Operation support system of rolling equipment

Abstract

The operation support system includes a control value setting unit, an operation amount acquisition unit, an actual data acquisition unit, a deterioration evaluation unit, an operation amount correction unit, and a corrected operation amount presentation unit. The control value setting unit sets a control value calculated on the basis of the rolling plan to the rolling equipment. The operation amount acquisition unit acquires an operation amount at which the production efficiency of the rolling equipment for which the control value has been set is maximized. The actual data acquisition unit acquires time-series actual data of the rolling equipment. The deterioration evaluation unit evaluates the deterioration state of the rolling equipment on the basis of the time-series actual data. The operation amount correction unit corrects the operation amount on the basis of the deterioration state of the rolling equipment. The corrected operation amount presentation unit presents the corrected operation amount.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an operation support system for a rolling apparatus, and more particularly, to an operation support system that supports manual operation (hereinafter also referred to as "manual intervention") by an operator of a rolling apparatus. BACKGROUND

[0002] For example, in a rolling mill, a rolling apparatus is operated by setting a process control value (hereinafter also referred to as "control value") calculated on the basis of an operation plan to a rolling apparatus such as a finishing mill. In order to prevent a failure of the rolling apparatus during operation, a limit value is set to the control value. If the control value exceeds the limit value, the rolling apparatus is forcibly stopped, and a long recovery time is required before the rolling apparatus is operated again. Therefore, at the time of quasi-exceeding in which the control value is about to exceed the limit value, an operator is notified, and the operator can manually operate (manual intervention) the control value.

[0003] Unlike the manual operation for avoiding such exceeding of the limit value (limit violation), manual operation for maximizing the production efficiency of the rolling apparatus is performed. For example, in a case where the control value of the rotational speed of a motor of a finishing mill has a margin, the manual operation is performed to the optimal value (higher rotational speed) at which the production efficiency is maximized.

[0004] However, it is known that a rolling apparatus deteriorates due to long-term use. A process monitoring system is disclosed in Patent Literature 1, which includes a state change judgment unit that judges a change in a state of a factory.

[0005] PRIOR ART DOCUMENT PATENT LITERATURE Patent Literature 1: Japanese Patent No. 5868784 SUMMARY

[0006] PROBLEMS TO BE SOLVED BY THE INVENTION In a case where a rolling apparatus deteriorates, if manual operation is performed to become the optimal value as in a state where the rolling apparatus is not deteriorated, that is, if manual operation is performed with the same operation amount as in a state where the rolling apparatus is not deteriorated, there is a concern that the limit value is exceeded. Therefore, an operator needs to perform manual operation corresponding to the deteriorated state of the rolling apparatus. However, manual operation in a state where a rolling apparatus deteriorates is not easy, particularly for an operator with little experience.

[0007] The present disclosure has been achieved in order to solve the above-described problem. An object of the present disclosure is to provide an operation support system for a rolling apparatus, which enables manual operation for maximizing the production efficiency of a deteriorated rolling apparatus for an operator with little experience.

[0008] MEANS FOR SOLVING THE PROBLEM The first aspect of the present disclosure relates to an operation support system that supports manual operation by an operator of a rolling apparatus. The operation support system includes a control value setting unit, an operation amount acquisition unit, an actual data acquisition unit, a deterioration evaluation unit, an operation amount correction unit, and a corrected operation amount presentation unit. The control value setting unit sets a control value calculated based on a rolling plan to the rolling apparatus. The operation amount acquisition unit acquires an operation amount at which a production efficiency of the rolling apparatus to which the control value is set becomes maximum. The actual data acquisition unit acquires time-series actual data of the rolling apparatus. The deterioration evaluation unit evaluates a deterioration state of the rolling apparatus based on the time-series actual data. The operation amount correction unit corrects the operation amount based on the deterioration state of the rolling apparatus. The corrected operation amount presentation unit presents the corrected operation amount.

[0009] The second aspect includes the first aspect and has the following feature. The operation amount correction unit is configured to correct the operation amount within a range that does not exceed a limit value set to the control value.

[0010] The third aspect includes the first aspect and has the following feature. The deterioration evaluation unit is configured to evaluate the deterioration state from a decrease amount of the reference actual data from the time-series actual data when the actual data of the rolling apparatus having no deterioration is used as the reference actual data.

[0011] The fourth aspect includes the first to third aspects and has the following feature. The operation support system further includes a corrected operation amount evaluation unit that evaluates the corrected operation amount. The corrected operation amount display unit is configured to display the evaluation result of the corrected operation amount in association with the corrected operation amount.

[0012] Effects of Invention According to the present disclosure, in a case where it is evaluated that the rolling apparatus is deteriorated, instead of presenting the operation amount at which the production efficiency of the rolling apparatus having no deterioration becomes maximum to the operator, the operation amount corrected based on the deterioration state of the rolling apparatus is presented to the operator. Thus, even an operator with little experience can perform manual operation that maximizes the production efficiency of the deteriorated rolling apparatus. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1 is a diagram that represents an example of a rolling factory of an operation support system of a rolling apparatus to which the embodiment is applied.

[0014] Figure 2 is a block diagram that represents the operation support system of the rolling apparatus of the embodiment.

[0015] Figure 3 is a diagram for explaining a method of evaluating a deterioration state of a rolling apparatus.

[0016] Figure 4 is a diagram that represents an example of a display of a corrected operation amount.

[0017] Figure 5 is a flowchart showing an example of an action of the operation support system.

[0018] Figure 6 is a diagram showing an example of a hardware configuration of the operation support system. DETAILED DESCRIPTION

[0019] Hereinafter, the operation support system of the rolling apparatus of the embodiment of the present application will be described with reference to the drawings. In addition, the same symbols are attached to common elements in each drawing and repeated description is omitted.

[0020] Figure 1 is a diagram showing an example of a rolling mill 1 of the rolling apparatus to which the operation support system of the embodiment is applied. In the rolling mill 1, a heating furnace 2, a rough rolling mill 3, a crop shearing machine 4, a finish rolling mill 5, a cooling device 6, and a coiling machine 7 are provided as main rolling apparatuses. A conveyance table (omitted from the drawing) for conveying a rolled material Mr between the rolling apparatuses is provided in the rolling mill 1. These rolling apparatuses are driven by an electrical system of a motor, an actuator.

[0021] The heating furnace 2 is configured to heat a rolled material (slab) Mr before rolling to a prescribed temperature (for example, 1200°C). The rough rolling mill 3 has at least one (typically, one to three) rolling stand. The rough rolling mill 3 performs multi-pass rolling on the heated rolled material Mr while switching the rolling direction of the rolled material Mr.

[0022] The finish rolling mill 5 is a tandem rolling mill provided with, for example, seven rolling stands Fl to F7 arranged side by side in the rolling direction of the rolled material Mr. Each of the rolling stands Fl to F7 is provided with two upper and lower work rolls 51, two upper and lower backup rolls 52, and a motor 53 for roll rotation. A press-down device 54 is provided at the backup roll 52, and is configured to be able to adjust the gap between the upper and lower work rolls 51 by the press-down device 54. The rolling load of each of the rolling stands Fl to F7 is measured by a rolling load sensor 55. The cooling device 6 cools the rolled material Mr by injecting water to the rolled material Mr by a cooling bed. The cooled rolled material Mr is coiled into a coiled material by the coiling machine 7.

[0023] Various sensors as measurers are provided at important points of the rolling mill 1. The important points of the rolling mill 1 are, for example, the exit side of the heating furnace 2, the exit side of the rough rolling mill 3, the entry side and the exit side of the finishing rolling mill 5, and the entry side of the coiling machine 7. Various sensors can also be provided between the rolling mill stands F1 to F7 of the finishing rolling mill 5. The various sensors include a shape detector 81 that measures the shape of the rolled material Mr at the exit side of the rough rolling mill 3, a thermometer 82 that measures the surface temperature of the rolled material Mr at the entry side of the finishing rolling mill 5, a speed detector 83 that measures the speed of the rolled material Mr at the exit side of the finishing rolling mill 5, a thickness, width meter 84 that measures the thickness of the rolled material Mr and the thickness and width of the sheet at the exit side of the finishing rolling mill 5, a thermometer 85 that measures the surface temperature of the rolled material Mr at the entry side of the coiling machine 7, and the above-mentioned rolling load sensor 55. The various sensors sequentially measure the state of the rolled material Mr and each rolling apparatus. The measured values are acquired as actual data.

[0024] The rolling mill 1 is operated by using a control system that has a hierarchical structure of computers. The computers include a process control computer 11 of a level 1 and a host computer 12 of a level 2 that are connected to each other via a network. For the process control computer 11, an interface screen 13 as an operation screen is connected to the process control computer 11 via the network by an operator of the rolling mill 1 performing a manual operation. When an operation plan is input to the host computer 12, a rolling plan is sent from the host computer 12 to the process control computer 11. In addition to the input of the rolling plan, rolling information is also input from the host computer 12 to the process control computer 11. The rolling information includes the thickness, width, length, steel type, and the like of the slab information of the rolled material Mr before rolling, i.e., the slab, and the target thickness, target width, target temperature, and the like of the coiled material target information of the rolled material Mr after rolling, i.e., the coiled material. The process control computer 11 accepts the input from the host computer 12, calculates control values of each rolling apparatus as a control object in a series of rolling processes, and sets the control values to each rolling apparatus. Thereby, each rolling apparatus of the rolling mill 1 is operated, and the rolled material Mr is rolled.

[0025] In such an operation, the operator controls the control values by a manual operation so as to maximize the production efficiency of the rolling apparatus. Hereinafter, a case where the rolling apparatus is the finishing rolling mill 5 and the control value is the rotational speed of the work roll 51 will be described as an example.

[0026] However, if the finishing mill 5 is used for a long time, the finishing mill 5 deteriorates. For example, the work roll 51, the motor 53 of the finishing mill 5 deteriorate over time. In the deterioration of the work roll 51, the surface of the work roll 51 is roughened. If the roll surface is roughened, the rolling load increases, resulting in a decrease in the rotational speed. Furthermore, if the motor 53 deteriorates, the motor efficiency decreases, and even if the torque is the same, the required current becomes high, resulting in a decrease in the rotational speed. In this case, hunting of the motor 53 occurs, and it is possible to reach a limit value, and therefore, it is not possible to simply increase the rotational speed by manual operation.

[0027] Thus, in the case where the finishing mill 5 deteriorates, if manual operation is performed to be the optimum value in the same state as the non-deteriorated state, that is, if manual operation is performed with the same operation amount as in the non-deteriorated state, it is possible to cause an excess of the limit value. Manual operation in the state where the finishing mill 5 deteriorates is not easy, particularly for an inexperienced operator. The rolling mill 1 described above is provided with the operation support system 110 of the rolling apparatus of the embodiment.

[0028] Figure 2 is a block diagram showing the operation support system 110 of the rolling apparatus of the embodiment. The operation support system 110 is provided with a control value calculation section 111, a control value setting section 112, an operation amount acquisition section 113, an actual data acquisition section 114, a deterioration evaluation section 115, an operation amount correction section 116, a corrected operation amount evaluation section 117, and a corrected operation amount display section 118.

[0029] The control value calculation section 111 calculates the control value of each rolling apparatus including the finishing mill 5, a limit value (restriction value) with respect to the control value, based on the rolling plan input from the upper computer 12.

[0030] The control value setting section 112 sets the control value and the limit value calculated by the control value calculation section 111 to the rolling apparatus, respectively. The set limit value is also input to the operation amount correction section 116.

[0031] The operation amount acquisition section 113 acquires the operation amount at which the production efficiency of the finishing mill 5 becomes the maximum. The operation amount acquisition section 113 acquires the actual value of the operation amount at which the operator performs manual operation to make the production efficiency of the non-deteriorated finishing mill 5 the maximum.

[0032] The actual data acquisition section 114 acquires time-series actual data of the finishing mill 5. In the time-series actual data, the above-described rolling information input from the upper computer 12, the measured values of each sensor including the rolling load sensor 55, and the like are included.

[0033] The deterioration evaluation section 115 evaluates the deterioration state of the finishing mill 5 based on the time-series actual data. Figure 3 is a diagram for explaining the evaluation method of the deterioration state of the rolling apparatus. As shown inFigure 3 As shown, when actual data under similar rolling conditions (rotation speed) is observed over a long period of time, the actual data gradually decreases at a certain period tl. Therefore, the deterioration evaluation section 115 defines the actual data at the time of no deterioration as reference actual data Dst, and evaluates the presence or absence of deterioration of the rolling apparatus based on the amount of decrease in the actual data from the reference actual data Dst. Figure 3 In the example shown, the deterioration state is evaluated in two stages, but evaluation can be performed in three stages or more. The evaluated deterioration state is input to the operation amount correction section 116.

[0034] The operation amount correction section 116 corrects the operation amount acquired by the operation amount acquisition section 113 based on the deterioration state of the finishing mill 5. The correction of the operation amount is performed within a range that does not exceed a limit value. The amount of correction of the operation amount can be determined using a table, a mathematical expression, or the like based on actual values of manual operation performed in the past by a skilled operator. The skilled operator is able to correct the operation amount according to the deterioration state of the finishing mill 5 based on abundant experience, and therefore, the amount of correction can be utilized as an actual value. In the case where the deterioration state is evaluated in three stages or more by the deterioration evaluation section 115, a table, a mathematical expression, or the like can be prepared in advance so as to also be able to determine the amount of correction in stages in correspondence thereto. The corrected operation amount is input to the corrected operation amount evaluation section 117 and the corrected operation amount display section 118.

[0035] The corrected operation amount evaluation section 117 evaluates the corrected operation amount based on time-series actual data after manual operation is performed with the corrected operation amount. The skilled operator is able to perform evaluation of the corrected operation amount itself based on abundant experience. The evaluation of the corrected operation amount can be performed in two stages of good (O) and bad (X), or can be performed in three stages or more of excellent ( ), good (O), and bad (X) as described later. The evaluation result can also be performed in numerical grades. The evaluation result is input to the corrected operation amount display section 118.

[0036] The corrected operation amount display section 118 displays the corrected operation amount on the operation screen 13. The corrected operation amount display section 118 also displays the evaluation result in association with the corrected operation amount on the operation screen 13. This is effective in the case where there are a plurality of corrected operation amounts. Figure 4 is a diagram showing an example of display of the corrected operation amount. Thereby, the operator is able to easily determine whether to adopt the corrected operation amount Mvl, Mv2. Furthermore, it is preferable to display the corrected operation amount Mv3, which has a poor evaluation result, in addition to the corrected operation amounts Mvl, Mv2, which have good evaluation results. The operator is able to use the corrected operation amount Mv3, which has a poor evaluation result, as a reference when adopting the corrected operation amount Mvl or Mv2. This is particularly useful for an operator with little experience.

[0037] Next, the operation of the rolling apparatus operation support system 110 will be described. Figure 5 is a flowchart showing an example of the operation of the operation support system 110.

[0038] When the control values of the respective rolling apparatuses including the finishing mill 5 are calculated based on the rolling plan input from the host computer 12, limit values (restriction values) with respect to the control values are calculated (step S1). Thereby, the rolling apparatuses are operated, and time-series actual data of the rolling apparatuses are acquired. In the operation, the operator manually operates the control values so that the production efficiency of the rolling apparatuses becomes maximum. In step S2, the operation amount of the manual operation is acquired.

[0039] Next, in step S3, the deterioration state of the finishing mill 5 is evaluated based on the time-series actual data. That is, it is determined whether or not the finishing mill 5 is deteriorated (refer to Figure 3 ).

[0040] Next, in step S4, the operation amount Mv is corrected based on the deterioration state of the finishing mill 5. Thereafter, in step S5, the corrected operation amounts Mvl, Mv2, Mv3 are evaluated. That is, evaluation results corresponding to the respective corrected operation amounts Mvl, Mv2, Mv3 are acquired.

[0041] In the final step S6, the evaluation results corresponding to the corrected operation amounts Mvl, Mv2, Mv3 are displayed on the operation screen (interface screen 13).

[0042] Figure 6 is a diagram showing an example of the hardware configuration of the operation support system 110. The above-described respective functions of the operation support system 110 can be realized by a processing circuit as shown in Figure 5 . The processing circuit can also be a dedicated hardware 110a. The processing circuit can also be provided with a processor 110b and a memory 110c. The processing circuit can also be partly formed of the dedicated hardware 20a, and further provided with the processor 110b and the memory 110c. In Figure 6In the example of FIG. 10, a part of the processing circuitry is formed as a dedicated hardware 110a, and the processing circuitry also has a processor 110b and a memory 110c. The processing circuitry can also be at least one dedicated hardware 110a. In this case, the processing circuitry corresponds to, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC, an FPGA, or a combination thereof. The processing circuitry can also have at least one processor 110b and at least one memory 110c. In this case, each function of the operation support system 110 is implemented by software, firmware, or a combination of software and firmware. The software and firmware are described as programs stored in the memory 110c. The processor 110b implements each function of the operation support system 110 by reading out and executing the programs stored in the memory 110c. The processor 110b is also referred to as a CPU (Central Processing Unit), a processing device, an arithmetic device, a microprocessor, a microcomputer, a DSP. The memory 110c corresponds to, for example, a nonvolatile or volatile semiconductor memory such as a RAM, a ROM, a flash memory, an EPROM, an EEPROM, or the like. In this way, the processing circuitry can implement each function of the operation support system 110 by hardware, software, firmware, or a combination thereof.

[0043] As explained above, according to the present embodiment, in the case where the finishing mill (rolling apparatus) 5 is evaluated as deteriorated, instead of the production efficiency of the finishing mill 5 that is not deteriorated being prompted to the operator as the maximum operation amount Mv, the operation amount Mvl, Mv2 corrected based on the deterioration state of the finishing mill 5 is prompted to the operator. Thereby, even an operator with little experience can perform manual operation that maximizes the production efficiency of the deteriorated finishing mill 5.

[0044] The above describes an embodiment of the present disclosure, but the present disclosure is not limited to the above-described embodiment and can be variously modified and implemented without departing from the gist of the present invention. In the case where the number, quantity, amount, range, or the like of each element in the above-described embodiment is mentioned, the present invention is not limited to the mentioned number except for the case where it is explicitly determined as the number in principle or the case where it is explicitly determined as such in principle. Further, the configuration and the like described in the above-described embodiment are not necessarily essential in the present invention except for the case where it is explicitly determined as such in principle or the case where it is explicitly determined as such in principle.

[0045] Further, in the above-described embodiment, the finishing mill 5 is exemplified as the rolling apparatus, but the present disclosure can be applied to other rolling apparatuses of the rolling mill plant 1.

[0046] Symbol explanation: 1: Rolling mill; 5: Finishing mill (rolling apparatus); 51: Work roll; 53: Motor; 55: Rolling load sensor (sensor); 11: Process control computer; 12: Host computer; 13: Interface screen, operation screen; 110: Operation support system of rolling apparatus; 111: Control value calculation section; 112: Control value setting section; 113: Operation amount acquisition section; 114: Actual data acquisition section; 115: Deterioration evaluation section; 116: Operation amount correction section; 117: Corrected operation amount evaluation section; 118: Corrected operation amount display section.

Claims

1. An operation support system for rolling mill equipment, supporting manual operation by operators of the rolling mill equipment, comprising: The control value setting unit sets the control values ​​calculated based on the rolling plan into the rolling equipment; The operation quantity acquisition unit acquires the maximum operation quantity by setting the production efficiency of the rolling equipment to the control value; The actual data acquisition unit acquires the actual time-series data of the rolling equipment; The degradation evaluation department evaluates the degradation status of the rolling equipment based on the actual time series data. The operation amount correction unit corrects the operation amount based on the deterioration state of the rolling equipment; as well as The calibration operation quantity display unit displays the calibrated operation quantity.

2. The operation support system for the rolling equipment according to claim 1, wherein, The operation quantity correction unit is configured to correct the operation quantity within a range that does not exceed the limit value set for the control value.

3. The operation support system for the rolling equipment according to claim 1, wherein, The degradation evaluation unit is configured to evaluate the degradation state based on the amount of reduction in the time series actual data from the baseline actual data, when using the actual data of the undegraded rolling equipment as the baseline actual data.

4. The operation support system for the rolling mill according to any one of claims 1 to 3, wherein, The operation support system of the rolling equipment also includes a correction operation quantity evaluation unit for evaluating the corrected operation quantity. The correction operation quantity display unit is configured to display the evaluation result in association with the corrected operation quantity.

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