A quality control method suitable for thin plate rockwell hardness automatic line

Abstract

The application discloses a quality control method suitable for a thin plate Rockwell hardness automatic line, and relates to the technical field of Rockwell hardness measurement of cold-rolled thin plates. The quality control method suitable for the thin plate Rockwell hardness automatic line is characterized in that: the specific operation is as follows: S1, the measurement method is intelligentized, and an automatic integrated software is connected to a hardness tester PLC, different force value scales of the hardness tester can be remotely controlled, detection rules are sorted out according to national Rockwell hardness measurement standards and product standards, and specifically include: 1) "original generation rule": corresponding historical data according to the grade and product thickness. The quality control method suitable for the thin plate Rockwell hardness automatic line realizes intelligentization of automatic Rockwell hardness measurement of thin plates, writes the inspection rules in the national standards into the automatic measurement system program, forms "original generation rule", "subsequent switching rule" and "intelligent database", and realizes intelligent Rockwell hardness measurement of thin plates with different thicknesses and grades.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cold-rolled sheet Rockwell hardness measurement, in particular to a quality control method suitable for a cold-rolled sheet Rockwell hardness automatic line. BACKGROUND

[0002] The current intelligent technology is integrated into the detection method, and in 2023, Ma Steel introduced the cold-rolled sheet Rockwell hardness automatic detection technology, built the first sheet Rockwell hardness detection automatic line in the detection center, and covered automatic feeding, automatic measurement and automatic archiving. At present, the Rockwell hardness detection automatic line is also applied in other steel enterprises in China, but there are the following problems in actual application: ① The Rockwell hardness measurement method requires that different products use different measurement scales, and there are six measurement scales for surface Rockwell hardness. Most of the automatic Rockwell hardness meters of other steel enterprises only use a fixed measurement scale to execute the automatic process, and when the measurement scale needs to be replaced, manual judgment and manual switching are required; ② The control of the measurement system precision of the Rockwell hardness automatic line has no precedent to refer to, and other steel enterprises still use the same verification method as the single hardness meter, that is, the standard material is placed on the hardness meter measurement platform by manual to check whether the hardness meter measurement state is controlled; ③ The thickness of the hardness standard material is greatly different from the thickness of the product to be measured, and it is not suitable for direct application in the automatic mode.

[0003] The measurement method of the present application realizes the intelligentization of the automatic measurement of the sheet Rockwell hardness, the measurement force value scale is implemented according to the actual product, the measurement precision is guaranteed, and the human error in manual operation is avoided.

[0004] The quality control method of the present application realizes the control of the whole measurement process in the automatic mode, improves the pre-production verification efficiency of each shift, reduces the safety hidden danger of the automatic field, and realizes the cost reduction and efficiency increase by using the self-made internal control sample. SUMMARY

[0005] (I) Technical problems solved

[0006] In view of the deficiencies of the prior art, the present application provides a quality control method suitable for a cold-rolled sheet Rockwell hardness automatic line, which solves the problems existing in the prior art.

[0007] (II) Technical scheme

[0008] In order to achieve the above purpose, the present application is realized by the following technical scheme: a quality control method suitable for a cold-rolled sheet Rockwell hardness automatic line, characterized in that: the specific operation is as follows:

[0009] S1, the intelligentization of the measurement method, the automatic integration software is connected to the hardness tester PLC, the hardness tester different force value scale switching can be remotely controlled, according to the national Rockwell hardness measurement standard and product standard, the detection rules are sorted out, including:

[0010] 1) "original generation rule": according to the grade, product thickness, corresponding historical data, priority is given to the force value to automatically generate corresponding scale and conversion;

[0011] 2) when the measurement value of the automatically selected force value scale exceeds the applicable range specified in the national standard, it is automatically switched according to the "subsequent switching rule", such as the measurement value of the 30T scale exceeding the upper limit of the national standard applicable range, automatically switching to the HRB scale; or the measurement value of the 30T scale exceeding the lower limit of the national standard applicable range, automatically switching to the 15T scale;

[0012] 3) establish a historical database, according to the hardness data (this does not need to be maintained, automatically generated), priority is given to the force value to automatically generate corresponding scale and conversion, which can prevent frequent use of "subsequent switching rule"

[0013] S2, automatic measurement system verification, the specific circumstances are as follows:

[0014] ① Automatic operation area sets hardness control sample special gear, establishes "hardness standard sample or control sample automatic sub-process", realizes comprehensive verification of hardness automatic measurement system, whether controlled or not;

[0015] ② Hardness control sample can be purchased from the platform or self-made internal control sample of similar products.

[0016] ③ Hardness internal control sample should be based on the actual production of steel enterprises, meet the automatic measurement verification range covering product range. When the production detection demand is single, "high value control sample" and "low value control sample" automatic sub-process can be set respectively; when the production detection requirement is multiple, automatic sub-process of different force value scales can be set respectively.

[0017] ④ Before each shift production detection, the control sample process is automatically triggered by the centralized control software. The control sample measurement passes the test, indicating that the automatic line measurement system is controlled and can be put into production. Otherwise, the automatic line is disabled, the software is warned, and manual intervention is reminded to find and analyze the abnormal reason. The software database will stage the real-time measurement value of the control sample and form a trend chart.

[0018] Preferably, in the step S2, ②, the hardness control sample can be purchased from the platform or self-made internal control sample of similar products, and the specific method is as follows:

[0019] Method one: purchase hardness control sample (with certificate) from platform, currently the certificate control sample with the same shape and size as the production product can be purchased from the platform, all are thin gauge round sheet, but the diameter (35mm) is smaller than the production product round sheet diameter (50mm), need to make "ring nest" (attached Figure 1 ), install the purchased hardness control sample into the nest, so that the mechanical hand can be automatically grabbed, automatically sampled and automatically archived.

[0020] Method two: innovative internal control sample production method: select the uniformity and stability of the brand from the production line, such as MAF2 galvanized sheet, as shown in Figure 2 , five sample sheets (Φ50mm) are prepared in cross distribution, and the Rockwell hardness values of sample sheets 2, 3, 4 and 5 are measured by a controlled instrument. 1 is the center sample, and 2, 3, 4 and 5 are satellite samples. If the uniformity of the measurement values of the four samples (firstly, 5-n indents are pressed on the entire test surface of each sample, and then the average hardness values of the 5-n indents of each sample are calculated and sorted, and finally the maximum average value is subtracted from the minimum average value) is less than the maximum allowable difference of the hardness standard block specified in the national standard, the average value of the four samples is taken as the Rockwell hardness of sample 1, and sample 1 is taken as the internal control sample.

[0021] (Three) beneficial effects

[0022] The application provides a quality control method suitable for a thin plate Rockwell hardness automatic line. The quality control method has the following beneficial effects:

[0023] (1) The quality control method suitable for the thin plate Rockwell hardness automatic line realizes intelligentization of thin plate Rockwell hardness automatic measurement, codes the inspection rules in the national standard into the automatic measurement system program, forms "original generation rules", "subsequent switching rules" and "intelligent database", realizes intelligent measurement of thin plates with different thicknesses and brands, greatly improves the accuracy of measurement, and can be popularized in the later period.

[0024] (2) The method realizes the calibration and verification function of the thin plate Rockwell hardness automatic measurement system

[0025] At present, other domestic steel enterprises even if they introduce the Rockwell hardness automatic line, the confirmation method of whether the automatic line measurement system is controlled still adopts the manual verification mode, and the standard substance used for verification has obvious differences with the measurement characteristics of the thin plate, in other words, the standard substance can be used to verify the accuracy of the measuring instrument, but cannot guarantee the accuracy of the automatic measurement system for product detection. Therefore, using similar substances close to the application product as internal control samples has more practical application significance. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1The schematic diagram of the annular nested structure of the present application;

[0027] Figure 2 The schematic diagram of the cross-shaped distribution sampling of the present application. DETAILED DESCRIPTION

[0028] The technical solutions in the embodiments of the present application will be clearly and completely described in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the present application.

[0029] Please refer to Figures 1-2 The present application provides a technical solution: a quality control method suitable for a thin plate Rockwell hardness automatic line, and the specific operation is as follows:

[0030] S1, the measurement method is intelligentized, and the automatic integrated software is connected to the hardness tester PLC, the hardness tester different force value scale switching can be remotely controlled, the detection rules are sorted out according to the national Rockwell hardness measurement standard and product standard, and the specific steps include:

[0031] 1) "original generation rule": according to the grade, product thickness, corresponding historical data, the force value is automatically generated corresponding scale and conversion;

[0032] 2) when the measurement value of the automatically selected force value scale exceeds the applicable range specified in the national standard, the "subsequent switching rule" is automatically switched, such as the measurement value of the 30T scale exceeds the upper limit of the national standard applicable range, the HRB scale is automatically switched; or the measurement value of the 30T scale exceeds the lower limit of the national standard applicable range, the 15T scale is automatically switched;

[0033] 3) establish a historical database, according to the hardness data (this does not need to be maintained, automatically generated), the force value is automatically generated corresponding scale and conversion, which can prevent frequent use of "subsequent switching rule"

[0034] S2, the automatic measurement system is checked, and the specific conditions are as follows:

[0035] ① The hardness control sample special gear is set in the automatic operation area, the "hardness standard sample or control sample automatic sub-process" is established, and the hardness automatic measurement system is fully checked whether it is controlled or not;

[0036] ② The hardness control sample can be purchased from the platform or self-made internal control sample of similar products.

[0037] ③ Hardness internal control samples should be designed based on the actual production conditions of the steel company, ensuring that the automated measurement verification scope covers the entire product range. When production testing requirements are simple, separate automated sub-processes for "high-value control samples" and "low-value control samples" can be set up. When production testing requirements are diverse, separate automated sub-processes for different force scales can be set up.

[0038] ④ Before each production inspection, the centralized control software automatically triggers the control sample process. Passing the control sample measurement indicates that the automatic line measurement system is under control and can be put into production. Otherwise, the automatic line is deactivated and the software issues an alert, prompting manual intervention to identify and analyze the cause of the abnormality. The software database collects the real-time measurement values ​​of the control samples and generates periodic statistics to form trend charts.

[0039] In step S2 (2), the hardness control sample can be purchased from the platform or a similar product can be used to make a self-made internal control sample. The specific methods are:

[0040] Method 1: Purchase hardness control samples (with certificates) from the platform. The shapes and sizes of the certified control samples currently available on the platform are the same as those of the production products, which are thin discs. However, the diameter (35mm) is smaller than the diameter of the production product disc (50mm). Therefore, a "ring nesting" is required (see attached). Figure 1 ), put the purchased hardness control samples into the nest, so that the robot can automatically grab, automatically inject and automatically archive.

[0041] Method 2: Innovative method for making internal control samples: Select a brand with good uniformity and stability such as MAF2 galvanized sheet from the production line, and press Figure 2 The following example shows five specimens (Φ50mm) prepared in a cross-shaped pattern. The Rockwell hardness values ​​of specimens 2, 3, 4, and 5 are measured using a controlled instrument. Specimen 1 is the center specimen, and specimens 2, 3, 4, and 5 are satellite specimens. If the uniformity of the measured values ​​for the four specimens (first, 5 to n indentations are evenly distributed across the entire test surface of each specimen, then the average hardness values ​​of each of the 5 to n indentations are calculated and ranked, and finally, the maximum average value minus the minimum average value) is less than the maximum allowable deviation of the hardness standard block specified in the national standard, the average value of the four specimens is taken as the Rockwell hardness value of specimen 1, and specimen 1 is used as the internal control specimen.

[0042] Example:

[0043] (1) Intelligent detection rules:

[0044] ① The automated integrated software is connected to the hardness tester PLC, which can remotely control the switching of different force scales of the hardness tester;

[0045] ② Based on the national Rockwell hardness measurement standards and product standards, specific testing rules are sorted out, including:

[0046] 1) "Original generation rule": according to the brand, product thickness, corresponding historical data, priority selection of force value to automatically generate corresponding scale and conversion;

[0047] 2) When the automatically selected force value exceeds the applicable range specified in the national standard, automatically switch according to the "subsequent switching rule", such as when the measurement value of the 30T scale exceeds the upper limit of the national standard applicable range, automatically switch to execute the HRB scale; or when the measurement value of the 30T scale exceeds the lower limit of the national standard applicable range, automatically switch to execute the 15T scale;

[0048] 3) Establish a historical database according to the hardness data (this does not need to be maintained, automatically generated), and automatically generate the corresponding scale and conversion according to the priority selection of force value, which can prevent frequent use of the "subsequent switching rule".

[0049] (2) Measurement system verification automation:

[0050] ① Automatic operation area sets hardness control sample dedicated gear, establishes "hardness sample or control sample automation sub-process", which can realize comprehensive control of hardness automation measurement system and whether it is controlled.

[0051] ② Hardness control sample can be purchased from the platform or self-made internal control sample of similar products, and the specific methods are as follows:

[0052] 1) Method one: purchase hardness control sample (with certificate) from the platform, the shape and size of the certified control sample that can be purchased from the platform are the same as the production products, which are thin gauge round pieces, but the diameter is smaller than the production product round piece, and "ring nest" (see Figure 1 ) needs to be made, and the purchased hardness control sample is installed in the nest, which can realize automatic grabbing, automatic sampling and automatic archiving of the mechanical hand.

[0053] 2) Method two: innovative internal control sample making method: select a uniform and stable brand such as MAF2 from the production line, as shown in Figure 2 , five samples are prepared in cross shape, and the Rockwell hardness of samples 2, 3, 4 and 5 is measured by the controlled instrument. 1 is the center sample, and 2, 3, 4 and 5 are satellite samples. If the uniformity of the measurement values of the four samples (firstly, 5-n indents are pressed on the entire test surface of each sample, and then the average hardness values of 5-n indents of each sample are calculated and sorted, and finally the maximum average value is subtracted from the minimum average value) is less than the maximum allowable difference of the hardness standard block specified in the national standard, the average value of the four samples is taken as the Rockwell hardness of sample 1, and sample 1 is taken as the internal control sample.

[0054] ③ Hardness internal control samples should be designed based on the actual production conditions of the steel company, ensuring that the automated measurement verification scope covers the entire product range. When production testing requirements are simple, separate automated sub-processes for "high-value control samples" and "low-value control samples" can be set up. When production testing requirements are diverse, separate automated sub-processes for different force scales can be set up.

[0055] ④ Before each production shift, the centralized control software automatically triggers the control sample process. Passing the control sample measurement indicates that the automated line is under control and can be put into production. Otherwise, the automated line is deactivated and the software issues an alert, prompting manual intervention to identify and analyze the cause of the anomaly. The software database compiles the collected real-time control sample measurement values ​​into periodic statistics and generates trend charts.

[0056] 1) "Original generation rule": Based on the brand, product thickness, and corresponding historical data, the force value is automatically generated and converted;

[0057] 2) When the measured value of the automatically selected force exceeds the applicable range specified by the national standard, it will automatically switch according to the "subsequent switching rules". For example, when the measured value of the 30T scale exceeds the upper limit of the applicable range of the national standard, it will automatically switch to the HRB scale; or when the measured value of the 30T scale exceeds the lower limit of the applicable range of the national standard, it will automatically switch to the 15T scale; 3) Establish a historical database, and based on the previous hardness data (this does not require maintenance and is automatically generated), give priority to the force value to automatically generate the corresponding scale and conversion.

[0058] ① After the inspection rules are compiled into the program, the intelligent measurement of Rockwell hardness of thin plate products with different thicknesses, grades and material properties is realized, avoiding the errors in force scale selection caused by manual operation. Accurate data is a responsibility to the inspected products.

[0059] ② The implementation of the internal control sample automatic process method reduces the difficulty for inspectors to control whether the automatic line system is under control. Inspectors can quickly determine whether the status of the automatic measurement system is under control and meets production requirements.

[0060] ③ The application of self-made internal control samples can ensure full coverage of the measurement range of steel companies' products. On the premise of meeting the calibration specifications, it improves the efficiency of automatic line verification and eliminates safety hazards during manual verification.

[0061] ④Currently, the invention has been implemented and applied on site.

[0062] In summary, this quality control method for the thin plate Rockwell hardness automatic line has achieved a leap from automatic measurement of thin plate Rockwell hardness to intelligent measurement. The inspection rules in the national standard are written into the automatic measurement system program to form "original generation rules", "subsequent switching rules" and "intelligent database", which realizes the intelligent measurement of Rockwell hardness of thin plates of different thicknesses and grades, greatly improving the accuracy of measurement. It can be promoted in the future.

[0063] The method realizes the calibration and verification function of the thin plate Rockwell hardness automatic measurement system;

[0064] At present, other domestic steel enterprises even if introduced Rockwell hardness automatic line, the confirmation method of whether the automatic line measurement system is controlled still adopts artificial verification method, the standard substance used for verification and the measurement characteristics of the thin plate exist obvious difference, in other words, using the standard substance to verify the accuracy of the measuring instrument, and cannot guarantee the accuracy of the automatic measurement system for product detection, which contains sample conversion and other factors affecting measurement. Therefore, using similar substances as internal control samples has more practical application significance.

[0065] It should be noted that in this text, relational terms such as first and second are used merely to distinguish one entity or action from another, without necessarily requiring or implying any such actual relationship or order between or among the entities or actions. Moreover, the terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0066] Although embodiments of the present application have been shown and described, it is to be understood that various modifications, substitutions, replacements and changes can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A quality control method for a thin plate Rockwell hardness automatic line, characterized by: The specific operations are as follows: S1. Intelligent measurement method. The automated integrated software is connected to the hardness tester PLC, which can remotely control the switching of different force scales of the hardness tester. According to the national Rockwell hardness measurement standard and product standard, the test rules are sorted out, including: 1) "Original Generation Rules": Based on the brand, product thickness, and corresponding historical data, force values ​​are prioritized to automatically generate the corresponding scale and conversion; 2) When the measurement value of the automatically selected force scale exceeds the applicable range specified by the national standard, the system will automatically switch to the HRB scale according to the "subsequent switching rules". For example, if the measurement value of the 30T scale exceeds the upper limit of the applicable range of the national standard, the system will automatically switch to the HRB scale; or if the measurement value of the 30T scale exceeds the lower limit of the applicable range of the national standard, the system will automatically switch to the 15T scale. 3) Establish a historical database. Based on the previous hardness data, the historical database does not need to be maintained and is automatically generated. The force value is automatically generated to the corresponding scale and conversion, which can prevent the frequent use of "subsequent switching rules"; S2. Verification of the automated measurement system, details of which are as follows: ① Set up a dedicated working position / shift for hardness control samples in the automated operation area, and establish an "automated sub-process for hardness standard samples or control samples" to achieve a comprehensive check on the hardness automated measurement system to ensure it is under control; ②Hardness control samples can be purchased from the platform or made into internal control samples using similar products; ③ The hardness internal control sample should be based on the actual production of the steel company to ensure that the scope of automated measurement and verification can cover the product range. When the production inspection requirements are single, the "high value control sample" and "low value control sample" automated sub-processes can be set up separately; when the production inspection requirements are diversified, the automated sub-processes of different force scales can be set up separately; ④ Before each production inspection, the centralized control software automatically triggers the sample control process. If the sample control measurement passes, it indicates that the automatic line measurement system is under control. Otherwise, the automatic line will be disabled and the software will issue an alarm, prompting manual intervention to find and analyze the cause of the abnormality. The software database will collect the real-time measurement values ​​of the sample control and perform periodic statistics to form a trend chart.

2. A quality control method for a thin plate Rockwell hardness automatic line according to claim 1, characterized in that: In step S2 (2), the hardness control sample can be purchased from the platform or a similar product can be used to make a self-made internal control sample. The specific methods are: Method 1: Purchase hardness control samples from the platform. These samples come with their own certificates. Currently, the certified control samples available on the platform are the same shape and size as the production products, all thin discs, but with a diameter of 35mm, which is smaller than the 50mm diameter of the production product discs. Therefore, a "ring nest" needs to be made and the purchased hardness control samples are placed into the nest. This allows for automatic gripping, sample feeding, and archiving by a robot arm. Method 2: Innovative method for making internal control samples: Select a brand with good uniformity and stability, such as MAF2 galvanized sheet, from the production line, and make 5 samples (Φ50mm) in a cross-shaped distribution. Use a controlled instrument to measure the Rockwell hardness values ​​of samples 2, 3, 4, and 5. Sample 1 is the central sample, and samples 2, 3, 4, and 5 are satellite samples. If the uniformity of the measured values ​​of the 4 samples is poor, first make 5 to n indentations evenly distributed on the entire test surface of each sample, and then calculate the average hardness value of the 5 to n indentations of each sample and sort them. Finally, subtract the minimum average value from the maximum average value. If it is less than the maximum allowable difference of the hardness standard block specified in the national standard, then take the average value of the 4 samples as the Rockwell hardness value of sample 1, and sample 1 as the internal control sample.

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