High-integration industrial personal computer plate shape detection system based on whole-roller plate shape instrument

Abstract

The invention provides a high-integration industrial personal computer strip shape detection system based on a whole-roller strip shape instrument, and the system comprises a signal collection and drive module which is used for driving the whole-roller strip shape instrument to collect an AD signal, a rolling speed signal, a temperature signal and a positive and negative rotation signal of each channel sensor; the signal packing and unpacking module is used for packing the collected original signals according to a self-defined coding rule; the calibration module is used for performing polynomial fitting on the AD value of each channel; the process error compensation module is used for compensating the original strip shape signal to generate an effective strip shape signal; the plate shape signal processing module is used for converting the radial force signal into an elongation / plate shape signal; according to the invention, based on the whole roller type plate shape instrument, any protocol and port in the Ethernet, the USB protocol, the DP and the serial port are automatically scanned through the watchdog, automatic connection is realized, stable communication and plate shape detection are always kept, and in combination with process error compensation, a plate shape detection signal is ensured to be accurate, and the actual plate shape state is truly reflected.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of rolling strip equipment automation, in particular, especially relates to a high-integration industrial computer plate shape detection system based on a whole roller type plate shape instrument. BACKGROUND

[0002] The plate shape instrument is a high-precision instrument for detecting cold-rolled strips, and especially for the hidden plate shape defects under the condition of large tension rolling, the contact type plate shape instrument is an indispensable core equipment for the cold-rolled strip production line. With the current cold-rolled strip width-thickness ratio becoming larger and larger, the plate shape is more likely to be unstable and appear non-typical local wave shape, rib wave, small edge wave and other defects, and the plate shape measurement and control is more and more difficult, which puts forward higher requirements for the plate shape detection precision.

[0003] In the traditional plate shape detection process, the analog signal is usually sent to the controller to be converted into a digital signal, the communication link is more, the response cycle is long, the signal interference is large, the subtle plate shape information is easy to be lost, and in addition, the plate shape deviation caused by the field working condition factors is not considered in the plate shape signal, which also leads to the distortion of the plate shape signal and cannot reflect the real plate shape state, especially cannot accurately identify the subtle local plate shape information. In order to improve the plate shape detection precision and consider the ease of operation, it is necessary to design a high-integration industrial computer plate shape detection system for the whole roller type plate shape instrument. SUMMARY

[0004] According to the technical problem of the distortion of the detection result of the existing plate shape detection technology, a high-integration industrial computer plate shape detection system based on a whole roller type plate shape instrument is provided. The plate shape detection communication, decoding, calibration, pattern recognition, waveform monitoring, process error compensation, plate shape display, plate shape control, target curve, early warning, statistical evaluation and other functions are integrated in the industrial computer. On the one hand, various plate shape states can be simulated and tested and analyzed, and on the other hand, the functions of signal acquisition, communication, processing, display, calibration, mode decomposition, control quantity calculation and parameter setting can be met in one industrial computer.

[0005] The technical means adopted by the present application is as follows: A high-integration industrial computer plate shape detection system based on a whole roller type plate shape instrument, comprising: A signal acquisition and driving module is used for driving the whole roller type plate shape instrument to collect AD signals of each channel sensor, rolling speed signals, temperature signals and forward and reverse rotation signals; the output end of the signal acquisition and driving module is connected to a signal packaging and unpacking module; The signal packaging and unpacking module is used for packaging the collected original signals according to a self-defined coding rule, and performing unpacking operation on the received data packet, decomposing each channel sensor signal, rolling speed signal, temperature signal and forward and reverse rotation signal, and performing correctness verification by using a check code; The communication interface adaptive module is used for periodically scanning and automatically identifying any one of Ethernet, USB protocol, DP protocol and serial port protocol and port, and realizing automatic connection with the plate shape instrument and stable communication; the communication interface adaptive module is used for transmitting the packaged signal and receiving external data, and the unpackaged signal is sequentially transmitted to the calibration module, the process error compensation module and the plate shape signal processing module for processing; The calibration module is used for performing polynomial fitting on the AD values of each channel, obtaining the calibration coefficient between the AD values and the radial force values, and storing the calibration coefficient into a database; the calibration module supports single-channel independent calibration; The process error compensation module is used for compensating the original plate shape signal to generate an effective plate shape signal; The plate shape signal processing module is used for converting the radial force signal into an elongation / plate shape signal, and performing high-order mode identification to obtain plate shape component information; an output end of the plate shape signal processing module is connected with the control quantity calculation module; The control quantity calculation module is used for calculating the control quantity of a plate shape regulation means according to the plate shape deviation; the regulation means includes a tilt roll, a bending roll, a transverse movement, a segmented cooling and an ASU; The data management module is used for storing the calibration coefficient, the rolling parameter and the plate shape data; the data management module is used for providing data storage and data calling for the calibration module and the plate shape signal processing module.

[0006] Further, the communication interface adaptive module automatically scans and identifies the available communication protocol and port, automatically identifies the IP address and the relative directory.

[0007] Further, the calibration module includes first-level calibration and second-level calibration; the first-level calibration is single-channel independent calibration, the zero AD value of the single channel is collected, different weights are sequentially applied and the AD value is recorded, the fitting coefficient button is clicked, the quadratic polynomial fitting is completed, and the calibration coefficient of the single channel is obtained; The second-level calibration automatically identifies the effective detection channel according to the bandwidth, and simultaneously automatically performs plate shape compensation of the process errors of the edge coverage, the run-out, the temperature, the installation precision and the wrap angle.

[0008] Further, the second-level calibration is used to determine whether the effective plate shape signal is consistent with the actual plate shape state; when the calibration coefficient and the process error compensation model are effective, the real-time plate shape signal is subjected to 4-8 order plate shape mode identification to obtain plate shape component information.

[0009] Further, the process error compensation module is used for compensating the plate shape signal deviation caused by the bandwidth, the run-out amount, the temperature and the installation precision factors.

[0010] Further, the plate shape signal processing module performs plate shape mode recognition of 4-8 orders.

[0011] Further, the control quantity calculation module obtains plate shape deviation by using target curve, and calculates control quantities of different control means according to effect function, wherein the control means are tilt roll, bending roll, transverse shift and segmented cooling for four-six roll mill, and ASU and transverse shift for twenty roll mill.

[0012] Compared with the prior art, the present application has the following advantages: The present application highly integrates collection, digital communication, decoding, waveform monitoring, calibration, mode recognition, process error compensation, plate shape display, plate shape control, target curve, early warning and statistical evaluation in the industrial computer, replaces a large number of plate cards of traditional analog communication, AD conversion and DA conversion, and increases watchdog automatic identification communication protocol and port, one-key installation plug-and-play, convenient and fast; all channel waveform states can be synchronously displayed, and a certain channel waveform signal can be observed alone, waveform signal-to-noise ratio, sensitivity, peak range are conveniently analyzed, and waveform stability and recognition precision are improved; two-stage calibration mode is implemented, AD value to radial force quadratic polynomial calibration is performed in the first stage, calibration coefficient is obtained by one-key curve fitting, a certain channel can be arbitrarily selected for calibration, calibration times and workload are reduced; plate shape mode recognition is increased, different order plate shape components can be recognized, plate shape control quantity calculation can be conveniently carried out; effective detection channels can be automatically identified according to bandwidth, plate shape compensation of process errors such as edge coverage, deviation, temperature, installation precision and wrap angle is automatically performed, the second stage calibration is performed, plate shape detection precision is improved, and online plate shape signal corresponds to actual plate shape state. BRIEF DESCRIPTION OF DRAWINGS

[0013] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0014] Figure 1 The signal collection, processing and display flowchart of the high-integration industrial computer plate shape detection system of the whole roll type plate shape instrument of the present application.

[0015] Figure 2 The layout and function diagram of the high-integration industrial computer plate shape detection system of the whole roll type plate shape instrument of the present application. DETAILED DESCRIPTION

[0016] It should be noted that the embodiments and features of the present application can be combined if there is no conflict. The present application will be described in detail below with reference to the drawings and embodiments.

[0017] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. The description of the at least one example embodiment is actually only illustrative, but not as any limitation on the present application and its application or use. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0018] It should be noted that the terms used herein are only intended to describe specific embodiments and are not intended to limit exemplary embodiments according to the present application. As used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise, and it should also be understood that the terms "comprise" and / or "include" as used in the specification indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0019] Unless specifically stated otherwise, the relative arrangement of components and steps, numerical expressions, and numerical values set forth in the various embodiments described herein are not meant to limit the scope of the present application. At the same time, it should be clear that the sizes of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those of ordinary skill in the relevant art can not be discussed in detail because such techniques, methods, and devices are considered to be part of the instant application. In all examples shown and discussed herein, any specific value should be interpreted as merely an example, and not as a limitation. Thus, other examples of the exemplary embodiments can have different values. It should be noted that like reference numerals and letters refer to like items in the following drawings, and thus, once an item is defined in one drawing, it need not be discussed further in subsequent drawings.

[0020] In the description of the present application, it should be understood that the orientation words such as "front, back, up, down, left, right", "transverse, vertical, perpendicular, horizontal" and "top, bottom" and the like indicate the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate and imply that the indicated device or element must have a particular orientation or be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the scope of protection of the present application: the orientation words "inner, outer" refer to the inner and outer relative to the contour of each component itself.

[0021] For the purposes of this description, spatially relative terms such as "beneath", "below", "lower", "above", "upper" and the like can be used to describe an element's or feature's position as relating to the position of other elements or features. It is to be understood that the spatially relative terms are intended to encompass different positions of the elements in the drawings as shown in the figures and in other uses or orientations of the device. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" or "over" the other elements or features. Thus, the exemplary term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0022] In addition, it should be noted that the use of "first", "second", and the like words of similar meaning in the description and claims to describe various embodiments is merely intended to distinguish between similar elements and is not intended to limit the scope of the application. Such terms should not be interpreted as having a special meaning or significance in and of themselves.

[0023] As shown in FIG. 1, the present application provides a high-integration industrial computer plate shape detection system based on a whole roller plate shape instrument, which comprises: Figure 1 a signal acquisition and driving module, which is used to drive the whole roller plate shape instrument to collect AD signals of each channel sensor, rolling speed signals, temperature signals and forward and reverse signals; the output end of the signal acquisition and driving module is connected to a signal packing and unpacking module; a signal packing and unpacking module, which is used to pack the collected original signals according to a self-defined coding rule, and unpack the received data packets to decompose each channel sensor signal, rolling speed signal, temperature signal and forward and reverse signal, and perform correctness verification by using a check code; The original signals of several cycles of the whole roller plate shape instrument are packed by using a driving program and a self-defined coding rule, and the original signals include each channel sensor signal, rolling speed signal, temperature signal and forward and reverse signal. A watchdog is set in the plate shape system, and the port and protocol are scanned periodically. Any one of Ethernet, USB protocol, serial port, DP and other protocols is automatically identified to realize fast communication and transmission to the plate shape measurement and control industrial computer. The original signal packet is unpacked by using a self-defined coding rule to decompose each channel sensor signal, rolling speed signal, temperature signal and forward and reverse signal, and correctness verification is performed by using a check code. The signals are displayed on a waveform monitoring interface according to the number of different cycles.

[0024] ​The communication interface adaptive module is used for periodically scanning and automatically identifying any one of Ethernet, USB protocol, DP protocol and serial port protocol and port, and realizing automatic connection with the plate shape instrument and stable communication; the communication interface adaptive module is used for transmitting the packaged signal and receiving external data, and the unpackaged signal is sequentially transmitted to the calibration module, the process error compensation module and the plate shape signal processing module for processing; The calibration module is used for polynomial fitting of AD values of each channel, obtaining calibration coefficients between AD values and radial force values, and storing the calibration coefficients into a database; the calibration module supports single-channel individual calibration; The process error compensation module is used for compensating the original plate shape signal to generate an effective plate shape signal; The plate shape signal processing module is used for converting the radial force signal into an elongation / plate shape signal, and performing high-order mode recognition to obtain plate shape component information; an output end of the plate shape signal processing module is connected with the control amount calculation module; The control amount calculation module is used for calculating the control amount of a plate shape regulation means according to plate shape deviation; the regulation means includes a tilt roll, a bending roll, a transverse movement, a segmented cooling and an ASU; The data management module is used for storing calibration coefficients, rolling parameters and plate shape data; the data management module is used for providing data storage and data calling for the calibration module and the plate shape signal processing module.

[0025] The application provides a high-integration industrial computer plate shape detection system based on a whole roll plate shape instrument, which highly integrates signal acquisition, communication, waveform monitoring, calibration, plate shape display, mode recognition, process error compensation, plate shape control, target curve, early warning, statistical evaluation and other functions of the whole roll plate shape instrument, and meets the industrial needs of rapid signal acquisition, processing, compensation, display and control of the whole roll plate shape instrument.

[0026] The application firstly realizes AD signal acquisition of the whole-roller shape meter sensor signal by using the whole-roller shape meter driving program, packs all signals of the whole-roller shape meter based on self-defined coding, and then automatically identifies the protocol type and port number by using the watchdog period scanning Ethernet, USB protocol, serial port, DP protocol and port, so as to meet the requirements of fast signal acquisition and communication of the whole-roller shape meter without manual setting, and the system automatically identifies the IP address and relative directory; the data packet is decomposed into AD signals of each channel and speed, rolling direction and temperature signals by using the self-defined coding rule for unpacking; on this basis, the AD values of each channel are calibrated by a polynomial of the first order to obtain the radial force values corresponding to the AD values, so as to obtain the original shape signal; due to the influence of factors such as field temperature, deflection, installation accuracy, runout and edge coverage, the original shape signal often deviates from the actual shape state, so necessary process error compensation is performed on the original shape signal to form an effective shape signal, and the polynomial of the second order is calibrated for each channel in combination with the engineering actual data to determine whether the effective shape signal is consistent with the actual shape state; when the calibration coefficient and the process error compensation model are effective, the real-time shape signal is subjected to shape mode recognition of 4-8 orders to obtain shape component information, so as to facilitate the evaluation of different types of shape defects and thus targeted shape early warning; the rolling direction of the reversible mill is automatically determined, the outlet shape is taken as a feedback signal, and the shape deviation is obtained by using a target curve based on the basic rolling parameters and the shape state; the control amount of different control means is calculated according to an effect function, and the control means are tilt roll, bending roll, transverse shift and segmented cooling for a four-six roll mill, and ASU and transverse shift for a twenty-roll mill; after the control amount of different control means is transmitted to the rolling mill control system in real time, the shape closed-loop control requirement is realized.

[0027] As shown in Figure 2 The whole-roller shape meter shape system includes a top menu bar, a rolling basic information bar, a rolling speed and rolling direction dynamic diagram, a communication light display state, a user unit and a manufacturer icon, a shape measurement and control interface, a smoothing calibration interface, a waveform monitoring interface and a bottom information bar. The shape measurement and control interface displays a radial force column chart, an elongation / shape column chart and a shape control interface, and the shape control interface includes a shape curve, a target curve, a mechanical control means, a segmented cooling control and an overall shape record.

[0028] When applied online, in order to improve the response speed, the radial force, elongation and shape chart are displayed, and in the top menu bar, there are manufacturer name, screen recording, screen clearing, pause, display, background, setting, on / off communication, record, help and exit buttons to meet different functional requirements; in the upper middle area, the unit icon and text, time, communication light, rolling direction and speed dynamic diagram and basic rolling information are displayed.

[0029] After clicking the "background" button, the background color and line color can be set to facilitate different operation habits.

[0030] The calibration interface can quickly calibrate different channels, synchronously record zero positions, automatically record corresponding AD values under different weights, automatically obtain calibration coefficients after clicking ''fitting coefficients'', store in a database for subsequent calling, and quickly recover system default calibration values.

[0031] In the waveform monitoring interface, the waveform graphs of all channels are synchronously displayed, one red dot represents one cycle, two red dots display two AD peak values, the average value of the two is taken as the cycle peak signal, the abscissa is the data packet number, and the ordinate is the AD range, so as to facilitate the scaling of the waveform graph; clicking a channel waveform graph can perform overall amplification, full-screen display of the waveform state of a single channel, and selection of different channel numbers to quickly switch the corresponding waveform graph.

[0032] The present application can display the proofreading IP address and rolling parameters, communicate with the rolling mill to obtain, and also manually input to accurately calculate the plate shape state.

[0033] The present application can display a basic plate shape state interface, the upper left side displays the elongation rate, the lower left side displays the radial force, the upper right side displays the plate shape state and mode recognition plate shape component and the history curve of the overall plate shape.

[0034] The present application can display a basic plate shape control interface, the upper left side displays the plate shape deviation and target curve, the lower left side displays the segmented cooling regulation information, the upper right side displays the control amount of the plate shape regulation means, and the lower right side displays the history curve of the overall plate shape.

[0035] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A highly integrated industrial control computer-based plate shape detection system based on a whole-roll plate shape analyzer, characterized in that, include: The signal acquisition and drive module is used to drive the roll shaper to acquire AD signals, rolling speed signals, temperature signals, and forward and reverse rotation signals from the sensors in each channel; the output of the signal acquisition and drive module is connected to the signal packing and unpacking module. The signal packing and unpacking module is used to pack the acquired raw signals according to the custom encoding rules, and to unpack the received data packets, decompose them into the sensor signals of each channel, rolling speed signals, temperature signals and forward and reverse signals, and use check codes to verify their correctness. The communication interface adaptive module is used to periodically scan and automatically identify any one of the protocols and ports, such as Ethernet, USB, DP, and serial port, to achieve automatic connection and stable communication with the board shape analyzer. The communication interface adaptive module is used to transmit the packaged signal and receive external data. The unpacked signal is sequentially sent to the calibration module, the process error compensation module and the board shape signal processing module for processing. The calibration module is used to perform polynomial fitting on the AD values ​​of each channel, obtain the calibration coefficients between the AD values ​​and the radial force values, and store the calibration coefficients in the database. The calibration module supports single-channel individual calibration. The process error compensation module is used to compensate the original plate shape signal to generate an effective plate shape signal; The plate shape signal processing module is used to convert the radial force signal into an elongation / plate shape signal and perform high-order pattern recognition to obtain plate shape component information; the output of the plate shape signal processing module is connected to the control quantity calculation module. The control quantity calculation module is used to calculate the control quantity of the plate shape control method based on the plate shape deviation; the control method includes tilting roller, bending roller, lateral movement, segmented cooling, and ASU. The data management module is used to store calibration coefficients, rolling parameters, and plate shape data; the data management module is used to provide data storage and data retrieval for the calibration module and the plate shape signal processing module.

2. The highly integrated industrial control computer-based plate shape detection system based on a whole-roll plate shape analyzer according to claim 1, characterized in that, The adaptive communication interface module automatically scans and identifies available communication protocols and ports, and automatically identifies IP addresses and relative directories.

3. The highly integrated industrial control computer-based plate shape detection system based on a whole-roll plate shape analyzer according to claim 1, characterized in that, The calibration module includes a first-level calibration and a second-level calibration. The first-level calibration is a single-channel calibration. It involves collecting the zero-point AD value of a single channel, applying different weights sequentially and recording the AD values, and clicking the fitting coefficient button to complete a quadratic polynomial fitting and obtain the calibration coefficient of the single channel. The second-level calibration automatically identifies the effective detection channel based on the bandwidth, and at the same time automatically performs plate shape compensation for edge coverage, deviation, temperature, installation accuracy, and corner wrapping process errors.

4. The highly integrated industrial control computer-based plate shape detection system based on a whole-roll plate shape analyzer according to claim 3, characterized in that, The second-level calibration is used to determine whether the effective plate shape signal is consistent with the actual plate shape state. If they are consistent, the calibration coefficient and the process error compensation model are considered to be effective. The plate shape pattern recognition of the real-time plate shape signal is performed at the 4th to 8th order to obtain the plate shape component information.

5. The highly integrated industrial control computer-based plate shape detection system based on a whole-roll plate shape analyzer according to claim 1, characterized in that, The process error compensation module is used to compensate for board shape signal deviations caused by factors such as bandwidth, deviation amount, temperature, and installation accuracy.

6. The highly integrated industrial control computer-based plate shape detection system based on a whole-roll plate shape analyzer according to claim 1, characterized in that, The plate shape signal processing module performs plate shape pattern recognition at levels 4 to 8.

7. The highly integrated industrial control computer-based plate shape detection system based on a whole-roll plate shape analyzer according to claim 1, characterized in that, The control quantity calculation module uses the target curve to obtain the plate shape deviation and calculates the control quantity of different control methods according to the effect function. For a four- or six-roll mill, the control quantities are tilting roll, bending roll, lateral movement and segmented cooling. For a twenty-roll mill, the control quantities are ASU and lateral movement.

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