Wire feeding processing fault early warning method and system for preventing secondary spheroidization

Abstract

The invention relates to the technical field of program control systems, in particular to a wire feeding processing fault early warning method and system for preventing secondary spheroidization. In order to solve the problem of how to carry out dynamic self-adaptive accurate early warning on the virtual package wire breakage risk according to the operation and maintenance state and the operation environment of a wire feeder so as to reduce the risk probability of secondary spheroidization, the invention provides a wire feeding processing fault early warning method, which comprises the following steps of: obtaining the operation state of the wire feeder, marking the wire feeders with the same operation state and the same classification reference library as related wire feeding equipment; obtaining a target product of related wire feeding equipment, and generating a corresponding control range according to the target product; the operation state of the related wire feeding equipment is monitored in real time, operation parameters are obtained, and the operation parameters are compared with the control range.

Description

Technical Field

[0001] This invention relates to the field of program control system technology, and in particular to a method and system for early warning of feeding process failures to prevent secondary balling. Background Technology

[0002] In the iron and steel metallurgical industry, wire feeding technology is a key refining process for achieving final deoxidation, alloying, and inclusion morphology control in molten steel. The cored wire is fed deep into the ladle, where its core material melts and reacts in the high-temperature molten steel, thereby purifying the molten steel and improving the as-cast microstructure. However, in actual production, "false ladle breakage" is a highly concealed and serious fault. False ladle breakage refers to undetected defects such as incomplete welding, cracking, or powder leakage in the outer steel strip of the cored wire, preventing the effective release of alloy core material during molten iron feeding. This leads to uncontrolled steel composition and ultimately causes major quality defects such as secondary spheroidization in the steel. Existing online fault monitoring techniques for false ladle breakage mainly rely on simple current threshold alarms or manual inspection, which are significantly insufficient. The main shortcomings are the lack of dynamic perception and adaptive adjustment capabilities for key variables affecting wire feeding stability, such as differences in cored wire manufacturers, changes in ambient temperature and humidity, and the degree of equipment mechanical wear. Rigid warning parameters result in high false alarm and false negative rates, and the inability to effectively prevent secondary spheroidization caused by interrupted element addition. Therefore, how to dynamically and adaptively provide accurate early warning of the risk of false package breakage based on the operation and maintenance status and operating environment of the wire feeder, thereby reducing the probability of secondary balling, is one of the problems that urgently need to be solved by those skilled in the art. Summary of the Invention

[0003] The problem solved by this invention is: how to dynamically and adaptively provide accurate early warning of the risk of false packet breakage based on the operation and maintenance status and operating environment of the wire feeder, thereby reducing the probability of secondary spheroidization.

[0004] To address the aforementioned problems, this invention provides a method for early warning of feeding process failures to prevent secondary spheroidization. The method includes: acquiring production data from the target factory; establishing multiple classification benchmark libraries based on the production data; monitoring the classification benchmark libraries through a monitoring unit to obtain environmental parameters; and sending the environmental parameters to a data management unit; acquiring the operating status of the feeding machines; recording feeding machines with the same operating status and belonging to the same classification benchmark library as relevant feeding equipment; acquiring the target product of the relevant feeding equipment; generating a corresponding control range based on the target product; monitoring the operating status of the relevant feeding equipment in real time to obtain operating parameters; comparing the operating parameters with the control range; calculating the corresponding alarm level based on the operating parameters and issuing an alarm message when the operating parameters are outside the control range; and detecting the target product when the operating parameters are within the control range, obtaining the detection results, and correcting the control range based on the detection results.

[0005] Compared with existing technologies, the technical effects achieved by adopting this solution are as follows: By acquiring production data from the target factory and establishing multiple classification benchmark libraries, various factors in the production process can be systematically classified and standardized for management. Monitoring units monitor these benchmark libraries, acquire environmental parameters, and monitor the real-time operating status of the wire feeder. This allows for timely understanding of environmental changes and equipment operation during production, helping to identify potential problems early. The setup of related wire feeder equipment transforms a group of isolated machines into a production team capable of mutual support and collaborative learning, facilitating rapid root cause identification and dissemination. This makes the management of the wire feeder more refined. By calculating alarm levels, simple yes / no alarms are upgraded to graded risk assessments, reducing production interruptions and providing clearer information. Clear decision priorities are established, and corresponding control ranges are generated based on target products. This allows process monitoring to directly serve the final product quality. Through a series of operations such as real-time monitoring, comparison, alarms, and control range correction, dynamic optimization of the production process can be achieved. As production progresses, the control range and strategies are continuously adjusted according to the actual situation to keep the production process in an optimal state, improve production stability and reliability, and promote continuous improvement of the production process. The above solution achieves standardized production management by establishing a classification benchmark library. Combined with real-time monitoring to obtain environmental and equipment operating parameters, the wire feeder is grouped for control, and control ranges are dynamically generated and corrected. Ultimately, this achieves real-time early warning, risk control, efficiency improvement, and product quality assurance in the production process, realizing refined, dynamic, and continuous optimization management of the entire production process.

[0006] In one embodiment of the present invention, production data of the target factory is acquired, multiple classification benchmark libraries are established based on the production data, and environmental parameters are obtained by monitoring the classification benchmark libraries through a monitoring unit and then sent to a data management unit. Specifically, this includes: acquiring production data of the target factory, classifying the production data according to its source to obtain a first benchmark library; classifying the production data according to its function to obtain a second benchmark library; and classifying the production data according to the production environment in which the production data is located to obtain a third benchmark library.

[0007] Compared with existing technologies, the technical effects achieved by adopting this technical solution are as follows: The establishment of the first benchmark library helps to clarify the source of production materials, making it easier to trace the supplier, batch, and other information of materials or equipment, and providing a basis for quality traceability and supply chain management. The second benchmark library focuses on the use of production materials, which can quickly locate equipment or materials with different functions, facilitating functional matching and scheduling in the production process. The third benchmark library is associated with the environment in which the production materials are located, directly providing classification targets for subsequent environmental parameter monitoring, ensuring that the monitoring direction accurately corresponds to the actual application scenario of the production materials. By classifying production materials through three different dimensions, a complementary benchmark library system is formed, solving the problems of incomplete coverage and imprecise management of a single classification dimension.

[0008] In one embodiment of the present invention, the operation status of the wire feeder is obtained, and wire feeders with the same operation status and belonging to the same classification benchmark library are recorded as related wire feeders. Specifically, this includes: obtaining the service life and maintenance number of the wire feeder; obtaining the operation status of the wire feeder based on the service life and maintenance number; obtaining a standard benchmark library based on the first benchmark library, the second benchmark library, and the third benchmark library; and recording wire feeders with the same operation status and belonging to the same standard benchmark library as related wire feeders.

[0009] Compared with existing technologies, the technical effects achieved by adopting this technical solution are as follows: by using two quantitative indicators, namely, the number of years and the number of maintenance, to evaluate the operating status, the bias of judging the equipment status based solely on subjective experience is avoided. A standard benchmark library is obtained based on the first benchmark library, the second benchmark library, and the third benchmark library, which helps to ensure that related wire feeding equipment in the same group is not only in the same status, but also in the same production context. Subsequent control measures can be more accurately matched with scenario requirements. By screening related wire feeding equipment based on the dual conditions of the same operating status and being in the same standard benchmark library, the fine grouping of equipment is achieved.

[0010] In one embodiment of the present invention, the target product of the relevant wire feeding equipment is obtained, and a corresponding control range is generated based on the target product. Specifically, this includes: recording the historical time period corresponding to the current time period as the comparison time period; obtaining the current fluctuation range of the relevant wire feeding equipment for different target products in the comparison time period, which is recorded as the comparison range; obtaining the target current range based on the comparison range and the detection results of the target product, which is recorded as target range one; recording the environmental parameters corresponding to target range one as target range two; and obtaining the control range of the target product obtained by the relevant wire feeding equipment based on target range one and target range two.

[0011] Compared with existing technologies, the technical effects achieved by adopting this technical solution are as follows: using the historical time period corresponding to the current time period as a comparison benchmark, and combining the historical current fluctuation range to determine the control basis, the blindness of setting control standards out of thin air is avoided. The historical comparison range is combined with the target product detection results to generate the target current range target range one, realizing the direct link between control standards and product quality. Environmental parameters are included in the control range target range two, which supplements the shortcomings of simply relying on equipment operating parameters for control.

[0012] In one embodiment of the present invention, the control range of the target product obtained by the relevant fiber feeding equipment is obtained according to target range one and target range two, specifically including: the calculation formula of the control range is as follows: I t =β0+β1×T t +β2×H+β3×(T t ×H t )+θ; ; Among them, I t This is the current predicted value, β0 is the theoretical base current value, β1 is the temperature coefficient, and T is the temperature coefficient. t H represents the current ambient temperature. t Let β2 be the current ambient humidity, β3 be the humidity interaction coefficient, and θ be the random error of the current operating environment. The standard error of the prediction model can be obtained by fitting historical data, and k is the confidence level of the standard error of the prediction model. r For the scope of control.

[0013] Compared with existing technologies, the technical effects achieved by adopting this technical solution are as follows: By constructing a current prediction model through a multivariate formula, the ambient temperature, humidity and their interaction are incorporated into the calculation, which solves the problem that a fixed control range cannot adapt to environmental changes. By using a quantitative formula to deeply couple environmental parameters with equipment current parameters, a scientific, dynamic and calculable control range is generated, which helps to improve the control accuracy and adaptability of the wire feeder.

[0014] In one embodiment of the present invention, when the operating parameters are not within the control range, the corresponding alarm level is calculated based on the operating parameters, and alarm information is issued. Specifically, this includes: obtaining the abnormal current of the relevant wire feeding equipment during the comparison period; obtaining the duration, current form, and current extreme value of the abnormal current; classifying the alarm level based on the duration, current form, current extreme value, abnormal current, and the detection results of the target product; and issuing corresponding alarm information based on the alarm level.

[0015] Compared with existing technologies, the technical effects achieved by adopting this solution are as follows: By collecting data on three key dimensions—duration, current form, and current extreme values—this approach replaces the single method of judging anomalies based solely on current values. It enables a more comprehensive assessment of the severity of risks. By combining the abnormal current assessment results with the target product detection results to classify alarm levels, it ensures that the alarm levels match the actual impact on product quality. This makes the control of the wire feeder more reasonable. Issuing corresponding alarm information based on the classification results allows staff to quickly clarify the priority of handling and avoid waste of resources or delays in addressing critical risks.

[0016] In one embodiment of the present invention, when the operating parameters are within the control range, the target product is detected to obtain the detection result, and the control range is corrected according to the detection result. Specifically, if the detection result meets the target expectation, the control range is not corrected; if the detection result does not meet the expectation, the control range is corrected.

[0017] Compared with existing technologies, the technical effects achieved by adopting this technical solution are as follows: the control range is only corrected when the test results do not meet expectations, which can ensure the effectiveness of the control range and avoid ineffective adjustments. When the test results do not meet expectations, the control range is corrected in a timely manner to solve the problem of control standard failure, ensuring that control can keep up with the changes in variables in production. The control range is corrected by triggering the objective indicator of product test results, which replaces the mode of relying on human experience to judge whether to adjust, and reduces subjective bias.

[0018] In one embodiment of the present invention, a feed processing fault early warning system for preventing secondary spheroidization is also provided. The feed processing fault early warning method for preventing secondary spheroidization described in the above embodiment is applied to the feed processing fault early warning system. The feed processing fault early warning system includes: a storage module, with a data management unit located in the storage module; a monitoring module, with a monitoring unit located in the monitoring module, used to monitor environmental parameters and the operating status of related feed equipment; a calculation module, used to calculate the control range and correct the control range; a judgment module, used to judge whether there is a fault risk in the operating status of related feed equipment and generate an alarm level; and an early warning module, used to send alarm information. The feed processing fault early warning system has all the technical features of the above-described feed processing fault early warning method, which will not be described in detail here. Attached Figure Description

[0019] Figure 1 This is one of the flowcharts for the early warning method of the wire feeding process to prevent secondary balling in this invention; Figure 2 The second flowchart is a method for early warning of feeding process failures to prevent secondary balling according to the present invention. Figure 3 This is the third flowchart of the method for early warning of feeding process failures to prevent secondary balling according to the present invention; Figure 4 This is the fourth flowchart of the method for early warning of feed processing failures to prevent secondary balling in this invention; Figure 5 This is a schematic diagram of the early warning system for preventing secondary balling in the wire feeding process according to the present invention. Explanation of reference numerals in the attached figures: 100 - Wire feeding fault early warning system; 110 - Storage module; 120 - Monitoring module; 130 - Calculation module; 140 - Judgment module. Detailed Implementation

[0020] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0021] [First Embodiment] See Figure 1 In one specific embodiment, the present invention provides a method for early warning of feeding process failures to prevent secondary spheroidization. The method includes: S100: Obtain production data from the target factory, establish multiple classification benchmark databases based on the production data, monitor the classification benchmark databases through the monitoring unit to obtain environmental parameters, and send the environmental parameters to the data management unit. S200: Obtain the operating status of the wire feeder, and record the wire feeders with the same operating status and the same classification benchmark library as the relevant wire feeder equipment; S300: Obtain the target product of the relevant wire feeding equipment and generate the corresponding control range based on the target product; S400: Real-time monitoring of the operating status of relevant wire feeding equipment, obtaining operating parameters, and comparing the operating parameters with the control range; S500: When the operating parameters are outside the control range, calculate the corresponding alarm level based on the operating parameters and issue an alarm message. S600 When the operating parameters are within the control range, the target product is tested, the test results are obtained, and the control range is corrected based on the test results.

[0022] In step S100, production data typically refers to the collective term for various resource elements used in the wire feeding balling process. It can be divided into core material data and equipment operation data. Core material data mainly refers to the model parameters, material composition data, batch and traceability data of the cored wire. Equipment operation data mainly refers to the basic configuration data of the wire feeder, such as equipment model, service life, and maintenance frequency. Production data plays a crucial role in the online monitoring of false coil breakage. For example, supplier A's cored wire has a smooth surface, precise diameter, and tight filling, resulting in a stable feeding process and a current that fluctuates steadily between 14A and 16A. Supplier A's cored wire has a rough surface, slightly deviated diameter, and minor false coil breakage. Due to greater friction, the basic current fluctuates between 16A and 18A, and at some point, it drops to a low of 14A due to false coil breakage. If supplier A's cored wire is used and 17A is set as the wire jamming alarm threshold, then when switching to supplier B's cored wire, this threshold is too low, leading to continuous false alarms.

[0023] The storage environment of the cored wire and the operating environment of the wire feeder also affect the online monitoring effect of false wire breakage. The environmental factors affecting the online monitoring effect of false wire breakage mainly include power grid voltage fluctuations, ambient temperature, mechanical vibration, dust pollution, and ambient humidity. Taking ambient temperature as an example, high temperature thins the grease of the wire feeder, reducing the lubrication effect, while low temperature causes it to solidify, increasing the starting and running resistance. Due to the change in mechanical resistance, the no-load and load current of the wire feeder will change systematically with the ambient temperature. Taking ambient humidity as an example, the core powder inside the cored wire, especially the magnesium-based spheroidizing agent, is a highly reactive metal that will react chemically with the moisture in the air, thereby reducing the effective magnesium content in the cored wire, directly damaging its metallurgical properties, and ultimately leading to a decrease in casting quality and an increase in production costs. Therefore, it is necessary to continuously monitor the storage environment of the cored wire and the operating environment of the wire feeder.

[0024] It should be noted that in the actual production process, there may be coupling effects between various environmental factors. Therefore, it is necessary to take into account the coupling effects between various environmental factors.

[0025] In step S200, the operating status of the wire feeder refers to a comprehensive assessment of the equipment's health and production process stability obtained through sensors, control systems, or manual inspection. Its operating status is a prerequisite for accurate online monitoring. Generally, the operating status of the wire feeder is related to its service life and the number of maintenance cycles. Typically, as the equipment ages, its performance undergoes a slow but irreversible decline, which alters the normal standards upon which the monitoring system relies. For example, a new wire feeder's normal feeding current is 14-16A, and the system is set to trigger a wire jamming alarm if the current exceeds 18A. After five years, due to long-term wear and tear on components such as bearings, guide rails, and gears... Wear and tear increases frictional resistance, causing the current required to perform the same task to slowly rise to 16-18A. In addition, each maintenance, especially the replacement of core components, will have a certain impact on the operating status of the wire feeder. For example, the old drive wheel has a smooth surface and slight slippage, with a wire feeding current of 13-15A. The new drive wheel has deeper grooves and a rougher surface, with stronger grip but also greater friction, and the wire feeding current becomes 19-20A. When the wire feeder is operating normally at 19A after maintenance, the system will immediately determine that it is continuously overloaded and alarm, causing production to stop. Furthermore, the maintenance skills of the maintenance personnel will also affect the operating status of the wire feeder.

[0026] Generally speaking, differences in design, manufacturing precision, and component quality among different manufacturers directly affect the baseline performance and service life of wire feeders. In addition, the wear and tear of the same model of wire feeder will vary depending on the environment. For example, wire feeders in dusty environments will have different mechanical wear even if they have the same service life. Therefore, when monitoring wire feeders, priority should be given to those with the same operating status and belonging to the same classification benchmark library, i.e., relevant wire feeding equipment.

[0027] It should be noted that if there is no other wire feeder with the same operating status and belonging to the same classification benchmark library, it shall be managed separately.

[0028] In step S300, generally speaking, different target products need to meet different qualification standards, and the qualification standards of target products will lead to different production processes, which may change the load conditions of the wire feeding process. For example, when the target product has a thick cross section, the peak value of the current curve of the wire feeder will be higher and have more violent fluctuation characteristics. Therefore, it is necessary to generate corresponding control ranges according to different target products.

[0029] Generally, it is necessary to obtain at least 3 years of operating data for the relevant wire feeding equipment. The control scope is determined based on the historical operating data of the relevant wire feeding equipment. In addition, if the operating period of the relevant wire feeding equipment has not reached 3 years, the control scope is set according to the operating data of the same type of wire feeder and the operating standards of that type.

[0030] In step S400, the operating parameters of the wire feeder are the core data for monitoring its working status, ensuring the accuracy of process execution, and preventing faults. The relevant operating parameters of the wire feeder refer to the drive motor current.

[0031] In step S500, in general, in order to improve production efficiency during the production process, different measures need to be taken for different alarm levels. For example, the alarm levels are divided into three levels: Level 1 warning: observation level, slight fluctuation of current, initial trend, or brief abnormality of a single sensor, with a comprehensive fault probability of less than or equal to 0.5; Level 2 warning: operation level, current continuously deviates from the dynamic threshold, or the comprehensive fault probability is between 0.5 and 0.85; Level 3 warning: emergency stop level, current is severely abnormal, or the comprehensive fault probability is greater than or equal to 0.85, or multiple pieces of evidence confirm that a fault has occurred.

[0032] It should be noted that in actual production, alarm levels need to be classified according to specific circumstances in order to ensure the smooth completion of production tasks to the greatest extent possible.

[0033] In step S600, during the production process, a malfunction may occur, but the operating parameters of the wire feeder are within the control range. Therefore, it is necessary to modify the control range according to the actual quality test results of the target product. For example, due to changes in climate, environmental factors may become more variable, causing the original control range to no longer be applicable to the current production.

[0034] By acquiring production data from the target factory and establishing multiple classification benchmark databases, various factors in the production process can be systematically classified and standardized for management. Monitoring units monitor these benchmark databases, acquiring environmental parameters and monitoring the real-time operating status of the wire feeder. This allows for timely understanding of environmental changes and equipment operation during production, facilitating early detection of potential problems. The setup of related wire feeder equipment transforms a group of isolated machines into a production team capable of mutual support and collaborative learning, aiding in rapid root cause identification and dissemination. This makes wire feeder management more refined. By calculating alarm levels, simple yes / no alarms are upgraded to graded risk assessments, reducing production interruptions and providing clear decision-making priorities based on the target... The corresponding control scope for product generation enables process monitoring to directly serve the final product quality. Through a series of operations such as real-time monitoring, comparison, alarms, and correction of the control scope, dynamic optimization of the production process can be achieved. As production progresses, the control scope and strategies are continuously adjusted according to the actual situation to keep the production process in an optimal state, improve production stability and reliability, and promote continuous improvement of the production process. The above solution achieves standardized production management by establishing a classification benchmark library. Combined with real-time monitoring to obtain environmental and equipment operating parameters, the wire feeder is grouped for control and the control scope is dynamically generated and corrected. Ultimately, it achieves real-time early warning, risk control, efficiency improvement, and product quality assurance in the production process, achieving refined, dynamic, and continuous optimization management of the entire production process.

[0035] [Second Embodiment] See Figure 2 In one specific embodiment, production data of the target factory is acquired, multiple classification benchmark databases are established based on the production data, and the classification benchmark databases are monitored by a monitoring unit to obtain environmental parameters. These environmental parameters are then sent to a data management unit. Specifically, this includes: S110. Obtain the production data of the target factory, classify the data according to its source, and obtain the first benchmark library; S120. Classify the means of production according to their functions to obtain the second benchmark library; S130. Classify the means of production according to their production environment to obtain the third benchmark library.

[0036] In step S110, the source of production materials refers to the manufacturer, model, and production batch of the wire feeder and cored wire. Generally speaking, production materials from different sources have significant differences in performance and quality. For example, manufacturer C's equipment has high power and a normal current of 8A. When the current rises to 9.5A, the system alarms, which is an effective warning. Manufacturer D's equipment has low power and a normal current of only 4A. When the current rises to 7A, the equipment is already close to stalling, which is extremely risky. However, the system does not react because it has not reached 10A, which will lead to false alarms.

[0037] In addition, different batches of cored wire can also affect the monitoring results. For example, different batches of the same type of cored wire may have slight rust or be less smooth on the surface of the earlier batch due to the humid storage environment. This will significantly increase the friction with the wire feed wheel and guide tube, resulting in a continuous increase in current.

[0038] In step S120, the function of the production materials refers to dividing the production materials into a wire feeder and a cored wire.

[0039] In step S130, generally speaking, the production environment has a significant impact on the monitoring results of the wire feeder current. For example, when large equipment is turned on or off, the current of the wire feeder will change to a certain extent. Therefore, it is necessary to set the control range of the wire feeder precisely according to the environment in which it is located.

[0040] For example, the performance of cored wires of the same model and batch can be affected by different storage environments. For instance, a humid environment can affect the effective magnesium content of the cored wire, thereby affecting the change in the current of the wire feeder.

[0041] The establishment of the first benchmark library helps to clarify the source of production materials, making it easier to trace the supplier, batch, and other information of materials or equipment, and providing a basis for quality traceability and supply chain management. The second benchmark library focuses on the use of production materials, which can quickly locate equipment or materials with different functions, facilitating functional matching and scheduling in the production process. The third benchmark library is associated with the environment in which the production materials are located, directly providing classification targets for subsequent environmental parameter monitoring, ensuring that the monitoring direction accurately corresponds to the actual application scenario of the production materials. By classifying production materials through three different dimensions, a complementary benchmark library system is formed, solving the problems of incomplete coverage and imprecise management of a single classification dimension.

[0042] [Third Embodiment] In one specific embodiment, the operating status of the wire feeder is obtained, and wire feeders with the same operating status and belonging to the same classification benchmark library are recorded as relevant wire feeding devices, specifically including: S210. Obtain the service life and maintenance frequency of the wire feeder, and obtain the operating status of the wire feeder based on the service life and maintenance frequency. S220. Obtain the standard benchmark library based on the first benchmark library, the second benchmark library, and the third benchmark library; S230. Wire feeders with the same operating status and both in the standard reference library are recorded as related wire feeders.

[0043] In step S210, generally speaking, the current signal of the wire feeder after maintenance can be divided into three situations: baseline rise, baseline fall, and increased baseline fluctuation and distortion. When the maintenance quality is poor, or the replaced parts introduce greater friction, the baseline may rise. When the wire feeder is maintained, such as after lubrication, cleaning, adjustment, or replacement of severely worn old parts, the baseline may fall. When maintenance solves a problem, but unintentionally introduces new unstable factors, such as small gaps or vibrations in the transmission system after maintenance, the baseline may fluctuate and become distorted.

[0044] Furthermore, based on the maintenance effect of the wire feeder, maintenance is divided into three categories: maintenance maintenance, recovery maintenance, and improper maintenance. Maintenance maintenance refers to baseline reduction, recovery maintenance refers to baseline elevation, and improper maintenance refers to increased baseline fluctuation and distortion. The number of times each of the three maintenance categories of the wire feeder is counted and recorded.

[0045] It should be noted that if the limit standard does not change after the repair, then this repair will not be counted in the number of repairs.

[0046] The operating status of the wire feeder can be obtained using the following formula: S=max(0, 100−ɑ×t−μ×M) r −ŋ×M i +d×M m ); Where S is the operating status score, t is the service life, and M is the service life. m M represents the number of maintenance repairs. r M represents the number of restorative repairs. i The number of improper maintenance, α is the attenuation coefficient of service life, which can be obtained from operating data, μ is the penalty coefficient for restorative maintenance, which can be obtained from operating data, ŋ is the penalty coefficient for improper maintenance, which can be obtained from operating data, and d is the reward coefficient for maintenance, which can be obtained from operating data.

[0047] For example, assuming a wire feeder has a service life of 5 years, with 5 maintenance repairs, 4 recovery repairs, and 2 improper repairs, then substituting the above data into the formula yields an operating status score of 80 points for the wire feeder.

[0048] Based on the actual operating conditions, the operating status of the wire feeder is divided into three different status levels: Level 1: operating status score of 80-100 points; Level 2: operating status score of 60-80 points; and Level 3: operating status score of less than 60 points.

[0049] In steps S220 and S230, the standard reference library refers to production materials that have the same source, the same function, and the same production environment. For example, cored wires with the same manufacturer, production batch, model, and storage environment are classified into the standard reference library.

[0050] By using two quantitative indicators, namely, the number of years of service and the number of maintenance visits, the deviation of judging equipment status based solely on subjective experience is avoided. A standard benchmark library is obtained based on the first, second, and third benchmark libraries, which helps to ensure that related wire feeding equipment in the same group is not only in the same state but also in the same production context. Subsequent control measures can more accurately match the needs of the scenario. By screening related wire feeding equipment based on the dual conditions of the same operating status and being in the same standard benchmark library, the fine grouping of equipment is achieved.

[0051] [Fourth Embodiment] See Figure 3 In one specific embodiment, the target product of the relevant fiber feeding equipment is obtained, and a corresponding control range is generated based on the target product, specifically including: S310. Record the historical time period corresponding to the current time period as the comparison time period, and obtain the current fluctuation range of the relevant wire feeding equipment for different target products in the comparison time period, and record it as the comparison range. S320. Based on the comparison range and the detection results of the target product, the target current range is obtained and denoted as target range one. S330. Record the environmental parameters corresponding to Target Range One as Target Range Two; S340. Based on target range one and target range two, obtain the control range of the target product from the relevant wire feeding equipment.

[0052] In step S310, under normal circumstances, different seasons will cause changes in the operating parameters of the wire feeder. For example, high heat in summer will reduce the heat dissipation efficiency of the motor and increase the winding resistance. High humidity will increase the surface friction coefficient of the cored wire and increase the pushing resistance. These changes will increase the current of the wire feeder. During the spring and autumn seasons, the temperature changes suddenly and the large temperature difference will cause uneven thermal expansion and contraction of the internal and external components of the equipment, which may cause additional mechanical stress and make the operating current unstable. Therefore, it is necessary to divide a natural year into 12 historical time periods according to the months. The month in which the current natural day is located is recorded as the current time period, and the months before the current time period are recorded as historical time periods. When the month of the historical time period is the same as that of the current time period, the historical time period is recorded as the comparison time period of the current time period.

[0053] Due to differences in the manufacturers, models, batches, and production environments of production materials, the current fluctuation range corresponding to the same target product may also be different. The steps for classifying the production target product based on the relevant wire feeding equipment and cored wire are as follows: S311. Classify the target products according to their different characteristics, and record the classification results as the first classification result. S312. Classify the first classification result according to the manufacturer, model, batch and storage environment of the cored wire to obtain the second classification result. Record the target product obtained according to the second classification result as the first target product.

[0054] For example, a factory produces three target products: target product A, target product B, and target product C. Target products A, B, and C constitute the first classification result. Taking target product A as an example, target product A is classified according to the manufacturer, model, batch, and storage environment of the cored wire. The classification result is the first target product. For instance, cored wires with the same manufacturer, model, and batch but different storage environments are classified as first target product a; those with the same manufacturer, model, and storage environment but different batches are classified as first target product b; those with the same model, batch, and storage environment but different manufacturers are classified as first target product c, and so on, classifying different first target products.

[0055] In steps S320 to S340, based on the first target product obtained in step 310, the current fluctuation range of the relevant wire feeding equipment for the first target product for at least the most recent three years is obtained. When the quality test result of the target product meets the production requirements, the current fluctuation range corresponding to the same type of target product that meets the requirements is recorded as the target current range, i.e., target range one.

[0056] It should be noted that when the service life of the relevant wire feeding equipment is less than three years, the current fluctuation range of the wire feeding machine of the same model is obtained by measuring the trend of the current fluctuation range.

[0057] In addition, when the wire feeder is standalone and there is no associated wire feeding equipment, the wire feeder is monitored separately.

[0058] By using the historical time period corresponding to the current time period as a comparison benchmark and combining the historical current fluctuation range to determine the control basis, the blindness of setting control standards out of thin air is avoided. By combining the historical comparison range with the target product detection results, the target current range target range one is generated, realizing the direct link between control standards and product quality. Environmental parameters are included in the control range target range two, which supplements the shortcomings of simply relying on equipment operating parameters for control.

[0059] [Fifth Embodiment] In a specific embodiment, the control range of the target product obtained by the relevant fiber feeding equipment is obtained according to target range one and target range two, specifically including: The formula for calculating the scope of control is as follows: I t =β0+β1×T t +β2×H+β3×(T t ×H t )+θ; ; Among them, I t This is the current predicted value, β0 is the theoretical base current value, β1 is the temperature coefficient, and T is the temperature coefficient. t H represents the current ambient temperature. t Let β2 be the current ambient humidity, β3 be the humidity interaction coefficient, and θ be the random error of the current operating environment. The standard error of the prediction model can be obtained by fitting historical data, and k is the confidence level of the standard error of the prediction model. r For the scope of control.

[0060] The theoretical basis current value (β0) refers to the basic current value of the relevant wire feeding equipment when producing the target product. The basic current value is obtained by calculating the target current range of each production of the target product in the target time period of the past three years, or by expert prediction. The temperature coefficient (β1), humidity coefficient (β2), and temperature-humidity interaction term coefficient (β3) are obtained based on historical operating data. θ is the random error of the current operating environment, which is closely related to time. For example, other large equipment will be turned on during a fixed time period every day, which will affect the current of the relevant wire feeding equipment.

[0061] By constructing a current prediction model using a multivariate formula, the environmental temperature, humidity, and their interaction are incorporated into the calculation. This solves the problem that a fixed control range cannot adapt to environmental changes. By using a quantitative formula to deeply couple environmental parameters with equipment current parameters, a scientific, dynamic, and calculable control range is generated, which helps to improve the control accuracy and adaptability of the wire feeder.

[0062] [Sixth Embodiment] See Figure 4 In one specific embodiment, when the operating parameters are outside the control range, the corresponding alarm level is calculated based on the operating parameters, and an alarm message is issued, specifically including: S510. Obtain the abnormal current of the relevant wire feeding equipment during the comparison period; S520: Obtain the duration, current form, and current extreme value of the abnormal current; classify the alarm level based on the duration, current form, current extreme value, abnormal current, and the detection results of the target product. S530: Issue corresponding alarm information according to the alarm level.

[0063] In steps S510 and S520, abnormal current refers to the current fluctuation of the relevant wire feeding equipment when a false package or wire break occurs during the production of the target product within the target time period.

[0064] In step S520, generally speaking, the current characteristic of normal wire feeding is that the curve is stable and accompanied by regular fluctuations. The current extreme value fluctuates within a relatively high and stable range, and the duration is completely consistent with the wire feeding time set by the program. False bulges or wire breaks may occur throughout the entire wire feeding process. Their impact is mainly related to their location and the total length of the false bulge. When there is a false bulge, the current curve will lose its normal sawtooth fluctuations and become abnormally flat. The current extreme value will be significantly and continuously low, and the current duration is basically normal. When a wire break occurs, the current will suddenly stop, the current shape will change drastically and then return to zero, and the current extreme value will return to zero. Sometimes, abnormal spikes will appear. Therefore, it is possible to determine whether a false bulge or wire break has occurred by obtaining the basic characteristics of the abnormal current.

[0065] In actual production, the length of the false packet has different effects on the quality of the target product. The alarm level of the false packet can be set according to historical production records.

[0066] For example, based on historical production records, the impact of the length of the dummy package on the quality of the target product is obtained, and three alarm levels are set according to the consequences of the impact: First alarm level: Total length of virtual packets ≥ first length threshold; Second alarm level: Second length threshold < total virtual packet length < first threshold; Third alarm level: Total length of virtual packets ≤ second length threshold.

[0067] When the first alarm level is triggered, production must be stopped immediately and corresponding rectifications must be carried out. When the second alarm level is triggered, it is necessary to determine whether to add a spheroidizing agent based on the actual situation. When the third alarm level is triggered, it is necessary to record the incident and monitor it continuously.

[0068] The first alarm threshold and the second alarm threshold can be obtained from historical data.

[0069] In addition, the number of false bubbles also affects the quality of the target product. For example, when multiple false bubbles occur but the length of each false bubble is small, the current curve may drop slightly and recover multiple times, which is not as obvious as a single long false bubble. This situation may lead to intermittent input of the spheroidizing agent, and the spheroidizing effect in different areas of the molten iron may be uneven. Therefore, it is necessary to set the alarm level according to the number of false bubbles.

[0070] Three alarm levels are set according to the impact of the consequences: First alarm level: Number of virtual packets ≥ First quantity threshold; Second alarm level: Second quantity threshold < number of virtual packets < first quantity threshold; Third alarm level: Number of virtual packets ≤ Second quantity threshold.

[0071] When the first alarm level is triggered, production must be stopped immediately and corresponding rectifications must be carried out. When the second alarm level is triggered, the trend must be monitored and the cause analyzed in a timely manner. When the third alarm level is triggered, it must be recorded and continuously monitored.

[0072] It should be noted that when monitoring the number of false packets, the length of each false packet and the cumulative length of the false packets need to be recorded simultaneously. When the cumulative length reaches the required alarm length, an alarm message is issued. In addition, during the production process, the number, length and location of false packets can be identified based on changes in current, so as to facilitate the implementation of corresponding countermeasures accurately.

[0073] When a core wire breaks, the location of the broken wire is recorded, and an alarm message is issued according to the location of the break. Generally speaking, when the break occurs in the later stage, the impact on the target product is relatively small, while when the break occurs in the early stage, the impact on the target product is very serious.

[0074] By collecting data on three key dimensions—duration, current form, and current extreme values—instead of relying solely on current values ​​to determine anomalies, a more comprehensive assessment of risk severity can be achieved. By combining the abnormal current assessment results with the target product detection results to classify alarm levels, it is ensured that the alarm level matches the actual impact on product quality. This makes the control of the wire feeder more reasonable. Issuing corresponding alarm information based on the classification results allows staff to quickly clarify the priority of handling and avoid waste of resources or delays in addressing critical risks.

[0075] [Seventh Embodiment] In one specific embodiment, when the operating parameters are within the control range, the target product is detected, the detection results are obtained, and the control range is corrected based on the detection results. Specifically, this includes: S610. If the test results meet the target expectations, the control scope shall not be modified. S620. If the test results do not meet expectations, the control scope shall be revised.

[0076] In step S620, generally speaking, when no alarm information occurs in the production process, it is necessary to determine whether the control scope is appropriate based on the quality results of the target product.

[0077] Adjusting the control scope only when the test results do not meet expectations ensures the effectiveness of the control scope and avoids ineffective adjustments. When the test results do not meet expectations, the failure of the control standard can be resolved in a timely manner by adjusting the control scope, ensuring that the control can keep up with the changes in variables in production. The control scope adjustment is triggered by the objective indicator of product test results, which replaces the mode of relying on human experience to judge whether to adjust, and reduces subjective bias.

[0078] [Eighth Embodiment] See Figure 5 In one specific embodiment, the present invention also provides a feeding process fault early warning system 100 for preventing secondary spheroidization. The feeding process fault early warning method for preventing secondary spheroidization described in the above embodiment is applied to the feeding process fault early warning system 100. The feeding process fault early warning system includes: a storage module 110, with a data management unit located in the storage module 110; a monitoring module 120, with a monitoring unit located in the monitoring module 120, used to monitor environmental parameters and the operating status of related feeding equipment; a calculation module 130, used to calculate the control range and correct the control range; a judgment module 140, used to judge whether there is a fault risk in the operating status of related feeding equipment and generate an alarm level; and an early warning module 150, used to send alarm information. The feeding process fault early warning system 100 has all the technical features of the above-mentioned feeding process fault early warning method, which will not be described in detail here.

[0079] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A method for early warning of a failure of a wire feeding process that prevents secondary spheroidization, characterized in that, The yarn feeding process failure early warning method comprises: Obtaining production materials of a target factory, establishing a plurality of classification benchmark libraries according to the production materials, monitoring the classification benchmark libraries through a monitoring unit to obtain environmental parameters, and sending the environmental parameters to a data management unit; Obtaining the running state of a yarn feeding machine, and recording the yarn feeding machines with the same running state and the same classification benchmark library as relevant yarn feeding equipment; Obtaining target products of the relevant yarn feeding equipment, and generating a corresponding control range according to the target products; Real-time monitoring the running state of the relevant yarn feeding equipment to obtain running parameters, and comparing the running parameters with the control range; When the running parameters are not within the control range, calculating a corresponding alarm level according to the running parameters, and issuing an alarm information; When the running parameters are within the control range, detecting the target products to obtain detection results, and modifying the control range according to the detection results.

2. The yarn feeding trouble early warning method according to claim 1, characterized by, The obtaining of the production materials of the target factory, the establishment of a plurality of classification benchmark libraries according to the production materials, the monitoring of the classification benchmark libraries through a monitoring unit to obtain environmental parameters, and the sending of the environmental parameters to a data management unit specifically comprises: Obtaining the production materials of the target factory, classifying the production materials according to the sources of the production materials to obtain a first benchmark library; Classifying the production materials according to the functions of the production materials to obtain a second benchmark library; Classifying the production materials according to the production environments of the production materials to obtain a third benchmark library.

3. The yarn feeding trouble early warning method according to claim 2, characterized by, The obtaining of the running state of the yarn feeding machine, and the recording of the yarn feeding machines with the same running state and the same classification benchmark library as relevant yarn feeding equipment specifically comprises: Obtaining the service life and the number of repairs of the yarn feeding machine, and obtaining the running state of the yarn feeding machine according to the service life and the number of repairs; Obtaining a standard benchmark library according to the first benchmark library, the second benchmark library, and the third benchmark library; Recording the yarn feeding machines with the same running state and the same standard benchmark library as the relevant yarn feeding equipment.

4. The yarn feeding trouble early warning method according to claim 3, characterized by, The obtaining of the target products of the relevant yarn feeding equipment, and the generation of a corresponding control range according to the target products specifically comprises: Recording a historical time period corresponding to a current time period as a comparison time period, obtaining the current fluctuation range of the current of the relevant yarn feeding equipment for different target products in the comparison time period as a comparison range; Obtaining a target current range according to the comparison range and the detection results of the target products as a target range one; Recording the environmental parameters corresponding to the target range one as a target range two; Obtaining the control range of the target products of the relevant yarn feeding equipment according to the target range one and the target range two.

5. The yarn feeding trouble early warning method according to claim 4, characterized by, The obtaining of the control range of the target products of the relevant yarn feeding equipment according to the target range one and the target range two specifically comprises: The calculation formula of the control range is as follows: I t = β0+ β1× T t + β2× H + β3× (T t × H t )+ θ; ； wherein I t is the current current prediction value, β0 is a theoretical basic current value, β1 is a temperature coefficient, T t is the current ambient temperature, H t is the current ambient humidity, β2 is a humidity coefficient, β3 is a temperature and humidity interaction term coefficient, θ is a random error of the current operating environment, is the standard error of the prediction model, which can be obtained after fitting historical data, k is the confidence level of the standard error of the prediction model, I r is the control range.

6. The yarn feeding trouble early warning method according to claim 5, characterized by, The when the running parameters are not within the control range, calculating a corresponding alarm level according to the running parameters, and issuing an alarm information specifically comprises: acquiring an abnormal current of the relevant yarn feeding device in the comparison time period; acquiring a duration, a current form and a current extreme value of the abnormal current, and dividing an alarm level according to the duration, the current form, the current extreme value and the detection result of the target product; sending corresponding alarm information according to the alarm level.

7. The monitoring method of claim 1, wherein, when the operation parameter is within the control range, detecting the target product to obtain a detection result, and correcting the control range according to the detection result, specifically including: if the detection result meets the target expectation, not correcting the control range; if the detection result does not meet the expectation, correcting the control range.

8. A secondary globulation prevention feed failure warning system characterized by, The yarn feeding process failure early warning method according to any one of claims 1 to 7 is applied to a yarn feeding process failure early warning system, and the yarn feeding process failure early warning system includes: a storage module, wherein the data management unit is arranged in the storage module; a monitoring module, wherein the monitoring unit is arranged in the monitoring module and is used for monitoring the environmental parameter and the operation state of the relevant yarn feeding device; a calculation module, wherein the calculation module is used for calculating the control range and correcting the control range; a judgment module, wherein the judgment module is used for judging whether the operation state of the relevant yarn feeding device has a failure risk and generating the alarm level; an early warning module, wherein the early warning module is used for sending the alarm information.

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