Method and device for calculating power consumption per ton of steel based on roller type straightening machine

Abstract

The invention provides a method and device for calculating power consumption per ton of steel based on a roller type straightening machine, and relates to the technical field of energy-saving calculation. The method comprises the steps that in the process that a plate is straightened through the roller type straightening machine, straightening time corresponding to all stages of the straightening process at all rollers is obtained; according to the motor power of each roller in the corresponding straightening time and the time interval value corresponding to each stage, the straightening power consumption corresponding to each roller is calculated; and summing the straightening power consumption corresponding to each roller to obtain the straightening power consumption of the single plate in the single pass, and calculating the ton steel power consumption of the single plate in the single pass according to the straightening power consumption and the mass of the single plate. The device executes the method. According to the ton steel power consumption calculation method and device based on the roller type straightening machine, ton steel power consumption calculation can be accurately carried out.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of energy-saving computing, in particular to a ton steel power consumption calculation method and device based on a roller straightening machine. BACKGROUND

[0002] In the production process of medium plate, a series of operations such as rolling, hot straightening and cold straightening are needed. The straightening process is particularly important, and the roller straightening machine can eliminate the unevenness of the plate produced in the rolling production process, eliminate residual stress or redistribute residual stress, so the roller straightening machine has also developed from the past auxiliary equipment to an important equipment indispensable in the production line.

[0003] The roller straightening machine generally has 7, 9, 11 rollers, such as Figure 1 As shown in the figure, it is a commonly used 9-roller cold straightening machine with an upper row of rollers inclined arrangement and large deformation. The No. 1 and No. 9 straightening rollers in the lower row can be adjusted independently, the No. 3, No. 5 and No. 7 straightening rollers always remain in the original position and cannot be adjusted. The upper row of straightening rollers can realize linearly decreasing press-down mode and parallel press-down mode. The roller spacing of the upper row of rollers (No. 2, No. 4, No. 6 and No. 8) is constant, and the roller spacing of the lower row of rollers (No. 3, No. 5 and No. 7) is also constant. The roller spacing at the inlet (No. 1 and No. 3) and the outlet (No. 7 and No. 9) of the lower row can be changed. The press-down range of the first and last rollers in the upper row is -25~+300mm, and the press-down range of the first and last rollers in the lower row is -25~+10mm.

[0004] The main drive system of the roller straightening machine transmits the torque of the main motor to the straightening roller. The main drive system of the straightening machine generally adopts the transmission mode of motor, reduction gear distribution box, safety coupling, universal coupling to the straightening roller. Accurate calculation of the power consumption of the roller straightening machine during the straightening process can help enterprises accurately grasp the power consumption of the equipment, accurately predict the operation health status of the roller straightening machine, and at the same time, through parameter adjustment of the roller straightening machine, energy saving and emission reduction can be realized, and green development of enterprises can be promoted.

[0005] The straightening torque is a key force parameter in the working process of the roller straightening machine, and is the basis for solving the straightening power and power consumption. In the production process, the press-down mode often adopts the upper row of rollers inclined press-down strategy, which will cause the bending curvature of the plate to be different when passing through each roller during the straightening process, resulting in different torque values required by each roller for straightening, and further affecting the calculation of power and power consumption.

[0006] During the straightening process of the steel plate, it will go through the processes of biting, acceleration, uniform speed and throwing. In this process, due to the different steel types, temperatures, lengths, widths and heights of incoming steel plates, and for each steel plate, the roller straightening machine will have a corresponding straightening strategy, and the press-down amount of the upper roller will also change. Under the optimal straightening strategy, how to accurately calculate the motor power of each straightening roller and the power consumption during the straightening process through the straightening principle has not yet been a special calculation method. SUMMARY

[0007] In order to solve the problems in the prior art, the embodiments of the present application provide a ton steel power consumption calculation method and device based on a roller straightening machine, which can at least partially solve the problems in the prior art.

[0008] In one aspect, the present application provides a ton steel power consumption calculation method based on a roller straightening machine, comprising:

[0009] obtaining the corresponding straightening time of each roller at each stage of the straightening process during the straightening process of the plate by the roller straightening machine;

[0010] According to the motor power of each roller at the corresponding straightening time and the time interval value corresponding to each stage, the straightening power consumption corresponding to each roller is calculated;

[0011] Summing up the straightening power consumption corresponding to each roller to obtain the power consumed by the straightening of a single plate in a single pass, and calculating the ton steel power consumption of a single plate in a single pass according to the power consumed by the straightening and the mass of the single plate.

[0012] Among them, the corresponding straightening time of each roller at each stage of the straightening process during the straightening process of the plate by the roller straightening machine comprises:

[0013] obtaining the corresponding first straightening time of each roller at the bite-in stage during the straightening process of the plate by the roller straightening machine;

[0014] obtaining the corresponding second straightening time of each roller at the post-bite-in acceleration stage during the straightening process of the plate by the roller straightening machine;

[0015] obtaining the corresponding third straightening time of each roller at the uniform speed straightening stage during the straightening process of the plate by the roller straightening machine.

[0016] Among them, obtaining the first straightening time comprises:

[0017] The ratio of the bite-in length of the plate corresponding to each roller to the bite-in speed of the plate is taken as the first straightening time.

[0018] Among them, obtaining the second straightening time comprises:

[0019] The first difference value is obtained by subtracting the maximum straightening speed from the bite-in speed of the plate, and the ratio of the first difference value to the straightening acceleration is taken as the second straightening time.

[0020] Among them, obtaining the third straightening time comprises:

[0021] Subtracting the plate bite length corresponding to each roller from the plate length and the straightening length during the speed increasing process to obtain a second difference, and taking the ratio of the second difference to the maximum straightening speed as the third straightening time.

[0022] The straightening length during the speed increasing process is obtained by:

[0023] The straightening length during the speed increasing process is obtained by the second straightening time, the plate bite speed and the straightening acceleration.

[0024] The straightening power consumption corresponding to each roller is obtained by the motor power of each roller during the corresponding straightening time and the time interval value corresponding to each stage.

[0025] The first motor power during the first straightening time is integrated in the first time interval value corresponding to the bite stage to obtain the first straightening power consumption.

[0026] The second motor power during the second straightening time is integrated in the second time interval value corresponding to the post-bite acceleration stage to obtain the second straightening power consumption.

[0027] The third motor power during the third straightening time is integrated in the third time interval value corresponding to the constant-speed straightening stage to obtain the third straightening power consumption.

[0028] The first straightening power consumption, the second straightening power consumption and the third straightening power consumption are summed to obtain the straightening power consumption corresponding to each roller.

[0029] In one aspect, the present application provides a ton steel power consumption calculation device based on a roller straightening machine, comprising:

[0030] The acquisition unit is configured to acquire the straightening time of each roller during each stage of the straightening process of the plate by the roller straightening machine.

[0031] The first calculation unit is configured to obtain the straightening power consumption corresponding to each roller by the motor power of each roller during the corresponding straightening time and the time interval value corresponding to each stage.

[0032] The second calculation unit is configured to sum the straightening power consumption corresponding to each roller to obtain the power consumption of a single plate in a single pass, and to obtain the ton steel power consumption of a single plate in a single pass by the power consumption of the straightening and the mass of the single plate.

[0033] In still another aspect, the embodiment of the present application provides a computer device, comprising a memory, a processor and a computer program stored in the memory and executable on the processor, and the processor implements the following method when executing the computer program:

[0034] In the process of straightening the plate by the roller straightener, the straightening time corresponding to each stage of the straightening process at each roller is obtained;

[0035] According to the motor power of each roller in the corresponding straightening time and the time interval value corresponding to each stage, the straightening power consumption corresponding to each roller is calculated;

[0036] The straightening power consumption corresponding to each roller is summed up to obtain the power consumed by the straightening of a single plate in a single pass, and the ton steel power consumption of the single plate in the single pass is calculated according to the power consumed by the straightening and the mass of the single plate.

[0037] The embodiment of the present application provides a computer readable storage medium, comprising:

[0038] The computer readable storage medium stores a computer program, and the computer program is executed by a processor to implement the following method:

[0039] In the process of straightening the plate by the roller straightener, the straightening time corresponding to each stage of the straightening process at each roller is obtained;

[0040] According to the motor power of each roller in the corresponding straightening time and the time interval value corresponding to each stage, the straightening power consumption corresponding to each roller is calculated;

[0041] The straightening power consumption corresponding to each roller is summed up to obtain the power consumed by the straightening of a single plate in a single pass, and the ton steel power consumption of the single plate in the single pass is calculated according to the power consumed by the straightening and the mass of the single plate.

[0042] The embodiment of the present application provides a ton steel power consumption calculation method and device based on a roller straightener, which obtains the straightening time corresponding to each stage of the straightening process at each roller in the process of straightening the plate by the roller straightener, calculates the straightening power consumption corresponding to each roller according to the motor power of each roller in the corresponding straightening time and the time interval value corresponding to each stage, sums up the straightening power consumption corresponding to each roller to obtain the power consumed by the straightening of a single plate in a single pass, and calculates the ton steel power consumption of the single plate in the single pass according to the power consumed by the straightening and the mass of the single plate, so that the ton steel power consumption can be accurately calculated. BRIEF DESCRIPTION OF DRAWINGS

[0043] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings:

[0044] Figure 1 This is a schematic diagram of a 9-roll cold straightening machine with inclined upper roller arrangement, commonly used in existing technology for thick plates, to achieve large deformation.

[0045] Figure 2 This is a flowchart illustrating a method for calculating the power consumption per ton of steel based on a roller straightener, according to an embodiment of the present invention.

[0046] Figure 3 This is a schematic diagram illustrating the MA curve of a rectangular plate provided in an embodiment of the present invention.

[0047] Figure 4 This is a schematic diagram illustrating the timing of the hot straightening speed of the sheet metal according to an embodiment of the present invention.

[0048] Figure 5 This is a schematic diagram illustrating the start and stop timing of single-pass straightening provided in an embodiment of the present invention.

[0049] Figure 6 This is a schematic diagram of the structure of a power consumption calculation device per ton of steel based on a roller straightener provided in an embodiment of the present invention.

[0050] Figure 7 This is a schematic diagram of the physical structure of a computer device provided in an embodiment of the present invention. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Here, the illustrative embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be arbitrarily combined with each other.

[0052] Figure 2 This is a flowchart illustrating a method for calculating the power consumption per ton of steel based on a roller straightener, according to an embodiment of the present invention. Figure 2 As shown, the method for calculating the power consumption per ton of steel based on a roller straightener provided in this embodiment of the invention includes:

[0053] Step S1: During the process of straightening the sheet material using a roller straightener, obtain the straightening time at each roller in each stage of the straightening process.

[0054] Step S2: Calculate the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage.

[0055] Step S3: Sum the straightening power consumption corresponding to each roller to obtain the power consumption of a single plate in a single pass. Calculate the power consumption per ton of steel per pass based on the straightening power consumption and the mass of the single plate.

[0056] In step S1 above, the device acquires the straightening time at each roller during each stage of the straightening process in the roller straightener. The device can be a computer device, such as a server, that executes the method. The acquisition, storage, use, and processing of data in this application's technical solution all comply with relevant regulations.

[0057] Before step S1, the relevant parameters need to be derived and calculated, as explained below:

[0058] 1. Calculation of sheet metal compression and deflection during the straightening process:

[0059] The pressing adjustment scheme for a roller straightener involves adjusting the overall tilt of the upper row of straightening rollers. First, the pressing amount of the inlet and outlet straightening rollers needs to be determined. The inlet straightening roller is the first straightening roller in the upper roller system, and the outlet straightening roller is the last straightening roller in the upper roller system. Taking an n-roll straightener as an example, these can be represented by the symbols δ2 and δ... n-1 This indicates that the side rollers of the roller straightener can also be adjusted by pressing down; that is, the first and last straightening rollers involved in straightening are adjusted by δ1 and δ2 respectively. n This indicates that since it cannot form a complete straightening unit, it does not have a relative reduction amount, but its reduction amount will affect the calculation of the relative reduction amount of the 2 rolls and the n-1 rolls.

[0060] After determining δ2 and δ n-1 Next, calculate the reduction of the remaining straightening rollers in the upper row, considering the principle of linear distribution. The specific calculation is shown in formula (1):

[0061]

[0062] In the formula, n is the number of straightening rollers; i is the number of the upper row of straightening rollers, which takes the value 2, 4, 6, ... n-1.

[0063] Excluding the side rollers, the other lower rollers, although they do not provide a reduction amount, are considered to have a relative reduction amount. Considering the positional relationship between each straightening roller and the front and rear rollers, the relative reduction amount of each roller is calculated as shown in formula (2):

[0064]

[0065] In the formula, δR_i P represents the relative reduction of each roller, in mm; i is the number of the lower row straightening rollers, with values ​​of 3, 5, 7...n-2; R_i The actual position of the straightening roller is shown, with the upper surface of the lower roller set to position 0.

[0066] Taking a straightening unit as an example, this paper analyzes the relationship between the straightening roller reduction and deflection. From the bending condition of the sheet metal, it can be seen that the relative reduction δ... R_i Including the deflection value υ of the plate at the i-roller i The deflection value υ of the plate at roll i-1 i-1 The deflection value υ of the plate at roll i+1 i+1 The three parts conform to the following relationship (3):

[0067]

[0068] In the formula, υ i Let be the deflection of the sheet material between the zero bending moment points at the i-th roller, in mm;

[0069] υ i-1 Let be the deflection of the sheet material between the zero bending moment points at the (i-1)th roller, in mm;

[0070] υ i+1 Let be the deflection of the sheet material between the zero bending moment point at the (i+1)th roller, in mm.

[0071] Considering that the reduction model is the tilt adjustment of the upper straightening roller, and υ i υ i-1 With υ i+1 The differences between them are very small, and the relationship between the three can be simplified to equation (4):

[0072]

[0073] Substituting equation (4) into equation (3) and rearranging, we can obtain the relationship between deflection and relative reduction as shown in equation (5):

[0074]

[0075] 2. Calculation of sheet curvature during straightening process:

[0076] By using the intermediate variable deflection to establish the relationship between curvature and relative reduction, the above process has already established the relationship between deflection and relative reduction. This part will establish the relationship between deflection and curvature, and then obtain the solution relationship between curvature and relative reduction.

[0077] Based on the geometric relationship between the triangles, a set of equations can be constructed between the radius of curvature, the roll gap, and the deflection, as shown in equation (6). Furthermore, the relationship between the deflection and the bending radius can be established, and the relationship between the deflection and the bending curvature can be determined, as shown in equation (2-7).

[0078]

[0079] In the formula, l is the distance between the straightening rollers, in meters;

[0080] ρ i Let the radius of curvature at roller i be the radius of curvature, in meters.

[0081] X is an intermediate variable, m;

[0082] υ i Let m be the deflection at roller i.

[0083]

[0084] In the formula, A i Let m be the curvature of the sheet metal at each roller. -1 .

[0085] Substituting equation (5) into equation (7), we can obtain the relationship between the curvature and the relative reduction, as shown in equation (8):

[0086]

[0087] Through the above calculation process, the relationship between the straightening roller reduction and the achievable bending curvature of the sheet can be determined. Since the sheet straightening process does not involve very large plastic deformation, the bending curvature A can be established using the principle of elastic unloading. i , elastic curvature A f Residual curvature A c The relationship between them.

[0088] Straightening of metallic materials mainly utilizes the elastic-plastic deformation characteristics of metallic materials. When the strain is less than ε... t When the strain is greater than or equal to ε, the sheet material undergoes only elastic deformation and no plastic deformation during the straightening process, so the shape of the sheet material will not change after straightening. t During the straightening process of the sheet metal, no significant plastic deformation occurs. Therefore, the elastic strain ε of the sheet metal after straightening by each roller is [value missing]. f The elastic limit strain ε can be used as a reference. t Therefore, the elastic curvature A f It can also be determined by the limiting elastic curvature A t It is indicated that, since the sheet material has two bending curvatures in two directions during the straightening process, the bending curvature is defined as positive when the sheet material is concave and negative when it is convex. At the same time, the elastic curvature also needs to be distinguished by positive and negative values, and its sign is the same as that of the bending curvature.

[0089] After determining the calculation methods for the bending curvature and elasticity of each roller, the residual curvature of the sheet material after moving away from each straightening roller can be expressed as:

[0090] A ci =A i -A f =A i -A t (9)

[0091] In the formula, A ci m is the residual curvature after i-roller straightening. -1 ;

[0092] A i For the curvature of the i-roller straightening bend, m -1 ;

[0093] A fi m is the elastic recovery curvature after i-roller straightening. -1 When i = 2, 4, ..., n-1 (upper roller), it is a positive value; otherwise, it is a negative value.

[0094] A t For the limiting elastic bending curvature, m -1 .

[0095] 3. Calculation of straightening moment and straightening force:

[0096] During the straightening process, the sheet material passes through straightening rollers alternately. At each straightening roller, the curvature change includes the following components: the original curvature A0 of the sheet material, the bending curvature A... i After unloading, the curvature A of the elasticity is reduced. f Residual curvature A after stabilization c Taking a straightening roller as an example, for the case of a rectangular cross-section of a sheet metal, its bending moment M... i As in equation (10):

[0097]

[0098] In the formula, M i Let i be the straightening bending moment at roller i, in N·m;

[0099] M t The elastic limit bending moment is expressed in N·m.

[0100] A Σi Let m be the total curvature at roller i. -1 ;

[0101] B is the width of the steel plate, in meters (m).

[0102] H is the thickness of the steel plate, in meters (m).

[0103] σ t The yield strength is Pa;

[0104] E represents the elasticity model, pa.

[0105] The straightening force can be solved by starting with the bending moment of the sheet at each roller. This is given by the total curvature A of the sheet at each roller. Σi Once determined, the bending moment M can be calculated. i The straightening force expression can be written according to the three-moment equation of a continuous beam, as shown in equation (14):

[0106]

[0107] In the formula, F i Let N be the straightening force of roller i.

[0108] 4. Calculation of straightening torque:

[0109] The resistance that straightening rollers need to overcome under straightening force mainly consists of three types: bearing friction resistance, rolling friction resistance between the steel plate and the roller surface, and the resistance of the steel plate's own elastic-plastic deformation. Therefore, the straightening torque is also mainly divided into three parts: bearing friction torque, rolling friction torque between the steel plate and the roller surface, and the torque required for the steel plate's own elastic-plastic deformation.

[0110] (1) Calculation of rolling friction torque of steel plate between straightening rolls:

[0111] The steel plate will consume a certain amount of torque due to rolling friction between the straightening rollers, as expressed in equation (15):

[0112] T fi =fF i (15)

[0113] In the formula: T fi The rolling friction torque at each roller is kN·m;

[0114] f is the rolling friction coefficient between the workpiece and the roller surface during the straightening process, which is 0.0008m for high-temperature plates;

[0115] F i The straightening force acting on the i-th straightening roller is kN.

[0116] (2) Friction torque model of straightening roller bearing:

[0117] The straightening roller bearing consumes torque due to friction, as shown in equation (16):

[0118]

[0119] In the formula: T mi The bearing friction torque at each roller is kN·m.

[0120] μ is the bearing friction coefficient, which is 0.005-0.01 for rolling bearings, 0.02-0.03 for nylon bearings, and 0.03-0.05 for bronze bearings;

[0121] d is the diameter of the straightening roller shaft, in meters.

[0122] (3) Elastic-plastic deformation torque during steel plate straightening:

[0123] The calculation of the torque required for the elastic-plastic deformation of a sheet metal is mainly based on the principle of work-energy theorem. When a metal strip bends under external force, the work done by the external force is used for both elastic and plastic deformation, with a small portion dissipated as heat, which can be ignored. Deformation during straightening includes both elastic and plastic deformation. The initial stage of deformation is elastic deformation, followed by an elastic-plastic deformation stage, which is a mixed stage of elastic and plastic deformation. Elastic deformation is an energy-storing deformation; this energy is released after the external force is removed. Plastic deformation is permanent deformation, and its energy consumption determines the amount of energy consumed. Before calculating energy consumption, the mixed deformation is separated into elastic and plastic deformations and calculated separately.

[0124] Plot the MA relationship curve according to equation (10), as follows: Figure 3 As shown, the area under the curve is the deformation energy during the straightening process of the plate, which is the integral value of the product of variables M and A.

[0125] Since it is equal to the sum of the integral values ​​of the elastic bending segment and the elastic-plastic bending segment, the bending deformation energy per unit length of rectangular material is as shown in equation (17):

[0126]

[0127] From equations (11) and (12), it can be seen that the elastic deformation energy part can be expressed as the following calculation expression, as shown in equation (18):

[0128]

[0129] In the formula, u t The elastic deformation energy is kJ;

[0130] σ t The yield strength is given in kPa.

[0131] E is the elastic modulus, in kPa.

[0132] Therefore, the formula for total deformation energy can be expressed as shown in equation (19):

[0133]

[0134] In the formula, u is the total deformation energy, kJ.

[0135] After the workpiece is bent in reverse and the external force is removed, it will inevitably be in accordance with... Figure 3 The triangle springs back along the middle oblique dashed line and releases energy, namely the elastic deformation energy. This energy can be represented by the area of ​​the triangle, i.e., equation (20):

[0136]

[0137] In the formula, u f The elastic deformation energy is kJ;

[0138] The curvature of the elastic element will completely follow the elastic deformation rule, and can be written as equation (21):

[0139]

[0140] Therefore, the energy released during the rebound process can be transformed into equation (22):

[0141]

[0142] The energy released during springback will inevitably be fed back to the straightening machine. Although this energy is not entirely converted into usable energy, the vast majority will help the machine operate. Therefore, the energy used by the machine for straightening deformation can be basically written as equation (23):

[0143]

[0144] In the formula, u J The energy is the pure plastic deformation energy, kJ;

[0145] During the bending process of a sheet metal, both pure plastic deformation and residual deformation consume kinetic energy. Let the torque required for these two types of deformation be T. J The energy consumed after the roller rotates by an angle θ is T. J Let θ be the length Rθ that the workpiece has traveled. From the above, we can deduce that the straightening deformation energy required per unit length of the workpiece is u. J Therefore, the following equation (24) can be written:

[0146] T J θ=Rθu J (twenty four)

[0147] Therefore, the torque at the i-th roller can be written as in equation (25):

[0148]

[0149] Therefore, the total torque of the i-th roller of the straightener is as shown in equation (26):

[0150] T i =T fi +T mi +T Ji (26)

[0151] In the formula, T i The total torque at each roller is expressed in kN·m.

[0152] T fiThe rolling friction torque at each roller is kN·m, as shown in equation (15);

[0153] T mi The bearing friction torque at each roller is kN·m, as shown in equation (16);

[0154] T Ji The elastic-plastic deformation torque at each roller is kN·m, as shown in equation (25).

[0155] The process of obtaining the straightening time at each roller during each stage of the straightening process in the roller straightening machine includes:

[0156] During the process of straightening the sheet material using a roller straightener, the first straightening time corresponding to the biting stage of each roller is obtained.

[0157] During the straightening process of the plate by the roller straightener, the second straightening time corresponding to the acceleration stage after biting of each roller is obtained;

[0158] During the straightening process of the plate by the roller straightener, the third straightening time corresponding to the uniform speed straightening stage of each roller is obtained.

[0159] The straightening process mainly includes three stages: steel plate biting, straightening, and ejection. The straightening speed of each stage is different, and the straightening time of each straightening roller is different. Therefore, the required straightening power and power consumption are different. It is necessary to calculate the straightening time and straightening speed of each roller in stages. The calculation is carried out by taking a certain straightening roller as an example.

[0160] In the actual production of medium and heavy plates, the single-pass straightening time includes: the time for the rolled piece to complete the biting stage, the time for the rolled piece to accelerate to the maximum straightening speed, and the time for uniform straightening. Since the straightener speed does not decrease during the steel ejection stage, this part of the time belongs to the uniform straightening period. According to the straightening process, the biting time and uniform straightening time of each roller on the straightener are different, while the acceleration stage time is the same. The specific straightening speed sequence is as follows: Figure 4 As shown.

[0161] Calculate the straightening time for each stage based on the straightening process and set conditions:

[0162] Bite phase:

[0163]

[0164] In the formula, t in_i The biting time of the sheet metal at roller i (corresponding to the first straightening time), in seconds;

[0165] L in_i Let i be the biting length of the sheet metal at roller i, in meters.

[0166] v inThe biting speed of the board is expressed in m / s.

[0167] Acceleration phase after biting in:

[0168]

[0169] In the formula, t a1 The time (corresponding to the second straightening time) is increased by the straightening speed, in seconds;

[0170] v max The maximum straightening speed is expressed in m / s.

[0171] a in The straightening acceleration is in m / s².

[0172] L a1 The straightening length, in meters, is increased by the speed during the process.

[0173] Uniform speed straightening stage:

[0174]

[0175] In the formula, t max The time for uniform straightening of the sheet material (corresponding to the third straightening time), in seconds;

[0176] L b , where is the length of the board, in meters (m).

[0177] In step S2 above, the device calculates the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage. The calculation of the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage includes:

[0178] The power of the first motor during the first straightening time is integrally calculated within the first time interval corresponding to the biting stage to obtain the first straightening power consumption.

[0179] The second motor power during the second straightening time is integrally calculated within the second time interval corresponding to the acceleration phase after biting in, to obtain the second straightening power consumption.

[0180] The power of the third motor within the third time interval corresponding to the uniform speed straightening stage is integrated to obtain the third straightening power consumption.

[0181] The first straightening power consumption, the second straightening power consumption, and the third straightening power consumption are summed to obtain the straightening power consumption corresponding to each roller.

[0182] The torque required to output by the motor-driven straightening roller mainly includes the straightening torque and the friction torque. Since the power of each roller in the straightening machine is different, the torque of each roller needs to be calculated separately. Therefore, the total torque can be calculated using the following formula (31):

[0183]

[0184] In the formula, T 总 The total torque required to output the motor-driven straightening roller is expressed in kN·m.

[0185] I i The transmission ratio from the main motor to the i-straightening roller.

[0186] The power of each straightening roller during the straightening process is as shown in equation (32):

[0187]

[0188] In the formula, P i Let i be the straightening power of roller i, in kW;

[0189] n i The motor speed is expressed in r / min.

[0190] During the first straightening time:

[0191] During the biting process, there are bending torque and friction torque. The power of the i-roller motor can be expressed as shown in equation (33):

[0192]

[0193] In the formula, n in P represents the motor speed during the biting process, in r / min. in (i) refers to the power of the first motor.

[0194] During the second straightening time:

[0195] During the acceleration process after biting in, there are bending torque and friction torque. At this time, the motor speed is a value that changes with time. Therefore, the straightening power in this segment can be expressed as shown in equation (34):

[0196]

[0197] In the formula, n_a in The acceleration is expressed in r / min / s.

[0198] t2-t1 is the acceleration time, in seconds. a1 (i) refers to the power of the second motor.

[0199] During the third straightening period:

[0200] During the uniform speed straightening process, there are bending torque and friction torque. The power of the i-roller motor can be expressed as shown in equation (35):

[0201]

[0202] In the formula, n max The motor speed during the uniform straightening process is given in r / min, and P is given. max (i) refers to the power of the third motor.

[0203] The power consumption per pass of a single roller is calculated by integrating the power over time. As can be seen from the previous calculation process, the straightening power is a function of the straightening speed during the straightening process, and the straightening speed changes with time. Therefore, the power consumption per pass of i roller can be expressed as shown in equation (36):

[0204]

[0205] Specifically, the straightening speed single-pass timing diagram is as follows: Figure 5 As shown, the power consumption of the i-roller in a single straightening process can be divided into the biting stage Q according to the time sequence. in_i Accelerated straightening stage Q a1_i Uniform speed straightening stage Q max_i .

[0206] During the straightening process, the relationship between speed and time can be expressed as shown in equation (37):

[0207]

[0208] Among them, 0 < t < t1 corresponds to the first time interval value, t1 < t < t2 corresponds to the second time interval value, and t2 < t < t3 corresponds to the third time interval value.

[0209] Power P can be expressed as a function of time t. Differentiating the single-pass straightening process yields the differential of electrical energy, and integrating it gives the single-pass straightening power consumption. See formula (2-38):

[0210]

[0211] Substituting equations (33) to (35) into equation (38) yields equation (39):

[0212]

[0213] The formula for calculating the power consumption of a single pass i-roller straightening is given by equation (40):

[0214]

[0215] In the formula, Q iThe power consumption required for the entire straightening process of roller i (and the straightening power consumption corresponding to each roller) is kJ.

[0216] In step S3 above, the device sums up the straightening power consumption corresponding to each roller to obtain the power consumption of a single plate in a single pass. Based on the power consumption of straightening and the mass of the single plate, the power consumption per ton of steel in a single pass is calculated. By summing up the straightening power consumption of each roller in a single pass, the power consumption of a single steel plate in a single pass can be obtained, as shown in equation (41):

[0217]

[0218] The power consumption per ton of steel can then be expressed as shown in equation (42):

[0219]

[0220] Where D is the power consumption per ton of steel, kW·h / t; m is the mass of a single steel plate (mass of a single sheet), t.

[0221] Based on the mechanical properties of steel plates, a certain straightened plate is selected as the calculation object. The specific calculation input parameters are shown in Table 1. The power consumption is calculated using this steel plate as an example. A roller straightening model based on the curvature integral method is used for modeling and calculation analysis. This yields the contact angle, bending curvature, and straightening trajectory at each roller of the plate under the given pressing process parameters. These directly obtained results allow for further calculation of parameters during the straightening process, such as the plastic deformation rate at each straightening roller, the bending moment and straightening force at each pass, and the torque. The straightening process mainly includes three stages: steel plate biting, straightening, and ejection. The straightening speed varies in each stage, and the straightening time of each roller differs, resulting in different required straightening power and power consumption. Therefore, calculations must be performed stage by stage based on the straightening time and speed of each roller. The power consumption per roller per pass is obtained by integrating the power over time. Summing the power consumption of each roller in a single pass yields the power consumption of a single steel plate per pass. The final calculated power consumption per ton of steel during a single pass straightening process was 0.35 kW·h / t. This provides a calculation method for accurately measuring the annual power consumption of the straightening machine and also provides a calculation basis for selecting the power of the main motor for each roller of the straightening machine. If the actual power consumption deviates significantly from the theoretical calculation value during the straightening process, the occurrence of straightening machine failures can be predicted. Furthermore, changing the relevant model parameters of the straightening machine will affect the calculation results, providing technical support for energy-saving optimization design in the straightening process.

[0222] Table 1

[0223]

[0224]

[0225] The method for calculating the power consumption per ton of steel based on a roller straightener provided in this invention has the following beneficial technical effects:

[0226] This system can be used to calculate the sheet metal compression and deflection, curvature, bending moment and straightening force, torque, power and electrical energy of multi-roll straighteners with different numbers of rollers, through formula derivation. It calculates the power of each roller motor in a multi-roll straightener based on physical principles, as well as the power consumption during the straightening process. This plays a significant role in the selection of the main motor, power consumption prediction, fault diagnosis, and energy conservation and emission reduction of straighteners.

[0227] The present invention provides a method for calculating the power consumption per ton of steel based on a roller straightener. During the straightening process of a plate by the roller straightener, the straightening time corresponding to each roller at each stage of the straightening process is obtained. Based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage, the power consumption for straightening at each roller is calculated. The power consumption for straightening at each roller is summed to obtain the power consumption of a single plate in a single pass. Based on the power consumption for straightening and the mass of a single plate, the power consumption per ton of steel in a single pass is calculated, enabling accurate calculation of power consumption per ton of steel.

[0228] Furthermore, the step of obtaining the straightening time at each roller during each stage of the straightening process in the roller straightener includes:

[0229] During the straightening process of the plate by the roller straightener, the first straightening time corresponding to the biting stage of each roller is obtained; this can be referred to the above embodiment for explanation, and will not be repeated here.

[0230] During the straightening process of the plate by the roller straightener, the second straightening time corresponding to the acceleration stage after each roller bites in the roller straightening machine is obtained; this can be referred to the above embodiment for explanation, and will not be repeated here.

[0231] During the straightening process of the plate by the roller straightener, the third straightening time corresponding to each roller being in the uniform speed straightening stage is obtained. This can be referred to the above embodiment for explanation, and will not be repeated here.

[0232] Further, obtaining the first straightening time includes:

[0233] The ratio of the plate bite length to the plate bite speed at each roller is taken as the first straightening time. This can be referred to the above embodiment for explanation, and will not be repeated here.

[0234] Further, obtaining the second straightening time includes:

[0235] The maximum straightening speed is subtracted from the biting speed of the sheet metal to obtain a first difference. The ratio of the first difference to the straightening acceleration is used as the second straightening time. This can be referred to the above embodiment for further explanation, and will not be repeated here.

[0236] Further, obtaining the third straightening time includes:

[0237] The second difference is obtained by subtracting the length of the sheet material from the biting length of the sheet material at each roller and the straightening length during the speed increase process. The ratio of the second difference to the maximum straightening speed is used as the third straightening time. This can be referred to the above embodiment for explanation, and will not be repeated here.

[0238] Further, obtaining the straightening length during the speed increase process includes:

[0239] The straightening length during the speed increase process is calculated based on the second straightening time, the biting speed of the sheet metal, and the straightening acceleration. This can be referred to the above embodiment for further explanation and will not be repeated here.

[0240] Further, the step of calculating the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage includes:

[0241] The power of the first motor during the first straightening time is integrally calculated within the first time interval corresponding to the biting stage to obtain the first straightening power consumption; this can be referred to the above embodiment for explanation, and will not be repeated here.

[0242] The second motor power during the second straightening time is integrally calculated within the second time interval corresponding to the acceleration phase after biting in, to obtain the second straightening power consumption; this can be referred to the above embodiment for explanation, and will not be repeated here.

[0243] The power of the third motor within the third time interval corresponding to the uniform straightening stage is integrated to obtain the third straightening power consumption; this can be referred to the above embodiment for explanation, and will not be repeated here.

[0244] The first straightening power consumption, the second straightening power consumption, and the third straightening power consumption are summed to obtain the straightening power consumption corresponding to each roller. This can be referred to the above embodiment for further explanation, and will not be repeated here.

[0245] Figure 6 This is a schematic diagram of the structure of a power consumption calculation device per ton of steel based on a roller straightener according to an embodiment of the present invention, as shown below. Figure 6 As shown, the power consumption calculation device per ton of steel based on a roller straightener provided in this embodiment of the invention includes an acquisition unit 601, a first calculation unit 602, and a second calculation unit 603, wherein:

[0246] The acquisition unit 601 is used to acquire the straightening time corresponding to each roller at each stage of the straightening process during the straightening of the plate by the roller straightener; the first calculation unit 602 is used to calculate the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage; the second calculation unit 603 is used to sum up the straightening power consumption corresponding to each roller to obtain the power consumption of a single plate in a single pass, and calculate the power consumption per ton of steel of a single plate in a single pass based on the power consumption of straightening and the mass of a single plate.

[0247] Specifically, the acquisition unit 601 in the device is used to acquire the straightening time corresponding to each roller at each stage of the straightening process during the straightening of the plate by the roller straightener; the first calculation unit 602 is used to calculate the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage; the second calculation unit 603 is used to sum up the straightening power consumption corresponding to each roller to obtain the power consumption of a single plate in a single pass, and calculate the power consumption per ton of steel of a single plate in a single pass based on the power consumption of straightening and the mass of a single plate.

[0248] The power consumption calculation device per ton of steel based on a roller straightener provided in this invention obtains the straightening time corresponding to each roller at each stage of the straightening process during the straightening of the plate by the roller straightener; calculates the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage; sums up the straightening power consumption corresponding to each roller to obtain the power consumption of a single plate in a single pass of straightening; and calculates the power consumption per ton of steel of a single plate in a single pass based on the power consumption of straightening and the mass of a single plate, thus enabling accurate calculation of power consumption per ton of steel.

[0249] The embodiments of the present invention provide an embodiment of a power consumption calculation device for ton of steel based on a roller straightener, which can be used to execute the processing flow of the above-described method embodiments. Its functions will not be repeated here, but can be referred to the detailed description of the above-described method embodiments.

[0250] Figure 7 This is a schematic diagram of the physical structure of a computer device provided in an embodiment of the present invention, such as... Figure 7 As shown, the computer device includes: a memory 701, a processor 702, and a computer program stored in the memory 701 and executable on the processor 702. When the processor 702 executes the computer program, it implements the following method:

[0251] During the process of straightening the sheet metal using a roller straightener, the straightening time at each roller is obtained at each stage of the straightening process.

[0252] Based on the motor power at each roller during the corresponding straightening time and the time interval values ​​corresponding to each stage, the straightening power consumption corresponding to each roller is calculated.

[0253] The straightening power consumption corresponding to each roller is summed to obtain the power consumption of a single plate in a single pass. Based on the power consumption of straightening and the mass of a single plate, the power consumption per ton of steel in a single pass is calculated.

[0254] This embodiment discloses a computer program product, which includes a computer program that, when executed by a processor, implements the following method:

[0255] During the process of straightening the sheet metal using a roller straightener, the straightening time at each roller is obtained at each stage of the straightening process.

[0256] Based on the motor power at each roller during the corresponding straightening time and the time interval values ​​corresponding to each stage, the straightening power consumption corresponding to each roller is calculated.

[0257] The straightening power consumption corresponding to each roller is summed to obtain the power consumption of a single plate in a single pass. Based on the power consumption of straightening and the mass of a single plate, the power consumption per ton of steel in a single pass is calculated.

[0258] This embodiment provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the following method:

[0259] During the process of straightening the sheet metal using a roller straightener, the straightening time at each roller is obtained at each stage of the straightening process.

[0260] Based on the motor power at each roller during the corresponding straightening time and the time interval values ​​corresponding to each stage, the straightening power consumption corresponding to each roller is calculated.

[0261] The straightening power consumption corresponding to each roller is summed to obtain the power consumption of a single plate in a single pass. Based on the power consumption of straightening and the mass of a single plate, the power consumption per ton of steel in a single pass is calculated.

[0262] Compared with existing technical solutions, the present invention provides a method for calculating the power consumption per ton of steel based on a roller straightener. This method obtains the straightening time at each roller during each stage of the straightening process. Based on the motor power at each roller during the corresponding straightening time and the time interval corresponding to each stage, the power consumption per ton of steel is calculated. The power consumption per ton of steel is then summed to obtain the power consumption per pass for a single sheet of steel. Finally, the power consumption per ton of steel is calculated based on the power consumption per pass and the mass of the single sheet of steel, enabling accurate calculation of power consumption per ton of steel.

[0263] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0264] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0265] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0266] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process.Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0267] In the description of this specification, the references to terms such as "an embodiment," "a specific embodiment," "some embodiments," "for example," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0268] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for calculating the power consumption per ton of steel based on a roller straightener, characterized in that, include: During the process of straightening the sheet metal using a roller straightener, the straightening time at each roller is obtained at each stage of the straightening process. Based on the motor power at each roller during the corresponding straightening time and the time interval values ​​corresponding to each stage, the straightening power consumption corresponding to each roller is calculated. The straightening power consumption corresponding to each roller is summed to obtain the power consumption of a single plate in a single pass. Based on the power consumption of straightening and the mass of a single plate, the power consumption per ton of steel in a single pass is calculated.

2. The method for calculating the power consumption per ton of steel based on a roller straightener according to claim 1, characterized in that, The process of obtaining the straightening time at each roller during each stage of the straightening process in the roller straightening machine includes: During the process of straightening the sheet material using a roller straightener, the first straightening time corresponding to the biting stage of each roller is obtained. During the straightening process of the plate by the roller straightener, the second straightening time corresponding to the acceleration stage after biting of each roller is obtained; During the straightening process of the plate by the roller straightener, the third straightening time corresponding to the uniform speed straightening stage of each roller is obtained.

3. The method for calculating the power consumption per ton of steel based on a roller straightener according to claim 2, characterized in that, Obtaining the first straightening time includes: The ratio of the plate bite length to the plate bite speed at each roller is taken as the first straightening time.

4. The method for calculating the power consumption per ton of steel based on a roller straightener according to claim 3, characterized in that, Obtaining the second straightening time includes: The first difference is obtained by subtracting the maximum straightening speed from the biting speed of the plate, and the ratio of the first difference to the straightening acceleration is used as the second straightening time.

5. The method for calculating the power consumption per ton of steel based on a roller straightener according to claim 4, characterized in that, Obtaining the third straightening time includes: The second difference is obtained by subtracting the length of the sheet material from the biting length of the sheet material at each roller and the straightening length during the speed increase process. The ratio of the second difference to the maximum straightening speed is used as the third straightening time.

6. The method for calculating the power consumption per ton of steel based on a roller straightener according to claim 5, characterized in that, Obtaining the straightening length during the speed increase process includes: The straightening length during the speed increase process is calculated based on the second straightening time, the biting speed of the plate, and the straightening acceleration.

7. The method for calculating the power consumption per ton of steel based on a roller straightener according to claim 2, characterized in that, The step of calculating the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage includes: The power of the first motor during the first straightening time is integrally calculated within the first time interval corresponding to the biting stage to obtain the first straightening power consumption. The second motor power during the second straightening time is integrally calculated within the second time interval corresponding to the acceleration phase after biting in, to obtain the second straightening power consumption. The power of the third motor within the third time interval corresponding to the uniform speed straightening stage is integrated to obtain the third straightening power consumption. The first straightening power consumption, the second straightening power consumption, and the third straightening power consumption are summed to obtain the straightening power consumption corresponding to each roller.

8. A device for calculating the power consumption per ton of steel based on a roller straightener, characterized in that, include: The acquisition unit is used to acquire the straightening time of each roller at each stage of the straightening process during the straightening of the plate by the roller straightener; The first calculation unit is used to calculate the straightening power consumption corresponding to each roller based on the motor power at each roller during the corresponding straightening time and the time interval value corresponding to each stage. The second calculation unit is used to sum and calculate the straightening power consumption corresponding to each roller, so as to obtain the power consumption of a single plate in a single pass. Based on the power consumption of straightening and the mass of a single plate, the power consumption per ton of steel in a single pass is calculated.

9. A computer device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method of any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that, when executed by a processor, implements the method of any one of claims 1 to 7.

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