Method for rapid emergency handling of faults in a high line packer

Abstract

The application discloses a kind of high line packing machine fast emergency processing failure method, belong to packing machine technical field, solve the technical problem of low efficiency of current processing high line packing machine failure, method is: by field measurement, comparison, comprehensive experimental measurement comparison design optimal ethernet line, and in high line electrical room complete the installation of PLC program control software of industrial computer, man-machine control picture software;The use of high line packing machine's electric control system PLC program and HMI man-machine interface engineer station is optimized, realizes running main station anti-interference;Visual optimization is carried out to input and output signal of core program;Establish the program source file based on the core action link of high line packing machine and visual logic comparison system;According to program analysis and field action time sequence comparison design coil position failure emergency program;In program, the opening degree of proportional valve is designed to force program;Establish packing machine high-speed data acquisition system;Increase emergency operation control system in high line electrical room.

Description

A method for rapid emergency troubleshooting of high-speed wire packing machines Technical Field

[0001] This invention relates to the field of baling machine technology, and more specifically, to a method for quickly handling emergency malfunctions in a high-speed wire baling machine. Background Technology

[0002] The baling machine on the high-speed wire rod production line of a steel rolling mill is crucial. As a vital component of the production line, any malfunction of the baling machine necessitates a production shutdown to investigate the cause, as there is no quick method for troubleshooting. This troubleshooting process is always very time-consuming. Furthermore, even after a lengthy investigation, identifying the cause of the malfunction still requires significant time to resolve. Because current technology lacks rapid emergency troubleshooting methods, every baling machine failure leads to prolonged production downtime, resulting in reduced output and a substantial increase in the cost per ton of steel.

[0003] Current methods for handling faults have the following drawbacks:

[0004] 1. When the baling machine malfunctions, there is no quick way to find the fault. Therefore, it is necessary to conduct a thorough inspection of all circuits, all components, and all control systems, which takes a lot of time. This will lead to long-term production interruptions and a significant reduction in output, which will result in a significant increase in the production cost per ton of steel.

[0005] 2. After spending a long time finding the cause of the baling machine malfunction, since there is no quick emergency troubleshooting method, it is necessary to spend a long time dealing with the malfunction, including replacing the wiring, replacing the components, and optimizing the control system. This will also lead to a long production interruption and a significant reduction in output, which in turn will lead to a significant increase in the comprehensive energy medium consumption costs of water, electricity and compressed air per ton of steel at the production site.

[0006] 3. Because there is no method for quickly locating and handling faults in high-speed wire baling machines, deviations may occur in the process of finding the cause of the fault and handling it. This may lead to the replacement of incorrect circuits and components, resulting in wasted costs and a significant increase in the cost of spare parts per ton of steel. Summary of the Invention

[0007] 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 a method for rapid emergency handling of faults in high-speed wire packing machines, which can quickly find faults and quickly handle them in an emergency, thereby ensuring production efficiency.

[0008] The technical solution of this invention is: a method for rapid emergency handling of malfunctions in a high-speed wire packing machine, comprising the following steps:

[0009] Step 1. Establish a fixed engineering station based on communication connection. Design the optimal Ethernet line through on-site measurement, comparison, and comprehensive experimental measurement comparison. Then lay the Ethernet cable, make the network cable connector, and conduct continuity test. In the high-speed line electrical room, complete the installation of PLC program control software and human-machine interface software of industrial control computer.

[0010] Step 2. Design a state-matching anti-interference system, optimize the PLC program of the electrical control system of the high-wire packaging machine and the usage method of the HMI human-machine interface engineering station, disconnect the communication network cable when not in use, and block the industrial control computer to ensure that there is no interference to the main station. And determine the quick connection method through experiments.

[0011] Step 3. Design a core program visualization control system, optimize the input and output signals of all core programs through visualization, verify through on-site point marking and actual operation, and combine the entire process of experimental action to realize the visualization display of the core program, so as to significantly shorten the time for fault cause analysis and handling.

[0012] Step 4. Establish a program source file and visual logic comparison system. Establish a program source file and visual logic comparison system based on the core action links of the high-wire packer. The comparison system mainly consists of a program comparison unit, a clear logic comparison unit, and a gradient connection trigger condition matching unit. By realizing the visual and rapid comparison of the core control links, it is possible to quickly analyze and process abnormal faults.

[0013] Step 5. Design of emergency procedure for coil position failure. Based on the program analysis and on-site action sequence comparison, an emergency procedure for coil position failure is designed. The quantization state of the coil is replaced by the photoelectric switch above the No. 2 pressure plate sensing the quantization state of the coil at a forward distance of 1200mm. When the photoelectric switch fails, it will not cause an accident and can ensure the continuity of production.

[0014] Step Six. Design a rapid fault handling unit for the proportional valve. In the program, design a program to force the opening degree of the proportional valve: "Given LocSpoolRef, LX%, T#LocSpoolRef". The program will automatically calculate the Counts value written to the channel address of the analog output module.

[0015] Counts = (LocSpoolRef + 1.0) * 27648 / 2. Based on the corresponding current setpoint that can be measured between pin D and pin E of the proportional valve connector, the fault point of the proportional valve execution failure of the baler can be quickly located.

[0016] Step 7. Establish a high-speed data acquisition system for the packing machine. First, establish the IBA system, add one engineering station and establish communication, then debug it, sort out all input and output points, and check them one by one with the actual situation on site. After establishing the IBA system, add signals one by one and confirm signal feedback.

[0017] Step 8. Add an emergency operation control system to the control panel. Add an emergency operation control system to the high-speed wire electrical room. The emergency operation control system mainly consists of an industrial control computer, control software, communication connection cable, online program, and online human-machine operation screen. It can realize rapid switching in the event of a failure of the control panel, thereby saving troubleshooting time.

[0018] As a further improvement, in step one, the PLC program control software is Step7 program control software, and the human-machine interface software is InTouch software.

[0019] Furthermore, an Ethernet line refers to the actual selected transmission line from the packaging machine control panel to the high-wire electrical room; continuity testing refers to the process of measuring the continuity between the two ends of a network cable using a network cable continuity testing instrument.

[0020] Furthermore, in step two, the non-use state refers to a specific time state during the normal production rolling process and when the equipment is not in a faulty state; disconnecting the communication network cable means isolating the network cable plug from the industrial control computer's network port; blocking the industrial control computer means encrypting the industrial control computer's login interface.

[0021] Furthermore, in step three, the core program refers to the control program related to the timing of the packing machine's actions, the connection of key steps, and safety interlocks; the input signal refers to the digital or analog signal that is collected, identified, and input into the control system from the field; the output signal refers to the digital or analog signal that is output from the control system to the field actuators; and the full-process operation of the experimental action refers to the preset action timing, and then conducting a full-process action experiment of the packing machine based on signal acquisition and signal feedback verification.

[0022] Furthermore, in step four, the program source file refers to an uncompiled text file written according to certain programming language specifications that is readable by technical personnel. The program source file is written in a programming language. Visual logic comparison refers to converting program statements into visual language logic, thereby achieving quick visual comparison.

[0023] Furthermore, in step five, the coil position fault refers to the deviation between the detected coil position and the actual coil position, which will lead to errors in the associated control sequence; the quantization state of the No. 2 pressure plate forward distance of 1200mm refers to the quantization distance state measured by the encoder; the photoelectric switch is a measuring sensor used to detect the presence or absence of the coil.

[0024] Furthermore, in step six, the opening degree enforcement procedure refers to the ability to accurately execute a preset opening degree through program execution, thereby enabling the detection of relevant states; Counts

[0025] =(LocSpoolRef+1.0)*27648 / 2 is a specific data conversion formula, and the relevant data is converted according to the predetermined formula; pinD and pinE of the proportional valve connector refer to the connection between two specific terminals.

[0026] Furthermore, in step seven, establishing the IBA system refers to installing high-speed data acquisition software in the industrial control computer and associating the signal acquisition points; all input and output points refer to digital input signals, digital output signals, analog input signals, and analog output signals; and verifying each one with the actual situation on site refers to comprehensively verifying the actual action sequence and action logic to ensure the accuracy of the acquired signals.

[0027] Furthermore, in step eight, the emergency operation control system refers to the ability to quickly switch operating units in the event of a communication failure or industrial control computer failure on the packaging machine's operating console, without affecting the packaging timing and logic; the online program refers to a program in normal communication status; and the online human-machine interface refers to an touch control interface in normal communication status.

[0028] Beneficial effects

[0029] Compared with the prior art, the advantages of this invention are as follows:

[0030] 1. Compared with the prior art, the present invention can quickly find the cause of packaging machine failure by intelligently collecting data and signals in all dimensions, as well as big data analysis and intelligent step-by-step tracking throughout the process. At the same time, by using multi-dimensional emergency handling methods, the failure can be handled quickly.

[0031] 2. This invention can quickly find the cause of a fault, quickly handle the fault, avoid misjudgment and incorrect handling of faults, improve production efficiency, and reduce the production cost per ton of steel. Attached Figure Description

[0032] Figure 1 is a flowchart of the present invention. Detailed Implementation

[0033] The present invention will be further described below with reference to specific embodiments shown in the accompanying drawings.

[0034] Referring to Figure 1, a method for rapid emergency handling of malfunctions in a high-speed wire packing machine is characterized by comprising the following steps one through eight:

[0035] Step 1. Establish a fixed engineering station based on communication connection. Design the optimal Ethernet line through on-site measurement, comparison, and comprehensive experimental measurement comparison. Then lay the Ethernet cable, make the network cable connector, and conduct continuity test. In the high-speed line electrical room, complete the installation of PLC program control software and human-machine interface software of industrial control computer.

[0036] The PLC program control software is STEP 7 (i.e., program control software for Siemens PLCs), and the human-machine interface software is InTouch software.

[0037] Ethernet line refers to the actual selected transmission line from the packing machine control panel to the high-wire electrical room; continuity test refers to the process of measuring the continuity between the two ends of a network cable using a network cable continuity tester.

[0038] Step 2. Design a state-matched anti-interference system, optimize the PLC program of the high-wire packaging machine's electrical control system and the usage method of the HMI human-machine interface engineering station to improve efficiency. Disconnect the communication network cable when not in use, and block the industrial control computer to ensure no interference to the main station. Determine a quick connection method through experiments.

[0039] "Non-use state" refers to a specific timeframe during normal production and rolling processes and when the equipment is not malfunctioning. Disconnecting the communication network cable means isolating the network cable plug from the industrial control computer's network port. Blocking the industrial control computer means encrypting its login interface.

[0040] Step 3. Design a core program visualization control system, optimize the input and output signals of all core programs through visualization, verify through on-site point marking and actual operation, and combine the entire process of experimental actions to achieve a visual display of the core programs, thereby significantly shortening the time for fault cause analysis and handling.

[0041] The core program refers to the control program related to the timing of the baler's actions, the connection of key steps, and safety interlocks. Input signals refer to digital or analog signals acquired, identified, and input to the control system from the field. Output signals refer to digital or analog signals output from the control system to the field actuators. The full-process operation of the experimental actions refers to pre-setting the action sequence and then conducting a full-process experiment of the baler's actions based on signal acquisition and feedback verification.

[0042] Step 4. Establish a program source file and visual logic comparison system. Establish a program source file and visual logic comparison system based on the core action links of the high-wire packer. The comparison system mainly consists of a program comparison unit, a clear logic comparison unit, and a gradient connection trigger condition matching unit. By realizing the visual and rapid comparison of the core control links, it is possible to quickly analyze and handle abnormal faults.

[0043] A program source file is an uncompiled text file written according to a specific programming language specification, readable by technical personnel. Program source files are written in a programming language. Visual logic comparison refers to converting program statements into visual language logic, thereby enabling quick and easy comparison.

[0044] Step 5. Design of emergency procedure for coil position failure. Based on the program analysis and on-site action sequence comparison, an emergency procedure for coil position failure is designed. The quantization state of the No. 2 pressure plate (the working pressure plate in the existing baler) is 1200mm forward to replace the photoelectric switch above the No. 2 pressure plate sensing the quantization state of the coil. When the photoelectric switch fails, it will not cause an accident and can ensure the continuity of production.

[0045] A coil position fault refers to a deviation between the detected coil position and the actual coil position, which can lead to errors in the associated control sequence. The quantized state of the 1200mm forward distance of pressure plate 2 refers to the quantized distance measured by the encoder; the movement distance of pressure plate 2 is measured by the encoder. A photoelectric switch is a measuring sensor used to detect the presence or absence of a coil.

[0046] Step Six. Design a rapid fault handling unit for the proportional valve. In the program, design a program to force the opening degree of the proportional valve: "Given LocSpoolRef, LX%, T#LocSpoolRef". The program will automatically calculate the Counts value written to the channel address of the analog output module.

[0047] Counts = (LocSpoolRef + 1.0) * 27648 / 2. Based on the corresponding current setpoint that can be measured between pin D and pin E of the proportional valve connector, the fault point of the proportional valve execution failure of the packing machine can be quickly located.

[0048] The forced opening degree program refers to the ability to precisely execute a preset opening degree through program execution, thereby enabling the detection of related states. Counts = (LocSpoolRef + 1.0) * 27648 / 2 is a specific data conversion formula; related data is converted according to the predetermined formula. The connection between pin D and pin E of the proportional valve connector refers to the connection between two specific wiring terminals.

[0049] Step 7. Establish a high-speed data acquisition system for the packing machine. First, establish the IBA system, add one engineering station and establish communication, then debug it, sort out all input and output points, and check them one by one with the actual situation on site. After establishing the IBA system, add signals one by one and confirm signal feedback.

[0050] Setting up an IBA system involves installing high-speed data acquisition software on an industrial control computer and connecting the signal acquisition points. All input and output points refer to digital input signals, digital output signals, analog input signals, and analog output signals. Verifying each point against the actual field conditions involves comprehensively checking the actual action sequence and logic to ensure the accuracy of the acquired signals.

[0051] Step 8. Add an emergency operation control system to the control panel. Add an emergency operation control system to the high-speed wire electrical room. The emergency operation control system mainly consists of an industrial control computer, control software, communication connection cable, online program, and online human-machine operation screen. It can realize rapid switching in the event of a failure of the control panel, thereby saving troubleshooting time.

[0052] An emergency operation control system refers to a system that can quickly switch operating units in the event of a communication failure or industrial control computer failure on the packaging machine's control panel, without affecting the packaging sequence or logic. An online program refers to a program in a normal communication state; an online human-machine interface refers to an Intouch control interface in a normal communication state.

[0053] This method can quickly identify the causes of various circuit faults, component faults, and control logic faults in the packaging machine, thereby saving a significant amount of time in troubleshooting, increasing the operating rate during the rolling process, improving production efficiency and output, and ultimately reducing the production cost per ton of steel.

[0054] This invention can also enable rapid emergency handling of various circuit faults, component faults, and control logic faults in high-speed wire rod packing machines, thereby saving a lot of fault handling time, increasing hourly output, shift output, and daily output, reducing water consumption, electricity consumption, and compressed air consumption per ton of steel, and thus significantly saving costs.

[0055] This invention can also avoid misjudgment and replacement of good circuits and components during fault handling, thereby avoiding waste of spare parts material costs and significantly saving spare parts material costs.

[0056] 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 rapid emergency troubleshooting of a high-speed wire packing machine, characterized in that, Includes the following steps: Step 1. Establish a fixed engineering station based on communication connection. Through on-site measurement, comparison, and comprehensive experimental measurement comparison, design the optimal Ethernet line, then lay the Ethernet cable, fabricate the cable connectors, and conduct continuity tests. Install the PLC program control software and HMI interface software for the industrial control computer in the high-speed wire rod packaging machine electrical room. Step 2. Design a state-matching anti-interference system. Optimize the usage of the PLC program and HMI interface engineering station of the high-speed wire rod packaging machine's electrical control system. Disconnect the communication network cable when not in use and block the industrial control computer to ensure no interference to the main station. Determine a quick connection method through experiments. Step 3. Design a core program visualization control system. Optimize the visualization of input and output signals for all core programs. Verify through on-site point marking and actual operation, and combine with the full range of experimental actions. The process runs smoothly, thus enabling the visualization of the core program and significantly shortening the time for fault analysis and handling. Step 4: Establish a program source file and visualization logic comparison system. This system, based on the core action links of the high-speed wire rod packer, consists of a program comparison unit, a clear logic comparison unit, and a gradient-type connection trigger condition matching unit. By realizing the visualization and rapid comparison of the core control links, it enables rapid analysis and handling of abnormal faults. Step 5: Design an emergency procedure for coil position faults. Based on program analysis and on-site action sequence comparison, an emergency procedure for coil position faults is designed. The quantization state of the No. 2 pressure plate, which is 1200mm forward, replaces the photoelectric switch above the No. 2 pressure plate sensing the quantization state of the coil. When the photoelectric switch malfunctions, it will not cause an accident and can ensure the continuity of production. Step Six. Design a rapid fault handling unit for the proportional valve. In the program, design a program to force the opening degree of the proportional valve: "Given LocSpoolRef, LX%, T#LocSpoolRef". The program will automatically calculate the Counts value written to the channel address of the analog output module: Counts = (LocSpoolRef + 1.0) * 27648 / 2. Based on the corresponding current setpoint that can be measured between pin D and pin E of the proportional valve connector, the fault point of the proportional valve execution in the baling machine can be quickly located. Step Seven. Establish a high-speed data acquisition system for the baling machine. The system first establishes an IBA system, adds one engineering station and establishes communication, then performs debugging, sorts out all input and output points, and verifies them one by one with the actual situation on site. After establishing the IBA system, signals are added one by one and signal feedback is confirmed. Step 8. Add an emergency operation control system to the control panel. Add an emergency operation control system to the high-speed line electrical room. The emergency operation control system mainly consists of an industrial control computer, control software, communication connection lines, online programs, and online human-machine operation screens. It can realize rapid switching in the event of a failure in the control panel, thereby saving troubleshooting time.

2. The method for rapid emergency handling of faults in a high-speed wire packing machine according to claim 1, characterized in that, In step one, the PLC program control software is Step7 program control software, and the human-machine interface software is InTouch software.

3. The method for rapid emergency handling of faults in a high-speed wire packing machine according to claim 2, characterized in that, Ethernet line refers to the actual selected transmission line from the packing machine control panel to the high-wire electrical room; continuity test refers to the process of measuring the continuity between the two ends of a network cable using a network cable continuity tester.

4. The method for rapid emergency handling of faults in a high-speed wire packing machine according to claim 1, characterized in that, In step two, "non-use state" refers to a specific time state during normal production rolling process and when the equipment is not malfunctioning; "disconnecting the communication network cable" means isolating the network cable plug from the industrial control computer's network port; "blocking the industrial control computer" means encrypting the industrial control computer's login interface.

5. A method for rapid emergency troubleshooting of a high-speed wire packing machine according to claim 1, characterized in that, In step three, the core program refers to the control program related to the timing of the packing machine's actions, the connection of key steps, and safety interlocks; the input signal refers to the digital or analog signal that is collected, identified, and input into the control system from the field; the output signal refers to the digital or analog signal that is output from the control system to the field actuators; the full-process operation of the experimental action refers to the preset action timing, and then conducting a full-process action experiment of the packing machine based on signal acquisition and signal feedback verification.

6. A method for rapid emergency troubleshooting of a high-speed wire packing machine according to claim 1, characterized in that, In step four, the program source file refers to an uncompiled text file written according to certain programming language specifications, which is readable by technical personnel. The program source file is written in a programming language. Visual logic comparison refers to converting program statements into visual language logic, thereby realizing quick visual comparison.

7. A method for rapid emergency troubleshooting of a high-speed wire packing machine according to claim 1, characterized in that, In step five, a coil position fault refers to a deviation between the detected coil position and the actual coil position, which can lead to errors in the associated control sequence. The quantization state of the No. 2 pressure plate forward distance of 1200mm refers to the quantization distance state measured by the encoder; the photoelectric switch is a measuring sensor used to detect the presence or absence of the coil.

8. A method for rapid emergency troubleshooting of a high-speed wire packing machine according to claim 1, characterized in that, In step six, the opening degree forced procedure refers to the precise execution of the preset opening degree through the execution of the program, thereby enabling the detection of related states; Counts=(LocSpoolRef+1.0)*27648 / 2 is a specific data conversion formula, and the relevant data is converted according to the predetermined formula; pinD and pinE of the proportional valve connector refer to the connection between two specific terminals.

9. A method for rapid emergency troubleshooting of a high-speed wire packing machine according to claim 1, characterized in that, In step seven, establishing the IBA system refers to installing high-speed data acquisition software in the industrial control computer and connecting the signal acquisition points; all input and output points refer to digital input signals, digital output signals, analog input signals, and analog output signals; and verifying each one with the actual situation on site refers to comprehensively verifying the actual action sequence and action logic to ensure the accuracy of the acquired signals.

10. A method for rapid emergency handling of faults in a high-speed wire packing machine according to claim 1, characterized in that, In step eight, the emergency operation control system refers to the ability to quickly switch operating units in the event of a communication failure or industrial control computer failure on the packaging machine control panel, without affecting the packaging timing and logic; the online program refers to the program in normal communication status; and the online human-machine interface refers to the touch control interface in normal communication status.

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