Remote centralized control system for cast pipe production line

Abstract

The invention discloses a remote centralized control system for a cast pipe production line, which comprises an operation interface module, an intelligent parameter adaptation module, a monitoring module and a data management module, and is characterized in that the operation interface module is based on Siemens WinCC software, and the intelligent parameter adaptation module applies a button C action code technology in the Siemens WinCC software; the whole spheroidal graphite cast pipe production line is connected into a centralized control system, operators perform remote operation in a centralized control room in a unified manner, the operation interface module is partitioned according to the production process, the operation state, the parameter setting range and the real-time parameters of equipment in each link are clearly displayed, and the operators can quickly acquire key information through different colors, icons and text descriptions, so that the production efficiency is improved. Information transmission is changed from manual transmission to system real-time sharing, communication between posts is free of any difficulty and obstruction, communication is rapid and effective, problems of each working section can be rapidly transmitted and efficiently processed, and the production efficiency and the product quality are greatly improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of ductile iron pipe production, and particularly relates to a remote centralized control system for a pipe casting production line. Background Art

[0002] As an indispensable key material in infrastructure construction, ductile iron pipes are widely used in many fields such as water supply, drainage, and gas transmission. With the acceleration of the global urbanization process and the continuous advancement of infrastructure construction, the market demand for ductile iron pipes shows a steady growth trend.

[0003] Currently, the information flow between the processes of the ductile iron pipe production line mainly relies on manual transmission. This method has obvious limitations. The speed of information transmission is slow, and delays and errors are prone to occur, resulting in insufficient close cooperation between the processes. For example, key information such as the molten iron temperature and composition in the melting process cannot be transmitted to the casting process in a timely and accurate manner, making it difficult for the casting workers to adjust the casting parameters according to the actual situation, thus affecting the quality and production efficiency of the ductile iron pipes. In addition, due to the lack of an effective information sharing mechanism, production managers are difficult to timely grasp the real-time situation on the production line and cannot make scientific and reasonable production decisions, further restricting the improvement of production efficiency. Summary of the Invention

[0004] The purpose of the present invention is to provide a remote centralized control system for a ductile iron pipe production line to solve the problems mentioned in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solution: A remote centralized control system for a ductile iron pipe production line, comprising:

[0006] An operation interface module, which is based on Siemens WinCC software and constructs a computer operation screen according to the layout of the on-site control switches of the ductile iron pipe production line, the operation habits, and the logic of each production link.

[0007] An intelligent parameter adaptation module, which uses the button C action code technology in Siemens WinCC software.

[0008] A monitoring module, which installs high-definition panoramic cameras and multi-dimensional sensor arrays at each key node of the ductile iron pipe production line, including the inlet and outlet of the melting furnace, the casting mold, the conveying track, and the grinding station, and combines with the multi-sensor fusion pipe type recognition device of the intelligent parameter adaptation module.

[0009] A data management module, which sets a system health status monitoring unit for real-time monitoring of the operating status of hardware devices, the performance indicators of Siemens WinCC software, and the stability of network communication.

[0010] Preferably, the operation interface of the operation interface module is partitioned according to the production process, covering the control and status display areas of processes such as smelting, casting, molding, and polishing. Each area is visually presented with the equipment operation status, parameter setting range, and current real-time parameters through different colors, icons, and text descriptions, and supports the remote issuance and confirmation of operation instructions.

[0011] Preferably, the operation screens in the operation interface module support multi-user permission management. Users with different permissions have different operation and viewing scopes, and the system security is ensured through the authentication and authorization mechanism.

[0012] Preferably, the parameter database in the intelligent parameter adaptation module adopts distributed storage and cloud computing technologies, with data redundancy and disaster recovery capabilities to ensure the security and reliability of data.

[0013] Preferably, the high-definition panoramic camera in the monitoring module generates a three-dimensional virtual model of the production line on the operation interface of the centralized control room in the operation interface module through video stitching and augmented reality technologies to achieve real-time visual monitoring. The multi-dimensional sensor array adopts wireless communication technology to reduce wiring costs and potential faults, and at the same time has self-diagnosis and automatic calibration functions to ensure the accuracy of data.

[0014] Preferably, the system health status monitoring unit in the data management module has remote diagnosis and fault repair functions, and can achieve remote debugging and maintenance of on-site equipment through network connection.

[0015] Preferably, the operation interface module also includes a data interface connected to an external enterprise management system to achieve seamless docking with systems such as enterprise resource planning (ERP) and manufacturing execution system (MES), and supports the automatic generation of production plans, accurate calculation of material requirements, and full-process management of quality traceability.

[0016] Preferably, the button C action code technology has an anti-misoperation function. When an operator performs a wrong operation or enters unreasonable parameters, the system automatically prompts and prevents the wrong execution to ensure production safety.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] (1) The entire ductile iron pipe production line is connected to the centralized control system. Operators uniformly perform remote operations in the centralized control room. The operation interface module is partitioned according to the production process, clearly displaying the operating status of equipment in each link, the parameter setting range, and real-time parameters at all levels. Through different colors, icons, and text descriptions, operators can quickly obtain key information. The information transmission has changed from manual transmission to real-time system sharing, solving the problems of information delay and error between processes. This enables operators in each section to communicate with on-site personnel using walkie-talkies, and operators in the centralized control room can communicate face-to-face. There are no difficulties or obstacles in communication between positions. The communication is fast and effective, and problems in each section can be quickly conveyed and efficiently processed, greatly improving production efficiency and product quality.

[0019] (2) The high-definition panoramic camera of the monitoring module uses video stitching and augmented reality technologies to generate a three-dimensional virtual model of the production line on the operation interface in the centralized control room, achieving real-time visual monitoring. Operators can view the operation of the production line comprehensively and from multiple angles, and promptly discover problems such as equipment failures and product defects. This enables operators in the centralized control room to control on-site equipment using a computer. Since the production line already has the ability of automated production, operators only need to perform remote monitoring through the monitoring module in the centralized control room.

[0020] (3) The button C action code technology has an anti-misoperation function. When operators perform incorrect operations or input unreasonable parameters, the system automatically prompts and prevents the incorrect execution. When adjusting the casting speed, if the input speed exceeds the reasonable range, the system will immediately pop up a prompt box to inform the operator of the reason for the error, avoiding production accidents caused by misoperations and ensuring production safety. Description of the Drawings

[0021] Figure 1 is the system principle block diagram of the present invention. Detailed Embodiments

[0022] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0023] The present invention provides a remote centralized control system for a ductile iron pipe production line as shown in Figure 1 and includes:

[0024] An operation interface module, the operation interface module is based on Siemens WinCC software, and constructs a computer operation screen according to the layout of on-site control switches of the ductile iron pipe production line, operation habits, and the logic of each production link;

[0025] Intelligent parameter adaptation module, which uses button C action code technology in Siemens WinCC software;

[0026] Monitoring module, which installs high-definition panoramic cameras and multi-dimensional sensor arrays at key nodes of the cast pipe production line, including the inlet and outlet of the melting furnace, casting molds, conveying tracks, and grinding stations. It combines with the multi-sensor fusion pipe type recognition device of the intelligent parameter adaptation module. The multi-sensor fusion pipe type recognition device is a device that comprehensively uses various sensor technologies to accurately identify the pipe type of cast pipes. It integrates multiple different types of sensors such as laser range sensors, image recognition sensors, and electromagnetic induction sensors, and through a data processing unit and specific algorithms, fuses and processes the data collected by each sensor, and finally accurately judges the pipe type information such as the pipe diameter, wall thickness, material, and model of the cast pipe;

[0027] Data management module, which sets a system health status monitoring unit for real-time monitoring of the operating status of hardware devices, the performance indicators of Siemens WinCC software, and the stability of network communication.

[0028] The operation interface of the operation interface module is partitioned according to the production process, covering the control and status display areas of links such as melting, casting, forming, and grinding. Each area is visually presented with the device operating status, parameter setting range, and current real-time parameters through different colors, icons, and text descriptions, and supports the remote issuance and confirmation of operation instructions.

[0029] The operation screens in the operation interface module support multi-user permission management. Users with different permissions have different operation and viewing scopes, and ensure system security through an authentication and authorization mechanism.

[0030] The parameter database in the intelligent parameter adaptation module uses distributed storage and cloud computing technologies, with data redundancy and disaster recovery capabilities to ensure the security and reliability of data.

[0031] In the monitoring module, the high-definition panoramic camera generates a three-dimensional virtual model of the production line on the operation interface of the centralized control room in the operation interface module through video stitching and augmented reality technologies to achieve real-time visual monitoring. The multi-dimensional sensor array uses wireless communication technology to reduce wiring costs and potential faults, and at the same time has self-diagnosis and automatic calibration functions to ensure the accuracy of data.

[0032] The system health status monitoring unit in the data management module has remote diagnosis and fault repair functions, and can achieve remote debugging and maintenance of on-site equipment through network connection.

[0033] The operation interface module also includes a data interface connected to an external enterprise management system, which realizes seamless docking with systems such as enterprise resource planning (ERP) and manufacturing execution system (MES), and supports the automatic generation of production plans, accurate calculation of material requirements, and full-process management of quality traceability.

[0034] The button C action code technology has an anti-misoperation function. When an operator makes a wrong operation or enters unreasonable parameters, the system will automatically prompt and prevent the wrong execution to ensure production safety. The button C action code technology is a code program written in C script language in Siemens WinCC software and is associated with a multi-sensor fusion pipe type recognition device. It can be triggered according to the pipe type recognition result, retrieve the corresponding production parameters of the pipe type from the parameter database, and display them on the operation interface to assist the operator in reference and adjustment.

[0035] I. Operation interface module:

[0036] The operation interface module is carefully constructed based on Siemens WinCC software. Entering the centralized control room, the operation interface faced by the operator is clearly divided according to the production process;

[0037] In the melting area, the high-temperature alarm area of the furnace is highlighted in red and shows green during normal operation. Parameters such as the temperature and pressure of the furnace are displayed in real time dynamically, and the molten iron melting progress is also shown through a progress bar. When the furnace temperature approaches the set upper limit, the interface will flash a warning to remind the operator to adjust in time. In this area, the operator can remotely control actions such as feeding, heating, and cooling of the furnace through simple button operations;

[0038] The casting area will automatically give recommended casting speed, casting volume and other parameters according to the molten iron parameters obtained from the melting area in real time and combined with the pipe type information identified by the intelligent parameter adaptation module. For example, when it is identified that a cast pipe with a pipe diameter of 800 mm is to be produced and the molten iron temperature is 1450 °C, the system recommends a casting speed of 5 L / s and a casting volume of 300 kg. The operator can fine-tune according to the actual situation and then issue an instruction, and the instruction is accurately transmitted to the casting equipment through the network;

[0039] The forming area and the grinding area also show the equipment operation status through colors and icons. For example, the rotational speed of the centrifuge in the forming area is displayed in real time in green numbers and turns red when abnormal; the operation status of the grinding equipment in the grinding area is distinguished by different icons, showing a rotating grinding wheel icon when running and a gray grinding wheel icon when stopped, and it can also display the grinding time and grinding progress;

[0040] In addition, the operation interface supports multi-user permission management. After ordinary operators log in, they can only operate the basic control buttons and view the operating status of the equipment; senior engineers can enter the parameter setting interface to adjust the key parameters of the equipment; production supervisors can view production reports and formulate production plans. When logging in, they need to enter their usernames and passwords for identity verification. The system allocates the operation and viewing scope based on permissions.

[0041] The operation interface is also equipped with a data interface connected to the external enterprise management system. Production data is synchronized in real time to the Enterprise Resource Planning (ERP) system for material inventory management; and synchronized to the Manufacturing Execution System (MES) to support production progress tracking and quality traceability.

[0042] II. Application of the Action Code of Button C in the WinCC Software Screen:

[0043] On the production line, the multi-sensor fusion pipe type identification device continuously monitors the pipe type of cast pipes. When a new type of cast pipe enters the production line, the device quickly identifies features such as pipe diameter, wall thickness, and material through technologies such as laser ranging and image recognition to determine the pipe type.

[0044] After the identification is completed, the action code of Button C is triggered, and the program quickly retrieves the corresponding parameters from the parameter database that adopts distributed storage and cloud computing technologies. For example, after identifying a new type of cast pipe, the system automatically retrieves parameters such as a melting temperature of 1480 °C, a casting speed of 4.5 L / s, and a cooling time of 30 minutes, and displays them on the operation interface of the operation interface module.

[0045] The parameter database has data redundancy and disaster recovery capabilities. If a certain storage node fails, the system automatically switches to the backup node to obtain data to ensure that production is not affected. At the same time, the system will repair the faulty node and automatically synchronize the data after the repair is completed to ensure data consistency.

[0046] III. Real-time Monitoring and Precise Control:

[0047] High-definition panoramic cameras and multi-dimensional sensor arrays are installed at key nodes such as the inlet and outlet of the furnace, casting molds, conveying tracks, and grinding stations.

[0048] The high-definition panoramic camera at the inlet and outlet of the furnace monitors the feeding and discharging of the furnace 24 hours a day. Once it detects a blockage at the feeding port, an alarm prompt will immediately pop up on the monitoring screen. Through video stitching and augmented reality technologies, in the three-dimensional virtual model of the centralized control room operation interface, this area will flash a red warning, and the operator can view the blockage location and situation through the camera and arrange personnel to clean it up in a timely manner.

[0049] A multi-dimensional sensor array at the casting mold monitors parameters such as mold temperature and pressure in real time. If the mold temperature is too high, the sensor transmits the data to the monitoring system. The system performs self-diagnosis and automatic calibration, issues an alarm after determining an anomaly, and transmits the data to the operation interface. Operators adjust the parameters of the cooling system through remote control according to the prompts to ensure normal casting.

[0050] The cameras and sensors on the conveying track work together to monitor the conveying speed and position of the cast pipe. When the conveying speed of the cast pipe is abnormal or the position is offset, the system automatically adjusts the conveying equipment to ensure the continuity of production.

[0051] The camera at the grinding station can clearly capture the grinding quality. If uneven grinding is found, the operator can remotely adjust the parameters of the grinding equipment to improve the product quality.

[0052] IV. Application of the data management module:

[0053] The system health status monitoring unit of the data management module monitors the hardware devices, software systems, and network communications in real time.

[0054] If the monitoring unit finds that the CPU usage rate of a server continuously exceeds 80%, it immediately issues an alarm and remotely connects to the server through the network. Technical personnel remotely analyze the server logs and performance data, find that a certain process occupies too many resources, and after remotely shutting down the process, the server resumes normal operation.

[0055] The system also deeply analyzes the production data, counts the production quantity and quality data of the cast pipes every day to generate reports; by analyzing the production data of different time periods and different devices, it finds the bottleneck of production efficiency and the root cause of quality problems.

[0056] Production process:

[0057] 1. Production preparation stage

[0058] Raw material preparation

[0059] The main raw materials for cast pipe production are iron ore, coke, limestone, etc. The raw material warehouse is equipped with sensors to monitor parameters such as the inventory quantity, humidity, and particle size of the raw materials in real time, and transmits the data to the operation interface of the remote centralized control system.

[0060] The system automatically generates a raw material procurement plan based on the production plan and real-time inventory data, and docks with the enterprise's ERP system to achieve precise management of raw material procurement.

[0061] Equipment debugging

[0062] Operators remotely debug various equipment on the production line through the operation interface module in the centralized control room. For example, start equipment such as furnaces, casting machines, centrifuges, and grinders, and check the operating status and parameter settings of the equipment;

[0063] The intelligent parameter adaptation module retrieves the corresponding equipment operating parameters from the parameter database according to the pipe type produced in this production, such as the melting temperature of the furnace, the casting speed of the casting machine, the rotation speed of the centrifuge, etc., and automatically sets them into the equipment control system;

[0064] Process planning

[0065] Production managers formulate production plans on the operation interface according to order requirements and equipment conditions. The plan content includes the pipe type, quantity, production time arrangement, etc. for production;

[0066] The system decomposes the production plan into specific tasks for each process and assigns them to the corresponding equipment and operators. At the same time, based on historical production data and real-time equipment status, it predicts possible problems during the production process and provides corresponding preventive measure suggestions.

[0067] 2. Melting stage

[0068] Raw material input

[0069] According to the pre-set formula, the system controls the raw material conveying equipment to input raw materials such as iron ore, coke, and limestone into the furnace in proportion. The sensors on the raw material conveying equipment real-time monitor the input quantity of the raw materials and feed the data back to the operation interface;

[0070] Operators can monitor the raw material input process in real time through the operation interface to ensure the accuracy of the input quantity. If there is an abnormal raw material input, the system will automatically issue an alarm and suspend the raw material input operation;

[0071] Melting process control

[0072] A multi-dimensional sensor array such as temperature sensors, pressure sensors, and gas composition sensors is installed in the furnace to real-time monitor parameters such as temperature, pressure, and gas composition in the furnace. These parameters are transmitted to the monitoring module through wireless communication technology;

[0073] The monitoring module compares and analyzes the real-time data with the pre-set process parameters, and automatically adjusts parameters such as the heating power and ventilation volume of the furnace according to the analysis results to ensure that the melting process is carried out under the best process conditions. For example, when the temperature in the furnace is lower than the set value, the system automatically increases the heating power; when the gas composition does not meet the requirements, the ventilation volume is adjusted;

[0074] A high-definition panoramic camera monitors the internal conditions of the melting furnace in real time. Operators can visually observe the melting conditions inside the furnace through a 3D virtual model on the operation interface in the centralized control room. If any abnormal conditions are detected, such as furnace wall damage or abnormal boiling of molten iron, the system will immediately issue an alarm and provide corresponding emergency treatment plans.

[0075] 3. Casting stage

[0076] Pipe type identification and parameter adaptation

[0077] When the molten iron is ready for casting, the multi-sensor fusion pipe type identification device quickly and accurately identifies the pipe type of the cast pipe to be produced. Combining laser ranging, image recognition, and electromagnetic induction technologies, this device can identify cast pipes with different diameters, wall thicknesses, and materials;

[0078] The intelligent parameter adaptation module retrieves corresponding casting parameters, such as casting speed, casting volume, casting temperature, etc., from the parameter database according to the identified pipe type, and automatically sets these parameters into the casting machine control system. At the same time, the parameters are displayed on the operation interface for operators to confirm and fine-tune.

[0079] Casting operation

[0080] Operators issue casting instructions through the operation interface in the centralized control room. The casting machine injects molten iron into the mold according to the preset parameters. During the casting process, sensors on the casting machine monitor parameters such as the flow rate and temperature of the molten iron in real time and feed the data back to the operation interface;

[0081] The monitoring module monitors the casting process in real time to ensure that the casting speed and casting volume meet the process requirements. If any casting abnormalities occur, such as unstable molten iron flow rate, too high or too low temperature, etc., the system will automatically adjust the casting parameters or suspend the casting operation and issue an alarm to notify the operator.

[0082] 4. Forming stage

[0083] Centrifugal forming

[0084] For the centrifugal cast pipe process, the cast mold is sent into the centrifuge, and the centrifuge rotates according to the preset speed and time, so that the molten iron is evenly distributed on the inner wall of the mold under the action of centrifugal force to form the shape of the cast pipe;

[0085] Speed sensors and vibration sensors are installed on the centrifuge to monitor the operating status of the centrifuge in real time. The monitoring module compares and analyzes the monitored data with the preset parameters to ensure the stable operation of the centrifuge. If any abnormal speed or excessive vibration occurs, the system will automatically adjust the operating parameters of the centrifuge or stop the centrifuge and issue an alarm;

[0086] Cooling and forming

[0087] The formed cast pipes need to be cooled to achieve the required strength and hardness. The cooling system automatically adjusts the flow rate and temperature of the cooling medium according to the material and specifications of the cast pipes to ensure a uniform and stable cooling process.

[0088] Temperature sensors are installed in the cooling area to monitor the cooling temperature of the cast pipes in real time. The monitoring module adjusts the operating parameters of the cooling system based on the monitoring data to avoid quality problems such as cracks and deformations caused by too fast or too slow cooling of the cast pipes.

[0089] 5. Post - processing stage

[0090] Demoulding and cleaning

[0091] The cooled cast pipes are removed from the mold. The demoulding process is completed by specialized demoulding equipment, and the operating parameters of the demoulding equipment are automatically set by the system according to the pipe type and size of the cast pipes.

[0092] There may be some impurities and burrs remaining on the surface of the demoulded cast pipes, which need to be cleaned. Cleaning equipment such as grinders and sandblasters cleans the surface of the cast pipes according to the preset parameters of the system to improve the surface quality of the cast pipes.

[0093] Quality inspection

[0094] After a series of production processes, the cast pipes need to undergo a comprehensive quality inspection. The inspection items include dimensional accuracy, wall thickness uniformity, surface quality, chemical composition, etc.

[0095] Quality inspection equipment such as calipers, ultrasonic flaw detectors, and spectrometers transmit the inspection data to the remote centralized control system in real time. The system analyzes and judges the inspection data according to the preset quality standards, sends the qualified cast pipes to the finished product warehouse, and marks the unqualified cast pipes and transfers them to the repair or scrapping process.

[0096] Data recording and traceability

[0097] During the entire production process, the system records the data of each link in real time, including raw material information, equipment operating parameters, process parameters, quality inspection data, etc. These data are stored in the database of the data management module.

[0098] Through the data management module, the enterprise can achieve full - process traceability of the cast pipe production process. When quality problems occur, it can quickly query information such as the production time, production equipment, operators, and raw materials used for the problematic cast pipes, so as to take timely measures for rectification and prevention.

[0099] Finally, it should be noted that the above are only preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A remote centralized control system for a cast pipe production line, characterized in that: include: An operation interface module, which is based on Siemens WinCC software and constructs a computer operation screen according to the on-site control switch layout, operation habits and logic of each production link of the cast pipe production line; An intelligent parameter adaptation module, which uses button C action code technology in Siemens WinCC software; Monitoring module, which installs high-definition panoramic cameras and multi-dimensional sensor arrays at key nodes of the cast pipe production line, including furnace inlet and outlet, casting molds, conveyor tracks, and polishing stations, and is combined with a multi-sensor fusion pipe type recognition device with an intelligent parameter adaptation module; The data management module is provided with a system health status monitoring unit for real-time monitoring of the operating status of hardware devices, the performance indicators of Siemens WinCC software and the stability of network communications.

2. A remote centralized control system for a cast pipe production line according to claim 1, characterized in that: The operation interface of the operation interface module is divided into sections according to the production process, covering the control and status display areas of smelting, casting, molding, polishing and other links, and each area intuitively presents the equipment operation status, parameter setting range and current real-time parameters through different colors, icons and text descriptions.

3. A remote centralized control system for a cast pipe production line according to claim 1, characterized in that: The operation screen in the operation interface module supports multi-user authority management, and users with different authorities have different operation and viewing ranges.

4. A remote centralized control system for a cast pipe production line according to claim 1, characterized in that: The parameter database in the intelligent parameter adaptation module adopts distributed storage and cloud computing technology and has data redundancy and disaster recovery capabilities.

5. A remote centralized control system for a cast pipe production line according to claim 1, characterized in that: The high-definition panoramic camera in the monitoring module generates a three-dimensional virtual model of the production line on the control room operation interface of the operation interface module through video stitching and augmented reality technology, realizing real-time visual monitoring. The multi-dimensional sensor array adopts wireless communication technology to have self-diagnosis and automatic calibration functions.

6. A remote centralized control system for a cast pipe production line according to claim 1, characterized in that: The system health status monitoring unit in the data management module has remote diagnosis and fault repair functions.

7. A remote centralized control system for a cast pipe production line according to claim 1, characterized in that: The operation interface module also includes a data interface connected to an external enterprise management system.

8. A remote centralized control system for a cast pipe production line according to claim 1, characterized in that: The button C action code technology has an anti-misoperation function.

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