Hot rolling process fault early warning method based on data integration

Abstract

The invention belongs to the technical field of hot rolling safety early warning, and particularly discloses a hot rolling process fault early warning method based on data integration, which comprises the following steps: acquiring equipment operation data of each equipment in a first layer, and outputting the equipment operation data to a data integration module in a second layer, the data integration module integrates the equipment operation data to obtain full-equipment operation data, the full-equipment operation data is input to terminal equipment in a third layer, the terminal equipment judges whether equipment in the first layer has faults or not according to the full-equipment operation data, if yes, the corresponding current fault level is determined through a preset early warning strategy, and if not, the corresponding current fault level is determined; and the current fault level is input to the control module in the second layer, and the control module controls the early warning equipment corresponding to the first layer to carry out early warning by using an early warning level control strategy and carries out early warning prompt on the terminal equipment in the third layer. According to the invention, differential early warning is carried out according to different fault degrees, and the fault identification precision and the early warning practicability are improved.

Description

Technical Field

[0001] The invention relates to the technical field of hot rolling safety early warning, and in particular to a hot rolling process failure early warning method based on data integration. Background Art

[0002] The hot rolling process includes heating, high-pressure water descaling, rough rolling, uncoiling, shearing, finishing rolling, cooling, curling and other process flows, and involves the joint operation of multiple units. During the rolling process operation, if the impending failure of the unit equipment cannot be discovered and eliminated in advance, it will greatly affect the rolling of the material steel and reduce the steel output rate.

[0003] At present, most steel enterprises use automated production operations, and the data of steel rolling needs to be monitored in real time to ensure smooth production. However, due to the different communication protocols between multiple sets of equipment, each equipment needs to be equipped with a data acquisition module with the same communication protocol, which increases production costs, and the accuracy of equipment fault identification is not high. When there are abnormal problems in the equipment, management personnel and maintenance personnel cannot make judgments and handle them in the first time, which leads to the expansion of abnormal problems and affects the entire rolling system. Summary of the invention

[0004] The purpose of the present invention is to provide a hot rolling process fault early warning method based on data integration to solve the problem that the existing automated production cannot timely identify and warn the faults of the unit equipment in the hot rolling process.

[0005] To achieve the above object, the basic solution provided by the present invention is: a hot rolling process fault early warning method based on data integration, comprising:

[0006] S1: Obtain the equipment operation data of each equipment in the first layer;

[0007] S2: output the equipment operation data to the data integration module in the second layer, so that the data integration module integrates the equipment operation data to obtain the full equipment operation data;

[0008] S3: inputting the operation data of all equipment into the terminal equipment in the third layer, so that the terminal equipment determines whether there is a fault in each equipment in the first layer according to the operation data of all equipment, and if there is a fault, determines the corresponding current fault level by using the preset early warning strategy;

[0009] S4: Input the current fault level to the control module in the second layer, so that the control module controls the corresponding warning equipment in the first layer to issue a warning based on the current fault level and uses the warning level control strategy, and issues a warning prompt to the terminal equipment in the third layer.

[0010] The first layer includes the unit equipment involved in the hot rolling process, and the second layer includes a data integration module and a control module. The data integration module is used to collect the equipment operation data of each equipment in the first layer, and the control module is used to analyze the instructions issued by the third layer, perform early warning control on the equipment in the first layer, and issue early warning prompts to the terminal equipment in the third layer. The third layer includes multiple terminal devices. When receiving the full equipment operation data sent by the data integration module of the second layer, the preset early warning strategy is used to determine the current fault of the whole equipment and the corresponding current fault level, so that the control module of the second layer can perform the corresponding control operation according to the current fault level, realize differential early warning according to different fault degrees, and improve the accuracy of fault identification and the practicality of early warning.

[0011] Preferably, it also includes:

[0012] Obtain communication logs of each device in the first, second and third layers in real time;

[0013] Determine whether there are abnormal logs in the communication logs of each device;

[0014] If so, generate and send a communication abnormality alarm SMS corresponding to the communication abnormality device to the terminal device of the maintenance personnel in the third floor; if not, execute step S1.

[0015] When communication between devices fails, the device operation information cannot be normally transmitted to the terminal device on the third layer for fault identification, nor can it be normally controlled to perform related early warning operations. Therefore, before fault identification, it is necessary to analyze the communication logs of each device on the first, second and third layers to determine whether there are any abnormal logs. If there are any abnormalities, it means that there is an abnormality in the device communication, and maintenance personnel are required to repair the device to ensure smooth communication, and generate text messages to be sent to the terminal devices of maintenance personnel on the third layer to remind them of communication failures.

[0016] Preferably, the process of integrating the equipment operation data by the data integration module in step S2 specifically includes:

[0017] Receive device operation data of corresponding devices through different communication protocol interfaces;

[0018] The equipment operation data of different communication protocols are converted according to the preset output format standard to obtain the standard operation data corresponding to each device.

[0019] The standard operation data corresponding to each device is integrated to obtain the operation data of the entire device.

[0020] There are differences in the communication protocols between the various devices in the first layer, and the data formats under different communication protocols are also different. Therefore, the present invention sets up a data integration module in the second layer, and integrates multiple different protocol interfaces on the data integration module. Different protocol interfaces are used to receive device operation data of corresponding protocols, and the device operation data of different protocols are converted into a unified data format, converted into a data format specified by the communication protocol of the third-layer terminal device, and all converted standard operation data are integrated into full device operation data and output to the third-layer terminal device to realize the function of multi-source heterogeneous data integration.

[0021] Preferably, the pre-set warning strategy in step S3 includes:

[0022] According to the fault discrimination indicators corresponding to different fault types, the whole equipment operation data is divided into current operation data corresponding to different fault discrimination indicators;

[0023] Determine whether the current operating data exceeds the preset operating threshold of the corresponding fault type;

[0024] If not, it is indicated that there is no fault corresponding to the current operating data in the entire device; if so, the fault overflow rate is determined based on the overflow operating data of the current operating data exceeding the preset operating threshold, and the fault degree corresponding to the fault type is graded according to the fault overflow rate to obtain the current fault level; wherein the current fault level includes level one fault, level two fault and level three fault.

[0025] Equipment failure usually manifests itself as a process. In the case of a first-level failure, the equipment can still operate normally. The overflow operation data of the current operation data exceeding the preset operation threshold is small, and the degree of failure is low. In the case of a second-level failure, the equipment operation may be stuck, the overflow operation data increases, and the degree of failure is medium. In the case of a third-level failure, the equipment may crash, the overflow operation data is large, and the degree of failure is high. By setting three fault levels, the accuracy of fault identification is improved, and the data basis for differential early warning is improved.

[0026] Preferably, the warning level control strategy in step S4 specifically includes:

[0027] According to the first-level fault, generate and push the first-level fault information to the internal management system in the terminal equipment in the third layer, and generate and send the first-level fault prompt email to the mailbox of the administrator terminal;

[0028] According to the secondary fault, a secondary fault SMS is generated and sent to the personal mobile terminals of maintenance personnel and managers in the third layer for prompting, and the secondary fault information is generated and pushed to the fault management APP in the personal mobile terminals of managers in the third layer.

[0029] According to the third-level fault, a call is pushed to the personal mobile terminal of the manager in the third layer, the red light of the alarm light in the first layer is controlled to flash, and the sound system equipment in the first layer is controlled to sound an alarm.

[0030] The terminal equipment in the third layer is divided into computers and personal mobile terminals. An internal management system is set up in the computer. Each employee in the hot rolling mill can view the hot rolling process information by logging into the personal terminal of the internal management system. A fault management APP is installed on the personal mobile terminal to receive fault reminders at any time. When it is determined that the current hot rolling process is in a first-level fault, it only needs to send the first-level fault information to the internal management system, and send a first-level fault prompt email to the mailbox of the manager's terminal; when it is determined that the current hot rolling process is in a second-level fault, a second-level fault SMS is generated and sent to the personal mobile terminals of the maintenance personnel and managers in the third layer for prompts, and the second-level fault information is generated and pushed to the fault management APP in the personal mobile terminal of the manager in the third layer; when it is determined that the current hot rolling process is in a third-level fault, a call is pushed to the personal mobile terminal of the manager in the third layer, the red light of the alarm light in the first layer is controlled to flash, and the sound system equipment in the first layer is controlled to sound an alarm, realizing differential progressive fault warning according to different fault degrees, and improving fault handling efficiency.

[0031] Preferably, the method further comprises:

[0032] When the current device is in a level 2 fault, obtain the processing status of the level 2 fault information on the fault management APP in the personal mobile terminal of the third-layer manager. If the level 2 fault information has not been processed, make a fault push call to the personal mobile terminal of the third-layer manager; if the level 2 fault information has been processed, do not perform any operation;

[0033] When the current fault is at level three, real-time monitoring is performed to determine whether the personal mobile terminal of the manager in the third layer answers the fault push call. If not, the fault push call is continuously made to the personal mobile terminal of the manager; if answered, the fault push call is stopped after the current fault push call is answered.

[0034] The manager may not be able to receive the fault information in time due to busy work. Therefore, when the current device is in a level 2 fault, the present invention obtains the processing status of the level 2 fault information on the fault management APP in the personal mobile terminal of the manager in the third layer. If the level 2 fault information is not processed, a fault push call is made to the personal mobile terminal of the manager in the third layer; when the current device is in a level 3 fault, real-time monitoring is performed on whether the personal mobile terminal of the manager in the third layer answers the fault push call. If not, the fault push call is continuously made to the personal mobile terminal of the manager; if answered, the fault push call to the personal mobile terminal of the manager is stopped after the current fault push call is answered, so as to urge the manager to handle the fault information as soon as possible, thereby improving the fault handling efficiency. DETAILED DESCRIPTION

[0035] The present invention is further described in detail below through specific embodiments:

[0036] This embodiment proposes a hot rolling process fault early warning method based on data integration, including:

[0037] This embodiment divides the entire hot rolling process control system into three layers. The first layer includes the unit equipment involved in the hot rolling process, the second layer includes the data integration module and the control module, and the third layer includes multiple terminal devices. The terminal devices are divided into computers and personal mobile terminals. An internal management system is set up in the computer. Each employee in the hot rolling plant can view the hot rolling process information by logging into the personal terminal of the internal management system, and a fault management APP is installed on the personal mobile terminal to receive fault reminders at any time.

[0038] When communication between devices fails, the device operation information cannot be normally transmitted to the terminal device on the third layer for fault identification, nor can it be normally controlled to perform related early warning operations. Therefore, before step S1, it is necessary to ensure that the device communication is unobstructed. Specifically: obtain the communication logs of each device in the first layer, the second layer and the third layer in real time, and determine whether there are abnormal logs in the communication logs of each device. If so, generate and send a communication abnormality alarm SMS corresponding to the communication abnormal device to the terminal device of the maintenance personnel on the third layer to remind the maintenance personnel to repair the equipment to ensure equipment communication; if not, execute step S1.

[0039] S1: Obtain the device operation data of each device in the first layer.

[0040] S2: Output the equipment operation data to the data integration module in the second layer, so that the data integration module integrates the equipment operation data to obtain the whole equipment operation data.

[0041] It is understandable that there are differences in the communication protocols between the various devices in the first layer, and the data formats under different communication protocols are also different. Therefore, the present invention sets a data integration module in the second layer, integrates multiple different protocol interfaces on the data integration module, uses different protocol interfaces to receive the device operation data of the corresponding protocol, and converts the device operation data of different protocols into a unified data format, converts it into the data format specified by the communication protocol of the third-layer terminal device, and integrates all the converted standard operation data into the full device operation data and outputs it to the third-layer terminal device to realize the function of multi-source heterogeneous data integration. For example, by realizing the integration of common PLC communication protocols such as Modbus, SiemensTCPIP, etc., the collection of different types of PLC data is realized, and the data collection of systems such as DCS is realized through the OPC protocol. Finally, the full device operation data is output to the database of the third-layer terminal device through the POC communication protocol.

[0042] S3: Input the operation data of all equipment into the terminal equipment in the third layer, so that the terminal equipment can judge whether there is a fault in each device in the first layer according to the operation data of all equipment. If there is a fault, the corresponding current fault level is determined using the preset early warning strategy.

[0043] The preset warning strategy specifically includes: according to the fault discrimination indicators corresponding to different fault types, the operation data of the whole equipment is divided into current operation data corresponding to different fault discrimination indicators, and it is judged whether the current operation data exceeds the preset operation threshold of the corresponding fault type. If not, it is indicated that there is no fault corresponding to the current operation data in the whole equipment; if so, the fault overflow rate is determined according to the overflow operation data of the current operation data exceeding the preset operation threshold, and the fault degree corresponding to the fault type is graded according to the fault overflow rate to obtain the current fault level; among which, the current fault level includes level one fault, level two fault and level three fault. In the case of level one fault, the equipment can still operate normally, and the overflow operation data of the current operation data exceeding the preset operation threshold is small, and the fault degree is low. In the case of level two fault, the equipment operation may be stuck, the overflow operation data increases, and the fault degree is medium. In the case of level three fault, the equipment may crash, the overflow operation data is large, and the fault degree is high. For example, the ratio of the overflow operation data to the preset operation threshold is recorded as the fault overflow rate. When the fault overflow rate is ≤40%, it is recorded as a first-level fault. When the fault overflow rate is greater than 40% and less than or equal to 80%, it is recorded as a second-level fault. When the fault overflow rate is greater than 80%, it is recorded as a third-level fault.

[0044] S4: Input the current fault level to the control module in the second layer, so that the control module controls the corresponding warning equipment in the first layer to issue a warning based on the current fault level and uses the warning level control strategy, and issues a warning prompt to the terminal equipment in the third layer.

[0045] The control module is provided with an early warning level control strategy, and the control module stores the communication information of each terminal device in the third layer, which can realize information sending and telephone calls to the terminal devices. It also stores the dispatch control parameters of each early warning device in the first layer. The early warning equipment specifically includes alarm lights and sound systems, and the sound system can broadcast through speakers and other broadcasting equipment.

[0046] The early warning level control strategy specifically includes: according to the first-level fault, generating and pushing the first-level fault information to the internal management system in the terminal equipment in the third layer, generating and sending the first-level fault prompt email to the mailbox of the management personnel terminal; according to the second-level fault, generating and sending the second-level fault SMS to the personal mobile terminals of the maintenance personnel and management personnel in the third layer for prompting, generating and pushing the second-level fault information to the fault management APP in the personal mobile terminals of the management personnel in the third layer, according to the third-level fault, making a call push to the personal mobile terminals of the management personnel in the third layer, controlling the red light of the alarm light in the first layer to flash, and controlling the sound system equipment in the first layer to sound an alarm, thereby realizing differentiated progressive fault early warnings according to different fault degrees.

[0047] It is understandable that the manager may not be able to receive the fault information in time due to busy work. Therefore, in this embodiment, when the current device is in a level 2 fault, the processing status of the level 2 fault information on the fault management APP in the personal mobile terminal of the manager in the third layer is obtained. If the level 2 fault information is not processed, a fault push call is made to the personal mobile terminal of the manager in the third layer; when the current device is in a level 3 fault, real-time monitoring is performed on the personal mobile terminal of the manager in the third layer to see whether the fault push call is answered. If not, the fault push call is continued to be made to the personal mobile terminal of the manager; if answered, the fault push call to the personal mobile terminal of the manager is stopped after the fault push call is answered, so as to urge the manager to handle the fault information as soon as possible, thereby improving the fault handling efficiency.

[0048] The above is only an embodiment of the present invention, and the common knowledge such as the known specific structure and characteristics in the scheme is not described in detail here. It should be pointed out that for those skilled in the art, several deformations and improvements can be made without departing from the structure of the present invention, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. A hot rolling process fault early warning method based on data integration, It is characterized in that include: S1: Obtain the equipment operation data of each equipment in the first layer; S2: outputting the equipment operation data to a data integration module in the second layer, so that the data integration module integrates the equipment operation data to obtain full equipment operation data; S3: inputting the full equipment operation data into the terminal device in the third layer, so that the terminal device determines whether each device in the first layer has a fault according to the full equipment operation data, and if a fault exists, determines the corresponding current fault level by using a preset early warning strategy; S4: Input the current fault level into the control module in the second layer, so that the control module controls the warning device corresponding to the first layer to issue a warning based on the current fault level and uses the warning level control strategy, and issues a warning prompt to the terminal device in the third layer.

2. According to claim 1, a hot rolling process failure early warning method based on data integration, Features , also includes: Obtain communication logs of each device in the first, second and third layers in real time; Determine whether there are abnormal logs in the communication logs of each device; If so, generate and send a communication abnormality alarm SMS corresponding to the communication abnormality device to the terminal device of the maintenance personnel in the third floor; if not, execute step S1.

3. According to claim 1, a hot rolling process failure early warning method based on data integration, It is characterized in that The process of integrating the equipment operation data by the data integration module in step S2 specifically includes: Receive device operation data of corresponding devices through different communication protocol interfaces; The equipment operation data of different communication protocols are converted according to the preset output format standard to obtain the standard operation data corresponding to each device. The standard operation data corresponding to each device is integrated to obtain the full device operation data.

4. According to claim 1, a hot rolling process failure early warning method based on data integration, It is characterized in that The preset warning strategy in step S3 includes: According to the fault discrimination indicators corresponding to different fault types, the whole equipment operation data is divided into current operation data corresponding to different fault discrimination indicators; Determine whether the current operating data exceeds the preset operating threshold of the corresponding fault type; If not, it indicates that no fault corresponding to the current operating data exists in the entire device; If so, the fault overflow rate is determined based on the overflow operating data of the current operating data exceeding the preset operating threshold, and the fault degree corresponding to the fault type is graded according to the fault overflow rate to obtain the current fault level; wherein the current fault level includes level one fault, level two fault and level three fault.

5. According to claim 1, a hot rolling process failure early warning method based on data integration, Features ,The warning level control strategy described in step S4 specifically includes: According to the first-level fault, generate and push the first-level fault information to the internal management system in the terminal device in the third layer, and generate and send the first-level fault prompt email to the mailbox of the administrator terminal; According to the secondary fault, a secondary fault SMS is generated and sent to the personal mobile terminals of maintenance personnel and managers in the third layer for prompting, and secondary fault information is generated and pushed to the fault management APP in the personal mobile terminals of managers in the third layer. According to the three-level fault, a call is pushed to the personal mobile terminal of the manager in the third layer, the red light of the alarm light in the first layer is controlled to flash, and the sound system equipment in the first layer is controlled to sound an alarm.

6. A hot rolling process fault early warning method based on data integration according to claim 1, It is characterized in that The method further comprises: When the current device is in a level 2 fault, obtain the processing status of the level 2 fault information on the fault management APP in the personal mobile terminal of the third-layer manager. If the level 2 fault information has not been processed, make a fault push call to the personal mobile terminal of the third-layer manager; if the level 2 fault information has been processed, do not perform any operation; When the current fault is at level three, real-time monitoring is performed to determine whether the personal mobile terminal of the manager in the third layer answers the fault push call. If not, the fault push call is continued to be made to the personal mobile terminal of the manager; if answered, the fault push call is stopped after the current fault push call is answered.