Process control system and method for high-speed air cooling line

Abstract

The invention discloses a process control system and method for a high-speed air cooling line. Comprising the following control units: a transmission PLC used for collecting state information of field equipment, processing and generating operation and fault signals of the equipment and sending the operation and fault signals to a flow control PLC; receiving a control command of the flow control PLC; the flow control PLC is used for receiving the equipment state and fault signals of the transmission PLC, mapping the equipment state and fault signals to the equipment information processing module, and generating a condition judgment module and a speed distribution module; in the working area, an operation module is generated through operation and is sent to the transmission PLC; and the logic control area distributed in the flow control PLC performs logic operation through a working area operation command, so that the action of the field equipment is controlled and the state of the working area is synchronously fed back. Complex process control logic is converted into a simple pin module, the programming amount of programmers is reduced, the maintenance difficulty of maintainers is reduced, and the system has good expandability.

Description

Technical Field

[0001] The present invention relates to a process control system and method for a high-speed wire air-cooling line. Background Art

[0002] A certain iron and steel plant currently has 2 high-speed wire production lines. Each air-cooling line has 12 sections of air-cooling roller tables. The original air-cooling roller tables have no speed cascade and upstream-downstream interlock relationship, and are manually selected by the operator on the control interface. The signals in the front area are not communicated to the PLC control system in the rear area, so the functions of automatically stopping and accelerating the front-end roller tables cannot be realized, and the tail-section roller tables also have no temporary pause function to adjust the coil shape. The operators in the control room contact the on-site personnel by phone, and then the on-site personnel manually control the front-section and tail-section roller tables through the electrical operation box. This semi-automatic control method occupies a large amount of manpower, has low efficiency, and has a large human interference factor, belonging to a backward production method. Summary of the Invention

[0003] To overcome the above defects, the purpose of the present invention is to provide a process control system and method for a high-speed wire air-cooling line.

[0004] To achieve the above purpose, the process control system for a high-speed wire air-cooling line of the present invention includes the following control units:

[0005] The drive PLC is used to collect the status information of on-site equipment, process and generate the operation and fault signals of the equipment and send them to the process control PLC; receive the control commands from the process control PLC, including commands such as start, stop, emergency stop, and speed setting, and control the equipment actions;

[0006] The process control PLC receives the equipment status and fault signals from the drive PLC, maps them into the equipment information processing module, and generates a condition judgment module and a speed distribution module; generates a start module, a stop module, a pause module, and a position module through operations in the working area and sends them to the drive PLC;

[0007] The working area is the logical control area allocated in the process control PLC, which is used to load the information processing module, the condition judgment module, the speed distribution module, and the fault module, perform logical operations through the working area operation commands, generate the start module, the stop module, the pause module, and the position module, so as to control the actions of on-site equipment and synchronously feedback the status of the working area.

[0008] Further, the drive PLC and the process control PLC exchange data through a high-speed industrial Ethernet.

[0009] Further, the working area further includes:

[0010] 1) The operation unit is used to control the processes loaded into the working area, and the control includes selection, start, sequential stop, emergency stop, reset, and cancellation;

[0011] 2) Status output unit, used to monitor the operating status of the working area, and the operating status includes selected, enabled, started, rotational speed, linear speed, frequency converter fault, fan fault, start timeout.

[0012] Furthermore, the system further includes the following operation modules:

[0013] Device processing module, which reads the prepared parameters in the drive PLC and converts them into a format available for the working area through logical operation. Commands such as start, stop, and speed setting sent from the working area are converted by the device processing module and then sent to the drive PLC;

[0014] Condition judgment module, which judges the manual / automatic condition of the air-cooled line according to the digital input signal of the process control PLC, and judges the acceleration and deceleration time of the air-cooled line according to the rear area ready signal sent after communicating with the main rolling PLC system and receiving the main rolling equipment signal;

[0015] Speed distribution module, which calculates the speeds of various steel grades through the process specification parameters and the setting coefficients on the HMI interface, and issues them to the drive PLC.

[0016] Furthermore, it also includes a fault module, which obtains equipment faults and alarm status through the drive PLC, maps them to the equipment module for generation, and reflects the fault and alarm codes on the HMI interface.

[0017] Furthermore, it also includes

[0018] Start module, which is generated after logical operation in the working area, mapped to the equipment module, sent to the drive PLC, and controls the equipment to start;

[0019] Stop module, which is generated after logical operation in the working area, mapped to the equipment module, sent to the drive PLC, and controls the equipment to stop;

[0020] Position module, which calculates the traveling distances of the steel head and steel tail per unit time according to the incoming steel signal in the previous section, the length of the roller table, and the linear speed of the roller table, so as to realize the position tracking of a single-section coil on the air-cooled roller table.

[0021] Furthermore, it includes a pause module; the pause module includes:

[0022] Full-line pause: When it is necessary to pause the air-cooled line to handle problems during production, this module stops the air-cooled roller table and sends the rear area unready signal to the rolling line PLC. After the problem is handled, the roller table resumes to the operating state before pausing;

[0023] Tail section pause: When the tail of the air-cooled line needs to urgently process the adjustment of the coil shape on the tail roller table during coiling, only the last two roller sections of the air-cooled roller table are stopped through this module, and no unready signal is sent. After the problem is solved, the roller table resumes its operation state before pausing.

[0024] Furthermore, the working area loads the corresponding process matrix into the working area through the process number of the process matrix.

[0025] To achieve the above object, a process control method for a high-speed wire air-cooled line of the present invention includes the following steps:

[0026] The drive PLC controls the frequency converters of the air-cooled roller table and the PLC of the air-cooled fans. They are connected by optical fibers to form a high-speed industrial Ethernet for data communication with the process control PLC located in the central control room. The collected on-site equipment is sent to the process control PLC. At the same time, control commands such as start, stop, pause, and speed setting from the process control PLC are received, and the equipment actions are controlled through the local drive program.

[0027] The process control PLC receives the equipment parameters and fault signals from the drive PLC, maps them to the information processing module, and then loads them into the working area through the corresponding module.

[0028] According to the upstream and downstream relationships of the process equipment, all equipment is arranged to generate data blocks for each equipment, and data is exchanged through the high-speed industrial Ethernet. The read and written equipment information is stored in the data module. Then, the parameters of each equipment are transformed and calculated through the information processing module to obtain the data type available for the working area.

[0029] The working area is responsible for summarizing the information of modules such as information processing, condition judgment, speed distribution, and faults. After calculation, instructions are sent to the on-site equipment, and at the same time, the equipment status is fed back.

[0030] Among them, for the start module, stop module, pause module, and position module, the working area loads the information processing module and the condition judgment module, and then combines the operation commands of the working area to perform logical operations of "AND", "OR", "NOT", and "XOR" on the modules. While judging the operation value, the bits in the module are cyclically set or reset, and then mapped to the information processing data block for equipment control.

[0031] Specifically, the following operation commands exist for the process in the working area:

[0032] 1) Selection: The instructions of the on-site operation box or the HMI in the control room select the air-cooled roller table to be operated, and these roller tables will be started in subsequent control.

[0033] 2) Speed allocation: Calculate the cascade speed required for each grade of steel through the parameters in the production process specification, and adjust the base speed, creep speed, high-speed, and swing coefficient of each roller table on the HMI interface in the control room. Output to the equipment through the work area to complete the control;

[0034] 3) Start and stop: Start the equipment in the process according to the roller table selection situation and the speed mode sequence, and start or stop the equipment in the process normally according to the roller table selection situation and the speed mode. When the fault module detects a frequency converter fault, a fan fault, or a timeout when starting, automatically stop the equipment in the process;

[0035] 4) Emergency stop: When an emergency occurs on-site and the equipment does not stop, the staff presses the emergency stop button to immediately stop all equipment in the process;

[0036] 5) Pause;

[0037] Full-line pause: When it is necessary to pause the air-cooled line to handle problems during the production process, stop the air-cooled roller table through this module and send the unready signal of the rear area to the rolling line PLC. After the problem is handled, the roller table resumes to the operating state before the pause;

[0038] Tail-section pause: When it is necessary to urgently handle the coil shape adjustment of the tail roller table during the coiling process at the tail of the air-cooled line, only stop the two roller tables at the tail section of the air-cooled roller table through this module, without sending the unready signal. After the problem is handled, the roller table resumes to the operating state before the pause.

[0039] Compared with the prior art, the beneficial effects of the present invention are:

[0040] (1) Since the module algorithm is merely a logical operation program of several modules and does not depend on specific equipment, the programmer can add equipment and change parameters according to the actual situation. When adding an equipment, only a new program segment of the same type is added in the module. When changing parameters, only change them on the external pins of the module. This greatly reduces the programming workload of the programmer and the maintenance difficulty of the maintenance personnel.

[0041] (2) The operation of each process is responsible for by a dedicated work area, and the status information of the process is complete, which is convenient for the system above the second level to collect relevant information of the process. It is convenient for the organization of production and the real-time monitoring of the production status. Brief Description of the Drawings

[0042] Figure 1 It is a schematic diagram of the data transmission structure of the process control method applied to the high-speed wire air-cooled line in Embodiment 1 of the present invention.

[0043] Figure 2 It is a schematic diagram of the work area structure of the process control method applied to the high-speed wire air-cooled line in Embodiment 1 of the present invention. Detailed Embodiments

[0044] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0045] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0046] The terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise specified, the meaning of "a plurality" is two or more.

[0047] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "installed", "connected", and "coupled" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be directly connected, or indirectly connected through an intermediate medium, and it may be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0048] The present invention relates to a control method for the air-cooled roller table of wire rods in a steel mill. The loose coil cooling and transportation line is installed behind the coiling machine and transports the coils to the coiling area smoothly at a certain distance, and the coils are cooled during the transportation process. According to the cooling requirements of different steel grades, by adjusting the air volume of the fan and the speed of the roller table, different control requirements for wire rods of different steel grades and different specifications are realized, so as to obtain the optimal comprehensive mechanical properties of the materials. Using the integrated module algorithm, the complex process control logic is transformed into simple pin-type modules, effectively reducing the programming time and the maintenance difficulty, and at the same time having good scalability. It provides underlying technical support for the later production maintenance or the addition or reduction of equipment.

[0049] Embodiment 1:

[0050] As Figure 1 It can be seen that this example includes three control units, namely a drive PLC, a process control PLC, and a work area, a basic equipment information processing module, and seven operation modules, namely a condition judgment module, a speed distribution module, a fault judgment module, a start module, a stop module, a position tracking module, and a pause module.

[0051] Among them, the drive PLC controls the frequency converters of the air-cooled roller tables and the PLCs of the air-cooled fans, including models such as Siemens 400 PLC and ABB's AC500. They are connected by optical fibers to form a high-speed industrial Ethernet for data communication with the process control PLC located in the central control room. The field device data collected is sent to the process control PLC. At the same time, it receives control commands such as start, stop, pause, and speed setting from the process control PLC, and controls the device actions through its own driver program.

[0052] The process control PLC is a high-performance Siemens 400 PLC. It receives the device parameters and fault signals from the drive PLC, maps them into the information processing module, and then loads them into the working area through the corresponding module.

[0053] According to the upstream and downstream relationships of the process equipment, all the equipment is arranged, data blocks for each device are generated, and data is exchanged through the high-speed industrial Ethernet. The device information read and written is stored in the data module.

[0054] Then, through the information processing module, the parameters of each device are converted and calculated to obtain the data types available for the working area.

[0055] The working area is a program execution block in the process control PLC. It is responsible for summarizing the information of the information processing, condition judgment, speed distribution, and fault modules, issuing commands to the field devices after calculation, and at the same time feeding back the device status.

[0056] From Figure 2 It can be seen that for the start module, stop module, pause module, and position module, the working area loads the information processing module and the condition judgment module, and then combines with the working area operation commands to perform logical operations such as "AND", "OR", "NOT", and "XOR" on the modules. While judging the operation value, it loops to set or reset the bits in the module, and then maps them into the information processing data block for device control.

[0057] Specifically, the following operation commands exist for the process in the working area:

[0058] 6) Selection: The instructions of the on-site operation box or the control room HMI select the air-cooled roller tables that need to run, and these roller tables will be started in subsequent control.

[0059] 7) Speed distribution: Through the parameters in the production process specification, calculate the cascading speed required for each grade of steel, and adjust the base speed, creep, and swing coefficient of each section of the roller table on the control room HMI interface. It is output to the device through the working area to complete the control.

[0060] 8) Start / Stop: Start the equipment in the process according to the roller table selection and speed mode sequence, and start or stop the equipment in the process normally according to the roller table selection and speed mode. When the fault module detects an inverter fault, a fan fault, or a timeout when starting, the equipment in the process is automatically stopped.

[0061] 9) Emergency Stop: When an emergency occurs on-site and the equipment fails to stop, all equipment in the process is emergently stopped when the staff presses the emergency stop button.

[0062] 10) Pause: 1. Full-line Pause: When it is necessary to pause the air-cooled line to handle problems during production, this module stops the air-cooled roller table and sends the unready signal for the rear area to the rolling line PLC. After the problem is solved, the roller table resumes its operation state before the pause. 2. Tail-section Pause: When it is necessary to urgently handle the coil shape adjustment of the tail-section roller table during the coiling process at the tail of the air-cooled line, only the two roller tables at the tail section of the air-cooled roller table are stopped through this module, and the unready signal is not sent. After the problem is solved, the roller table resumes its operation state before the pause.

[0063] The present invention has been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those of ordinary skill in the art, various changes can be made without departing from the gist of the present invention. Many other changes and modifications made without departing from the concept and scope of the present invention should be regarded as within the protection scope of the present invention.

[0064] In the description of this specification, specific features, structures, materials, or characteristics can be combined in a suitable manner in any one or more embodiments or examples.

[0065] As mentioned above, the above are only the specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention can easily think of changes or substitutions, which should all be covered by the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.

Claims

1. A process control system for a high-speed air cooling line, characterized in that: The system comprises the following control unit: The transmission PLC is used to collect the status information of the on-site equipment, process and generate the operation and fault signals of the equipment and send them to the process control PLC; receive the control commands of the process control PLC, including start, stop, emergency stop, speed setting and other commands, and control the equipment action; The process control PLC receives the device status and fault signals of the transmission PLC, maps them to the device information processing module, generates the condition judgment module and the speed distribution module; generates the start module, stop module, pause module, and position module through calculation in the work area, and sends them to the transmission PLC; The workspace is a logical control area allocated in the process control PLC, which is used to load information processing modules, condition judgment modules, speed distribution modules, and fault modules. Through the workspace operation commands, logical operations are performed to generate start modules, stop modules, pause modules, and position modules, thereby controlling the action of on-site equipment and synchronously feeding back the workspace status.

2. A process control system for a high-speed wire air cooling line according to claim 1, characterized in that: The transmission PLC and process control PLC exchange data via high-speed industrial Ethernet.

3. A process control system for a high-speed wire air cooling line according to claim 1, characterized in that: The workspace also includes: 1) Operation unit, used to control the process loaded into the work area, the control includes selection, start, sequential stop, emergency stop, reset, and cancel; 2) Status output unit, used to monitor the operating status of the work area, the operating status includes selected, enabled, started, speed, line speed, inverter fault, fan fault, and start timeout.

4. A process control system for a high-speed wire air cooling line according to claim 1, characterized in that: The system also includes the following computing modules: The equipment processing module reads the prepared parameters in the transmission PLC and converts them into a format that can be used in the work area through logical operation. The start, stop, speed setting and other commands issued by the work area are converted by the equipment processing module and sent to the transmission PLC; The condition judgment module judges the manual and automatic conditions of the air cooling line according to the digital input signal of the process control PLC, and judges the acceleration and deceleration time of the air cooling line according to the communication with the main rolling PLC system to send the rear area ready signal and receive the main rolling equipment signal; The speed distribution module calculates the speed of each steel grade through the process specification parameters and HMI interface setting coefficients, and sends it to the transmission PLC.

5. A process control system for a high-speed wire air cooling line according to claim 1, characterized in that: It also includes a fault module, which obtains equipment faults and alarm status through the transmission PLC, maps them to the equipment module, and displays the fault and alarm codes on the HMI interface.

6. A process control system for a high-speed wire air cooling line according to claim 1, characterized in that: It also includes a startup module, which is mapped to the device module after the work area performs logical operations and is sent to the transmission PLC to control the startup of the device; Stop module, after the work area performs logical operations, it is mapped to the device module and sent to the transmission PLC to control the device to stop; The position module calculates the travel distance of the steel head and tail per unit time according to the previous steel incoming signal, roller length, and roller linear speed, thereby realizing the position tracking of a single-section wire coil on the air-cooled roller.

7. A process control system for a high-speed wire air cooling line according to claim 1, characterized in that: It also includes a pause module; the pause module includes: Full line suspension: When the air cooling line needs to be suspended to deal with problems during production, this module stops the air cooling roller and sends the rear area not ready signal to the rolling line PLC. After the problem is solved, the roller returns to the running state before the suspension. Tail section pause: When the tail of the air-cooled line needs to urgently deal with the tail roller coil adjustment during the winding process, this module only stops the two rollers at the tail of the air-cooled roller, and does not send an unready signal. After the problem is resolved, the roller returns to the operating state before the pause.

8. A process control system for a high-speed wire air cooling line according to claim 1, characterized in that: The workspace loads the corresponding process matrix into the workspace through the process number of the process matrix.

9. A process control method for a high-speed wire air cooling line, characterized in that: The method comprises the following steps: The transmission PLC controls the air-cooled roller table inverter and the air-cooled fan PLC, which are connected to form a high-speed industrial Ethernet through optical fiber, and communicate with the process control PLC in the central control room; the collected field equipment is sent to the process control PLC; at the same time, it receives control commands such as start, stop, pause, speed setting, etc. from the process control PLC, and controls the equipment action through the local driver; The process control PLC receives the equipment parameters and fault signals from the transmission PLC, maps them to the information processing module, and then loads them into the workspace through the corresponding module; Arrange all devices according to the upstream and downstream relationships of process flow equipment, generate data blocks for each device, exchange data through high-speed industrial Ethernet, and store the read and written device information in the data module; The information processing module then transforms and calculates the parameters of each device to obtain the data type that can be used in the workspace; The work area is responsible for summarizing information from modules such as information processing, condition judgment, speed distribution, and faults, issuing instructions to on-site equipment after calculation, and also providing feedback on equipment status; Among them, the start module, stop module, pause module, and position module are loaded by the workspace. The information processing module and the condition judgment module are then combined with the workspace operation command to perform "AND", "OR", "NOT", and "XOR" logical operations on the modules. While judging the operation value, the bits in the modules are set or reset in a loop, and then mapped to the information processing data block for device control. Specifically, the following operation commands exist for the processes in the workspace: 1) Select the air-cooled roller conveyor to be operated through the on-site operation box or the HMI command in the control room. These roller conveyors will be started in the subsequent control; 2) Speed ​​distribution: Calculate the cascade speed required for each type of steel through the parameters in the production process specification, and adjust the basic speed and creep, high speed, and swing coefficients of each roller in the control room HMI interface. The control is completed by outputting to the equipment through the workspace; 3) Start and stop, start the equipment in the process in sequence according to the roller selection and speed mode, and start or stop the equipment in the process normally according to the roller selection and speed mode. When the fault module detects a converter fault, a fan fault or a start timeout, the equipment in the process will be automatically stopped; 4) Emergency stop: when an emergency occurs on site and the equipment does not stop, the staff can press the emergency stop button to stop all equipment in the process; 5) Pause; Full line suspension: When the air cooling line needs to be suspended to deal with problems during production, this module stops the air cooling roller and sends the rear area not ready signal to the rolling line PLC. After the problem is solved, the roller returns to the running state before the suspension. Tail section pause: When the tail of the air-cooled line needs to urgently deal with the tail roller coil adjustment during the winding process, this module only stops the two rollers at the tail of the air-cooled roller, and does not send an unready signal. After the problem is resolved, the roller returns to the operating state before the pause.

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