Unattended high-speed line automatic weight checking method

Abstract

The invention relates to the field of centimeter weighing, in particular to an unattended high-speed line automatic weighing method which comprises the steps that a steel coil is weighed; weighing data are collected; weighing and stability judgment; standard roll identification; and abnormal roll identification and processing. The steel coil weighing device has the advantages that the RFID radio frequency card is arranged at the end of the C-shaped hook connected with the steel coil in a hung mode, automatic identification of the standard coil can be achieved, when the standard coil passes through an RFID scanning area, the PLC system can automatically detect and match weight information of the standard coil, and weighing accuracy is ensured; through the RFID technology, the information of the standard roll is accurately recorded and tracked, and subsequent data management and quality control are facilitated; the redundancy setting of stand-alone card playing and automatic card playing provides a backup and emergency scheme for an unattended weighing system, under the extreme condition of network failure of a roll collecting and weighing PLC control system and a weighing server, the stand-alone card playing function can ensure the continuity of production, and even if the network is interrupted, the production efficiency is greatly improved. Post workers can also manually input information such as the weight and the steel grade to play cards.

Description

Technical Field

[0001] The present invention relates to the field of weight measurement, and in particular to an unmanned high-line automatic weight checking method. Background Art

[0002] The high-speed line production process is fast-paced and has a large output. Each production line consists of an independent heating furnace, rolling mill, and PF chain area. After the billet is out of the furnace, it needs to go through rolling, spinning, slow cooling, coiling, packaging, weighing and other links in sequence, and finally be lifted away at the unloading position and put into storage. The PF chain area of ​​each production line is equipped with nearly 100 C-type hooks. The C-type hooks are suspended on the PF (Pacing Furnace) chain to continuously transport steel coils to various processes (such as weighing, carding, coiling, etc.), and a PLC control system is used for automatic control. Each production line is equipped with two scales, usually one in use and one in reserve to ensure the continuity and reliability of the weighing operation. The full-line data acquisition system constructed in the early stage has covered the links of heating, rolling, weighing and carding, and realized the functions of logistics tracking, performance collection, weighing and carding, and effectively opened up the data interaction between the previous and subsequent processes and the upper and lower level systems.

[0003] However, the existing system has the following problems:

[0004] 1. Interference between standard rolls (coils) and loose rolls: During the automatic matching and measurement process, standard rolls and loose rolls will be weighed along with the PF line, requiring manual intervention to stop the automatic measurement. If intervention is not timely, standard rolls may cause measurement accidents such as serial number mismatch and furnace mixing, and loose rolls may cause equipment accidents such as steel coils falling when weighed.

[0005] 2. Risk of damage to equipment caused by loose rolls: When loose rolls are placed on the scale, the scattered wire may cause impact, jamming, and other damage to the scale body, resulting in the equipment being unable to check weight normally and affecting production continuity;

[0006] 3. Impact of network failure: If a network failure occurs during automatic metering operation, the wire coil information will not be uploaded, resulting in unlicensed offline production. If manual processing is not timely, it may cause production suspension, abnormal shipment, abnormal outbound delivery, and mixed furnace accidents, seriously affecting production efficiency and product quality traceability. Summary of the Invention

[0007] The purpose of the present invention is to provide an unmanned high-line automatic weighing method to realize the automatic operation of weighing operations, improve business processing efficiency, and ensure the accuracy of finished product information.

[0008] To achieve the above object, the present invention is implemented through the following technical solutions:

[0009] An unmanned high-line automatic weighing method comprising:

[0010] S1, steel coil weighing;

[0011] S2. Weighing data collection:

[0012] The weighing control system obtains the weight data of the weighing instrument in real time and stores it in an array according to the set time interval;

[0013] S3, weighing and judging stability:

[0014] During the weighing process, set a value taking time;

[0015] When the sampling time arrives, the weight data 1 in the array of the first time interval is compared with the weight data 2 in the array of the nth time interval (n≤sampling time);

[0016] If weight data 2 - weight data 1 ≤ set error value, then weight data 2 is sent to the card playing system as the stable weight to perform the card playing operation;

[0017] S4. Standard volume identification:

[0018] Arrange an RFID radio frequency card at the end of the C-hook where the steel coil is hung;

[0019] When the steel coil bound to the RFID radio frequency card passes through the RFID scanning area, the RFID card reader transmits the steel coil tag information read from the RFID radio frequency card to the weighing control system;

[0020] When the weight of the current steel coil received by the weighing control system matches the stable weight, the current steel coil is determined to be a standard coil;

[0021] S5. Identification and processing of abnormal volumes.

[0022] In S1, the steel coil is placed on the scale and is hooked to the C-hook. When the C-hook occupies the detection area of ​​the proximity switch above the weighing table, the weighing table rises, allowing the steel coil to be separated from the C-hook and ready for weighing.

[0023] In S2, the steel coil separated from the C-hook is weighed by a weighing instrument.

[0024] In S3, if weight data 2 - weight data 1 > the set error value, all weight data in the array are cleared.

[0025] In S4, the RFID reader is unobstructed within a range of 2 to 3 meters.

[0026] In S4, if the difference between the current weight of the steel coil received by the weighing control system and the stable weight is less than 2‰, the current weight of the steel coil received by the weighing control system matches the stable weight, otherwise weighing is stopped.

[0027] In S5, abnormal volume identification and processing are as follows:

[0028] When a bulk package is abnormally rolled over the scale, a red round plate shall be hung on the end of the C-hook;

[0029] When the AI ​​video recognition system detects a red card, it issues an alarm signal, preventing the weighing table from rising for weighing;

[0030] Voice announcements are made to remind workers on duty that abnormal rolls in loose packages are being weighed.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. An RFID card is placed at the end of the C-hook where the steel coil is attached, enabling automatic identification of the standard coil. When the standard coil passes through the RFID scanning area, the PLC system automatically detects and matches its weight information to ensure weighing accuracy. This automatic identification method not only reduces manual intervention and errors caused by human factors, but also improves production efficiency and makes the weighing process more streamlined and automated. In addition, RFID technology can quickly and accurately record and track the information of the standard coil, facilitating subsequent data management and quality control.

[0033] 2. The redundant setting of single-machine card playing and automatic card playing provides a backup and emergency solution for the unattended weighing system. In the extreme case of network failure of the PLC control system of the roll weighing and the weighing server, the single-machine card playing function can ensure the continuity of production. Even if the network is interrupted, the workers can manually enter the weight, steel grade and other information to play cards, avoiding production stagnation caused by the card playing machine failure. This redundant design enhances the reliability and stability of the system and ensures the smooth progress of the production process under any circumstances.

[0034] 3. The weighing control system stores weight data in an array at set time intervals, which helps to achieve data smoothing and stability judgment. By continuously acquiring and updating instrument data, the system can collect multiple weight values ​​over a period of time, thereby more accurately judging whether the weight is stable. This method avoids misjudgments caused by instantaneous fluctuations or interference, and improves the reliability of weighing results. In addition, the data stored in the array can be used for subsequent trend analysis and fault diagnosis, providing valuable information for system optimization and maintenance;

[0035] 4. Weighing stability judgment is a system that analyzes the collected weight data to determine whether the weight has reached a stable state, thereby ensuring the accuracy of the weighing results. During the weighing process, various factors (such as mechanical vibration, airflow, etc.) may cause weight data to fluctuate. Through stability judgment, the system can identify these fluctuations and wait until the weight is truly stable before making the final reading, thus avoiding errors caused by unstable weight data. This not only improves the consistency of product quality, but also reduces quality objections and customer complaints that may be caused by inaccurate measurement;

[0036] 5. The identification and processing of abnormal rolls (such as loose rolls) are crucial to protecting equipment and ensuring production safety. After detecting abnormal rolls through AI video recognition technology, the system can promptly issue an alarm signal and control the weighing table not to rise, avoiding damage such as impact or jamming on the scale body caused by abnormal rolls. This automatic identification and processing mechanism not only reduces equipment maintenance costs and downtime, but also reduces the risk of production accidents caused by equipment failure. In addition, the identification of abnormal rolls helps maintain production order and ensures that only rolls that meet the standards can pass through the weighing area, thereby ensuring product quality and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a structural diagram of the unmanned high-line automatic weighing system.

[0038] Figure 2 This is the flow chart of unmanned high-line automatic weight inspection. DETAILED DESCRIPTION

[0039] The present invention will be described in detail below with reference to the accompanying drawings, but it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0040] The following examples are implemented under the premise of the technical solution of the present invention, and provide detailed implementation methods and specific operating processes, but the scope of protection of the present invention is not limited to the following examples. The methods used in the following examples are conventional methods unless otherwise specified.

[0041] Example 1

[0042] An unmanned high-speed wire automatic weight inspection method consists of the following systems: weighing instrument, standard coil recognition system, AI video recognition system, roll collection weighing PLC control system, PF line PLC control system, alarm system. The weighing instrument is used to obtain the weight data of the high-speed wire steel coil and transmit it to the roll collection weighing PLC control system; the standard coil recognition system includes an RFID radio frequency card and an RFID card reader for identifying the standard coil and calibrating it with the weighing instrument; the AI ​​video recognition system includes a camera, which is installed on the side facing the end of the C-hook for Identify abnormal loose rolls to prevent them from falling onto the scale and causing damage to the scale body; the PLC control system for roll collection and weighing includes a weighing PLC, which is used to collect weighing instrument status information, weighing weight data, etc., and is used to collect C-hook occupancy signals to control the rise and fall of the weighing table; the weighing system adds a basic information maintenance screen for standard weights / rolls, including number, weight, type, etc., and adds basic information maintenance functions such as weighing table maintenance information and out-of-tolerance alarm thresholds. The alarm system is used to trigger an alarm when abnormal rolls such as out-of-tolerance and loose packages occur during the weighing PLC calibration process. Figure 1 .

[0043] An unmanned high-line automatic weighing method comprising:

[0044] S1, steel coil weighing;

[0045] The steel coil is hung on the C-hook. When the C-hook occupies the detection area of ​​the proximity switch above the weighing table, the weighing PLC controls the weighing table to rise, so that the steel coil is separated from the C-hook and ready for weighing.

[0046] S2. Weighing data collection:

[0047] The steel coil separated from the C-hook is weighed by a weighing instrument, which continuously monitors the weight of the steel coil and is used to obtain the weight data of the weighing instrument in real time. The weighing control system stores the data in an array according to the set time interval.

[0048] S3, weighing and judging stability:

[0049] During the weighing process, set a value taking time, value taking time = 8s;

[0050] When the value acquisition time arrives, the weight data 1 in the array of the 1s time interval is compared with the weight data 2 in the array of the 5s time interval;

[0051] If weight data 2 - weight data 1 ≤ set error value 10kg, then weight data 2 is used as stable weight, and the weighing instrument will display stable weight (weight data 2). The stable weight is transmitted to the card playing system for card playing operation;

[0052] If weight data 2 - weight data 1 > set error value 10, clear all weight data in the array;

[0053] S4. Standard volume identification:

[0054] An RFID card is placed at the end of the C-hook where the steel coil is mounted, and the RFID reader is within a range of 2 to 3 meters without any obstructions.

[0055] When the steel coil bound to the RFID radio frequency card passes through the RFID scanning area, the RFID card reader transmits the steel coil tag information read from the RFID radio frequency card to the weighing PLC;

[0056] If the difference between the weight of the current steel coil received by the weighing PLC and the stable weight is less than 2‰, the weight of the current steel coil received by the weighing PLC matches the stable weight and the current steel coil is determined to be a standard coil, otherwise weighing is stopped;

[0057] S5. Identification and processing of abnormal volumes, the contents are as follows:

[0058] When a bulk package is weighed abnormally, a red card will be hung on the end of the C-hook;

[0059] When the AI ​​video recognition system detects a red card, it issues an alarm signal, preventing the weighing table from rising for weighing;

[0060] Voice announcements are made to remind workers on duty that abnormal rolls in loose packages are being weighed.

[0061] Example 2

[0062] In this embodiment, an unmanned high-line automatic weighing method is the same as that in embodiment 1, and an unmanned high-line automatic weighing workflow is added thereto. Figure 2 .

[0063] 1) Weighing and calibration business

[0064] An RFID card is installed on the hook head of the standard roll. When the scanning device detects the RFID card, a control message is triggered. This information is combined with the control logic of the weight of the roll. When the two pieces of information are present at the same time, it is judged that the standard roll is on the scale, and the weight of the standard roll is recorded and compared with the weight set by the weighing PLC. If the weight exceeds the tolerance, the weighing PLC will automatically block the scale and enable another scale to operate until manual intervention is made to repair and restore the scale.

[0065] 2) Weighing operation

[0066] During weighing operations, the weighing PLC performs logical judgment processing. If it is determined to be a standard weight / roll, the system will record it as a calibration record. Otherwise, the normal weighing operation process will be carried out to ensure that the actual results are not distorted by number, roll, or weight. It will automatically determine whether the weighing results are within the standard range. If the standard is exceeded, a color alarm will be given and the upload will be suspended, waiting for manual confirmation.

[0067] 3) Alarm collection

[0068] After each weighing operation, if the weighing instrument data does not return to zero, the weighing PLC will record and alarm, and automatically cut off the weighing operation; when weighing the standard roll, if the two pounds exceed the tolerance by 2kg, an alarm will be issued and a record will be made, waiting for manual disposal.

[0069] 4) Control distribution

[0070] During the weighing operation or when the weighing results are out of tolerance, a control signal needs to be sent to the weighing PLC in real time to realize the weighing system (switching) and the start and stop of the weighing PLC (the PF line cannot be shut down due to the weighing system).

[0071] 5) Intelligent processing of abnormal volumes

[0072] In order to solve the problem that the equipment cannot be checked for weight due to damage caused by abnormal rolls such as loose rolls on the scale, a camera is added to identify abnormal rolls and generate an API signal of the event. The weighing server is connected to the video server through the network, and the event signal is converted into a scale I / O control signal for the logical control of the weighing PLC scale, and the PF line is automatically released.

[0073] 6) Offline collection and processing

[0074] A stand-alone weighing collection and processing program is developed to realize real-time weight collection, stability judgment processing, data storage, etc. Each weighing record contains data such as weight, weighing time, matching mark, etc., and the screen displays the information of weighed but unmatched materials in real time; when the business screen is running, the weight records stored locally on the weighing computer are scanned in real time, and bound to the material information to be matched in time sequence to form a complete weighing record.

[0075] 7) Single-player card games

[0076] Develop a stand-alone screen program to manually enter the information necessary for playing cards, combine it with the collected weight, and play cards manually on demand.

[0077] 8) Network exception handling

[0078] When the network between the secondary system (the server used to send production information) and the weighing server is interrupted by a fault, the weighing operation can still proceed normally, and the weighing system caches the data of each weighing; the single-machine card playing function is enabled, and manual cards are played on demand to ensure production continuity; after the network is restored, the secondary system will automatically scan the weight data cached by the weighing system and match it with the information of materials to be weighed accumulated on the business screen; this process is completed with manual monitoring and auxiliary confirmation.

[0079] 9) Adaptive transformation of automation control system

[0080] The PF line PLC control system, the roll weighing PLC control system and the weighing server network are connected to realize remote control of the main / backup scale switching action of each production line.

[0081] 10) Empty hook and return line tracking

[0082] The PF line empty hooks and return line coils need to be manually hung with identification plates (red round plates) for AI identification, and AI video recognition technology is used for effective identification. After identification, a response is sent to the weighing server. The weighing server converts the signal into a roll weighing PLC control system, cuts the scale in the control logic, and the PF line operates normally.

[0083] Example 3

[0084] In this embodiment, an unmanned high-line automatic weighing method is the same as that in Example 1, with a stand-alone card playing system added on the basis of Example 1 and / or Example 2.

[0085] The stand-alone card playing system is used when the network between the secondary system (the server used to send production information) and the weighing server is disconnected due to a fault. The automatic card playing fails and the central database cannot receive weight data. Local emergency processing is required:

[0086] When manual intervention is required for single-machine printing, the operator can manually supplement the information and input key data such as coil weight, steel type, batch number, etc. on the printing screen to realize local printing of labels;

[0087] Generate and print steel coil labels (i.e. "playing cards") in stand-alone mode to ensure uninterrupted logistics and information flow. After the network failure is restored, the weighing control system automatically uploads the locally stored weighing data to the secondary server to ensure data integrity.

[0088] The stand-alone card playing system includes a local industrial computer, a card playing printer, and an input terminal. The stand-alone card playing software includes an embedded database (such as SQLite) for temporarily storing data and supports breakpoint resumption.

[0089] The comparison between the stand-alone card playing system and the automatic card playing system is shown in Table 1.

[0090] Table 1 is a comparison table between a stand-alone card playing system and an automatic card playing system.

[0091]

[0092] As shown in Table 1, the stand-alone card playing system is the "safety valve" in unmanned weighing. It ensures the continuity of the production process in extreme situations through a manual backup mechanism and is a key part of the system redundancy design.

Claims

1. An unmanned high-line automatic weighing method, characterized in that: include: S1, steel coil weighing; S2. Weighing data collection: The weighing control system obtains the weight data of the weighing instrument in real time and stores it in an array according to the set time interval; S3, weighing and judging stability: During the weighing process, set a value taking time; When the sampling time arrives, the weight data 1 in the array of the first time interval is compared with the weight data 2 in the array of the nth time interval (n≤sampling time); If weight data 2 - weight data 1 ≤ set error value, then weight data 2 is sent to the card playing system as the stable weight to perform the card playing operation; S4. Standard volume identification: Arrange an RFID radio frequency card at the end of the C-hook where the steel coil is hung; When the steel coil bound to the RFID radio frequency card passes through the RFID scanning area, the RFID card reader transmits the steel coil tag information read from the RFID radio frequency card to the weighing control system; When the weight of the current steel coil received by the weighing control system matches the stable weight, the current steel coil is determined to be a standard coil; S5. Identification and processing of abnormal volumes.

2. The unmanned high-line automatic weighing method according to claim 1, characterized in that: In S1, the steel coil is weighed and hung on a C-hook. When the C-hook occupies the detection area of ​​the proximity switch above the weighing table, the weighing table rises, allowing the steel coil to separate from the C-hook and prepare for weighing.

3. The unmanned high-line automatic weighing method according to claim 1, characterized in that: In S2, the steel coil separated from the C-hook is weighed by a weighing instrument.

4. The unmanned high-line automatic weighing method according to claim 1, characterized in that: In S3, if weight data 2 - weight data 1 > the set error value, all weight data in the array are cleared.

5. The unmanned high-line automatic weighing method according to claim 1, characterized in that: In S4, the RFID card reader is free from obstructions within a range of 2 to 3 meters.

6. The unmanned high-line automatic weighing method according to claim 1, characterized in that: In S4, if the difference between the current weight of the steel coil received by the weighing control system and the stable weight is less than 2‰, the current weight of the steel coil received by the weighing control system matches the stable weight, otherwise weighing is stopped.

7. The unmanned high-line automatic weighing method according to claim 1, characterized in that: In S5, the abnormal volume identification and processing is as follows: When a bulk package is abnormally rolled over the scale, a red round plate shall be hung on the end of the C-hook; When the AI ​​video recognition system detects a red card, it issues an alarm signal, preventing the weighing table from rising for weighing; Voice announcements are made to remind workers on duty that abnormal rolls in loose packages are being weighed.

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