Method for optimizing shape of quenched steel plate, electronic equipment comprising method and computer readable storage medium

Abstract

The invention relates to the technical field of quenched steel plate shape adjustment, and discloses a method for optimizing the shape of a quenched steel plate, which comprises a quenching machine, a quenching machine control system and a plate shape detector, s1, detecting the appearance of the quenched steel plate by using a plate shape detector; s2, judging whether the shape of the steel plate meets a preset standard or not, and if not, executing the step S3; if yes, executing the step S5; s3, the plate shape detector recognizes the defect type existing in the unqualified area and sends information to a quenching machine control system; s4, the quenching machine control system adjusts quenching process parameters according to defect types, and original parameters are covered with the adjusted parameters; and S5, the production process is cured by applying the quenching process parameters. According to the method, the product quality is improved and the rejection rate is reduced through systematic detection and flow adjustment. And the production process is cured by applying the adjusted process parameters, so that the subsequently produced steel plate is ensured to meet the standard, and the quenching qualification rate and the production efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of adjusting the shape of a quenched steel plate, and more specifically, to a method for optimizing the shape of a quenched steel plate, an electronic device comprising the method, and a storage medium. Background Art

[0002] Steel plates such as engineering machinery steel, wear-resistant steel, and cryogenic storage tank steel all need to be tempered during production. The quenching plate shape qualification rate of wide and thick plates is a bottleneck problem that plagues steel mills. Affected by equipment accuracy, temperature difference between summer and winter, temperature difference between morning and evening, and changes in quenching cooling water temperature, the same quenching process cannot guarantee the plate shape qualification rate of wide and thick plates during continuous quenching. Wide and thick plates usually refer to those steel plates with larger width and thickness. Such steel plates are widely used in heavy industrial fields such as construction, bridges, shipbuilding, pressure vessels, and engineering machinery. Specifically, the range of wide and thick plates is generally defined as follows: wide plates usually refer to steel plates with a width greater than or equal to 1500 mm, and thickness usually refers to steel plates greater than or equal to 6 mm.

[0003] In order to ensure that the shape of the steel plate after quenching meets the standard, the existing method usually includes the following steps:

[0004] Inspection: Use a plate shape detector to inspect the shape of the quenched steel plate to identify whether there are any plate shape defects.

[0005] Judgment: Determine whether the steel plate appearance is qualified according to the preset standards.

[0006] Adjustment: If the test results show unqualified, the quenching process parameters, such as nozzle water volume, are adjusted through manual or automatic control systems to compensate for the defects.

[0007] Curing: Apply the adjusted process parameters to cure the production process and ensure that the steel plates produced subsequently meet the standards.

[0008] Although the existing methods for adjusting the shape of quenched steel plates have achieved certain results, they still have the following shortcomings:

[0009] Insufficient detection accuracy: Traditional detection methods cannot accurately identify the specific defect types in different areas, resulting in inaccurate adjustment measures. Low adjustment efficiency: Existing methods mostly rely on empirical adjustments and lack a systematic adjustment strategy, which easily leads to repeated adjustments and increases production time and costs. Low degree of automation: Most adjustment processes still require manual intervention, which increases the complexity of operations and the possibility of human errors. Summary of the invention

[0010] The present invention aims to overcome at least one defect of the above-mentioned prior art, and provides a method for optimizing the plate shape of a quenched steel plate, an electronic device and a computer-readable storage medium, aiming to improve the technical problem of improving the accuracy of plate shape detection and the effectiveness of adjustment.

[0011] The technical solution adopted by the present invention is a method for optimizing the shape of a quenched steel plate, comprising a quenching machine, a quenching machine control system and a shape detector;

[0012] S1. Use a plate shape detector to detect the shape of the steel plate after quenching; the plate shape defects in different areas can be accurately identified through a high-precision plate shape detector.

[0013] S2. Determine whether the shape of the steel plate meets the preset standards. If it fails, execute step S3; if it passes, execute step S5. Being able to determine whether the shape of the steel plate is qualified based on the preset standards can perform more detailed inspection of the shape of the steel plate with higher inspection accuracy.

[0014] S3. The plate shape detector identifies the defect type in the unqualified area and sends the information to the quenching machine control system; the detector can not only identify defects, but also classify and send them to the control system to realize automatic processing, and can make systematic adjustments to avoid relying on empirical adjustments, which can effectively reduce the frequency of adjustments, reduce production time and reduce production costs.

[0015] S4. The quenching machine control system adjusts the quenching process parameters according to the defect type and overwrites the original parameters with the adjusted parameters; the control system selects the most appropriate adjustment strategy according to the specific defect type to ensure that each adjustment is the optimal solution, thereby improving the effectiveness of each adjustment.

[0016] S5. Use quenching process parameters to solidify the production process. This method improves the shape quality of the steel plate after quenching and reduces the scrap rate through a systematic detection and adjustment process. Use the adjusted process parameters to solidify the production process, ensure that the steel plates produced subsequently meet the standards, and improve the quenching qualification rate and production efficiency.

[0017] Furthermore, the step of the plate shape detector identifying the defect type in the unqualified area further includes:

[0018] S31. The steel plate is divided into the following sections, wherein the areas at the first preset distance from the head and the tail are the first zone and the second zone, the areas at the second preset distance from both sides are the third zone and the fourth zone, and the remaining middle part is the fifth zone;

[0019] S32. Inspect the shape of each section according to the preset standards and evaluate whether it is qualified. By accurately dividing the steel plate area and inspecting it separately, the specific defects in different areas can be accurately identified, so as to achieve targeted adjustments and improve adjustment efficiency and accuracy.

[0020] Furthermore, the first preset distance is 1.5-2.5m, and the second preset distance is 0.3-0.7m. The first preset distance and the second preset distance can be set on the plate shape detector. Defects in the first and second zones usually appear within 1.5-2.5m, and defects in the third and fourth zones usually appear within 0.3-0.7m, which is not limited by the size of the steel plate. Therefore, the first preset distance and the second preset distance in this reasonable range are selected to ensure the accuracy of the detection area and make the detection result more reliable, so as to adapt to steel plates of different sizes.

[0021] Furthermore, the types of defects present in the unqualified areas are as follows:

[0022] The defects occurring in the first area and the second area include warping and knocking, which are defined as warping in area 1, knocking in area 1, warping in area 2, and knocking in area 2, respectively;

[0023] The defects in the third and fourth zones are floating and curvature, which are defined as regional three-side waves and regional four-side waves respectively;

[0024] The defects in the fifth zone are concave and convex, which are defined as concave in zone 5 and convex in zone 5 respectively. This defect type is a defect zoning method summarized based on a large amount of previous experience in steel plate quenching. By clarifying all possible defect types and their definitions, it ensures that the control system can accurately identify and classify defects, providing a basis for subsequent adjustments.

[0025] Furthermore, the adjusted quenching process parameters include at least the roller speed and the upper and lower nozzle water ratio, and one or more combinations of these parameters are used during the adjustment. Selecting key quenching process parameters for adjustment can effectively compensate for defects, ensure that the shape of the steel plate after quenching meets the standard, and improve production quality.

[0026] Furthermore, the defects occurring in the first area, the second area, the third area, the fourth area and the fifth area are divided into two types, each of which adopts the following specific adjustment method:

[0027] The first type includes one or more of area one warp, area two warp, area five concave, area three side wave and area four side wave, which are adjusted by increasing the roller speed, increasing the upper and lower nozzle water ratio, or a combination thereof;

[0028] The second type includes one or more of the following: area 1 knock, area 2 knock and area 5 middle convex. Adjustment is performed by reducing the roller speed, reducing the upper and lower nozzle water ratio, or a combination thereof. Targeted adjustment measures are taken according to different types of defects to ensure the effectiveness and accuracy of the adjustment and reduce rework and waste.

[0029] Furthermore, after each adjustment:

[0030] If the product fails and the same defect still occurs, the adjustment range will be reduced;

[0031] If another defect occurs, reduce the current adjustment range and adjust in the opposite direction;

[0032] If the minimum adjustment range is reached and the product is still unqualified, the plate shape detector will sound an alarm and make manual plate shape adjustments. The step-by-step adjustment strategy ensures that each adjustment is basically the best solution, avoiding new problems caused by excessive adjustments, and setting an alarm mechanism to ensure the quality of the final product.

[0033] Furthermore, the adjustment range is reduced in the order of 5%, 3%, and 1%, with the minimum adjustment range being 1%. A specific adjustment range sequence is set to ensure standardization of the adjustment process and improve the success rate and efficiency of the adjustment.

[0034] An electronic device includes a processor; a memory on which a computer program that can be run on the processor is stored; wherein the computer program implements the aforementioned steps when executed by the processor. Automatic adjustment is achieved through the computer program, which improves the automation level and efficiency of production, reduces the impact of human factors, and enhances the stability and reliability of the system.

[0035] A computer-readable storage medium storing a computer program, wherein the computer program implements the steps of the aforementioned method when executed. Storage medium protection is provided to ensure that the method can be copied and distributed in the form of software, facilitating the application and promotion of the technology.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows: the plate shape detector can identify the specific defect type in the unqualified area and send it to the quenching machine control system, which can adjust the corresponding quenching process parameters according to the type of defect, thus realizing a systematic detection and adjustment process, ensuring that the plate shape of the steel plate after quenching meets the preset standard, improving the plate shape quality of the steel plate after quenching and reducing the scrap rate. The adjusted process parameters are used to solidify the production process, ensuring that the steel plates produced subsequently meet the standards, and improving the quenching qualification rate and production efficiency.

[0037] Through zoning inspection, the defect types in different areas can be identified more accurately, ensuring that the adjustment measures are more targeted. The systematic adjustment strategy reduces the number of repeated adjustments and improves production efficiency. Reducing manual intervention reduces the complexity of operations and the possibility of human errors, and improves the stability and reliability of production. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 The present invention is a flow chart for optimizing the plate shape of a quenched steel plate.

[0039] Figure 2It is a structural schematic diagram of the quenching machine of the present invention.

[0040] Figure 3 It is a schematic diagram of the partitioning of the steel plate of the present invention.

[0041] In the figure: 1 first nozzle; 2 second nozzle; 3 third nozzle; 4 fourth nozzle; 5 fifth nozzle; 6 sixth nozzle; 7 seventh nozzle; 8 eighth nozzle; 9 first zone; 10 second zone; 11 third zone; 12 fourth zone; 13 fifth zone; 14 steel plate; 15 lower roller; 16 upper roller. DETAILED DESCRIPTION

[0042] The drawings of the present invention are only for illustrative purposes and should not be construed as limiting the present invention. In order to better illustrate the following embodiments, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of the actual product; it is understandable to those skilled in the art that some well-known structures and their descriptions in the drawings may be omitted.

[0043] like Figure 1-3 As shown, the present invention discloses a method for optimizing the shape of a quenched steel plate. The quenching machine involved in the present invention comprises an upper roller 16 and a lower roller 15, which are respectively arranged on an upper frame and a lower frame. Specifically, the upper roller 16 is arranged on the upper part of the quenching machine, and the lower roller 15 is arranged below the upper roller 16, and a roller gap is left between the upper roller 16 and the lower roller 15 for the steel plate 14 to pass through; the rollers on the upper roller 16 and the rollers on the lower roller 15 are arranged opposite to each other up and down to form a plurality of pairs of rollers.

[0044] The quenching machine involved in the present invention is a roller gap quenching machine, which uses high-pressure water to quench the steel plate 14. The quenching machine is provided with a high-pressure section and a low-pressure section. The high-pressure section includes a first part and a second part. The first part of the high-pressure section includes a first nozzle 1, a second nozzle 2, a third nozzle 3 and a fourth nozzle 4. A group of first nozzles 1 is arranged above the steel plate 14, a group of second nozzles 2 is arranged below the steel plate 14, the first nozzle 1 and the second nozzle 2 are arranged oppositely, a group of third nozzles 3 is arranged above the steel plate 14, a group of fourth nozzles 4 is arranged below the steel plate 14, the third nozzle 3 and the fourth nozzle 4 are arranged oppositely, the first nozzle 1, the second nozzle 2, the third nozzle 3 and the fourth nozzle 4 are all slit nozzles, and the number of the above groups is not less than two (arranged side by side).

[0045] The second part of the high-pressure section includes the fifth nozzle 5 and the sixth nozzle 6. Four groups of the fifth nozzle 5 are arranged above the steel plate 14, and four groups of the sixth nozzle 6 are arranged below the steel plate 14. The fifth nozzle 5 and the sixth nozzle 6 are arranged opposite to each other one by one. The low-pressure section is provided with the seventh nozzle 7 and the eighth nozzle 8. Twelve groups of the seventh nozzle 7 are arranged above the steel plate 14, and twelve groups of the eighth nozzle 8 are arranged below the steel plate 14. The seventh nozzle 7 and the eighth nozzle 8 are arranged opposite to each other one by one.

[0046] All nozzles are equipped with flow meters for detecting flow and air valves for controlling flow. The water pressure of the nozzles in the high-pressure section is 0.79MPa-0.81MPa and the flow rate is 6550m 3 / h-10650m 3 / h, the water pressure of the nozzle in the low-pressure section is 0.39MPa-0.41MPa, and the flow rate is 5650m 3 / h-8050m 3 / h. The roller speed of the quenching machine is 1.5m / min-60m / min, the roller speed of the steel plate 14 passing through the plate shape detector is 1.5m / min-24m / min, and the distance between the upper roller 16 of the quenching machine and the upper surface of the steel plate 14 is 0.2mm-0.6mm.

[0047] A plate shape detector is installed at the quenching machine outlet, which is used to detect the plate shape of the steel plate 14 after quenching. A detection grating is installed at the quenching machine entrance, and an encoder is installed on the quenching machine roller. The position of the steel plate 14 in the quenching machine can be calculated through the quenching machine roller speed and the encoder output information.

[0048] The plate shape detector of the present invention can detect the steel plate 14 with a thickness of 6mm-100mm and a width of 1500mm-4100mm. The steel plates with a thickness of 6mm-100mm and a width of 1500mm-4100mm are selected to meet the diverse application requirements, adapt to the existing production equipment and technical capabilities, ensure the cooling uniformity and product quality during the quenching process, and take into account the market demand and economy, as well as comply with relevant industry standards and specifications. The selection of these size ranges is the result of comprehensive consideration of various factors, aiming to provide high-quality steel plate products to meet the needs of different customers.

[0049] The quenching machine control system includes the primary system, the secondary system and the tertiary system, among which:

[0050] The three-level system stores information such as the steel type, steel plate number, steel plate thickness, steel plate width, steel plate length and steel plate heating temperature of the steel plate 14 .

[0051] The secondary system stores the quenching processes corresponding to steel plates of different steel types, steel plate thicknesses, steel plate widths, and steel plate lengths (including information such as roller speed, roller gap width, and flow rates of each nozzle).

[0052] The primary system (primary PLC system) gives the time for the steel plate 14 to leave the heat treatment furnace based on the flow feedback of each nozzle on site. According to the content of the information transmitted by the secondary system, the roller speed of the on-site quenching machine, the cooling water flow of each nozzle, and the number of air valves opened in the nozzle are controlled. According to the grating detection signal at the entrance of the quenching machine, the start time of the head of the steel plate 14 entering the quenching machine is recorded, and the position of the steel plate 14 in the quenching machine is calculated based on the feedback value of the roller speed of the quenching machine. After calculating the position of the steel plate 14 in the quenching machine, the opening and closing time of the air valve of each nozzle is controlled according to the length data of the steel plate 14 itself and the position of the head and tail in the quenching machine.

[0053] The shape detector detects the shape of the steel plate 14. The shape detector system stores the judgment criteria for whether the steel plate 14 is qualified (for example, flatness, thickness, surface defects, etc.), and automatically judges whether the shape of the steel plate 14 is qualified according to the preset standards. If it is unqualified, the shape detector determines which area of ​​the steel plate 14 does not meet the standard based on the detection situation, and sends the information to the secondary system of the quenching machine, automatically calls the corresponding process adjustment strategy, and then adjusts the quenching parameters of the quenching machine through the primary system. If the shape is qualified, the curing process is used for production.

[0054] Before the steel plate 14 leaves the heat treatment furnace, the third-level system sends the information such as the steel plate number, steel type, steel plate thickness, steel plate width and other plate shape qualification standards to the plate shape detector system in advance. When the head of the steel plate 14 reaches the plate shape detector, the plate shape of the steel plate 14 is automatically detected. After the plate shape detection is completed, the plate shape detector feeds back the detection results to the plate shape detector system. The plate shape detector system automatically determines whether the plate shape of the steel plate 14 is qualified based on the detection results. If the plate shape of the steel plate 14 is qualified, the steel type, thickness and width of the next steel plate 14 are automatically retrieved. If the information of the steel plate 14 is the same as that of the previous qualified steel plate 14, the curing process is used for continuous production. If the plate shape of the steel plate 14 is detected to be unqualified, the position of the unqualified plate shape is automatically determined, and the information is sent to the second-level system. The second-level system retrieves the corresponding quenching parameter adjustment strategy according to the position defect given by the plate shape detector, and automatically adjusts the process parameters such as the flow rate of the cooling water of the nozzle and the speed of the quenching machine roller through the first-level system. After the adjustment is completed, the shape detector continues to detect the shape of the subsequent steel plate 14, and transmits the detection data to the secondary system. If the shape of the steel plate 14 is qualified, the process is solidified. If the shape is unqualified, the secondary system continues to adjust until the shape of the steel plate 14 is qualified.

[0055] The plate shape detector determines whether the current steel plate 14 is consistent with the previous steel plate in terms of steel type, width, thickness and other information of the steel plate 14. If any one of the steel type, width and thickness is different, the quenching machine will retrieve the corresponding process from the original database of the secondary system for quenching.

[0056] like Figures 1 to 3As shown, the method is applicable to high-strength steel plates or wear-resistant steel plates with a thickness of 6mm-100mm and a width of 1500mm-4100mm. Specifically, it includes the following steps:

[0057] Step 1, partition the steel plate 14, such as Figure 3 shown.

[0058] According to the deformation conditions that often occur in the steel plate 14, the deformation areas of the steel plate 14 are defined, and the steel plate 14 is divided into five zones, namely the first zone 9, the second zone 10, the third zone 11, the fourth zone 12 and the fifth zone 13. The first zone 9 is within 2 meters from the end length of the head of the steel plate 14, the second zone 10 is within 2 meters from the end length of the tail of the steel plate 14, after excluding the first zone 9 and the second zone 10, the third zone 11 is within 0.5 m from one side of the steel plate 14, and the fourth zone 12 is within 0.5 m from the other side of the steel plate 14, and after excluding the first zone 9, the second zone 10, the third zone 11 and the fourth zone 12 are the remaining middle part. The fifth zone 13.

[0059] The cooling speeds in the middle and periphery of the steel plate 14 are different. From a spatial perspective, the middle part of the steel plate 14 (the fifth zone 13) is surrounded by the peripheral part of the steel plate 14 (the first, second, third, and fourth zones), and the cooling is relatively slow before entering the quenching machine; the peripheral positions of the steel plate 14 (the first, second, third, and fourth zones) all have one side facing the air, and the heat dissipation is relatively fast; therefore, the steel plate 14 is divided into a peripheral zone and a middle zone; in the peripheral zone, because the steel plate 14 moves into and out of the quenching machine, the defects that are prone to occur at the head entering the quenching machine and the tail leaving the quenching machine are roughly the same, and the defects that appear on the left and right sides of the steel plate 14 are roughly the same, therefore, the periphery is divided into front and rear areas (the first zone and the second zone) with similar defects, and left and right areas (the third zone and the fourth zone) with similar defects. This zoning method is a reasonable division method obtained through scientific analysis after empirical summary of the heat dissipation temperature of the steel plate 14.

[0060] This partitioning method has the following advantages:

[0061] The main reasons and benefits of dividing the steel plate 14 into five zones (the first zone, the second zone, the third zone, the fourth zone, and the fifth zone) of front, back, left, right, and center can be understood from the following aspects: 1. It can be precisely adjusted according to the deformation characteristics of different zones; 2. Improve the accuracy and effectiveness of the adjustment. After the zoning, corresponding adjustment measures can be taken according to the specific problems of each zone, reduce the number of trial and error, and improve the adjustment efficiency. 3. After the zoning, a detailed automatic adjustment strategy can be formulated for each zone. When the plate shape detector detects that the plate shape of a certain area is unqualified, the quenching machine control system can automatically adjust the corresponding parameters (such as roller speed, nozzle flow, etc.) according to the preset strategy to achieve rapid response and precise control. The adjustment strategy after the zoning can accumulate a large amount of data, and through data analysis and machine learning, the strategy is continuously optimized to improve the plate shape qualification rate of the steel plate 14. 4. Improve production efficiency and quality: Zoning adjustment can significantly reduce the frequency of manual intervention, reduce the risk of human error, and improve the stability and consistency of production. Through precise zoning adjustment, the scrap rate caused by unqualified plate shape can be effectively reduced, and production efficiency and economic benefits can be improved.

[0062] It is usually recommended that the length of the head and tail partitions be about 2 meters. This is because the head and tail of the steel plate 14 are easily affected by the cooling rate during the quenching process, resulting in warping or knocking. The width of the edge partition is usually about 0.5 meters. This is because during the quenching process, the cooling conditions of the edge area are different from those of the center area, which is prone to edge waves (drifting). The center partition is the remaining part after removing the head, tail and edge partitions. This part usually occupies most of the area of ​​the steel plate 14 and is the main area.

[0063] The plate shape detector is equipped with an imaging system, including three groups of industrial cameras, which are used to collect images of steel plates in the three areas of the left, middle and right sides in real time, and each group of industrial cameras has three; this scheme uses three groups of industrial cameras to monitor the images of steel plates in the three areas of the left, middle and right sides of the moving track in real time. Three groups of industrial cameras are used, which have higher resolution. Through segmented acquisition, higher resolution can be used to shoot in each small area, so as to obtain clearer details; the imaging system also includes a laser, and three lasers are set up. Each laser corresponds to a group of industrial cameras. Each laser can emit three infrared laser lines and shoot them at the steel plate. After that, each industrial camera can shoot an infrared laser line reflected by the steel plate. By introducing lasers and using them in conjunction with industrial cameras, this design can use laser lines as references to enhance the recognition of surface features of steel plates, especially in poor lighting conditions. It can also maintain a high detection accuracy. The detection of specific defects in each area is achieved by the above-mentioned method. The principle of the cooperation between lasers and industrial cameras will not be described in detail here, which belongs to the conventional technology in this field.

[0064] Step 2, defining the unqualified plate shapes that may appear in all partitions of the steel plate 14.

[0065] The possible unqualified plate shapes that may appear in the first zone 9 include warping and knocking. The warping that appears in the first zone 9 is defined as warping in zone one, and the knocking that appears in the first zone 9 is defined as knocking in zone one. The possible unqualified plate shapes that may appear in the second zone 10 include warping and knocking. The warping that appears in the second zone 10 is defined as warping in zone two, and the knocking that appears in the second zone 10 is defined as knocking in zone two. The possible unqualified plate shapes that may appear in the third zone 11 include curvature (curvature: a surface defect of steel, which refers to the distortion of the steel surface), which is defined as zone three-side wave. The possible unqualified plate shapes that may appear in the fourth zone 12 include curvature, which is defined as zone four-side wave. The possible unqualified plate shapes that may appear in the fifth zone 13 include convexity and concaveness. The convexity that appears in the fifth zone 13 is defined as zone five convexity, and the concave that appears in the fifth zone 13 is defined as zone five concave.

[0066] Step 3, the steel plate 14 after shot blasting (surface treatment process) enters the heat treatment furnace for heating. 30 seconds before the steel plate 14 leaves the heat treatment furnace, the three-level system sends the information of the steel plate 14 (including the steel type, thickness, width, length, etc. of the steel plate 14) to the quenching machine. The quenching machine automatically selects the roller speed of the quenching machine, the number of open nozzles and the flow rate required for each nozzle according to the heat transmission information.

[0067] Step 4, after shot blasting is completed, the steel plate 14 is placed in a quenching machine for quenching. After quenching of the steel plate 14 is completed, the plate shape detector detects the steel plate 14 and sends the defect information of the unqualified area to the quenching machine control system. The quenching machine control system adjusts the quenching parameters according to the unqualified plate shape that appears in a certain partition of the steel plate 14.

[0068] Step 5, repeating steps 3 and 4 until the shape of the steel plate 14 is qualified, thereby achieving online automatic adjustment of the shape of the steel plate 14.

[0069] The following is an example of an automatic process adjustment strategy for quenching parameters of the quenched plate shape when unqualified plate shapes appear in various areas of the steel plate 14:

[0070] Adjustment strategy for region one upturn:

[0071] The plate shape detector detects the steel plate 14. If warping occurs in the first zone 9 of the steel plate 14, the speed of the quenching machine roller is increased by 5%. After the speed of the quenching machine roller is increased by 5%, if the plate shape of the first zone 9 is qualified, the speed of the quenching machine roller is fixed to the speed after the 5% increase. If the plate shape of the first zone 9 is still unqualified and warping continues, the roller speed is increased in accordance with the adjustment range of 3% and 1%. If warping is still unqualified after reaching the minimum adjustment range, the plate shape detector will sound an alarm and make manual plate shape adjustments.

[0072] If the plate shape of the first zone 9 is still unqualified and knocks after adjustment, the speed of the quenching machine roller will be reduced by 3%. After the speed of the quenching machine roller is reduced by 3%, if the plate shape of the first zone 9 is qualified, the speed of the quenching machine roller will be fixed to the speed after the 3% reduction. If the plate shape of the first zone 9 of the steel plate 14 is still unqualified and knocks, the roller speed will continue to be reduced by 1%. If it is still unqualified and knocks, the HMI screen on the plate shape detector will alarm and the plate shape will be adjusted manually.

[0073] In practice, there will not simply be warping or knocking, but there may be alternating warping and knocking. After each adjustment, if it is unqualified and the same defect still occurs, the adjustment range will be reduced and continued to adjust; if another defect occurs, the current adjustment range will be reduced and adjusted in the opposite direction; if it is still unqualified after reaching the minimum adjustment range, the plate shape detector will sound an alarm and perform manual plate shape adjustment.

[0074] The principle of speeding up and eliminating warping is as follows: 1. The cooling water on the upper surface will accumulate on the surface of the steel plate 14 to form a layer of water film. This layer of water film can provide a longer cooling effect because the presence of the water film increases the contact time between the cooling water and the surface of the steel plate 14. 2. The cooling water on the upper surface is easier to distribute evenly to form a continuous water film, which helps to improve cooling efficiency. The presence of the water film ensures that the cooling water covers the entire surface and reduces local overheating. The cooling water on the lower surface will form an immediate falling water flow due to gravity, resulting in more cooling water in some areas and less cooling water in some areas, resulting in uneven cooling.

[0075] There are two main reasons for the warping of the surface of the steel plate 14. One is that the cooling speed of the lower surface of the steel plate 14 is greater than that of the upper surface. The other is that the temperature of the head of the steel plate 14 drops faster and the temperature uniformity is poor, which leads to the deformation and warping of the steel plate 14. After the speed of the steel plate 14 is increased, the cooling speed of the upper surface is increased. On the other hand, the speed increase makes the cooling of the head of the steel plate 14 more uniform, avoiding the warping caused by the uneven temperature of the head of the steel plate 14.

[0076] Adjustment strategy for region 1:

[0077] The adjustment strategy for area 1 can be the opposite of that for area 1, which will not be described in detail here. In addition, the following adjustment strategies can also be adopted:

[0078] The plate shape detector detects the steel plate 14. If knocking occurs in the first zone 9 of the steel plate 14, the speed of the quenching machine roller is reduced by 5%. After the speed of the quenching machine roller is reduced by 5%, if the plate shape of the first zone 9 of the steel plate 14 is qualified, the speed of the quenching machine roller is fixed to the speed after the 5% reduction.

[0079] If the plate shape of the first zone 9 of the steel plate 14 is still unqualified and kowtows occur, the water ratio of the upper and lower nozzles will be reduced by 3%. If the plate shape of the first zone 9 of the steel plate 14 is qualified, the flow rate of the nozzle will be fixed. If the plate shape of the first zone 9 of the steel plate 14 is still unqualified and kowtows, the water ratio of the upper and lower nozzles can be further reduced by 1%. If kowtows occur again, the HMI screen will alarm and the plate shape will be adjusted manually.

[0080] In fact, the adjustment strategy in this scheme is mainly used in the state of extremely fast quenching speed. In this state, the speed of the roller is extremely high, the flow rate of the upper and lower nozzles is extremely large, the upper and lower surfaces of the steel plate 14 are rapidly cooled to directly form a hard shell, while the inside of the steel plate 14 is slowly cooled. In this state, the total quenching time is very short. Because a relatively stable water film will be formed on the upper surface of the steel plate 14, the means of increasing the upper flow rate to increase the upper cooling rate has little effect. Moreover, because the total time is short, the upper surface cannot have sufficient time to cool, and the means of upper surface cooling can no longer achieve good results. However, in this case, increasing the flow rate of the lower nozzle, that is, reducing the water ratio of the upper and lower nozzles, can be an effective adjustment strategy; specifically, by increasing the flow rate of the lower nozzle (such as the second nozzle 2 high-pressure nozzle), the lower surface can be quickly cooled to a lower temperature, so that a thicker hard shell can be formed on the lower surface more quickly. This hard shell can resist the tensile stress generated by the temperature drop in the upper and middle parts of the steel plate 14 during the subsequent cooling process, thereby reducing knocking; and this method of continuing to increase the flow rate of the lower nozzle to increase the cooling amount of the lower surface is more effective, because the lower surface cannot form a water film due to gravity.

[0081] If after the speed of the quenching machine roller is reduced by 5%, if the plate shape of the first zone 9 of the steel plate 14 is still unqualified and warping occurs, the water ratio of the upper and lower nozzles will be increased by 3%. After the increase of 3%, if the plate shape of the first zone 9 of the steel plate 14 is qualified, the flow parameters of the quenching machine nozzle will be fixed to the flow parameters after the 3% increase. If the plate shape of the first zone 9 of the steel plate 14 is still unqualified and warping occurs, the speed of the quenching machine roller will be reduced by 1%. If the plate shape of the first zone 9 of the steel plate 14 is still unqualified, the HMI screen will alarm and the plate shape will be adjusted manually.

[0082] Adjustment strategy for regional two-head:

[0083] The plate shape detector detects the steel plate 14. If the second zone 10 of the steel plate 14 shows warping, the water ratio of the upper and lower nozzles of the quenching machine is increased by 5%. After the increase of 5%, if the plate shape of the second zone 10 of the steel plate 14 is qualified, the flow rate is fixed to the flow rate after the 5% water ratio increase. If the plate shape of the second zone 10 of the steel plate 14 is still unqualified, and the first zone 9 of the steel plate 14 shows warping, the speed of the quenching machine roller is reduced by 3%. After the speed of the quenching machine roller is reduced by 3%, if the plate shape of the steel plate 14 is qualified, the speed of the quenching machine roller is fixed to the speed after the 3% reduction. If the plate shape of the steel plate 14 is still unqualified, the speed of the quenching machine roller is increased by 1% or the water ratio of the upper and lower nozzles is increased by 1%. If it is still unqualified, the HMI screen alarms and the plate shape is adjusted manually.

[0084] After the flow rate of the first nozzle 1 of the quenching machine is increased by 5%, if the plate shape of the second zone 10 of the steel plate 14 is still unqualified and warping occurs in the first zone 9 of the steel plate 14, the speed of the quenching machine roller is increased by 3%; after the speed of the quenching machine roller is increased by 3%, if the plate shapes of the first zone 9 and the second zone 10 of the steel plate 14 are qualified, the speed of the quenching machine roller is fixed to the speed after the 3% increase, if the plate shape of the first zone 9 and the second zone 10 of the steel plate 14 is still unqualified and still has warping, the speed of the quenching machine roller is increased by 1%, and if the plate shape is still not qualified, the HMI screen alarms and the plate shape is adjusted manually.

[0085] Adjustment strategy for Region 2:

[0086] The plate shape detector detects the steel plate 14. If the second zone 10 of the steel plate 14 shows knocking, the water ratio of the upper and lower nozzles is reduced by 5%. If the plate shape of the second zone 10 of the steel plate 14 is qualified, the flow rate of the nozzle of the quenching machine is fixed to the flow rate after the water ratio is reduced by 5%. If the plate shape of the second zone 10 of the steel plate 14 is still unqualified and knocking occurs in the first zone 9 of the steel plate 14, the speed of the quenching machine roller is reduced by 3%. If the plate shape is still unqualified and knocking occurs, the speed of the quenching machine roller is reduced by 1%. If the plate shape is still unqualified, the HMI screen alarm is issued and the plate shape is adjusted manually.

[0087] Adjustment strategy for regional three-sided waves or regional four-sided waves:

[0088] The plate shape detector detects the steel plate 14. If the third zone 11 or the fourth zone 12 of the steel plate 14 is warped, the speed of the quenching machine roller is increased by 5%. After the speed of the quenching machine roller is increased by 5%, if the plate shapes of the third zone 11 and the fourth zone 12 of the steel plate 14 are qualified, the speed of the quenching machine roller is fixed to the speed after the 5% increase. If the plate shapes of the third zone 11 and the fourth zone 12 of the steel plate 14 are still unqualified, the flow rate ratio of the upper and lower nozzles of the quenching machine is increased by 3%. After the flow rate ratio of the upper and lower nozzles of the quenching machine is increased by 3%, if the plate shape of the steel plate 14 is qualified, the speed of the quenching machine roller is fixed to the speed after the 3% increase. If the plate shape of the first zone 9 and the second zone 10 of the steel plate 14 is unqualified and has warping, the speed of the quenching machine roller is increased by 1%. If the plate shape is still unqualified, the HMI screen alarms and the plate shape is adjusted manually.

[0089] Edge waves indicate that the temperature on both sides drops more, while the temperature in the middle drops less. There are free-air edges on both sides, so the sides cool down faster and the middle cools down slower. At this time, increasing the roller speed can shorten the total cooling time, thereby shortening the difference in total cooling between the two sides and the middle, thereby eliminating the edge waves.

[0090] Adjustment strategy for area five middle convex (central convex):

[0091] When a bulge appears in the middle area, the following specific measures can be taken: reduce the speed of the quenching machine roller by 5%, and after the speed of the quenching machine roller is reduced by 5%, if the plate shape of the fifth zone of the steel plate 14 is qualified, the speed parameter of the quenching machine roller after the speed parameter of the quenching machine roller after the speed parameter of the quenching machine roller after the speed parameter of the quenching machine roller before ...

[0092] If the plate shape of the fifth zone of the steel plate 14 is unqualified and still convex, reduce the water ratio of the upper and lower nozzles of the quenching machine by 3%. Then, if the plate shape of the fifth zone of the steel plate 14 is qualified, use the flow parameters after reducing the water ratio by 3% to cover the flow parameters of the nozzle before reduction. If the plate shape of the fifth zone is still unqualified and convex, change the adjustment range to 1% and continue to adjust. If it is still unqualified, the HMI screen will alarm and the plate shape will be adjusted manually.

[0093] After the speed of the quenching machine roller is reduced by 5%, if the plate shape of the fifth zone of the steel plate 14 is unqualified and concave, the upper and lower water ratio of the nozzle is increased by 3%. Afterwards, if the plate shape of the fifth zone of the steel plate 14 is qualified, the flow parameters after the 3% increase in water ratio are used to cover the flow parameters of the nozzle before the increase. If the plate shape of the fifth zone of the steel plate 14 is still unqualified and convex, the upper and lower nozzle water ratio is reduced by 1%. If it is still unqualified after the reduction, the HMI screen will alarm and the plate shape will be adjusted manually.

[0094] The adjustment strategy for the concave in area 5 (the concave in the middle) can be the opposite of the adjustment strategy for the convex in area 5, which will not be described in detail here. This scheme is not only for the plate shape, but also for the adjustment under the premise of improving the quenching efficiency. Therefore, when adjusting, first accelerate, then increase the nozzle flow, and then decelerate when it is unqualified. Acceleration and increasing the nozzle flow will not reduce the overall quenching efficiency.

[0095] In summary, the defects in each area can be summarized into two types, and the following specific adjustment methods are adopted:

[0096] The first type includes one or more of area one warp, area two warp, area five concave, area three side wave and area four side wave, which are adjusted by increasing the roller speed, increasing the upper and lower nozzle water ratio, or a combination thereof;

[0097] The second type includes one or more of the knocking in area one, the knocking in area two and the convex in area five, which are adjusted by reducing the roller speed, reducing the water ratio of the upper and lower nozzles, or a combination thereof.

[0098] After each adjustment: if the product fails to meet the standard and the same defect still occurs, the adjustment range will be reduced; if another defect occurs, the current adjustment range will be reduced and the product will be adjusted in the opposite direction; if the product still fails to meet the standard after reaching the minimum adjustment range, the plate shape detector will sound an alarm and make manual plate shape adjustments. The adjustment range will be reduced in the order of 5%, 3%, and 1%, and the minimum adjustment range is 1%.

[0099] It is worth noting that in this solution, when the roller speed or the water ratio of the upper and lower nozzles is changed for a defect, the plate shape in other areas will not change, because this is closely related to the preconditions of the adjustment in this solution: This solution is mainly applicable to the effects of equipment accuracy, temperature difference in summer and winter, temperature difference in morning and evening, and change in quenching cooling water temperature. Obviously, when equipment accuracy, temperature difference in summer and winter, and temperature difference in morning and evening are manifested in each actual quenching process, the impact is very small, and it affects the entire steel plate 14, not a part. When such a small impact (for example, it will cause the stress in the steel plate 14 to change, but it is not manifested When the changes in the appearance of the steel plate 14 accumulate to a certain extent, they will appear as defects in a certain area. The adjustment ranges of 5%, 3%, and 1% in this scheme are also correspondingly very small, and the adjustment method is also for the entire plate. Its purpose is to eliminate the slight influence of equipment accuracy, temperature difference in summer and winter, and temperature difference in morning and evening on the overall steel plate 14, thereby improving the quality of quenching of the steel plate 14 as a whole and eliminating defects in local areas. On the surface, it is to eliminate defects in local areas, but in fact, some of the internal stress of the steel plate 14 caused by slight influences will also be eliminated. It is a quenching process parameter adjustment made to adapt to changes in the external environment.

[0100] Example 1

[0101] The inspection results are shown in Table 1, which includes the following steps:

[0102] (1) The three steel plates 14 are all made of NM400 steel, all have a thickness of 6 mm, and all have a width of 2500 mm.

[0103] (2) Before quenching, the steel plate 14 is shot blasted, the speed of the shot blasting roller is 2.0 m / min, and the diameter of the shot used for shot blasting is 1.0 mm to 1.2 mm.

[0104] (3) Heat treatment furnace heating process control: The quenching temperature of the heat treatment furnace is 910°C, and the steel plate 14 is in the furnace for 20 min.

[0105] (4) Quenching and cooling process control: the water pressure in the high-pressure section is set to 0.8 MPa, the water pressure in the low-pressure section is set to 0.4 MPa, the roll gap is set to 6.6 mm, the quenching machine roller speed is 12 m / min, and the flow rates of the first nozzle 1 and the second nozzle 2 are both 650 m 3 / h, the flow rate of the third nozzle 3 and the fourth nozzle 4 is 650m 3 / h, the flow rates of the fifth nozzle 5, the sixth nozzle 6, the seventh nozzle 7 and the eighth nozzle 8 are all 400m 3 / h, the total flow rate of all nozzles is 1700m 3 / h.

[0106] (5) After quenching, the first steel plate 14 enters the plate shape detector. The plate shape detector detects the first steel plate 14 and the result is that the area is warped and the unevenness is 17mm / 2m. Before the head of the second steel plate 14 leaves the heat treatment furnace, the third-level system sends the thickness, width and length of the steel plate 14 to the second-level system and the plate shape detector system (and checks the information sending time). The plate shape detector judges the shape of the steel plate 14 based on the steel type, width, thickness and other information of the steel plate 14. The plate shape detector sends the detection result of the first steel plate 14 and the corresponding process adjustment strategy to the second-level system. The second-level system automatically increases the roller speed of the quenching machine by 5% based on the existing speed, and sends the adjusted process to the first-level system of the quenching machine. The second steel plate 14 enters the quenching machine and is quenched according to the adjusted process. After quenching, the steel plate 14 enters the plate shape detector. The plate shape detector detects the area is warped and the unevenness is 8mm / 2m, which meets the national standard.

[0107] (6) Before the head of the third steel plate 14 comes out of the furnace, the heat treatment furnace sends the information of the steel plate thickness, steel plate width and steel plate length to the quenching machine, and the quenching machine's third-level system sends it to the plate shape detector (checking the information sending time). The plate shape detector detects and judges the shape of the steel plate 14. Because the detection result of the second steel plate 14 is qualified, the plate shape detector does not send a command to the quenching machine. The quenching machine automatically retrieves the quenching process of the second steel plate 14 for quenching, and automatically overwrites the process in the original quenching machine's second-level database.

[0108] Table 1: Test results of three steel plates 14 in Example 1

[0109]

[0110] Example 2

[0111] (1) The first steel plate is made of NM360 steel, 8 mm thick and 3600 mm wide. The second and third steel plates are made of NM400 steel, 10 mm thick and 2500 mm wide.

[0112] (2) Before quenching, the steel plate 14 is shot blasted, the speed of the shot blasting roller is 2.0 m / min, and the diameter of the shot used for shot blasting is 1.0 mm to 1.2 mm.

[0113] (3) Heat treatment furnace heating process control: quenching temperature is 910°C, and the steel plate 14 is in the furnace for 30 min.

[0114] (4) Quenching and cooling process control of the first steel plate 14: the water pressure of the high-pressure section is set to 0.8 MPa, the water pressure of the low-pressure section is set to 0.4 MPa, the roll gap is set to 8.8 mm, the roller speed of the quenching machine is 10 m / min, and the flow rates of the first nozzle 1, the second nozzle 2, the third nozzle 3 and the fourth nozzle 4 are all 760 m / min. 3 / h, the flow rates of the fifth nozzle 5, the sixth nozzle 6, the seventh nozzle 7 and the eighth nozzle 8 are all 800m 3 / h, the total flow rate of all nozzles is 2320m 3 / h.

[0115] (5) After quenching, the first steel plate 14 enters the plate shape detector. The plate shape detector detects that the area is one-knock and the unevenness is 16mm / 2m. Before the head of the second steel plate 14 comes out of the furnace, the third-level system sends the steel plate thickness, steel plate width, and steel plate length information of the second steel plate 14 to the plate shape detector. The plate shape detector determines that the steel type and thickness of the second steel plate 14 are inconsistent with those of the first steel plate 14, and automatically calls the corresponding process in the secondary original database of the quenching machine for quenching.

[0116] (6) Quenching and cooling process control of the second steel plate 14: the water pressure in the high-pressure section is set to 0.8 MPa, the water pressure in the low-pressure section is set to 0.4 MPa, the roll gap is set to 11 mm, the roller speed of the quenching machine is 8.6 m / min, and the flow rates of the first nozzle 1, the second nozzle 2, the third nozzle 3 and the fourth nozzle 4 are all 800 m / min. 3 / h, the flow rates of the fifth nozzle 5, the sixth nozzle 6, the seventh nozzle 7 and the eighth nozzle 8 are all 860m 3 / h, the total flow rate of all nozzles is 2460m 3 / h.

[0117] (7) After quenching, the second steel plate 14 enters the plate shape detector. The plate shape detector detects that the area is one knock, and the unevenness is 14mm / 2m. Before the head of the third steel plate 14 comes out of the furnace, the three-level system sends the steel plate thickness, steel plate width, and steel plate length information of the third steel plate 14 to the plate shape detector. The steel type, width, and thickness are all the same as the second one. After quenching, the third steel plate 14 enters the plate shape detector. The plate shape detector detects that the area is one knock, and the unevenness is 5mm / 2m, which meets the national standard.

[0118] Table 2: Test results of three steel plates 14 in Example 2

[0119]

[0120] From the above description, it can be seen that the above embodiments of the present invention achieve the following technical effects:

[0121] The problem of batch shape mismatch of 6mm-100mm thick wide and thick plate 14 caused by seasonal temperature changes and unstable equipment status has been solved, effectively reducing manual intervention and adjustment, greatly improving the qualified rate of quenched plate shape of steel plate 14, and reducing the number of straightening or re-quenching of steel plate 14 due to mismatch after quenching. The actual improvement of qualified rate is as follows:

[0122] The following is a comparison of multiple experiments, and the improvement of the pass rate is as follows:

[0123]

[0124]

[0125] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the technical solution of the present invention, and are not intended to limit the specific implementation methods of the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the claims of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. A method for optimizing the shape of a quenched steel plate, characterized in that: Including quenching machine, quenching machine control system and plate shape detector; S1. Use a plate shape detector to detect the shape of the steel plate after quenching; S2. Determine whether the shape of the steel plate meets the preset standard. If it fails, execute step S3; if it passes, execute step S5; S3. The plate shape detector identifies the defect type in the unqualified area and sends the information to the quenching machine control system; S4. The quenching machine control system adjusts the quenching process parameters according to the defect type and overwrites the original parameters with the adjusted parameters; S5. Apply quenching process parameters to solidify the production process.

2. The method according to claim 1, characterized in that The steps of the flatness detector identifying the defect type in the unqualified area include: S31. The steel plate is divided into the following sections, wherein the areas at the first preset distance from the head and the tail are the first zone and the second zone, the areas at the second preset distance from both sides are the third zone and the fourth zone, and the remaining middle part is the fifth zone; S32. Inspect the appearance of each section according to preset standards and evaluate whether it is qualified.

3. The method according to claim 2, characterized in that The first preset distance is 1.5-2.5 m, and the second preset distance is 0.3-0.7 m.

4. The method according to claim 2, characterized in that: The types of defects present in the unqualified areas are as follows: The defects occurring in the first area and the second area include warping and knocking, which are defined as warping in area 1, knocking in area 1, warping in area 2, and knocking in area 2, respectively; The defects in the third and fourth zones are floating and curvature, which are defined as regional three-side waves and regional four-side waves respectively; The defects appearing in the fifth zone are concave and convex, which are defined as concave in zone five and convex in zone five, respectively.

5. The method according to claim 4, characterized in that The adjusted quenching process parameters include at least the roller speed and the upper and lower nozzle water ratio. When adjusting, one or more combinations of these parameters are used.

6. The method according to claim 5, characterized in that The defects in the first, second, third, fourth and fifth zones are divided into two types, each of which adopts the following specific adjustment method: The first type includes one or more of area one warp, area two warp, area five concave, area three side wave and area four side wave, which are adjusted by increasing the roller speed, increasing the upper and lower nozzle water ratio, or a combination thereof; The second type includes one or more of the knocking in area one, the knocking in area two and the convex in area five, which are adjusted by reducing the roller speed, reducing the water ratio of the upper and lower nozzles, or a combination thereof.

7. The method according to claim 6, characterized in that After each adjustment: If the product fails and the same defect still occurs, the adjustment range will be reduced; If another defect occurs, reduce the current adjustment range and adjust in the opposite direction; If the plate is still unqualified after reaching the minimum adjustment range, the plate shape detector will sound an alarm and perform manual plate shape adjustment.

8. The method according to claim 7, characterized in that The adjustment range is reduced successively in the order of 5%, 3%, and 1%, and the minimum adjustment range is 1%.

9. An electronic device, characterized in that: Including processors; a memory having stored thereon a computer program executable on the processor; Wherein, when the computer program is executed by a processor, the method steps as claimed in any one of claims 1 to 8 are implemented.

10. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed, the method steps according to any one of claims 1 to 8 are implemented.

Images