A two-stage process control system and method for a 20-roll rolling mill

Abstract

This invention discloses a two-stage process control system and method for a 20-roll rolling mill, belonging to the field of cold-rolled strip steel production control technology in the metallurgical industry. It serves as a link between the primary basic automation system and the tertiary production management system. The main functions of this system include: material tracking, rolling procedures, roll management, production management, parameter management, and auxiliary functions. This invention can provide precise setpoints for the primary basic automation system based on the strip condition and mill status, thereby improving the yield and productivity of the 20-roll rolling mill.

Description

Technical Field

[0001] This invention belongs to the field of cold-rolled strip steel production control technology in the metallurgical industry, and more specifically, relates to a two-stage process control system and method for a twenty-roll mill. Background Technology

[0002] The 20-roll mill is a core unit and key component of high-end strip steel cold-rolling production lines, and is receiving increasing market attention. The secondary process control system of the 20-roll mill is a crucial part of the mill's control system, serving as the link between the primary basic automation system and the tertiary production management system. It is primarily responsible for production data setting, data processing and storage, material tracking, and production performance management. The secondary process control system possesses powerful computing and data analysis capabilities, enabling it to promptly detect and respond to changes in the condition of the incoming strip steel and the mill's own status, providing more accurate setpoints for the basic automation system. The secondary process control system can improve the mill's yield and product quality, aligning with the current development trend of the cold-rolled strip steel market shifting from quantitative expansion to qualitative improvement. Summary of the Invention

[0003] To address the aforementioned deficiencies or improvement needs of existing technologies, this invention proposes a two-stage process control system and method for a 20-roll rolling mill, serving as a connecting link between the primary basic automation system and the tertiary production management system. Its main functions include: material tracking, rolling schedule, roll management, production management, parameter management, and auxiliary functions. This invention can provide precise setpoints for the primary basic automation system based on strip condition and mill status, thereby improving the yield and productivity of the 20-roll rolling mill unit.

[0004] To achieve the above objectives, according to one aspect of the present invention, a two-level process control system for a 20-roll mill is provided, which serves as a link between a primary basic automation system and a tertiary production management system. The control system includes: a material tracking module, a rolling procedure module, a roll management module, a production management module, a parameter management module, and an auxiliary function module.

[0005] The material tracking module is used to track the steel coils after the information of the steel coils to be rolled is transmitted from the three-level production management system to the two-level process control system and a new raw material steel coil record is generated in the production plan. When the steel coils to be rolled enter the uncoiler, the module provides a set of set values ​​for the steel coils to be rolled by means of table lookup or model calculation. After checking that there are no errors, the module sends the set values ​​to the first-level basic automation system. During the rolling process, the two-level process control system continuously collects measured values ​​from the first-level basic automation system.

[0006] The rolling procedure module is used to generate a set of set values ​​for all steel coils entering the secondary process control system;

[0007] The roll management module is used to select the appropriate rolls using a roll matching model if roll replacement is required during the rolling process.

[0008] The production management module is used to generate a production performance record and a production report record for the steel coil to be rolled after the rolling process is completed.

[0009] The parameter management module is used by the self-learning model to optimize model coefficients;

[0010] The auxiliary function module is used to cancel the tracking of the steel coil to be rolled after rolling is completed, and at the same time save the measured value and set value of the steel coil to the database.

[0011] In some alternative implementations, the material tracking module includes a steel coil tracking unit and an emulsion spraying unit;

[0012] The coil tracking unit is used to track, identify, and display the position of the coil on the rolling mill production line. When the coil to be rolled is detected on the uncoiler, tracking of the coil to be rolled begins, and a set of set values ​​is generated for the coil to be rolled and sent to the primary basic automation system. When the coil to be rolled is detected on the rolling mill, the measured values ​​are obtained from the primary basic automation system. When the coil to be rolled is detected on the exit saddle, the production result data is saved and uploaded to the tertiary production management system, and the tracking of the coil to be rolled is canceled. During the coil tracking process, the unit displays information including thickness, tension, temperature, strip shape, rolling force, strip length, and coil diameter.

[0013] The emulsion spraying unit is used to display the set value and actual value of each emulsion spraying zone.

[0014] In some optional implementations, the rolling procedure module includes a procedure setting unit, a rolling procedure library unit, and a strategy setting library unit;

[0015] The procedure setting unit is used to generate a set of settings for all steel coils entering the secondary process control system. The settings include rolling procedure, strip shape setting, and emulsion setting. The rolling procedure settings include inlet thickness, outlet thickness, width, reduction, reduction rate, total reduction rate, rolling speed, inlet tension, outlet tension, forward slip, starting rolling force, steady-speed rolling force, transmission torque, uncoiling power, coiling power, and main motor power. The strip shape settings include the amount of intermediate roll shifting, ASU reduction, and target curve. The emulsion settings include the strip outlet set temperature, total emulsion injection flow rate, and flow rate of each zone.

[0016] The rolling procedure library unit is used to provide a set of standard setting values ​​for all steel grades based on experience and model calculations before the secondary process control system is put into use. After the secondary process control system is put into use, the standard setting values ​​are modified. If there are new steel grades, the corresponding standard setting values ​​are added to the rolling procedure library unit.

[0017] The strategy setting library unit is used to serve model calculation, including the parameters required for model calculation, and will select the corresponding strategy for calculation when calling the model.

[0018] In some optional implementations, the setpoints are generated by retrieving corresponding standard setpoints from the rolling schedule library unit based on the steel grade, total number of passes, raw material thickness, raw material width, and finished product thickness of the steel coil. If no corresponding standard setpoint is found in the rolling schedule library unit, the setpoints are calculated by calling the rolling force and energy parameter model, the strip shape model, and the emulsion model. Whether the setpoints are obtained by looking up tables or by calculation, some setpoints can be modified to obtain the final setpoints ready for issuance.

[0019] In some optional implementations, the roll management module includes a roll allocation unit, a roll storage unit, and a roll history unit;

[0020] The roll matching unit is used to provide the correct roll system configuration for the 20-roll mill and the appropriate adjustment amount for the backing rolls by calling the roll matching model, so as to ensure that the mill does not interfere and can adjust the roll gap to the required value.

[0021] The roll storage unit is used to manage available rolls and provide suitable rolls for the rolling mill;

[0022] The roll history unit is used to view the historical records of used rolls and export roll history reports.

[0023] In some alternative implementations, the roll matching unit is used to select the backing roll, the second intermediate roll, and the first intermediate roll; calculate the range of work rolls and select appropriate work rolls; determine whether the roll system interferes, and if interference exists, calculate the adjustment amount set value of the backing roll.

[0024] In some optional implementations, the production management module includes a production planning unit, a production performance unit, a production report unit, and a downtime record unit;

[0025] The production planning unit is used to display the steel coil information in the secondary process control system;

[0026] The production performance unit is used to display the raw material information, finished product information and set values ​​of the steel coils that have been produced, and can also select steel coils for self-learning.

[0027] The production report unit is used to view the quality, quantity, energy consumption, and process data of the steel coils that have been produced, and to export reports for single steel coils and multiple steel coils.

[0028] The shutdown recording unit is used to view shutdown record information during the rolling process.

[0029] In some optional implementations, the parameter management module includes a configuration parameter unit, a model coefficient unit, and a learning coefficient unit;

[0030] The configuration parameter unit is used to provide unchangeable parameters, including unit parameters, roll configuration parameters, rolling torque model limit coefficient, short-term self-learning model limit coefficient, and loss torque parameters;

[0031] The model coefficient unit is used to provide sub-models of the rolling force energy parameter model, including the yield strength model, friction coefficient model and rolling torque correction model, and to continuously update the model coefficients.

[0032] The learning coefficient unit is used to provide self-learning coefficients for rolling force, transmission torque, and forward slip, and to continuously update the self-learning coefficients.

[0033] In some optional implementations, the auxiliary function module includes a team management unit and an operation log unit;

[0034] The work group management unit is used to generate work schedules for each work group in the workshop.

[0035] The operation log unit is used to automatically record manual operations on the secondary process control system, including data modification, deletion, addition, import and export operations, but excluding operations that do not cause data changes.

[0036] According to another aspect of the present invention, a two-stage process control method for a 20-roll mill is provided, comprising:

[0037] When the information of the steel coil to be rolled is transmitted from the three-level production management system to the two-level process control system, a new raw material steel coil record is generated in the production plan.

[0038] When the steel coil to be rolled enters the uncoiler, the secondary process control system begins to track the steel coil to be rolled. It provides a set of set values ​​for the steel coil to be rolled by means of table lookup or model calculation. After manual inspection and verification, the set values ​​are sent to the primary basic automation system.

[0039] During the rolling process, the secondary process control system continuously collects measured values ​​from the primary basic automation system and uses them to optimize the model coefficients of the self-learning model.

[0040] Meanwhile, if it is necessary to change the rolls during the rolling process, a roll matching model is required to select the appropriate rolls.

[0041] After rolling is completed, the tracking of the steel coil to be rolled is cancelled, and the measured value and set value data of the steel coil are saved to the database.

[0042] At the same time, after rolling is completed, the secondary process control system generates a production performance record and a production report record for the steel coil to be rolled.

[0043] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects:

[0044] This invention serves as a link between the primary basic automation system and the tertiary production management system. Its main functions include: material tracking, rolling procedures, roll management, production management, parameter management, and auxiliary functions. This invention can provide precise setpoints for the primary basic automation system based on the strip condition and mill status, thereby improving the yield and productivity of a 20-roll mill. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the structure of a two-level process control system provided in an embodiment of the present invention;

[0046] Figure 2 This is a schematic diagram of a two-stage process control method provided in an embodiment of the present invention. Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0048] This invention provides a two-stage process control system for a 20-roll rolling mill, serving as a link between the primary basic automation system and the tertiary production management system. The system's main functions include: material tracking, rolling schedule, roll management, production management, parameter management, and auxiliary functions. This invention can provide precise setpoints to the primary basic automation system based on strip condition and mill status, thereby improving the yield and productivity of the 20-roll rolling mill unit.

[0049] Depend on Figure 1 The functions of the secondary system include:

[0050] Material tracking includes two functions: coil tracking and emulsion spraying. (1) Coil tracking identifies and displays the position of the coil on the rolling mill production line, thereby triggering the corresponding function block. When the secondary system identifies the coil on the uncoiler, it starts tracking the coil and generates a set of set values ​​for the coil and sends them to the primary system; when the secondary system identifies the coil on the rolling mill, it obtains the measured values ​​from the primary system; when the secondary system identifies the coil on the exit saddle, it saves the production result data and uploads it to the tertiary system, and cancels the tracking of the coil. Coil tracking also displays some important process information, including thickness, tension, temperature, strip shape, rolling force, strip length, coil diameter, etc. (2) Emulsion spraying mainly displays the set values ​​and actual values ​​of each emulsion spraying zone. This function is particularly important when rolling grain-oriented silicon steel.

[0051] The rolling schedule includes three functions: schedule setting, rolling schedule library, and strategy setting library. (1) Schedule setting generates a set of settings for all steel coils entering the secondary system. The settings include three parts: rolling schedule, strip shape setting, and emulsion setting. The rolling schedule settings include inlet thickness, outlet thickness, width, reduction, reduction rate, total reduction rate, rolling speed, inlet tension, outlet tension, forward slip, starting rolling force, steady speed rolling force, transmission torque, uncoiling power, coiling power, and main motor power; the strip shape settings include the amount of intermediate roll shifting, ASU reduction, and target curve; the emulsion settings include the strip outlet set temperature, total emulsion injection flow rate, and flow rate of each zone. The generation of the set value is based on the steel grade, total number of passes, raw material thickness, raw material width and finished product thickness of the steel coil. The corresponding standard set value is retrieved from the rolling procedure library. If there is no corresponding standard set value in the rolling procedure library, the rolling force and energy parameter model, plate shape model and emulsion model are called to calculate the set value. Whether the set value is obtained by looking up the table or by calculation, the process operator can also modify some of the set values ​​to obtain the final set value to be issued. (2) Before the secondary system is put into use, the rolling procedure library provides a set of standard set values ​​for all steel grades based on experience and model calculation. After the secondary system is used, the process operator can modify the standard set values. If there is a new steel grade, the corresponding standard set value can also be added to the rolling procedure library. (3) The strategy setting library serves the model calculation and mainly includes some parameters necessary for the model calculation. When calling the model, the corresponding strategy will be selected for calculation.

[0052] Roll management includes three functions: roll allocation, roll library, and roll history. (1) Roll allocation is to provide the correct roll system configuration for a 20-roll mill by calling the roll allocation model and to provide appropriate adjustment for the backing rolls, ensuring that the mill does not interfere and that the roll gap can be adjusted to the required value. The main steps are as follows: First, select the backing roll, the second intermediate roll, and the first intermediate roll; second, calculate the range of work rolls and select appropriate work rolls; third, determine whether the roll system interferes; fourth, calculate the adjustment setting value of the backing rolls. (2) The roll library manages the available rolls and provides appropriate rolls for the mill. (3) The roll history allows you to view the historical records of used rolls and export roll history reports.

[0053] Production management includes four functions: production planning, production performance, production reports, and downtime records. (1) Production planning displays steel coil information from the secondary system. Steel coils are generally imported from the tertiary system, but sometimes operators manually input them. (2) Production performance displays raw material information, finished product information, and set values ​​for steel coils that have been produced. Steel coils can also be selected for self-learning. (3) Production reports allow you to view information such as the quality, quantity, energy consumption, and process data of steel coils that have been produced. Reports for single steel coils and multiple steel coils can also be exported. (4) Downtime records allow you to view downtime information during the rolling process. Reasons for downtime include roll changing, strip breakage, and others.

[0054] Parameter management includes configuration parameters, model coefficients, and learning coefficients. (1) Configuration parameters are some unchangeable parameters, including unit parameters, roll configuration parameters, rolling torque model limit coefficients, short-term self-learning model limit coefficients, loss torque parameters, etc. (2) Model coefficients are some sub-models of the rolling force-energy parameter model, including yield strength model, friction coefficient model, and rolling torque correction model, etc. The model coefficients are constantly updated. (3) Learning coefficients are the self-learning coefficients of rolling force, transmission torque, and forward slip, and the self-learning coefficients are constantly updated.

[0055] The auxiliary functions include team management and operation logs. (1) Team management generates a shift schedule for each team in the workshop. (2) The operation log automatically records the operation records of the operator on the secondary system, including data modification, deletion, addition, import and export operations, but does not include operations that do not cause data changes (such as viewing details, searching, etc.).

[0056] Depend on Figure 2 The control method for the secondary system is:

[0057] (1) When the information of the steel coil to be rolled is transferred from the third-level system to the second-level system, a new raw material steel coil record is generated in the production plan; (2) When the steel coil to be rolled enters the uncoiler, the second-level system starts to track the steel coil and provides a set of set values ​​for the steel coil by means of table lookup or model calculation. After manual inspection and verification, the set values ​​are sent to the first-level system; (3) During the rolling process, the second-level system continuously collects measured values ​​from the first-level system and uses them for the self-learning model to optimize the model coefficients; (4) At the same time, if it is necessary to change the rolls during the rolling process, the roll matching model is used to select the appropriate rolls; (5) After the rolling is completed, the tracking of the steel coil is canceled, and the measured values ​​and set value data of the steel coil are saved to the database; (6) At the same time, after the rolling is completed, the second-level system will generate a production performance record and a production report record for the steel coil.

[0058] It should be noted that, depending on the implementation needs, the various steps / components described in this application can be broken down into more steps / components, or two or more steps / components or parts of the operation of steps / components can be combined into new steps / components to achieve the purpose of this invention.

[0059] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A two-stage process control system for a 20-roll rolling mill, serving as a link between a primary basic automation system and a tertiary production management system, characterized in that... The control system includes: a material tracking module, a rolling procedure module, a roll management module, a production management module, a parameter management module, and an auxiliary function module; The material tracking module is used to track the steel coils after the information of the steel coils to be rolled is transmitted from the three-level production management system to the two-level process control system and a new raw material steel coil record is generated in the production plan. When the steel coils to be rolled enter the uncoiler, the module provides a set of set values ​​for the steel coils to be rolled by means of table lookup or model calculation. After checking that there are no errors, the module sends the set values ​​to the first-level basic automation system. During the rolling process, the two-level process control system continuously collects measured values ​​from the first-level basic automation system. The rolling procedure module is used to generate a set of set values ​​for all steel coils entering the secondary process control system; The roll management module is used to select the appropriate rolls using a roll matching model if roll replacement is required during the rolling process. The production management module is used to generate a production performance record and a production report record for the steel coil to be rolled after the rolling process is completed. The parameter management module is used by the self-learning model to optimize model coefficients; The auxiliary function module is used to cancel the tracking of the steel coil to be rolled after rolling is completed, and at the same time save the measured value and set value of the steel coil to the database. The rolling procedure module includes a procedure setting unit; The program setting unit is used to generate a set of settings for all steel coils entering the secondary process control system. The settings include rolling program, strip shape settings, and emulsion settings. The rolling program settings include inlet thickness, outlet thickness, width, reduction, reduction rate, total reduction rate, rolling speed, inlet tension, outlet tension, forward slip, starting rolling force, steady-speed rolling force, transmission torque, uncoiling power, coiling power, and main motor power. The strip shape settings include the amount of intermediate roll shifting, ASU reduction, and target curve. The emulsion settings include the strip outlet set temperature, total emulsion injection flow rate, and flow rate of each zone.

2. The control system according to claim 1, characterized in that, The material tracking module includes a steel coil tracking unit and an emulsion spraying unit; The coil tracking unit is used to track, identify, and display the position of the coil on the rolling mill production line. When the coil to be rolled is detected on the uncoiler, it starts tracking the coil and generates a set of set values ​​for the coil to be rolled and sends them to the primary basic automation system. When the steel coil to be rolled is detected on the rolling mill, the measured value is obtained from the primary basic automation system; When the steel coil to be rolled is identified on the exit saddle, the production result data is saved and uploaded to the three-level production management system. At the same time, the tracking of the steel coil to be rolled is canceled. During the steel coil tracking process, the thickness, tension, temperature, strip shape value, rolling force, strip length and coil diameter are displayed. The emulsion spraying unit is used to display the set value and actual value of each emulsion spraying zone.

3. The control system according to claim 2, characterized in that, The rolling procedure module also includes a rolling procedure library unit and a strategy setting library unit; The rolling procedure library unit is used to provide a set of standard setting values ​​for all steel grades based on experience and model calculations before the secondary process control system is put into use. After the secondary process control system is put into use, the standard setting values ​​are modified. If there are new steel grades, the corresponding standard setting values ​​are added to the rolling procedure library unit. The strategy setting library unit is used to serve model calculation, including the parameters required for model calculation, and will select the corresponding strategy for calculation when calling the model.

4. The control system according to claim 3, characterized in that, The generation of the set values ​​involves retrieving the corresponding standard set values ​​from the rolling procedure library unit based on the steel grade, total number of passes, raw material thickness, raw material width, and finished product thickness of the steel coil. If no corresponding standard set value is found in the rolling procedure library unit, the rolling force and energy parameter model, plate shape model, and emulsion model are called to calculate the set values. Whether the set values ​​are obtained by looking up tables or by calculation, some set values ​​can be modified to obtain the final set values ​​ready for issuance.

5. The control system according to claim 4, characterized in that, The roll management module includes a roll allocation unit, a roll library unit, and a roll history unit; The roll matching unit is used to provide the correct roll system configuration for the 20-roll mill and the appropriate adjustment amount for the backing rolls by calling the roll matching model, so as to ensure that the mill does not interfere and can adjust the roll gap to the required value. The roll storage unit is used to manage available rolls and provide suitable rolls for the rolling mill; The roll history unit is used to view the historical records of used rolls and export roll history reports.

6. The control system according to claim 5, characterized in that, The roller matching unit is used to select the backing roller, the second intermediate roller, and the first intermediate roller; calculate the range of the working rollers and select the appropriate working rollers; determine whether the roller system interferes, and if interference exists, calculate the adjustment amount setting value of the backing roller.

7. The control system according to claim 6, characterized in that, The production management module includes a production planning unit, a production performance unit, a production report unit, and a downtime record unit; The production planning unit is used to display the steel coil information in the secondary process control system; The production performance unit is used to display the raw material information, finished product information and set values ​​of the steel coils that have been produced, and can also select steel coils for self-learning. The production report unit is used to view the quality, quantity, energy consumption, and process data of the steel coils that have been produced, and to export reports for single steel coils and multiple steel coils. The shutdown recording unit is used to view shutdown record information during the rolling process.

8. The control system according to claim 7, characterized in that, The parameter management module includes a configuration parameter unit, a model coefficient unit, and a learning coefficient unit; The configuration parameter unit is used to provide unchangeable parameters, including unit parameters, roll configuration parameters, rolling torque model limit coefficient, short-term self-learning model limit coefficient, and loss torque parameters; The model coefficient unit is used to provide sub-models of the rolling force energy parameter model, including the yield strength model, friction coefficient model and rolling torque correction model, and to continuously update the model coefficients. The learning coefficient unit is used to provide self-learning coefficients for rolling force, transmission torque, and forward slip, and to continuously update the self-learning coefficients.

9. The control system according to claim 8, characterized in that, The auxiliary function module includes a team management unit and an operation log unit; The work group management unit is used to generate work schedules for each work group in the workshop. The operation log unit is used to automatically record manual operations on the secondary process control system, including data modification, deletion, addition, import and export operations, but excluding operations that do not cause data changes.

10. A method for controlling the secondary process of a 20-roll mill based on the secondary process control system of any one of claims 1 to 9, characterized in that, include: When the information of the steel coil to be rolled is transmitted from the three-level production management system to the two-level process control system, a new raw material steel coil record is generated in the production plan. When the steel coil to be rolled enters the uncoiler, the secondary process control system begins to track the steel coil to be rolled. It provides a set of set values ​​for the steel coil to be rolled by means of table lookup or model calculation. After manual inspection and verification, the set values ​​are sent to the primary basic automation system. During the rolling process, the secondary process control system continuously collects measured values ​​from the primary basic automation system and uses them to optimize the model coefficients of the self-learning model. Meanwhile, if it is necessary to change the rolls during the rolling process, a roll matching model is required to select the appropriate rolls. After rolling is completed, the tracking of the steel coil to be rolled is cancelled, and the measured value and set value data of the steel coil are saved to the database. At the same time, after rolling is completed, the secondary process control system generates a production performance record and a production report record for the steel coil to be rolled.

Images