Method and system for adjusting deformed steel bar roll gap
By collecting and analyzing rolling process data in real time and using a control model to dynamically adjust the rebar roll gap, the problem of inaccurate manual adjustment was solved, and precise adjustment of the rebar roll gap was achieved, thereby improving product quality and production stability.
Patent Information
- Application Number
- CN202511801081.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-02
- Publication Date
- 2026-02-06
AI Technical Summary
In existing technologies, the adjustment of the rebar roll gap relies on manual open-loop and experience-based control, which leads to inaccurate adjustments, affects product qualification rate and yield, and cannot respond in a timely manner to dimensional changes caused by high-temperature wear of the rolling mill and fluctuations in billet temperature and composition.
By collecting contour data and rolling speed in real time during the rolling process, extracting contour feature values, calculating real-time negative deviation values, and using the control model to generate adjustment commands, the roll gap is dynamically adjusted to achieve precise rebar roll gap adjustment.
It improves the accuracy of roll gap adjustment during rebar rolling, reduces human error and measuring tool error, ensures the continuity and stability of production, avoids system instability caused by drastic adjustments, and improves product quality.
Smart Images
Figure CN121467482A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of roll gap control, and more particularly to a method and system for adjusting the roll gap of rebar. Background Technology
[0002] During production, the rolling groove wears down due to high temperatures and friction. Simultaneously, fluctuations in billet temperature and composition affect the metal's fluidity and deformation resistance. These factors cause continuous changes in the actual dimensions of the rebar (such as inner diameter and transverse rib height), leading to a deviation of its negative deviation value from the target range. This, in turn, affects the accuracy of the mill's roll gap adjustment. If the mill's roll gap (the gap between two rolls) is not adjusted in a timely manner, these changes cannot be compensated for, resulting in uncontrolled negative deviations. The product may either exceed standards and become a defective product, or fail to fully utilize the negative deviation standard, leading to steel waste.
[0003] Current technology for adjusting the roll gap of rebar during production primarily relies on a manual, open-loop, experience-based control model. Specifically, operators periodically take samples manually from the production line, allow them to cool, and then perform offline measurements using calipers or other tools, or indirectly calculate the negative deviation through weighing. Subsequently, operators judge the measurement results based on their experience and manually adjust the roll gap of the mill. Due to the randomness of manual sampling and the inherent errors in manual measurement, this adjustment model cannot guarantee accuracy, severely impacting product qualification rate and yield. Summary of the Invention
[0004] This invention provides a method and system for adjusting the roll gap of rebar, which can improve the accuracy of roll gap adjustment during the rebar rolling process.
[0005] An embodiment of the present invention provides a method for adjusting the roll gap of rebar, comprising: Real-time acquisition of profile data and rolling speed of each threaded steel bar during the rolling process; The corresponding contour feature values are extracted from each of the contour data, and the real-time negative deviation value of the rebar is calculated based on the contour feature values and the parameters of each specification of rebar. Based on the real-time negative deviation value, the target roll gap adjustment value is determined. An adjustment command for the mill roll gap is generated in real time according to the target roll gap adjustment value and the rolling speed through a preset control model. The mill is then driven to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range.
[0006] This invention, through real-time acquisition of the profile data and rolling speed of each rebar during the rolling process, can obtain data that truly reflects the current production status of the rolling mill, providing the control system with the most timely and comprehensive on-site data. By extracting profile feature values, the original profile data can be transformed into key physical quantities that can be used for quantitative calculations. By calculating real-time negative deviation values, subjective errors from human judgment and systematic errors from measuring tools can be eliminated, ensuring that subsequent roll gap adjustment decisions are always based on the most accurate current production status, thus ensuring the accuracy of adjustments at the source and in a timely manner. The invention replaces traditional methods by determining target roll gap adjustment values. Based on experience, the required roll gap adjustment amount to correct a specific negative deviation can be accurately calculated, achieving quantification and precision of the adjustment amount. Utilizing a control model, the urgency of the adjustment can be determined based on production speed and the target roll gap adjustment value, avoiding overly drastic adjustments during high-speed production that could lead to system instability, further improving the accuracy and stability of control. By adjusting the roll gap according to adjustment commands, on the one hand, the pain point of manual adjustment requiring machine stoppage and causing production interruption is solved, and continuous, minute, precise corrections can be achieved. On the other hand, precise decisions are translated into precise mill actions, thereby improving the accuracy of roll gap adjustment in the rebar rolling process. Compared with existing technologies, this invention can improve the accuracy of roll gap adjustment in the rebar rolling process.
[0007] Further, the step of extracting corresponding contour feature values from each of the contour data includes: The contour data are subjected to noise reduction and length direction filtering to obtain the target contour data; From the target contour data, contour feature values used to characterize the geometry of the rebar cross-section are identified and calculated.
[0008] By extracting contour feature values, the original contour data can be transformed into key physical quantities that can be used for quantitative calculations.
[0009] Further, the step of identifying and calculating contour feature values characterizing the cross-sectional geometry of the rebar from each of the target contour data includes: The target contour data is preprocessed and subjected to coordinate transformation to obtain a set of cross-sectional contour points; The scanning points are obtained in an orderly arrangement of the cross-sectional contour points. Based on the scanning points, the closed contour pattern formed by the sequential connection of the scanning points is determined, and the area of the closed contour pattern is calculated to obtain the contour area of the rebar. The cross-sectional profile point set is subjected to multiple rounds of elliptic curve fitting to obtain the fitting results, and the inner and outer diameters of the rebar are determined based on the fitting results. The profile feature values include the profile area and the inner and outer diameters.
[0010] By extracting contour feature values, the original contour data can be transformed into key physical quantities that can be used for quantitative calculations.
[0011] Further, the step of performing multi-round elliptic curve fitting on the set of cross-sectional profile points to obtain fitting results, and determining the inner and outer diameters of the rebar based on the fitting results, includes: The cross-sectional profile point set is subjected to multiple rounds of elliptic curve fitting to obtain a fitted elliptic curve. The multiple rounds of elliptic curve fitting iteratively optimize the position of the foci of the ellipse in the cross-sectional profile point set so as to minimize the variance of the sum of the distances from all points in the cross-sectional profile point set to the ellipse foci. The fitting result is determined based on the fitted elliptic curve, wherein the fitting result includes the minor axis length and the major axis length; The inner and outer diameters of the rebar are determined based on the length of the short axis and the length of the long axis, respectively.
[0012] By using multiple rounds of fitting to optimize the focal position and reduce the impact of measurement noise, more accurate inner and outer diameter values are obtained, which facilitates accurate adjustment of the threaded steel roll gap in the future.
[0013] Furthermore, the calculation of the real-time negative deviation value of the rebar based on the contour feature value and the parameters of each specification includes: Based on the outline area or the inner and outer diameters, geometric parameters are determined. According to the geometric parameters, density, and rolling speed, the actual weight of the rebar produced within a set rolling time period is calculated by integral calculation. The rebar parameters include the density and standard weight. The actual weight is compared with the standard weight to calculate the real-time negative deviation value based on the comparison result.
[0014] By calculating the real-time negative deviation value, subjective errors from human judgment and systematic errors from measuring tools can be eliminated. This ensures that subsequent roll gap adjustments are always based on the most realistic current production status, thereby guaranteeing the accuracy of adjustments at the source and in a timely manner.
[0015] Further, determining the target roll gap adjustment value based on the real-time negative deviation value includes: Based on the real-time negative deviation value and the preset influence factor, the initial roll gap adjustment value is calculated through a linear relationship model, wherein the linear relationship model is determined according to the component influence value, and the component influence value is calculated based on the steel grade composition of the rebar; The initial roll gap adjustment value is compared with the preset roll gap adjustment limit range. If it is within the roll gap adjustment limit range, the initial roll gap adjustment value is taken as the target roll gap adjustment value. If it exceeds the roll gap adjustment limit range, the initial roll gap adjustment value is limited until the target roll gap adjustment value within the roll gap adjustment limit range is obtained.
[0016] This approach, by determining the target roll gap adjustment value instead of traditional experience, allows for the precise calculation of the roll gap adjustment required to correct a specific negative deviation, thus achieving quantification and precision in the adjustment amount.
[0017] Furthermore, the step of generating mill roll gap adjustment commands in real time based on the target roll gap adjustment value and the rolling speed using a preset control model includes: Based on the target roll gap adjustment value and the rolling speed, the initial roll gap adjustment speed is calculated using the control model; The initial roll gap adjustment speed is limited to obtain a target roll gap adjustment speed within the speed limit range; The adjustment command is generated based on the target roll gap adjustment value and the target roll gap adjustment speed, wherein the adjustment command includes the target roll gap position and adjustment rate parameters.
[0018] By utilizing this control model, the urgency of the adjustment can be determined based on the production speed and the target roll gap adjustment value, avoiding overly drastic adjustments during high-speed production that could lead to system instability, thus further improving the accuracy and stability of the control.
[0019] Furthermore, the step of dynamically adjusting the roll gap during the rolling process according to the adjustment command to make the target negative deviation value of the subsequently rolled rebar approach the preset negative deviation range includes: The adjustment command is sent in real time from the preset PLC control system to the mechanical execution module of the rolling mill; The mechanical execution module drives the roll gap adjustment mechanism to operate according to the adjustment command, so as to adjust the mill roll gap to the target roll gap position according to the adjustment rate parameter under the preset conditions and without interruption of rolling production.
[0020] By adjusting the roll gap according to the adjustment instructions, on the one hand, the pain point of manual adjustment requiring machine shutdown and causing production interruption is solved, and continuous, minute, and precise corrections can be achieved. On the other hand, precise decisions are transformed into precise actions of the rolling mill, thereby improving the accuracy of roll gap adjustment in the rebar rolling process.
[0021] Furthermore, the real-time acquisition of the profile data of each rebar during the rolling process includes: setting a profiler at a preset position to acquire the profile data of each rebar during the rolling process, wherein the preset position includes any one of the following: the final rolling mill exit, the cooling exit, the fixed shearing length inlet, the fixed shearing length outlet, or the cooling bed inlet.
[0022] By collecting the contour data and rolling speed of each threaded steel bar in real time during the rolling process, data that truly reflects the production status of the rolling mill at the current moment can be obtained, providing the control system with the most timely and comprehensive field data.
[0023] Another embodiment of the present invention provides a rebar roll gap adjustment system, comprising: a data acquisition module, a calculation module, and an adjustment module; The acquisition module is used to acquire the contour data and rolling speed of each threaded steel bar in real time during the rolling process; The calculation module is used to extract the corresponding contour feature values from each of the contour data, and calculate the real-time negative deviation value of the rebar based on the contour feature values and the parameters of each specification of rebar. The adjustment module is used to determine the target roll gap adjustment value based on the real-time negative deviation value, generate the mill roll gap adjustment command in real time according to the target roll gap adjustment value and the rolling speed through a preset control model, and drive the mill to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range.
[0024] Another embodiment of the present invention provides a terminal device, including: a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor, wherein when the processor executes the computer program, it implements the steps of the method for adjusting the roll gap of rebar as described in the present invention.
[0025] Another embodiment of the present invention also provides a computer-readable storage medium item, including: a stored computer program, which, when the computer program is running, controls the device where the computer-readable storage medium is located to perform the steps of the threaded steel roll gap adjustment method of the present invention. Attached Figure Description
[0026] To more clearly illustrate the technical solution of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0027] Figure 1 This is a schematic flowchart of one embodiment of the method for adjusting the roll gap of rebar provided in this application; Figure 2 This is a schematic diagram of the acquisition process of the profilometer provided in this application; Figure 3 This is a flowchart illustrating one embodiment of steps S301 to S302 provided in this application; Figure 4 This is a flowchart illustrating one embodiment of steps S401 to S402 provided in this application; Figure 5 This is a schematic diagram of one embodiment of the rebar roll gap adjustment system provided in this application. Detailed Implementation
[0028] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.
[0030] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.
[0031] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0032] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.
[0033] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).
[0034] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.
[0035] During production, factors such as wear of the rolling mill groove and fluctuations in billet temperature and composition can cause continuous changes in the dimensions of rebar, leading to negative deviations from the target range. If the mill roll gap is not adjusted in time, the negative deviation will become uncontrollable, resulting in substandard products or wasted steel. Current technology mainly relies on manual open-loop control, requiring operators to periodically sample, measure offline after cooling, and then manually adjust the roll gap based on experience. This approach cannot achieve precise control of the rebar roll gap.
[0036] See Figure 1 To improve the accuracy of rebar roll gap adjustment during rebar rolling, an embodiment of the present invention provides a rebar roll gap adjustment method, including steps S101 to S103. Step S101: Real-time acquisition of profile data and rolling speed of each threaded steel bar during the rolling process; In some embodiments, the real-time acquisition of the profile data of each deformed steel bar during the rolling process includes: setting a profiler at a preset position to acquire the profile data of each deformed steel bar during the rolling process, where the preset position includes any position such as the exit of the finishing mill, the cooling exit, the entrance of the fixed shearing gauge, the exit of the fixed shearing gauge, or the entrance of the cooling bed. Specifically, first, according to the characteristics of different links in the deformed steel bar rolling process, a profiler is set at the preset position. The preset position can preferably be the exit of the finishing mill, or alternative positions such as the cooling exit, the entrance of the fixed shearing gauge, the exit of the fixed shearing gauge, or the entrance of the cooling bed can be selected according to actual requirements; during the continuous rolling production of the deformed steel bar, the 3D profiler continuously and real-time acquires the 3D profile raw data of each deformed steel bar, and at the same time, through the speed acquisition module (or sensor) associated with the PLC+L2 negative feedback control model supporting the production line, the rolling speed data of the current deformed steel bar is acquired in real time, and the acquired profile raw data and the rolling speed data are time-synchronized to ensure the matching of the two types of data in the time dimension, providing accurate and real-time data support for subsequent extraction of profile feature values, calculation of real-time negative deviation values, and generation of mill roll gap adjustment instructions. The schematic diagram of the acquisition process of the profiler is as Figure 2 shown.
[0037] It should be noted that the exit of the finishing mill is close to the core rolling link, and can acquire the profile data of the deformed steel bar just completed rolling for the first time, directly reflecting the rolling effect under the current mill roll gap state; at the cooling exit, the temperature of the deformed steel bar has been stabilized, which can avoid the temporary influence of high temperature on the profile shape, and the acquired profile data is more in line with the actual geometric state during subsequent processing and use; the entrance of the fixed shearing gauge, the exit of the fixed shearing gauge, and the entrance of the cooling bed correspond to the key nodes before shearing, after shearing, and before entering the cooling bed for cooling of the deformed steel bar respectively, and the profile data of different processing stages can be supplemented and acquired according to the monitoring requirements to achieve full-process coverage.
[0038] In this way, by real-time acquiring the profile data and rolling speed of each deformed steel bar during the rolling process, the data truly reflecting the production state of the mill at the current moment can be obtained, providing the most timely and comprehensive on-site data for the control system.
[0039] Step S102: Extract the corresponding profile feature values from the respective profile data, and calculate the real-time negative deviation value of the deformed steel bar based on the profile feature values and the parameters of deformed steel bars of each specification; In some embodiments, extracting corresponding contour feature values from each of the contour data includes: performing noise reduction processing and length direction filtering on each of the contour data to obtain target contour data; identifying and calculating contour feature values from each of the target contour data to characterize the geometry of the rebar cross-section, wherein the contour feature values include contour area and inner and outer diameters. Specifically, firstly, each rebar contour data is preprocessed, including noise reduction processing to eliminate signal noise introduced by interference from environmental vibration, iron oxide scale, water vapor, or temperature radiation, while performing length direction filtering to remove unstable segment data caused by irregular shaking at the head and tail of the rolled piece or shear cross-section, thereby obtaining target contour data that can represent the stable rolling state of the rebar; subsequently, based on the target contour data, the cross-sectional geometry of the rebar is identified and calculated using a built-in geometric recognition algorithm, and finally the core contour feature values used for subsequent negative deviation calculation are extracted, wherein the contour feature values mainly include contour area (referring to the measured value of cross-sectional area obtained through integration calculation) and inner diameter (referring to the diameter of the base circle of the rebar) and outer diameter (referring to the maximum diameter including the top of the longitudinal ribs).
[0040] In some embodiments, identifying and calculating contour feature values characterizing the geometry of the rebar cross-section from the target contour data includes: preprocessing and transforming the target contour data to obtain a set of cross-sectional contour points; acquiring ordered scanning points from the set of cross-sectional contour points; determining a closed contour shape formed by sequentially connecting the scanning points based on the scanning points; calculating the area of the closed contour shape to obtain the contour area of the rebar; performing multi-round elliptic curve fitting on the set of cross-sectional contour points to obtain fitting results; and determining the inner and outer diameters of the rebar based on the fitting results, wherein the contour feature values include the contour area and the inner and outer diameters.
[0041] In some embodiments, the preprocessing and coordinate transformation of the target contour data to obtain cross-sectional target contour data includes: performing coordinate transformation on the target contour data based on the installation position and orientation of the profilometer to convert the original point set data to a coordinate system based on the length direction of the rebar, obtaining a transformed point set; dividing the transformed point set according to a preset rule to determine several cross-sectional contour point sets, wherein the preset rule is that the points are at the same position along the length direction of the rebar and the number of points meets a preset threshold. Specifically, firstly, based on the actual installation position and orientation of the profilometer on the rolling production line, a coordinate transformation matrix and a displacement matrix are constructed to perform coordinate transformation on the target contour data collected by the profilometer; the specific transformation formula is: In the formula, A is the transformed three-dimensional coordinate point set, also known as the conversion point set; B is the coordinate transformation matrix, representing the x, y, and z three-dimensional directions after transformation; and C is the displacement matrix. This transformation converts the original point set data, based on the profilometer, to a standard coordinate system with the length of the rebar as the Z-axis, the horizontal direction perpendicular to the rebar as the X-axis, and the vertical direction as the Y-axis, resulting in the conversion point set. Subsequently, this conversion point set is divided according to preset rules to determine several cross-sectional profile point sets used for subsequent analysis.
[0042] It should be noted that the preset rule is to divide and classify all points that are in the same position (i.e., have the same Z coordinate or are within a very small tolerance range) along the length direction of the rebar (i.e., the Z-axis direction) and whose number of data points at that position meets the preset number threshold into the same cross-sectional profile point set.
[0043] In some embodiments, the contour area of the rebar is calculated by analyzing the contour point set. Specifically, first, an ordered sequence of scan points is obtained from the cross-sectional contour point set. These points are connected sequentially to form a closed contour graphic representing the cross-sectional shape of the rebar. Then, based on this ordered point set, the area of the closed contour graphic is directly calculated using a numerical integration method to obtain the contour area of each rebar.
[0044] It should be noted that one specific method for calculating the area of the outline is to use Green's formula. The surface integral is transformed into a line integral along a closed contour for calculation, and its discrete calculation formula is as follows: In the formula, S represents the area of the contour to be determined. Let xn+1 be the coordinates of n scan points arranged in a clockwise or counterclockwise direction on the closed contour graphic. To ensure the closure of the contour, the (n+1)th point is set to equal the first point during calculation, i.e., xn+1=x1, yn+1=y1. The algorithm iterates through all adjacent point pairs, accumulates the difference of their cross product, and finally takes half of the absolute value as the area value.
[0045] By extracting contour feature values, the original contour data can be transformed into key physical quantities that can be used for quantitative calculations.
[0046] In some embodiments, performing multi-round elliptic curve fitting on the cross-sectional profile point set to obtain fitting results, and determining the inner and outer diameters of the rebar based on the fitting results, includes: performing multi-round elliptic curve fitting on the cross-sectional profile point set to obtain a fitted elliptic curve, wherein the multi-round elliptic curve fitting iteratively optimizes the position of the foci of the ellipse in the cross-sectional profile point set to minimize the variance of the sum of the distances from all points in the cross-sectional profile point set to the foci of the ellipse; determining the fitting result based on the fitted elliptic curve, wherein the fitting result includes the minor axis length and the major axis length; and determining the inner and outer diameters of the rebar based on the minor axis length and the major axis length, respectively. Specifically, firstly, the inner and outer diameters of each point in the cross-sectional profile point set are calculated. To two focal points and The sum of distances The calculation formula is: In the formula, The x-coordinate of the data point The ordinate of the data point. Let be the sum of the distances from a point in the point set to its two foci. For the i-th data point, The x-coordinate of the focus is... As the focal point, the ordinate is 1. The x-coordinate of the second focus is... Let be the ordinate of the two foci. Next, calculate the sum of all distances. mean and based on the mean The calculation of variance and the optimization process involve finding the set of focal coordinates that minimizes the variance. and The variance calculation formula is as follows: In the formula, N is the total number of data points. Let Variance be the variance of the distances from the point set to the two foci. By minimizing this variance, we can ensure that the fitted elliptic curve best represents the overall distribution shape of the contour point set, effectively resisting the interference of measurement noise and local contour distortions (such as the influence of ribs). Therefore, the fitted elliptic curve can be drawn based on the optimal elliptic focus coordinates. Then, based on the optimized coordinates of the two foci (determined from the fitted elliptic curve), the coordinates of the ellipse's center point are calculated. And the distance c from the focus to the center, where the relevant formula for calculating the coordinates of the center point is: The relevant formula for calculating the distance c from the focus of an ellipse to its center is: Subsequently, the length of the major axis The mean distance obtained from the calculation Half of it is certain, that is The length of the minor axis By major axis length The focal length is calculated based on the geometric relationship of the ellipse, that is... Thus, the fitting result can be obtained. Finally, based on the aforementioned minor axis length... and the length of the major axis The inner and outer diameters of the rebar are determined separately. In the elliptical cross-section model of the rebar, the minor axis length is typically... Identify the inner diameter of the product and determine the length of the major axis. Identify the outer diameter of the product, that is, determine the inner and outer diameters.
[0047] By using multiple rounds of fitting to optimize the focal position and reduce the impact of measurement noise, more accurate inner and outer diameter values are obtained, which facilitates accurate adjustment of the threaded steel roll gap in the future.
[0048] By extracting contour feature values, the original contour data can be transformed into key physical quantities that can be used for quantitative calculations.
[0049] Please refer to Figure 3 In some embodiments, the step of calculating the real-time negative deviation value of the rebar based on the profile feature value and the parameters of each specification of rebar includes steps S301 to S302: Step S301: Based on the outline area or the inner and outer diameters, determine the geometric parameters. According to the geometric parameters, density and rolling speed, calculate the actual weight of the rebar produced within the set rolling time period through integral calculation. The rebar parameters include the density and standard weight. In some embodiments, firstly, the contour area directly measured by the profilometer is... The equivalent cross-sectional area calculated from the inner and outer diameters is used as a key geometric parameter to characterize the volume per unit length of the rebar; after determining the geometric parameter, it is combined with the density of the rebar of this specification obtained from the database. Standard weight In addition, the rolling speed v collected in real time is used to calculate the rolling speed within the set rolling time period through integral calculation. The core integral formula for the total actual weight of the rebar produced domestically is: In the formula, For velocity, where the formula is directly based on the contour area. The calculated total weight of continuous production is obtained by integrating the weight per unit length (geometric parameter × density) at each moment.
[0050] In some embodiments, the process of calculating the real-time negative deviation value based on the equivalent cross-sectional area is as follows: the comprehensive diameter is calculated based on the inner and outer diameters. One of the calculation formulas is: In the formula, d is the composite diameter. Inner diameter Where is the outer diameter, and a, b, and c are constants retrieved from a database based on different steel grades and process requirements. Another calculation yields the composite diameter. The calculation formula is: At this point, the geometric parameters are... At this point, the total actual weight of the rebar produced within the set rolling time period is... .
[0051] It should be noted that the density of rebar in the database can be set in three ways. The first method is to set the same density for all steel grades, typically within the range of 7.70-8.00. The second method involves manually setting different densities based on the type and specifications of the steel. The third method involves obtaining the density through a specific model based on the type, specifications, and composition of the steel. However, the specific methods are not the focus of this application and will not be elaborated here.
[0052] Step S302: Compare the actual weight with the standard weight to calculate the real-time negative deviation value based on the comparison result.
[0053] In some embodiments, the calculated actual weight The theoretical standard weight of this specification of rebar Compare these values to calculate the real-time negative deviation. The relevant formula is: That is, one calculation formula is: Another calculation formula is: When the calculation result is negative, it indicates that the product is in a negative deviation state.
[0054] By calculating the real-time negative deviation value, subjective errors from human judgment and systematic errors from measuring tools can be eliminated. This ensures that subsequent roll gap adjustments are always based on the most realistic current production status, thereby guaranteeing the accuracy of adjustments at the source and in a timely manner.
[0055] Step S103: Determine the target roll gap adjustment value based on the real-time negative deviation value. Generate a roll gap adjustment command in real time based on the target roll gap adjustment value and the rolling speed using a preset control model. Drive the rolling mill to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range.
[0056] Please refer to Figure 4 In some embodiments, determining the target roll gap adjustment value based on the real-time negative deviation value includes steps S401 to S402: Step S401: Based on the real-time negative deviation value and the preset influence factor, the initial roll gap adjustment value is calculated through a linear relationship model, wherein the linear relationship model is determined according to the component influence value, and the component influence value is calculated based on the steel grade composition of the rebar; In some embodiments, it is first necessary to calculate the influence value of steel composition. This value reflects the combined effect of different alloying elements on the rolling deformation resistance of materials, and its calculation formula is as follows: In the formula, The component influence values are for different steel grades. This refers to the content of various chemical components (such as C, Mn, Si, etc.) in rebar. The query constants are determined in advance through experiments and stored in the database; then, the calculated... With real-time negative deviation value Input the linear relationship model together to calculate the initial roll gap adjustment value. The relevant calculation formula is: In the formula, The influencing factor is determined based on process conditions such as steel grade and rolling temperature. n is the model exponent, which is usually taken as 1 to achieve a linear relationship, or determined by experiments based on the rolling characteristics of a specific steel grade to be other constant values.
[0057] In some embodiments, the actual negative deviation can also be obtained directly. negative deviation from the corresponding specifications required by national standards Calculate the initial roll gap adjustment value of the rolling mill. The relevant calculation formula is: In the formula, To retrieve the set constants from the database based on different steel grades, measurement temperatures, and process requirements.
[0058] Step S402: Compare the initial roll gap adjustment value with the preset roll gap adjustment limit range. If it is within the roll gap adjustment limit range, the initial roll gap adjustment value is taken as the target roll gap adjustment value. If it exceeds the roll gap adjustment limit range, the initial roll gap adjustment value is limited until the target roll gap adjustment value within the roll gap adjustment limit range is obtained.
[0059] In some embodiments, after obtaining the initial roll gap adjustment value Subsequently, to ensure the stability of the rolling process and the safety of the equipment, it is necessary to limit the roll gap. Specifically, firstly, a limit range for roll gap adjustment is preset. This range is set according to different rolling mills and process specifications, and consists of the minimum and maximum roll gap adjustment values. Then, the initial roll gap adjustment value is... Compared with the roll gap adjustment limit range, if the initial roll gap adjustment value If the value is within the roll gap adjustment limit, it is directly used as the target roll gap adjustment value; if it exceeds the limit, a limiting process is performed to constrain the theoretically calculated value within the physical range that the mechanical system can safely and reliably execute, ultimately outputting a target roll gap adjustment value that meets control requirements and ensures production safety. This lays the foundation for generating precise adjustment instructions, and its mathematical expression is: .
[0060] This approach, by determining the target roll gap adjustment value instead of traditional experience, allows for the precise calculation of the roll gap adjustment required to correct a specific negative deviation, thus achieving quantification and precision in the adjustment amount.
[0061] In some embodiments, the step of generating mill roll gap adjustment instructions in real time based on the target roll gap adjustment value and the rolling speed using a preset control model includes: calculating an initial roll gap adjustment speed using the control model based on the target roll gap adjustment value and the rolling speed; limiting the initial roll gap adjustment speed to obtain a target roll gap adjustment speed within the speed limit range; and generating the adjustment instructions based on the target roll gap adjustment value and the target roll gap adjustment speed, wherein the adjustment instructions include target roll gap position and adjustment rate parameters. Specifically, firstly, to achieve smooth and precise dynamic adjustment of the mill roll gap, the control model needs to set the target roll gap adjustment value... With production speed With unified dimensions, the theoretical initial roll gap adjustment speed was calculated. The relevant calculation formula is: In the formula, Adjust the speed for the roll gap; The measurement speed is also the generation speed; t is the roll gap adjustment time, which is a constant set by searching the database according to different steel grades, measurement temperature, and process requirements. and The maximum and minimum roll gap adjustment speeds are set constants retrieved from a database based on different steel grades, measurement temperatures, and process requirements. Then, the initial roll gap adjustment speed is directly calculated. The sudden changes in production conditions may cause the mechanical system to exceed its safe operating range. Therefore, it is necessary to limit the range of operation to protect the equipment and ensure the stability of the control process. The specific formula is as follows: Finally, after determining the precise and safe adjustment parameters, the system encapsulates them into specific adjustment instructions that can be recognized by lower-level actuators. These instructions mainly contain two key parameters: first, the target roll gap position, which is determined by the current roll gap reference value and the target roll gap adjustment value, specifying the absolute position the roll gap needs to reach; and second, the adjustment rate parameter, namely the target roll gap adjustment speed after the aforementioned amplitude limiting process, which specifies the speed at which the roll gap moves. This instruction, integrating position and speed information, provides a complete action basis for the subsequent precise linkage between the PLC and the mechanical execution module.
[0062] It should be noted that the limiting logic is as follows: if the initial roll gap adjustment speed is less than the minimum roll gap adjustment speed, the system will lock the adjustment speed at the minimum roll gap adjustment speed to avoid slow adjustment and loss of real-time performance; if the initial roll gap adjustment speed is greater than the maximum roll gap adjustment speed, it will be limited to the maximum roll gap adjustment speed to prevent excessively fast adjustment from impacting the equipment; if the initial roll gap adjustment speed is between the two, it will be used directly. After this processing, the target roll gap adjustment speed that meets both control requirements and ensures equipment safety is obtained.
[0063] The preset control model generates rolling mill roll gap adjustment instructions in real time based on the target roll gap adjustment value and the rolling speed, and drives the rolling mill to dynamically adjust the roll gap during the rolling process according to the adjustment instructions, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range.
[0064] In some embodiments, the step of driving the rolling mill to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range, includes: sending the adjustment command from a preset PLC control system to the mechanical execution module of the rolling mill in real time; the mechanical execution module driving the roll gap adjustment mechanism to operate according to the adjustment command, so as to adjust the rolling mill roll gap to the target roll gap position according to the adjustment rate parameter, under the premise of meeting preset conditions and uninterrupted rolling production. Specifically, the preset PLC control system, as a bridge between the core decision-making unit and the underlying hardware, after receiving the adjustment command calculated by the upstream control model, will send the command (which contains key parameters such as the target roll gap position and the target roll gap adjustment speed after amplitude limiting) to the mechanical execution module of the rolling mill in real time and reliably via industrial fieldbus or industrial Ethernet. This mechanical execution module typically consists of precision transmission components such as a servo driver, servo motor, reducer, and ball screw. Upon receiving an adjustment command from the PLC, the servo driver drives the servo motor to rotate precisely according to the adjustment rate parameters set in the command. This rotational motion is then converted into linear displacement of the roll gap adjustment mechanism via the mechanical transmission system. To ensure production continuity and stability, the entire adjustment process is automatically triggered after meeting preset safety interlock conditions (such as rolling force within allowable limits and no emergency stop alarms). It proceeds smoothly and strictly under uninterrupted rolling production conditions, ultimately precisely and stably adjusting the mill roll gap to the target position. This achieves closed-loop control of the negative deviation of the rebar, automatically approaching and stabilizing it within the preset optimal negative deviation range.
[0065] By adjusting the roll gap according to the adjustment instructions, on the one hand, the pain point of manual adjustment requiring machine shutdown and causing production interruption is solved, and continuous, minute, and precise corrections can be achieved. On the other hand, precise decisions are transformed into precise actions of the rolling mill, thereby improving the accuracy of roll gap adjustment in the rebar rolling process.
[0066] This invention, through real-time acquisition of the profile data and rolling speed of each rebar during the rolling process, can obtain data that truly reflects the current production status of the rolling mill, providing the control system with the most timely and comprehensive on-site data. By extracting profile feature values, the original profile data can be transformed into key physical quantities that can be used for quantitative calculations. By calculating real-time negative deviation values, subjective errors from human judgment and systematic errors from measuring tools can be eliminated, ensuring that subsequent roll gap adjustment decisions are always based on the most accurate current production status, thus ensuring the accuracy of adjustments at the source and in a timely manner. The invention replaces traditional methods by determining target roll gap adjustment values. Based on experience, the required roll gap adjustment amount to correct a specific negative deviation can be accurately calculated, achieving quantification and precision of the adjustment amount. Utilizing a control model, the urgency of the adjustment can be determined based on production speed and the target roll gap adjustment value, avoiding overly drastic adjustments during high-speed production that could lead to system instability, further improving the accuracy and stability of control. By adjusting the roll gap according to adjustment commands, on the one hand, the pain point of manual adjustment requiring machine stoppage and causing production interruption is solved, and continuous, minute, precise corrections can be achieved. On the other hand, precise decisions are translated into precise mill actions, thereby improving the accuracy of roll gap adjustment in the rebar rolling process. Compared with existing technologies, this invention can improve the accuracy of roll gap adjustment in the rebar rolling process.
[0067] like Figure 5 As shown, based on the above method embodiments, corresponding apparatus embodiments are provided; An embodiment of the present invention provides a rebar roll gap adjustment system, comprising: a data acquisition module 100, a calculation module 200, and an adjustment module 300; The acquisition module 100 is used to acquire the contour data and rolling speed of each threaded steel bar in real time during the rolling process. The calculation module 200 is used to extract the corresponding contour feature values from each of the contour data, and calculate the real-time negative deviation value of the rebar based on the contour feature values and the parameters of each specification of rebar. The adjustment module 300 is used to determine the target roll gap adjustment value based on the real-time negative deviation value, generate the mill roll gap adjustment command in real time according to the target roll gap adjustment value and the rolling speed through a preset control model, and drive the mill to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range.
[0068] It is understood that the above-described device embodiments correspond to the method embodiments of the present invention, and can implement the method for adjusting the rebar roll gap provided by any of the above-described method embodiments of the present invention.
[0069] It should be noted that the device embodiments described above are merely illustrative, and some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Furthermore, in the accompanying drawings of the device embodiments provided by this invention, the connection relationships between modules indicate that they have communication connections, which can specifically be implemented as one or more communication buses or signal lines. Those skilled in the art can understand and implement this without any creative effort.
[0070] Based on the above-described embodiments of the method for adjusting the rebar roll gap, another embodiment of the present invention provides a terminal device, which includes a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor. When the processor executes the computer program, it implements the method for adjusting the rebar roll gap of any embodiment of the present invention.
[0071] For example, in this embodiment, the computer program can be divided into one or more modules, which are stored in the memory and executed by the processor to complete the present invention. The one or more modules may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program in the terminal device.
[0072] The terminal device can be a desktop computer, laptop, handheld computer, or cloud server, etc. The terminal device may include, but is not limited to, a processor and memory.
[0073] The processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor can be a microprocessor or any conventional processor. The processor is the control center of the terminal device, connecting all parts of the terminal device via various interfaces and lines.
[0074] Based on the above-described method embodiments, another embodiment of the present invention provides a computer-readable storage medium including a stored computer program, wherein, when the computer program is executed, it controls the device where the computer-readable storage medium is located to execute the threaded steel roll gap adjustment method described in any of the above-described method embodiments of the present invention.
[0075] The modules / units integrated in the device / terminal equipment, if implemented as software functional units and sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the above embodiments of the present invention can also be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include: any entity or device capable of carrying the computer program code, a recording medium, a USB flash drive, a portable hard drive, a magnetic disk, an optical disk, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, etc.
[0076] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.
Claims
1. A method for adjusting the roll gap of rebar, characterized in that, include: Real-time acquisition of profile data and rolling speed of each threaded steel bar during the rolling process; The corresponding contour feature values are extracted from each of the contour data, and the real-time negative deviation value of the rebar is calculated based on the contour feature values and the parameters of each specification of rebar. Based on the real-time negative deviation value, the target roll gap adjustment value is determined. An adjustment command for the mill roll gap is generated in real time according to the target roll gap adjustment value and the rolling speed through a preset control model. The mill is then driven to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range.
2. The method for adjusting the roll gap of rebar according to claim 1, characterized in that, The step of extracting corresponding contour feature values from each of the contour data includes: The contour data are subjected to noise reduction and length direction filtering to obtain the target contour data; From the target contour data, contour feature values used to characterize the geometry of the rebar cross-section are identified and calculated.
3. The method for adjusting the roll gap of rebar according to claim 2, characterized in that, The step of identifying and calculating contour feature values characterizing the cross-sectional geometry of the rebar from each of the target contour data includes: The target contour data is preprocessed and subjected to coordinate transformation to obtain a set of cross-sectional contour points; The scanning points are obtained in an orderly arrangement of the cross-sectional contour points. Based on the scanning points, the closed contour pattern formed by the sequential connection of the scanning points is determined, and the area of the closed contour pattern is calculated to obtain the contour area of the rebar. The cross-sectional profile point set is subjected to multiple rounds of elliptic curve fitting to obtain the fitting results, and the inner and outer diameters of the rebar are determined based on the fitting results. The profile feature values include the profile area and the inner and outer diameters.
4. The method for adjusting the roll gap of rebar according to claim 2, characterized in that, The step of performing multi-round elliptic curve fitting on the set of cross-sectional profile points to obtain fitting results, and determining the inner and outer diameters of the rebar based on the fitting results, includes: The cross-sectional profile point set is subjected to multiple rounds of elliptic curve fitting to obtain a fitted elliptic curve. The multiple rounds of elliptic curve fitting iteratively optimize the position of the foci of the ellipse in the cross-sectional profile point set so as to minimize the variance of the sum of the distances from all points in the cross-sectional profile point set to the ellipse foci. The fitting result is determined based on the fitted elliptic curve, wherein the fitting result includes the minor axis length and the major axis length; The inner and outer diameters of the rebar are determined based on the length of the short axis and the length of the long axis, respectively.
5. The method for adjusting the roll gap of rebar according to claim 2, characterized in that, The calculation of the real-time negative deviation value of the rebar based on the contour feature value and the parameters of each specification includes: Based on the outline area or the inner and outer diameters, geometric parameters are determined. According to the geometric parameters, density, and rolling speed, the actual weight of the rebar produced within a set rolling time period is calculated by integral calculation. The rebar parameters include the density and standard weight. The actual weight is compared with the standard weight to calculate the real-time negative deviation value based on the comparison result.
6. The method for adjusting the roll gap of rebar according to claim 1, characterized in that, The step of determining the target roll gap adjustment value based on the real-time negative deviation value includes: Based on the real-time negative deviation value and the preset influence factor, the initial roll gap adjustment value is calculated through a linear relationship model, wherein the linear relationship model is determined according to the component influence value, and the component influence value is calculated based on the steel grade composition of the rebar; The initial roll gap adjustment value is compared with the preset roll gap adjustment limit range. If it is within the roll gap adjustment limit range, the initial roll gap adjustment value is taken as the target roll gap adjustment value. If it exceeds the roll gap adjustment limit range, the initial roll gap adjustment value is limited until the target roll gap adjustment value within the roll gap adjustment limit range is obtained.
7. The method for adjusting the roll gap of rebar according to claim 1, characterized in that, The step of generating mill roll gap adjustment commands in real time based on the target roll gap adjustment value and the rolling speed using a preset control model includes: Based on the target roll gap adjustment value and the rolling speed, the initial roll gap adjustment speed is calculated using the control model; The initial roll gap adjustment speed is limited to obtain a target roll gap adjustment speed within the speed limit range; The adjustment command is generated based on the target roll gap adjustment value and the target roll gap adjustment speed, wherein the adjustment command includes the target roll gap position and adjustment rate parameters.
8. The method for adjusting the roll gap of rebar according to claim 7, characterized in that, The step of driving the rolling mill to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range, includes: The adjustment command is sent in real time from the preset PLC control system to the mechanical execution module of the rolling mill; The mechanical execution module drives the roll gap adjustment mechanism to operate according to the adjustment command, so as to adjust the mill roll gap to the target roll gap position according to the adjustment rate parameter under the preset conditions and without interruption of rolling production.
9. The method for adjusting the roll gap of rebar according to any one of claims 1-8, characterized in that, The real-time acquisition of profile data of each rebar during the rolling process includes: setting a profiler at a preset position to acquire profile data of each rebar during the rolling process, wherein the preset position includes any one of the following: the final rolling mill exit, the cooling exit, the fixed shearing length inlet, the fixed shearing length outlet, or the cooling bed inlet.
10. A system for adjusting the roll gap of rebar, characterized in that, include: Acquisition module, calculation module, and adjustment module; The acquisition module is used to acquire the contour data and rolling speed of each threaded steel bar in real time during the rolling process; The calculation module is used to extract the corresponding contour feature values from each of the contour data, and calculate the real-time negative deviation value of the rebar based on the contour feature values and the parameters of each specification of rebar. The adjustment module is used to determine the target roll gap adjustment value based on the real-time negative deviation value, generate the mill roll gap adjustment command in real time according to the target roll gap adjustment value and the rolling speed through a preset control model, and drive the mill to dynamically adjust the roll gap during the rolling process according to the adjustment command, so that the target negative deviation value of the subsequently rolled rebar approaches the preset negative deviation range.