Bar direct rolling full-multiple-length closed-loop control method and closed-loop control system
By collecting and calculating data from the bar direct rolling production line in real time, the production line is automatically adjusted to achieve closed-loop control of the entire process, which solves the problem of sorting non-standard length bars in full-length production and improves yield and production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-26
- Publication Date
- 2026-04-10
AI Technical Summary
In existing bar direct rolling technology, it is difficult to achieve closed-loop adjustment of the entire process in full-length production, which makes it difficult to sort non-standard length bars, which is time-consuming and labor-intensive, and results in low yield and high scrap steel loss.
A closed-loop control method for full-length bar direct rolling is adopted. By collecting comprehensive direct rolling data in real time, calculating scrap data, and generating feedback control data, the bar direct rolling production line is automatically adjusted, including length correction and billet correction, to achieve closed-loop control of the entire process.
It achieves closed-loop adjustment throughout the entire process, improves yield, reduces scrap steel loss, increases production efficiency, and reduces the risk of personnel injury.
Smart Images
Figure CN121820356A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of bar direct rolling technology, specifically to a closed-loop control method and control system for full-length bar direct rolling. Background Technology
[0002] Direct bar rolling technology, also known as bar direct rolling technology, is an advanced short-process steel production technology. It eliminates the traditional "slab cooling-reheating-rolling" process, directly feeding the continuously cast, high-temperature slab into a rolling mill while maintaining its heat energy. Direct bar rolling technology has a simpler process flow and can significantly reduce energy consumption, thereby improving economic efficiency.
[0003] Multiple-length rolling, also known as full-length rolling or full-length production, is an optimized process that involves shearing the rolled stock during the finishing stage of bar or wire rolling. Its core objective is to maximize the production of finished products that meet multiple-length requirements. Then, offline shearing is performed in the subsequent finishing area to meet the required standard length, thereby minimizing end-cutting and non-standard-length waste during production and improving economic efficiency.
[0004] However, achieving full-length bar direct rolling still presents challenges. The main difficulty lies in the production process itself, where non-standard length bars are frequently generated due to factors such as billet length deviation, cross-sectional deviation, and cutting accuracy. These non-standard length bars are difficult to sort out smoothly in subsequent processes. Current technology primarily relies on manual selection to remove these non-standard length bars, followed by continuous optimization and adjustment of the rolling production line based on their specific characteristics – a time-consuming and labor-intensive process. Summary of the Invention
[0005] To address the shortcomings of existing technologies, this invention provides a closed-loop control method and control system for full-length direct rolling of bars, which can realize closed-loop adjustment of the entire process of full-length direct rolling, improve yield, and reduce scrap steel loss.
[0006] To achieve the above objectives, the specific solution adopted by the present invention is as follows: a closed-loop control method for full-length direct rolling of bar stock, comprising: After the bar direct rolling production line starts production, real-time comprehensive direct rolling data is collected, including tailings data; After confirming the stable operation of the bar direct rolling production line based on the direct rolling data, the waste data is calculated based on the tailings data. Feedback control data is generated based on scrap data, which includes length correction data and billet correction data. The bar direct rolling production line is adjusted in real time based on length correction data and billet correction data.
[0007] As a further optimization of the above-mentioned full-length closed-loop control method for direct bar rolling: the comprehensive direct rolling data includes billet data, rolling data, finished product data, and tailings data, wherein the billet data is generated by the continuous casting equipment of the direct bar rolling production line, and the rolling data, finished product data, and tailings data are generated by the rolling equipment of the direct bar rolling production line. The billet data and rolling data are transmitted between the continuous casting equipment and the rolling equipment and inside the rolling equipment based on the thermal detection signals in the direct bar rolling production line.
[0008] As a further optimization of the above-mentioned closed-loop control method for full-length direct rolling of bar stock: when the billet data is transmitted to the rolling equipment, rolling standard data matching the billet data is retrieved from the pre-built standard data set. When calculating the scrap data based on the tailings data, the rolling standard data and tailings data are merged to calculate the scrap data.
[0009] As a further optimization of the above-mentioned closed-loop control method for full-length direct rolling of bar stock: the rolling standard data includes the standard length of the tail stock, the number of cuts, and the actual weight per meter; the tail stock data includes the actual length of the tail stock; and the method for calculating scrap data by integrating the rolling standard data and the tail stock data is as follows: ; ; in, For the length of the waste material, This refers to the actual length of the tailings. This is the standard length for the tailings. This refers to the weight of the waste material. For the number of segments, This is the actual weight in meters.
[0010] As a further optimization of the above-mentioned closed-loop control method for full-length direct rolling of bar stock, the calculation method for the length correction data is as follows: ; in, For length correction data, For cross-sectional area, For length, Adjustment factor for size units; The length correction data is used to adjust the infrared length setting equipment of the bar direct rolling production line.
[0011] As a further optimization of the above-mentioned closed-loop control method for full-length direct rolling of bar stock, the calculation method for the billet correction data is as follows: ; ; in, To correct the length of the steel billet, To set the length of the steel billet, This is the preset maximum correction size; The billet correction data is used to adjust the continuous casting equipment.
[0012] As a further optimization of the above-mentioned bar direct rolling full-length closed-loop control method: if the length correction data falls within the pre-set dead zone range, the infrared length setting equipment will not be adjusted when the bar direct rolling production line is adjusted in real time.
[0013] As a further optimization of the above-mentioned bar direct rolling full-length closed-loop control method: during the real-time adjustment of the bar direct rolling production line based on the fixed length correction data, multiple adjustments are made based on the preset adjustment step amount.
[0014] A closed-loop control system for direct bar rolling full-length bar production, used to implement the above-mentioned closed-loop control method for direct bar rolling full-length bar production, the system comprising: The full-length control module is connected to the bar direct rolling production line to acquire comprehensive direct rolling data, calculate scrap data based on tailings data, and generate feedback control data. The human-machine interaction module is communicatively connected to the full-length control module and is used to display the comprehensive data of direct rolling.
[0015] As a further optimization of the above-mentioned bar direct rolling full-length closed-loop control system: the system also includes a standard database module, which is used to store a standard data set, and the standard data set is used to merge with tailings data to calculate waste data.
[0016] Beneficial effects: This invention enables closed-loop adjustment of the entire process of full-length direct rolling, improves yield, and reduces scrap steel loss; this invention can calculate scrap data based on the actual situation of tailings, and then generate fixed-length correction data and billet correction data for correcting the bar direct rolling production line, without manual intervention, which can significantly improve production efficiency and reduce the risk of personnel injury. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the data transfer process for direct rolling mill. Detailed Implementation
[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0019] like Figure 1 As shown, a closed-loop control method for full-length direct rolling of bar stock includes S1 to S4.
[0020] S1. After the bar direct rolling production line starts production, real-time comprehensive direct rolling data is collected, including tailings data. More specifically, the comprehensive direct rolling data includes billet data, rolling data, finished product data, and tailings data. The billet data is generated by the continuous casting equipment of the bar direct rolling production line, while the rolling, finished product, and tailings data are generated by the rolling equipment of the bar direct rolling production line. The billet data and rolling data are transmitted between the continuous casting equipment and the rolling equipment, as well as within the rolling equipment, based on the heat detection signals in the bar direct rolling production line.
[0021] In the comprehensive data of direct rolling, the billet data mainly includes billet length, flow number information and specifications, the rolling data includes multiple length setting value, and the finished product data includes finished product length and finished product model, which are all conventional parameters in this field and will not be described in detail here.
[0022] Furthermore, taking a conventional rolling mill with a three-part structure comprising a roughing mill, a finishing mill, and a flying shear section as an example, data transmission is achieved using pre-mill thermal inspection signals in the roughing mill, pre-flying shear thermal inspection signals in the finishing mill, and post-flying shear thermal inspection signals in the flying shear section. The forms and generation methods of each thermal inspection signal are conventional techniques in this field and will not be elaborated upon here.
[0023] S2. After confirming the stable operation of the bar direct rolling production line based on direct rolling data, calculate scrap data based on tailings data. Specifically, after the bar direct rolling production line starts production, manual sampling can be conducted for an initial period to determine the degree of deviation between the samples and the standard. If the same deviation and similar degree of deviation occur repeatedly, the bar direct rolling production line has stabilized, and scrap data can be calculated based on tailings data, i.e., closed-loop optimization can begin. On the other hand, during the initial period, the collected comprehensive direct rolling data is only displayed and not subsequently calculated or processed.
[0024] Furthermore, when the billet data is transmitted to the rolling equipment, rolling standard data that matches the billet data is retrieved from the pre-built standard data set. When calculating scrap data based on tailings data, the rolling standard data and tailings data are merged to calculate the scrap data.
[0025] Specifically, the rolling standard data includes the standard length of the tailings, the number of cuts, and the actual weight per meter. The tailings data includes the actual length of the tailings. The method for calculating the scrap data by integrating the rolling standard data and the tailings data is as follows: .
[0026] .
[0027] in, For the length of the waste material, This refers to the actual length of the tailings. This is the standard length for the tailings. This refers to the weight of the waste material. For the number of segments, This is the actual weight in meters.
[0028] In addition, rolling standard data may also include parameters such as the weight of a single billet, billet length, total length and number of billets, which are all commonly used data in the field of bar direct rolling. They can be determined according to the actual product processing requirements, and will not be elaborated here.
[0029] S3. Generate feedback control data based on scrap data. The feedback control data includes length correction data and billet correction data. The length correction data is used to adjust the infrared length correction equipment of the bar direct rolling production line, and the billet correction data is used to adjust the continuous casting equipment.
[0030] The calculation method for length correction data is as follows: ; in, For length correction data, For cross-sectional area, For length, Adjustment factor for size units.
[0031] In one embodiment of the present invention, the interface dimensions of the bar are 0.165m × 0.165m, and the total length is 7.7m. The value is 0.165 × 0.165. The value is 7.7.
[0032] The calculation method for billet correction data is as follows: ; ; in, To correct the length of the steel billet, To set the length of the steel billet, This is the preset maximum correction size.
[0033] S4. Real-time adjustment of the bar direct rolling production line based on length correction data and billet correction data.
[0034] Furthermore, if the length correction data falls within a pre-set dead zone, the infrared length correction device will not be adjusted during real-time adjustments to the bar rolling production line. By setting a dead zone range, processing errors can be tolerated within the dead zone, and the dead zone range is a positive range, meaning that a certain amount of scrap is allowed to ensure the accuracy of the bar products and avoid over-correction leading to substandard bar product length. In addition, absolute numerical constraints can be imposed on the length correction data, that is, the maximum value of the length correction data can be constrained within a certain range. For example, in one embodiment of the present invention, a single correction does not exceed ±50mm.
[0035] Based on this, during the real-time adjustment of the bar direct rolling production line based on the length correction data, multiple adjustments are made based on a preset adjustment step. Multiple adjustments prevent excessive adjustments in a single instance from causing substandard bars in subsequent production, thereby ensuring yield and reducing production costs. In one embodiment of the invention, the degree of a single adjustment is 35%-65% of the total, which can be adjusted according to actual needs, and will not be elaborated further here.
[0036] This invention enables closed-loop adjustment of the entire process of full-length direct rolling, improves yield, and reduces scrap steel loss. It can calculate scrap data based on the actual situation of tailings, and then generate fixed-length correction data and billet correction data for correcting the bar direct rolling production line. No manual intervention is required, which can significantly improve production efficiency and reduce the risk of personnel injury.
[0037] Taking one of the applicant's bar direct rolling production lines as an example, the production line has one set of continuous casting equipment and one set of direct rolling conveying equipment, and two sets of rolling equipment, forming two lines, A and B. After actual testing, the overall yield increased by 0.15%, and the total tangible benefits amounted to RMB 2,722,550 per year.
[0038] The present invention further provides a full-length closed-loop control system for direct bar rolling, used to implement the above-mentioned full-length closed-loop control method for direct bar rolling. The system includes a full-length control module, a human-machine interaction module, and a standard database module.
[0039] The full-length control module communicates with the bar direct rolling production line to acquire comprehensive direct rolling data, calculate scrap data based on tailings data, and generate feedback control data.
[0040] The human-machine interface module communicates with the full-length control module and is used to display comprehensive data of direct rolling.
[0041] The standard database module stores a standard data set, which is then integrated with tailings data to calculate waste data.
[0042] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems and devices described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. In the several embodiments provided in this disclosure, it should be understood that the disclosed systems, devices, and methods can be implemented in other ways. The device embodiments described above are merely illustrative. For example, the division of modules is only a logical functional division; in actual implementation, there may be other division methods. Furthermore, multiple modules or components may be combined or integrated into another system, or some features may be ignored or not executed. Another point is that the displayed or discussed mutual coupling or direct coupling or communication connection may be through some communication interfaces; the indirect coupling or communication connection of devices or modules may be electrical, mechanical, or other forms.
[0043] For example, in one embodiment of the present invention, the full-length control module uses an industrial controller, model S71500, manufactured by Siemens as its core. It communicates with other equipment on the bar rolling production line via an industrial Ethernet network based on the Siemens S7 protocol, achieving stable data interaction and seamless data flow throughout the entire process. The human-machine interface module may include a display unit and a data input unit. The display unit, centered on a screen, displays comprehensive rolling data, while the data input unit primarily uses conventional components such as a keyboard, mouse, and touchpad for manual intervention in system control.
[0044] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A closed-loop control method for full-length direct rolling of bar stock, characterized in that, include: After the bar direct rolling production line starts production, real-time comprehensive direct rolling data is collected, including tailings data; After confirming the stable operation of the bar direct rolling production line based on the direct rolling data, the waste data is calculated based on the tailings data. Feedback control data is generated based on scrap data, which includes length correction data and billet correction data. The bar direct rolling production line is adjusted in real time based on length correction data and billet correction data.
2. The closed-loop control method for full-length direct rolling of bar stock as described in claim 1, characterized in that, The comprehensive data of direct rolling includes billet data, rolling data, finished product data, and tailings data. The billet data is generated by the continuous casting equipment of the bar direct rolling production line, while the rolling data, finished product data, and tailings data are generated by the rolling equipment of the bar direct rolling production line. The billet data and rolling data are transmitted between the continuous casting equipment and the rolling equipment, as well as within the rolling equipment, based on the heat detection signals in the bar direct rolling production line.
3. The closed-loop control method for full-length direct rolling of bar stock as described in claim 2, characterized in that, When the billet data is transmitted to the rolling equipment, rolling standard data matching the billet data is retrieved from a pre-built standard data set. When calculating the scrap data based on the tailings data, the rolling standard data and tailings data are merged to calculate the scrap data.
4. The closed-loop control method for full-length direct rolling of bar stock as described in claim 3, characterized in that, The rolling standard data includes the standard length of the tail material, the number of cuts, and the actual weight per meter. The tail material data includes the actual length of the tail material. The method for calculating the scrap data by integrating the rolling standard data and the tail material data is as follows: ； ； in, For the length of the waste material, This refers to the actual length of the tail material. This is the standard length for the tailings. This refers to the weight of the waste material. For the number of segments, This is the actual weight in meters.
5. The closed-loop control method for full-length direct rolling of bar stock as described in claim 4, characterized in that, The method for calculating the length correction data is as follows: ； in, For length correction data, For cross-sectional area, For length, Adjustment factor for size units; The length correction data is used to adjust the infrared length setting equipment of the bar direct rolling production line.
6. The closed-loop control method for full-length direct rolling of bar stock as described in claim 5, characterized in that, The calculation method for the billet correction data is as follows: ； ； in, To correct the length of the steel billet, To set the length of the steel billet, This is the preset maximum correction size; The billet correction data is used to adjust the continuous casting equipment.
7. The closed-loop control method for full-length direct rolling of bar stock as described in claim 6, characterized in that, If the length correction data falls within the pre-set dead zone range, the infrared length correction equipment will not be adjusted when the bar direct rolling production line is adjusted in real time.
8. The closed-loop control method for full-length direct rolling of bar stock as described in claim 1, characterized in that, During the real-time adjustment of the bar direct rolling production line based on the aforementioned length correction data, multiple adjustments are made based on a preset adjustment step.
9. A closed-loop control system for direct rolling of bar stock in full length, characterized in that, For implementing the closed-loop control method for full-length direct rolling of bar stock as described in any one of claims 1-8, the system comprises: The full-length control module is connected to the bar direct rolling production line to acquire comprehensive direct rolling data, calculate scrap data based on tailings data, and generate feedback control data. The human-machine interaction module is communicatively connected to the full-length control module and is used to display the comprehensive data of direct rolling.
10. A closed-loop control system for direct rolling of bar stock with full length as described in claim 1, characterized in that, The system also includes a standard database module, which stores a standard data set and integrates it with tailings data to calculate waste data.