Online hot straightening method for steel bar production

Abstract

The invention relates to the technical field of steelmaking, and discloses a rigid bar production online hot straightening method which comprises the steps of S1 process route optimization, S2 hot straightening parameter precise regulation and control and S3 quality monitoring and feedback closed loop, and the S1 process route optimization comprises the steps of S101 steelmaking link integration and S102 refining synergistic interaction; s2, hot straightening parameter accurate regulation and control comprises S201, temperature window accurate setting and S202, straightening force dynamic adaptation; and S3, quality monitoring and feedback closed loop comprises S301, real-time defect detection and S302, feedback type process optimization, the on-line hot straightening method for steel bar production can improve the product quality, precise process optimization and real-time quality monitoring closed loop are achieved, internal defects and surface flaws are greatly reduced, and the production efficiency is improved. And internal impurities are accurately controlled, solidification parameters are intelligently optimized, and multi-mode detection and repair are carried out, so that the internal defect rate is reduced by about 40%, flaws such as surface scratches are reduced by about 50%, the comprehensive performance and the yield of the bar are improved, and the competitiveness is high.

Description

Technical Field

[0001] The invention relates to the technical field of steelmaking, in particular to an online hot straightening method for steel bar production. Background Art

[0002] The traditional steelmaking model is fragmented, with each plant operating independently and lacking coordination. The refining process is loosely connected, information exchange is slow, the quality stability of molten steel is poor, and composition fluctuations are difficult to control. The hot straightening process is highly dependent on manual experience, and the temperature and force parameters are roughly set, which cannot be accurately adapted to bars of multiple specifications. This directly leads to uncontrolled curvature of the bars, scars on the surface, large performance dispersion, uneven quality, and a long-term high defective rate. The economic benefits of the enterprise are seriously damaged, and the industry's reputation is also affected; The manufacturing industry is undergoing a turbulent wave of iteration, and the high-end manufacturing sector is booming, which has led to higher expectations for the quality of steel bars. In key application scenarios such as high-pressure boiler tubes, the requirements for steel bar purity, microstructure uniformity, and dimensional accuracy are almost stringent. Traditional processes are stuck in a technical quagmire and cannot catch up, so industrial upgrading is imminent. Summary of the invention

[0003] 1. Technical issues to be resolved In view of the shortcomings of the prior art, the present invention provides an online hot straightening method for steel bar production, which has the advantages of greatly reducing internal defects and surface flaws, precise control of internal impurities, intelligent optimization of solidification parameters and multi-modal detection and repair, which can reduce the internal defect rate by about 40%, and reduce surface scratches and other defects by about 50%, etc., and solves the problems of uncontrolled curvature of bars, scars on the surface, large performance dispersion and uneven quality.

[0004] (II) Technical solution To achieve the above-mentioned purpose, the present invention provides the following technical solutions: an online hot straightening method for steel bar production, including S1 process route optimization, S2 hot straightening parameter precise control and S3 quality monitoring and feedback closed loop, wherein the S1 process route optimization includes S101 steelmaking link integration and S102 refining synergy efficiency enhancement; S2 precise control of heat straightening parameters includes S201 precise setting of temperature window and S202 dynamic adaptation of straightening force; S3 quality monitoring and feedback closed loop includes S301 real-time defect detection and S302 feedback process optimization.

[0005] Preferably, the S101 steelmaking process is integrated to unify the standards of the converter smelting process of the original steelmaking plant and the wide and thick plate plant, and accurately allocate the furnace according to the bar specifications, such as Φ50 - Φ84mm specifications are prioritized in the steelmaking plant converter, and Φ85 - Φ160mm specifications are arranged in the wide and thick plate plant converter to ensure the stability of the initial quality of the molten steel; Optimize the slag blocking and steel tapping operation, and use an intelligent slag blocking system to accurately block slag according to the molten steel level and flow rate to reduce the slag content; When 1 / 4 of the steel is tapped, the deoxidation alloy is dynamically added according to the composition of the molten steel using an automated feeding device to improve the deoxidation efficiency and alloy recovery rate.

[0006] Preferably, the S102 refining is synergistically effective, and a molten steel composition pre-evaluation mechanism is set between the LF furnace and the VD furnace. The VD furnace composition fine-tuning amount is predicted in real time according to the LF furnace refining process, and the VD furnace uses this to accurately control the vacuum degree and argon blowing parameters; When the VD furnace is tapping steel, the intelligent temperature control module accurately controls the temperature according to the bar specifications and subsequent rolling rhythm, reducing the temperature error of the molten steel outgoing to within ±3°C.

[0007] Preferably, the S201 temperature window is precisely set, and a multi-stage temperature control zone is set in the bar rolling line. The starting temperature range of hot straightening of 950-1050°C is determined by thermal simulation test according to the material and specification of the bar near the rolling mill, and then a gradient cooling zone is set according to the cooling characteristics of the bar to ensure that the temperature of the bar drops to 600-700°C before entering the cooling bed to prevent straightening deviation caused by uneven cooling. Infrared thermal imager is used for real-time monitoring and temperature control parameters are adjusted according to feedback.

[0008] Preferably, the S202 straightening force is dynamically adapted, and high-precision stress and strain sensors are installed at the inlet and outlet of the straightening machine. According to the real-time curvature, diameter and hardness data of the rod, the PLC control system dynamically adjusts the pressure and spacing of the straightening rollers to build an adaptive straightening force model to achieve force changes with the material, improve straightening accuracy, reduce energy consumption and roller wear, such as the straightening force of Φ50mm rods is controlled at 80-120kN, and that of Φ160mm rods is controlled at 250-350kN, and the model parameters are dynamically optimized according to production.

[0009] Preferably, the S301 real-time defect detection is carried out, and a multimodal inspection station is set up after the cooling bed, which integrates ultrasonic, eddy current and machine vision technologies, conducts a full-scale scan of the bars after heat straightening, uses ultrasonic flaw detection to detect internal cracks and inclusions, uses eddy current detection to check surface microcracks and uneven hardness, and uses a visual system to identify surface scratches, pits and other defects, and classifies and labels the defects in real time according to their type, location and severity, and transmits the data to the central control system.

[0010] Preferably, in the S302 feedback process optimization, the central control system receives defect data and analyzes it in seconds, and exceeds the threshold value of defects to trigger an alarm and trace back the production link.

[0011] Preferably, in the S302 feedback process optimization, if scratches frequently appear on the surface of bars in a certain furnace, the roller surface conditions of the rolling and straightening equipment are quickly checked; if there are many internal defects, the impurity control in steelmaking and refining and the continuous casting solidification parameters are analyzed in detail, and the process optimization strategy is intelligently pushed to the corresponding process based on the analysis results. After simulation verification, adjustments are made, and the production process is iteratively optimized to ensure that the quality of the bars is steadily improved and the defective rate is continuously reduced, thereby building a quality-driven production self-optimization ecosystem.

[0012] (III) Beneficial effects Compared with the prior art, the present invention provides an online hot straightening method for steel bar production, which has the following beneficial effects: 1. The online hot straightening method for steel bar production can improve product quality, close the loop of precise process optimization and real-time quality monitoring, significantly reduce internal defects and surface flaws, accurately control internal impurities, intelligently optimize solidification parameters, and perform multi-modal detection and repair, which can reduce the internal defect rate by about 40%, and surface scratches and other defects by about 50%, thereby improving the comprehensive performance and yield rate of bars and strengthening competitiveness.

[0013] 2. The online hot straightening method for steel bar production can enhance production efficiency. Through precise setting of the temperature window and dynamic adaptation of the straightening force, the time consumption of hot straightening can be reduced by about 30% and the energy consumption by about 25%. Intelligent control can reduce the frequency of equipment adjustment and the probability of failure, improve continuous production capacity, increase output per unit time by about 20%, optimize process connection, shorten production cycle, reduce costs and increase production capacity.

[0014] 3. The online hot straightening method for steel bar production promotes process innovation, integrates multiple technologies to build a self-optimizing system, creates an intelligent adaptive hot straightening mode, provides an example for the digital and intelligent transformation of the industry, accumulates data to drive continuous process innovation, stimulates the development of new technologies and new equipment, fosters new business models, and leads the industry to high-quality development. DETAILED DESCRIPTION

[0015] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0016] This solution provides a technical solution, specifically, an online hot straightening method for steel bar production, including the following method steps: S1 process route optimization, S2 precise control of hot straightening parameters, and S3 quality monitoring and feedback closed loop; The S1 process route optimization includes the integration of the S101 steelmaking process and the synergistic efficiency enhancement of the S102 refining process; S2 precise control of heat straightening parameters includes S201 precise setting of temperature window and S202 dynamic adaptation of straightening force; S3 quality monitoring and feedback closed loop includes S301 real-time defect detection and S302 feedback process optimization.

[0017] S1 process route optimization: S101 steelmaking process integration, unified the converter smelting process standards of the original steelmaking plant and the wide and thick plate plant, and accurately allocated the furnaces according to the bar specifications. For example, the specifications of Φ50 - Φ84mm are prioritized in the converter of the steelmaking plant, and the specifications of Φ85 - Φ160mm are arranged in the converter of the wide and thick plate plant to ensure the stability of the initial quality of the molten steel; Optimize the slag blocking and steel tapping operation, and use an intelligent slag blocking system to accurately block slag according to the molten steel level and flow rate to reduce the slag content; When 1 / 4 of the steel is tapped, the deoxidation alloy is dynamically added according to the composition of the molten steel by means of an automated feeding device to improve the deoxidation efficiency and alloy recovery rate; S102 refining synergy, a molten steel composition pre-evaluation mechanism is set between the LF furnace and the VD furnace. The VD furnace composition fine-tuning amount is predicted in real time according to the LF furnace refining process, and the VD furnace uses this to accurately control the vacuum degree and argon blowing parameters; When the VD furnace is tapping steel, the intelligent temperature control module can accurately control the temperature according to the bar specifications and subsequent rolling rhythm, so that the temperature error of the molten steel out of the station is reduced to within ±3°C, enhancing the quality stability of the continuous casting billet and laying the foundation for rolling and hot straightening; S2 heat straightening parameters precise control: The S201 temperature window is precisely set, and a multi-stage temperature control zone is set in the bar rolling line. The starting temperature range of hot straightening is 950-1050℃ determined by thermal simulation test according to the bar material and specifications near the rolling mill. Then a gradient cooling zone is set according to the cooling characteristics of the bar to ensure that the temperature of the bar drops to 600-700℃ before entering the cooling bed to prevent straightening deviation caused by uneven cooling. Infrared thermal imager is used for real-time monitoring and temperature control parameters are adjusted according to feedback; S202 straightening force dynamic adaptation, high-precision stress and strain sensors are installed at the inlet and outlet of the straightening machine. According to the real-time curvature, diameter and hardness data of the bar, the PLC control system dynamically adjusts the pressure and spacing of the straightening rollers to build an adaptive straightening force model, so that the force changes with the material, improves the straightening accuracy, reduces energy consumption and roller wear. For example, the straightening force of Φ50mm bars is controlled at 80-120kN, and that of Φ160mm bars is controlled at 250-350kN. The model parameters are dynamically optimized according to production; S3 quality monitoring and feedback closed loop: S301 real-time defect detection, a multi-modal inspection station is set up behind the cooling bed, integrating ultrasonic, eddy current and machine vision technologies, to perform a full-scale scan of the bars after heat straightening, ultrasonic flaw detection to detect internal cracks and inclusions, eddy current detection to check surface micro-cracks and uneven hardness, and the visual system to identify surface scratches, pits and other defects, and classify and annotate them in real time according to the defect type, location and severity, and transmit the data to the central control system; S302 feedback process optimization, the central control system receives defect data and analyzes it in seconds, exceeding the threshold defect triggers an alarm and traces back to the production link; In the S302 feedback process optimization, if scratches frequently appear on the surface of a certain batch of bars, quickly check the roller surface conditions of the rolling and straightening equipment; if there are many internal defects, analyze the impurity control of steelmaking and refining and the continuous casting solidification parameters in detail, and intelligently push the process optimization strategy to the corresponding process based on the analysis results. After simulation verification, adjustments are made, and the production process is iteratively optimized to ensure that the quality of bars is steadily improved and the defective rate is continuously reduced, so as to build a quality-driven production self-optimization ecosystem; Furthermore, this method can improve product quality, close the loop of precise process optimization and real-time quality monitoring, significantly reduce internal defects and surface flaws, accurately control internal impurities, intelligently optimize solidification parameters, and perform multi-modal detection and repair, which can reduce the internal defect rate by about 40%, and surface scratches and other defects by about 50%, thus improving the comprehensive performance and yield rate of rods and strengthening competitiveness; Furthermore, this method can enhance production efficiency. Through precise setting of the temperature window and dynamic adaptation of the straightening force, the time consumption of heat straightening can be reduced by about 30% and the energy consumption by about 25%. Intelligent control can reduce the frequency of equipment adjustment and the probability of failure, improve continuous production capacity, increase the output per unit time by about 20%, optimize the process connection, shorten the production cycle, reduce costs, and increase production capacity. Furthermore, this method promotes the integration of multiple technologies in process innovation to build a self-optimizing system, creates an intelligent adaptive thermal straightening mode, provides an example for the industry's digital and intelligent transformation, accumulates data to drive continuous process innovation, stimulates the development of new technologies and new equipment, fosters new business models, and leads the industry to high-quality development.

[0018] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An online hot straightening method for steel bar production, including S1 process route optimization, S2 hot straightening parameter precise control and S3 quality monitoring and feedback closed loop, characterized in that: The S1 process route optimization includes the integration of S101 steelmaking links and the synergistic efficiency enhancement of S102 refining; S2 precise control of heat straightening parameters includes S201 precise setting of temperature window and S202 dynamic adaptation of straightening force; S3 quality monitoring and feedback closed loop includes S301 real-time defect detection and S302 feedback process optimization.

2. The method for online hot straightening of steel bars according to claim 1, characterized in that: The S101 steelmaking process is integrated to unify the converter smelting process of the original steelmaking plant and the wide and thick plate plant, and accurately allocate the furnaces according to the bar specifications. For example, the specifications of Φ50 - Φ84mm are prioritized in the converter of the steelmaking plant, and the specifications of Φ85 - Φ160mm are arranged in the converter of the wide and thick plate plant to ensure the stability of the initial quality of the molten steel; Optimize the slag blocking and steel tapping operation, and use an intelligent slag blocking system to accurately block slag according to the molten steel level and flow rate to reduce the slag content; When 1 / 4 of the steel is tapped, the deoxidation alloy is dynamically added according to the composition of the molten steel using an automated feeding device to improve the deoxidation efficiency and alloy recovery rate.

3. The method for online hot straightening of steel bars according to claim 1, characterized in that: The S102 refining synergy increases efficiency. A molten steel composition pre-evaluation mechanism is set between the LF furnace and the VD furnace. The VD furnace composition fine-tuning amount is predicted in real time according to the LF furnace refining process. The VD furnace uses this to accurately control the vacuum degree and argon blowing parameters. When the VD furnace is tapping steel, the intelligent temperature control module accurately controls the temperature according to the bar specifications and subsequent rolling rhythm, reducing the temperature error of the molten steel outgoing to within ±3°C.

4. The method for online hot straightening of steel bars according to claim 1, characterized in that: The S201 temperature window is precisely set, and a multi-stage temperature control zone is set in the bar rolling line. The starting temperature range of hot straightening is 950-1050℃ determined by thermal simulation test according to the material and specification of the bar near the rolling mill. Then a gradient cooling zone is set according to the cooling characteristics of the bar to ensure that the temperature of the bar drops to 600-700℃ before entering the cooling bed to prevent straightening deviation caused by uneven cooling. Infrared thermal imager is used for real-time monitoring and temperature control parameters are adjusted according to feedback.

5. The method for online hot straightening of steel bars according to claim 1, characterized in that: The S202 straightening force is dynamically adapted. High-precision stress and strain sensors are installed at the inlet and outlet of the straightening machine. According to the real-time curvature, diameter and hardness data of the bar, the PLC control system dynamically adjusts the pressure and spacing of the straightening rollers to build an adaptive straightening force model, so that the force changes with the material, the straightening accuracy is improved, and the energy consumption and roller wear are reduced. For example, the straightening force of Φ50mm bars is controlled at 80-120kN, and that of Φ160mm bars is controlled at 250-350kN. The model parameters are dynamically optimized according to production.

6. The method for online hot straightening of steel bars according to claim 1, characterized in that: The S301 real-time defect detection has a multi-modal inspection station behind the cooling bed, which integrates ultrasonic, eddy current and machine vision technologies to conduct a full-scale scan of the bars after heat straightening. Ultrasonic flaw detection is used to detect internal cracks and inclusions, eddy current detection is used to check surface microcracks and uneven hardness, and the visual system identifies surface scratches, pits and other defects. The defects are classified and labeled in real time according to their type, location and severity, and the data is transmitted to the central control system.

7. The method for online hot straightening of steel bars according to claim 1, characterized in that: In the S302 feedback process optimization, the central control system receives defect data and analyzes it in seconds. Defects exceeding the threshold trigger alarms and trace back to the production process.

8. The method for online hot straightening of steel bars according to claim 1, characterized in that: In the S302 feedback process optimization, if scratches frequently appear on the surface of bars in a certain furnace, quickly check the roller surface condition of the rolling and straightening equipment; if there are many internal defects, analyze the impurity control and continuous casting solidification parameters in detail, and intelligently push the process optimization strategy to the corresponding process based on the analysis results. After simulation verification, adjustments are made, and the production process is iteratively optimized to ensure that the quality of bars is steadily improved and the defective rate is continuously reduced, thereby building a quality-driven production self-optimization ecosystem.