positioning control in Step 2.
[0046] Step 4. When the single-run cycle time of the chain hoist changes under normal operating conditions, it needs to be run in learning mode. In learning mode, a switch signal sensor needs to be temporarily installed to locate the hoist chain. The cycle time of a large number of single runs of the hoist chain under normal operating conditions is reacquired. After eliminating abnormal running times, the reacquired single-run cycle times are saved in sequence, and the system switches back to intelligent positioning control in step 2.
[0047] In step 1, obtaining the single operation cycle time specifically involves: in automatic mode, obtaining the cycle time of one cycle of the hoisting chain in the original switch sensor positioning or encoder positioning control mode of the chain hoist, and storing it in a single-update storage unit A.
[0048] A storage area B is created, containing 1000 storage units, to store the cycle time of the lifting chain in automatic mode for a single acquisition from storage A. After each cycle, the data in A is transferred to B[X] for sequential saving, completing the memory learning process. B[X] represents the Xth storage unit in storage area B. This memory learning process can record the cycle time of the lifting chain in normal mode 1000 times. These 1000 cycle times are used as automatic positioning parameters for the lifting chain and stored sequentially in storage area B.
[0049] The specific runtime for anomaly removal is as follows:
[0050] In automatic operation mode, a normal operating cycle time is defined as the difference between three consecutive running cycles within 100ms.
[0051] The latest single-run cycle time needs to be referenced from the previous two run cycle times. After determining that it is a normal cycle time, a normal signal F is generated. The rising edge of F triggers the data in A to be transferred to the storage area B, and the storage area pointer is incremented by 1 to point to the storage for the next single-run cycle time.
[0052] If no F signal is generated during a cycle of the lifting chain, the cycle time is considered invalid, and the memory pointer remains unchanged to ensure that the data in each memory area B is continuous and valid.
[0053] The intelligent positioning control of the chain elevator is based on its normal operating state. Normal operating state refers to the stable time taken for the chain hook to automatically complete one cycle from low to high position within the normal operating conditions of the electromechanical equipment in the chain elevator system. For example, the automatic cycle time of the heating furnace lifting chain is 15 seconds, with an error within ±100ms. According to equipment maintenance experience data, the failure rate of the electromechanical components in the chain elevator is very low; the number of failures will not exceed 3 within 5 years.
[0054] Assuming the electromechanical equipment is in normal condition, the single operating cycle time can reflect its normal operating status. A large number of operating cycle times strung together can reflect its normal operating trajectory. By calling up the automatic operating time cycle under its status one by one to control the positioning of the lifting chain, its normal operating trajectory can be reproduced and a stable control effect can be obtained.
[0055] In step 2, the single-run cycle time of memory area B is read one by one through pointer addressing. At the end of each automatic run of the lifting chain, the next single-run cycle time is transmitted to the control parameter storage unit C to complete the update of the single-run cycle time in C.
[0056] After the lifting chain starts running, it begins to count and accumulate its running time. The accumulated value is compared with the single running cycle time in C. When the accumulated value is greater than the single running cycle time in C, a stop command is issued. Intelligent positioning control of the lifting chain's automatic operation mode is completed without relying on the positioning of switch quantity sensors or encoders.
[0057] Pointer addressing is a method of reading and writing to memory areas through addresses in programming. Position control refers to the process by which a device performs a specific action when it reaches a certain position, such as a stop position, where the device stops upon reaching the stop position.
[0058] The intelligent positioning control of a chain hoist relies on the normal operation of its electromechanical equipment. In case of equipment malfunction, using the previously normal cycle time for positioning may result in incomplete or excessive positioning, requiring manual intervention. Manual intervention involves selecting the hoist's correction mode, with the PLC program outputting a brake release command to ensure the motor brake is always open. This forces the hoist chain hook back to its original position, and the hoist is then positioned according to a fixed time interval. Once the equipment returns to normal, the system switches back to intelligent positioning mode.
[0059] "Insufficient positioning" means that the equipment fails to reach the set position when it ends its operation; "excessive positioning" means that the equipment exceeds the set position when it ends its operation.
[0060] This invention provides four control modes for the chain elevator: intelligent positioning control mode, manual intervention mode, manual operation mode, and intelligent learning mode. During production, the chain elevator is primarily controlled by intelligent positioning, supplemented by manual intervention and manual operation modes. When changes occur in the positioning time due to changes in normal operating conditions, it needs to operate in learning mode. Operating in learning mode requires the temporary installation of a switch signal sensor for positioning.
[0061] Manual intervention and manual operation modes are manual; all others are automatic. In manual mode, equipment actions require manual button operation to trigger, while in automatic mode, equipment actions are controlled through feedback signals from associated devices or sensors.
[0062] In intelligent learning mode, the chain hoist's positioning is controlled by a switch signal sensor. Temporary cooling equipment such as a human-operated fan is installed on-site, and a fixed sensor bracket and on-site terminal box facilitate temporary installation of the switch signal sensor. Intelligent learning mode is only used when equipment operating conditions change. Due to its low frequency of use and short duration, it avoids the negative impact of high-temperature and dusty environments on the hoist's control system while ensuring intelligent learning of positioning parameters.
[0063] The field terminal box serves as a transfer station between the main power room control cabinet or distribution cabinet and the field equipment. The main power room control cable or power cable is connected to the upper end of the terminal block inside the terminal box, and the field equipment cable is connected to the lower end of the terminal block, which facilitates the connection between the field equipment and the main power room.
[0064] A smart positioning system for a chain elevator in a heating furnace, comprising:
[0065] The acquisition module is used to acquire the cycle time of a large number of single runs of the chain hoist under normal working conditions, remove abnormal running times, and save the cycle time of each single run in sequence.
[0066] The intelligent positioning module is used to read and save the single running cycle time one by one. After each lifting chain starts running, it starts to count and accumulate its running time, compares the accumulated value with the read single running cycle time, and issues a stop command when the accumulated value is greater than the read single running cycle time to control the lifting chain to stop, thereby realizing intelligent positioning control.
[0067] The manual intervention module is used when the chain elevator malfunctions and the positioning is not accurate or is over-positioned when the saved single operation cycle time is used for positioning. Manual intervention is required to correct the situation and force the chain elevator back to its original position. The chain elevator is then positioned and controlled according to a fixed time. Once the chain elevator returns to normal, it switches back to intelligent positioning control.
[0068] The learning mode module is used when the single-run cycle time of the chain hoist changes under normal operating conditions. In learning mode, a switch signal sensor needs to be temporarily installed to locate the hoist chain. The learning mode reacquires the cycle time of a large number of single runs of the hoist chain under normal operating conditions. After eliminating abnormal running times, the reacquired single-run cycle times are saved in sequence, and the system switches back to intelligent positioning control.
[0069] A computer device includes a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the above-described intelligent positioning method for a heating furnace chain elevator.
[0070] A computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the above-described intelligent positioning method for a heating furnace chain elevator.
[0071] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.
Claims
1. A method for intelligent positioning of a chain elevator for a heating furnace, characterized in that, By learning and memorizing the automatic operation cycle time of a large number of lift chains, the normal state control of the lift chain is replicated and reproduced based on the memorized operation cycle time, and the lift chain is intelligently positioned and controlled based on the replicated operation cycle time. Specifically, the following steps are included: Step 1. Obtain the cycle time of a large number of single runs of the chain hoist under normal working conditions, remove abnormal running times, and save the cycle time of each single run in sequence; Step 2. Read the single-run cycle time saved in Step 1 one by one. After each hoist chain starts running, start counting and accumulating its running time. Compare the accumulated value with the read single-run cycle time. When the accumulated value is greater than the read single-run cycle time, issue a stop command to control the hoist chain to stop, thereby realizing intelligent positioning control. Step 3. When the chain elevator malfunctions and the saved single-run cycle time is used for positioning, it may result in inaccurate or excessive positioning. Manual intervention is required to correct this. After forcing the chain elevator back to its original position, the chain elevator is positioned and controlled according to a fixed time. Once the chain elevator returns to normal, switch back to the intelligent positioning control in Step 2. Step 4. When the single-run cycle time of the chain hoist changes under normal operating conditions, it needs to be run in learning mode. The learning mode requires the temporary installation of a switch signal sensor to locate the hoist chain, and to reacquire the cycle time of a large number of single runs of the hoist chain under normal operating conditions. After eliminating abnormal running times, the reacquired single-run cycle times are saved in sequence, and the system switches back to the intelligent positioning control in step 2. In step 1, obtaining the single operation cycle time specifically involves obtaining the cycle time of one cycle of the hoisting chain in the original switch sensor positioning or encoder positioning control mode of the chain hoist, and storing it in a single-update storage unit A. Create a storage area B. After each week of operation, transfer the data from A to B[X] for sequential saving to complete the memory learning process. B[X] represents the Xth storage unit in storage area B. The specific runtime for anomaly removal is as follows: In automatic operation mode, the time difference of three consecutive operation cycles within 100ms is considered to be the normal operation cycle time. The latest single-run cycle time needs to be referenced from the previous two run cycle times. After determining that it is a normal cycle time, a normal signal F is generated. The rising edge of F triggers the data in A to be transferred to the storage area B, and the storage area pointer is incremented by 1 to point to the storage for the next single-run cycle time. If no F signal is generated during a cycle of the lifting chain, the cycle time is considered invalid, and the memory pointer remains unchanged to ensure that the data in each memory area B is continuous and valid.
2. The intelligent positioning method for a chain elevator in a heating furnace according to claim 1, characterized in that, The normal operating condition of a chain hoist means that the chain hook can run automatically from low to high position for one cycle in a stable manner. According to equipment maintenance experience data, the failure rate of the electromechanical parts of the chain hoist is very low, and the number of failures will not exceed 3 within 5 years.
3. The intelligent positioning method for a chain elevator in a heating furnace according to claim 1, characterized in that, In step 2, the single-run cycle time of memory area B is read one by one through pointer addressing. When the lifting chain finishes each automatic run, the next single-run cycle time is transmitted to the control parameter storage unit C to update the single-run cycle time in C. After the lifting chain starts running, it begins to count and accumulate its running time. The accumulated value is compared with the single running cycle time in C. When the accumulated value is greater than the single running cycle time in C, a stop command is issued. Intelligent positioning control of the lifting chain's automatic operation mode is completed without relying on the positioning of switch quantity sensors or encoders.
4. An intelligent positioning system for a chain elevator in a heating furnace, characterized in that, include: The acquisition module is used to acquire the cycle time of a large number of single runs of the chain hoist under normal working conditions, remove abnormal running times, and save the cycle time of each single run in sequence. The intelligent positioning module is used to read and save the single running cycle time one by one. After each lifting chain starts running, it starts to count and accumulate its running time, compares the accumulated value with the read single running cycle time, and issues a stop command when the accumulated value is greater than the read single running cycle time to control the lifting chain to stop, thereby realizing intelligent positioning control. The manual intervention module is used when the chain elevator malfunctions and the positioning is not accurate or is over-positioned when the saved single operation cycle time is used for positioning. Manual intervention is required to correct the situation and force the chain elevator back to its original position. The chain elevator is then positioned and controlled according to a fixed time. Once the chain elevator returns to normal, it switches back to intelligent positioning control. The learning mode module is used when the single-run cycle time of the chain hoist changes under normal operating conditions. It needs to run in learning mode. The learning mode requires the temporary installation of a switch signal sensor to locate the hoist chain, reacquire the cycle time of a large number of single runs of the hoist chain under normal operating conditions, eliminate abnormal running times, save the reacquired single-run cycle times in sequence, and switch back to intelligent positioning control. The specific process of obtaining the single operation cycle time is as follows: obtain the cycle time of one cycle of the hoisting chain in the original switch sensor positioning or encoder positioning control mode of the chain hoist, and store it in a single-update storage unit A. Create a storage area B. After each week of operation, transfer the data from A to B[X] for sequential saving to complete the memory learning process. B[X] represents the Xth storage unit in storage area B. The specific runtime for anomaly removal is as follows: In automatic operation mode, the time difference of three consecutive operation cycles within 100ms is considered to be the normal operation cycle time. The latest single-run cycle time needs to be referenced from the previous two run cycle times. After determining that it is a normal cycle time, a normal signal F is generated. The rising edge of F triggers the data in A to be transferred to the storage area B, and the storage area pointer is incremented by 1 to point to the storage for the next single-run cycle time. If no F signal is generated during a cycle of the lifting chain, the cycle time is considered invalid, and the memory pointer remains unchanged to ensure that the data in each memory area B is continuous and valid.
5. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the intelligent positioning method for a heating furnace chain elevator as described in any one of claims 1-3.
6. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the intelligent positioning method for a heating furnace chain elevator as described in any one of claims 1-3.