A method for intelligent optimization of a high-line post-zone process tracking control system
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-25
- Publication Date
- 2026-08-11
Smart Images
Figure CN122546916A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of steel production technology, and in particular to a method for intelligent optimization of a process tracking and control system in the downstream zone of a high-speed wire rod mill. Background Technology
[0002] In hot rolling production lines in the steel industry, the PF chain conveyor system in the high-speed wire rod rear zone plays a crucial role in transporting the rolled wire rod to subsequent cooling and coiling processes. Its operational stability directly impacts the overall production line's efficiency, equipment safety, and product quality. Currently, most steel companies employ monitoring systems built around configuration software such as Siemens WinCC to track and control the PF chain process.
[0003] Existing PF chain monitoring systems typically employ the following technical solutions: First, based on the traditional WinCC basic configuration with a single monitor, all monitoring screens, parameters, and alarm information are displayed on a single screen; second, a simple multi-screen extension is implemented on this basis, distributing different screens across multiple monitors, but lacking a unified design and linkage logic; third, a general SCADA (Supervisory Control and Data Acquisition) platform interface is used, whose templated design fails to fully consider the special monitoring needs of PF chain devices, which have long layouts, many workstations, and strong status correlations.
[0004] Due to the large physical length of the PF chain and the numerous monitoring points, in order to display the panoramic view on a limited single screen or simply divided multiple screens, it is often necessary to scale the entire screen proportionally. This results in severe compression of key information such as device symbols, status characters, and parameter values, leading to the common problem of "incomplete screen display and illegible character labels." Operators need to frequently zoom, drag, and switch screens to view details, which greatly distracts them, reduces monitoring efficiency, and can easily delay judgment, especially in emergency situations.
[0005] The display parameters of existing systems (such as brightness, contrast, and font size) are usually statically set and cannot be automatically adjusted according to changing ambient lighting conditions in the control room (such as strong daylight and weak nightlight). This results in severe screen glare or dim display under certain lighting conditions, exacerbating the difficulty of visual recognition. At the same time, the system's human-computer interaction is rigid and cannot provide operators with personalized view configurations or task-based intelligent information guidance.
[0006] When anomalies such as "PF chain signal failure," "chain jamming," or "hook derailment" occur, existing systems typically only provide simple alarm prompts. Operators or maintenance engineers must rely on their personal experience to manually locate the fault point from a complex alarm list and static screens, and consult separate paper or electronic maintenance manuals to analyze the cause and find solutions. This process is time-consuming and labor-intensive, with a long average troubleshooting time, leading to unplanned production line downtime and potentially causing hundreds of thousands of yuan in economic losses annually. Summary of the Invention
[0007] In order to overcome the above-mentioned shortcomings of the prior art, the purpose of this invention is to provide a method for intelligent optimization of the high-speed wire rod post-process tracking control system, so as to solve the problems mentioned in the background art.
[0008] The technical solution adopted by this invention to solve its technical problem is: a method for intelligent optimization of the high-speed wire rod post-process tracking and control system, comprising the following steps:
[0009] Construct a multi-area associated display system for monitoring information, allocate the operating status information of the PF chain and device parameters to different display areas for associated display, and adopt a display layout strategy that scales differently from the global display.
[0010] Implement adaptive optimization of the display interface. Based on the acquired environmental information and the real-time running status information of the PF chain, automatically adjust the display attributes of the visual elements in the display area to optimize the overall recognizability of the interface.
[0011] A visual interface reflecting the PF chain layout and device status is constructed using graphical elements associated with device semantic information and data interface information.
[0012] Establish an alarm response mechanism so that when an alarm is triggered, the alarm information is associated with the corresponding graphical elements of the device in the visual interface.
[0013] The system performs embedded real-time fault diagnosis, continuously acquires the operating parameters of the PF chain, performs fault analysis based on the operating parameters through the diagnostic logic integrated into the system, and provides the diagnostic results on the visual interface.
[0014] As a further improvement of the present invention: the multi-regional associated display system for constructing monitoring information includes:
[0015] Configure at least one main display for panoramic display of the PF chain's operating status, and at least one auxiliary display for displaying detailed equipment parameters or alarm information; based on operator interaction hotspots or preset regional importance weights, determine the importance level of each area in the monitoring screen, and use different scaling ratios for non-uniform scaling of areas of different importance to display key areas with high definition, while maintaining the continuity of the overall layout of the PF chain.
[0016] As a further improvement of the present invention: the adaptive optimization of the display interface includes:
[0017] Ambient light data is collected in real time by ambient light sensors deployed in the monitoring area; based on the ambient light data and the real-time operating status of the PF chain, the preset display parameter scheme is automatically matched and invoked to dynamically adjust the overall brightness, contrast, color scheme and the size of key information characters of the monitoring screen to optimize visual recognition.
[0018] As a further improvement of the present invention: the construction of a visual interface reflecting the PF chain layout and device status includes:
[0019] A vector graphic element library containing various standardized equipment symbols is created. Each graphic element embeds metadata describing its equipment type, technical parameters, and associated PLC variable address. When configuring the monitoring screen, the system calls and combines the graphic elements to build a visualization interface. The system automatically binds the graphic elements to the real-time data source based on the metadata.
[0020] As a further improvement of the present invention: the establishment of the alarm response mechanism includes:
[0021] The system is equipped with a multi-level alarm mechanism that includes at least early warning, alarm, and emergency alarm. When an alarm is triggered, the system displays an alarm list in a fixed information bar on the screen, and simultaneously displays a dynamic alarm icon overlaid on the main screen of the multi-screen collaborative display system at the physical device graphic position corresponding to the alarm point, thereby achieving spatial positioning of the alarm information.
[0022] As a further improvement of the present invention: the embedded real-time fault diagnosis includes:
[0023] The system collects one or more key operating parameters from the PF chain drive motor, including current, speed, and position deviation, in real time. These operating parameters are then input into a built-in fault diagnosis engine, which integrates a rule-based reasoning module based on preset thresholds and / or a time-series anomaly detection model trained on historical data. When a fault or anomaly pattern is identified, the system automatically locates and highlights the fault point on the monitoring screen and outputs diagnostic information and processing suggestions.
[0024] As a further improvement of the present invention: the non-uniform scaling display specifically means: for key areas with high importance, a 1:1 pixel display or a low compression ratio display is used; for secondary areas with low importance, a linear compression display is used; and in the transition area between the key area and the secondary area, a curve smoothing algorithm is used to process the transition to achieve a natural transition of image deformation.
[0025] As a further improvement of the present invention: the scheme for automatically matching display parameters based on ambient light data includes: when the ambient light intensity is higher than a first threshold, a high-contrast, bold font strong light display scheme is enabled; when the ambient light intensity is lower than a second threshold, a low-brightness, dark background weak light or night display scheme is enabled; wherein, the first threshold is greater than the second threshold.
[0026] As a further improvement of the present invention: the multi-level alarm mechanism adopts a differentiated display strategy for different levels of alarms: for the warning level, a static or slowly moving icon is displayed next to the relevant parameters; for the alarm level, an alarm confirmation window automatically pops up with a flashing prompt; for the emergency alarm level, a prominent color block covering part or all of the main screen is triggered and the sound and light alarm is activated.
[0027] As a further improvement of the present invention: the fault diagnosis engine adopts a hybrid architecture that combines rule-based reasoning and machine learning models; the rule-based reasoning module is used to process parameter over-limit events that reach a clear threshold; the time-series anomaly detection model is used to analyze subtle parameter change patterns with complex time-series correlations that are not captured by rules; the system performs confidence weighting or logical synthesis on the diagnostic results of the two to form a final diagnostic conclusion.
[0028] Compared with the prior art, the beneficial effects of the present invention are:
[0029] This invention effectively solves the problem of the inability to simultaneously capture the panorama and details caused by traditional single-screen proportional scaling through multi-region display and non-uniform scaling strategies, ensuring that the status of critical equipment is always clearly visible. An adaptive optimization mechanism dynamically adjusts display attributes based on ambient lighting and equipment operating status, guaranteeing optimal recognizability under various operating conditions. An integrated semantic graphics component library enables rapid construction of monitoring screens and automatic data binding, improving system configuration and maintenance efficiency. The deep integration of alarm spatial positioning mechanisms and embedded intelligent diagnostic functions associates alarm information with physical device graphics and combines rules and machine learning models for fault analysis, achieving proactive early warning, rapid location, and intelligent diagnosis. This invention reduces the workload of personnel and improves fault handling speed and system preventative maintenance capabilities. Attached Figure Description
[0030] Figure 1 This is a schematic diagram of the method flow of the present invention.
[0031] Figure 2 This is a schematic diagram illustrating the implementation process of an embodiment of the present invention. Detailed Implementation
[0032] In order to clearly and completely understand the technical solution, the present invention will be further described in conjunction with the embodiments and accompanying drawings. Obviously, the described embodiments are only some 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.
[0033] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.
[0034] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.
[0035] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.
[0036] Embodiments of the present invention provide a method for intelligent optimization of a high-speed wire rod post-process tracking and control system, comprising the following steps:
[0037] Construct a multi-area associated display system for monitoring information, allocate the operating status information of the PF chain and device parameters to different display areas for associated display, and adopt a display layout strategy that scales differently from the global display.
[0038] Implement adaptive optimization of the display interface. Based on the acquired environmental information and the real-time running status information of the PF chain, automatically adjust the display attributes of the visual elements in the display area to optimize the overall recognizability of the interface.
[0039] A visual interface reflecting the PF chain layout and device status is constructed using graphical elements associated with device semantic information and data interface information.
[0040] Establish an alarm response mechanism so that when an alarm is triggered, the alarm information is associated with the corresponding graphical elements of the device in the visual interface.
[0041] The system performs embedded real-time fault diagnosis, continuously acquires the operating parameters of the PF chain, performs fault analysis based on the operating parameters through the diagnostic logic integrated into the system, and provides the diagnostic results on the visual interface.
[0042] This invention effectively solves the problem of the inability to simultaneously capture the panorama and details caused by traditional single-screen proportional scaling through multi-region display and non-uniform scaling strategies, ensuring that the status of critical equipment is always clearly visible. An adaptive optimization mechanism dynamically adjusts display attributes based on ambient lighting and equipment operating status, guaranteeing optimal recognizability under various operating conditions. An integrated semantic graphics component library enables rapid construction of monitoring screens and automatic data binding, improving system configuration and maintenance efficiency. The deep integration of alarm spatial positioning mechanisms and embedded intelligent diagnostic functions associates alarm information with physical device graphics and combines rules and machine learning models for fault analysis, achieving proactive early warning, rapid location, and intelligent diagnosis. This invention reduces the workload of personnel and improves fault handling speed and system preventative maintenance capabilities.
[0043] In one embodiment of the present invention, the multi-area associated display system for constructing monitoring information includes: configuring at least one main display for panoramic display of the PF chain's operating status, and at least one auxiliary display for displaying detailed device parameter tables or alarm information; determining the importance level of each area in the monitoring screen based on operator interaction hotspots or preset area importance weights, and using different scaling ratios for non-uniform scaling display of areas of different importance, so that key areas are displayed in high definition while maintaining the continuity of the overall layout of the PF chain.
[0044] Traditional single-monitor displays using global proportional scaling suffer from blurred details when viewing the entire panorama, and loss of overall layout when focusing on details. This solution addresses this by separating the functions of primary and secondary displays, decoupling the panoramic view from detailed parameters / alarms, and employing non-proportional scaling technology. This allows for both the continuity of the macroscopic layout and high-definition display of key microscopic areas within a single screen. Operators can grasp the overall operational status and key equipment status from a single viewpoint without frequent zooming and screen switching, significantly reducing visual search and cognitive load. Based on operator interaction hotspots or preset importance weights, the system automatically or semi-automatically focuses on the most relevant areas. This attention-oriented display optimization ensures that the most important information is always presented in the most readable way, precisely allocating valuable screen pixels to the most critical information, clearly mapping the layout of the power factor (PF) chain onto the screen, and maintaining the stability of the positional relationships of graphic elements.
[0045] In one embodiment of the present invention, the adaptive optimization of the display interface includes: real-time acquisition of ambient light data by an ambient light sensor deployed in the monitoring area; and automatic matching and invocation of a preset display parameter scheme based on the ambient light data and the real-time operating status of the PF chain, dynamically adjusting the overall brightness, contrast, color scheme, and size of key information characters of the monitoring screen to optimize visual recognition. By sensing ambient light in real time and dynamically invoking the preset display scheme accordingly, the monitoring screen can be automatically adjusted, eliminating problems such as screen glare and poor visibility due to ambient light interference, or glare at night. Simultaneously adjusting the color scheme in conjunction with the real-time operating status of the PF chain improves the efficiency and priority of conveying key status information, and enhances comfort and efficiency through personalized presets.
[0046] In one embodiment of the present invention, the construction of a visualization interface reflecting the PF chain layout and device status includes: creating a vector graphic element library containing various standardized device symbols, each graphic element embedding metadata describing its device type, technical parameters and associated PLC variable address; when configuring the monitoring screen, the visualization interface is constructed by calling and combining the graphic elements, and the system automatically binds the graphic elements to the real-time data source according to the metadata.
[0047] By creating a standardized vector graphics component library, the visual symbols and data interface definitions of similar devices are unified, eliminating inconsistencies in screen style caused by different personal drawing habits. During configuration, engineers no longer need to draw from scratch or repeatedly configure data connections; they can quickly build professional and standardized monitoring screens simply by calling and combining elements. The system can automatically bind to real-time data sources based on the metadata embedded in the graphic components, transforming the previously tedious and error-prone manual variable linking work into a reliable, automated process in the background. This significantly shortens the development, modification, and maintenance cycle of the monitoring system and substantially reduces labor costs.
[0048] In one embodiment of the present invention, the establishment of the alarm response mechanism includes: setting a multi-level alarm mechanism that includes at least early warning, alarm, and emergency alarm; when an alarm is triggered, the system displays an alarm list in a fixed information bar on the screen, and simultaneously displays a dynamic alarm icon overlaid at the physical device graphic position corresponding to the alarm point in the main screen of the multi-screen collaborative display system, thereby realizing the spatial positioning of the alarm information.
[0049] In one embodiment of the present invention, the process of performing embedded real-time fault diagnosis includes:
[0050] The system collects one or more key operating parameters from the PF chain drive motor, including current, speed, and position deviation, in real time. These operating parameters are then input into a built-in fault diagnosis engine, which integrates a rule-based reasoning module based on preset thresholds and / or a time-series anomaly detection model trained on historical data. When a fault or anomaly pattern is identified, the system automatically locates and highlights the fault point on the monitoring screen and outputs diagnostic information and processing suggestions.
[0051] In one embodiment of the present invention, the non-uniform scaling display specifically involves: for key areas with high importance, a 1:1 pixel display or a low compression ratio display is used; for secondary areas with low importance, a linear compression display is used; and in the transition area between the key area and the secondary area, a curve smoothing algorithm is used to process the transition, so as to achieve a natural transition of image deformation.
[0052] In one embodiment of the present invention, the automatic matching display parameter scheme based on ambient light data includes: when the ambient light intensity is higher than a first threshold, a high-contrast, bold font strong light display scheme is enabled; when the ambient light intensity is lower than a second threshold, a low-brightness, dark background weak light or night display scheme is enabled; wherein, the first threshold is greater than the second threshold.
[0053] In one embodiment of the present invention, the multi-level alarm mechanism adopts a differentiated display strategy for different alarm levels: for the warning level, a static or slowly moving icon is displayed next to the relevant parameters; for the alarm level, an alarm confirmation window automatically pops up with a flashing prompt; for the emergency alarm level, a prominent color block covering part or all of the main screen is triggered and the sound and light alarm is activated.
[0054] In one embodiment of the present invention, the fault diagnosis engine adopts a hybrid architecture combining rule-based reasoning and machine learning models; the rule-based reasoning module is used to process parameter over-limit events that reach a clear threshold; the temporal anomaly detection model is used to analyze subtle parameter change patterns with complex temporal correlations that are not captured by rules; the system performs confidence weighting or logical synthesis on the diagnostic results of the two to form a final diagnostic conclusion.
[0055] In one embodiment, the present invention provides a method for intelligent optimization of a high-speed wire rod post-process tracking control system. This method for intelligent optimization of the high-speed wire rod PF chain WinCC monitoring system requires the following steps:
[0056] Step 1: Design of a Multi-Screen Collaborative Display System
[0057] This embodiment designs a multi-screen collaborative display system for PF chain monitoring. The system employs a layout combining a 55-inch 4K main display (for panoramic display of the PF chain's operating status) and two 27-inch auxiliary displays (displaying detailed equipment parameters and alarm information, respectively). The main display uses non-uniform scaling technology to magnify key areas (such as hook positions and transmission parts) while maintaining overall layout continuity. The auxiliary displays support touch interaction, allowing for real-time curve and historical data comparison of specified devices at any time. The system utilizes a dedicated layout management module developed using the WinCC Open Development Kit (ODK) to achieve synchronous control and content linkage across the multiple screens.
[0058] The non-uniform scaling technology employs an attention-based image deformation algorithm. By analyzing the operator's gaze distribution (statistics from eye trackers or mouse hotspots), it automatically determines the importance weight of each region in the PF chain image. Important regions are displayed at a 1:1 pixel ratio, secondary regions are linearly compressed, and transition regions are smoothed using Bezier curves. This technology ensures that within a limited screen space, the full length of the PF chain can be displayed while clearly showing key details such as various character labels, thus solving the display incompleteness problem caused by traditional uniform scaling.
[0059] Step 2, Adaptive Interface Optimization Engine
[0060] This module features an environment-aware adaptive interface optimization engine. The system monitors the control room's lighting conditions in real time using an ambient light sensor, automatically adjusting screen brightness, contrast, and color temperature. Different color schemes are used for different operating states of the Power Factor (PF) chain (normal, warning, fault): cool tones are used primarily in the normal state, amber indicators are added in the warning state, and a high-contrast red and black display is used in the fault state. Font size is dynamically adjusted based on the importance of the displayed content; key parameters are displayed in large fonts of 24pt or larger, while auxiliary information uses standard fonts of 12-16pt. The engine includes multiple preset visual themes that can be switched with a single click to suit the visual preferences of different operators.
[0061] The ambient light sensor uses AMS's TSL2561 high-precision digital light sensor, with a measurement range of 0.1-40000 lux and an accuracy of ±0.1 lux. It connects to the industrial computer via an I2C interface. The sensor is installed at a suitable position above the display and collects ambient light data every 5 seconds. The system automatically applies the most suitable display scheme based on the light data: enhanced contrast and bolded fonts in strong light environments; reduced brightness and dark backgrounds in low light environments; and a red protective color scheme for night mode. This solution completely solves the problem of illegible character labels and provides a comfortable visual experience under various lighting conditions.
[0062] Step 3, PF chain dedicated graphics component library
[0063] This invention constructs a dedicated graphical library for Power Processing (PF) chains containing over 200 standardized graphic components. All components are drawn in vector format, supporting lossless scaling and dynamic coloring. Components are categorized by function into basic equipment (e.g., motors, reducers, hooks), status indicators (e.g., running, stopped, fault), and parameter displays (e.g., speed, load, temperature). Each component is associated with semantic tags and metadata, supporting intelligent retrieval and combined applications. The system provides a graphical configuration tool, allowing users to quickly build monitoring screens via drag-and-drop, automatically maintaining a consistent style. Specially designed animation effects visually display the PF chain's motion status and fault location.
[0064] The vector-format graphic elements are implemented using the SVG (Scalable Vector Graphics) standard, with each element consisting of XML elements such as path, group, and style. The innovation lies in adding industrial semantic annotations to each graphic element, storing meta-information such as device type, rated parameters, and associated variables through a custom namespace. For example, a motor graphic not only contains visual elements but also embeds technical parameters such as power and speed, along with corresponding PLC variable addresses. When the screen loads, the system automatically binds real-time data, achieving a WYSIWYG monitoring effect and significantly improving fault analysis efficiency.
[0065] Step 4, Intelligent Alarm Management Module
[0066] This module implements intelligent alarm management for the PF chain monitoring system. The system categorizes alarms into three levels: Level 1 is a warning (e.g., high bearing temperature), Level 2 is an alarm (e.g., speed deviation exceeding limits), and Level 3 is an emergency alarm (e.g., hook derailment). Different alarm levels employ differentiated display strategies: a warning status displays an amber icon next to the parameter; an alarm status automatically pops up an alarm bar and flashes; and an emergency alarm is displayed with a full-screen red overlay and triggers an audible and visual alarm. Alarm information is displayed in sorted order according to the physical location of the PF chain, supporting filtering by time, type, location, and other dimensions. The system also provides an alarm suppression function, which can temporarily block known non-critical alarms.
[0067] The alarm display strategy employs a multi-dimensional management approach combining spatial partitioning and time-series analysis. A fixed 20% width on the right side of the screen serves as the alarm information bar, displaying all active alarms in reverse chronological order. Simultaneously, dynamic markers (such as rotating warning icons) are displayed at the alarm location on the main screen. For critical alarms such as PF chain signal failures, the system automatically zooms in on the relevant area and overlays fault handling instructions. Alarm data is integrated with the factory's MES system via the OPC UA protocol, forming a complete alarm event chain and providing data support for subsequent analysis.
[0068] Step 5, Embedded Fault Diagnosis System
[0069] This invention presents a dedicated fault diagnosis system for power PF chains, embedded within the WinCC platform. The system monitors key parameters such as motor current, speed feedback, and position deviation in real time, identifying abnormal patterns through a rule engine and machine learning model. When a potential fault is detected, the system automatically locates the fault point and highlights it on the screen, while simultaneously providing possible causes and handling suggestions. The diagnostic knowledge base contains over 30 common fault cases, including dangerous situations such as power PF chain collisions. The system supports fault simulation, reproducing historical fault scenarios for training and analysis. All diagnostic results generate structured reports for easy follow-up and improvement.
[0070] The rule engine, implemented using the Rete algorithm, contains over 200 PF chain fault diagnosis rules. For example: IF Motor current > 120% of rated value for 5 seconds AND Speed < 80% of set value THEN Indicates an 85% probability of mechanical jamming. The system innovatively combines the rule engine with an LSTM anomaly detection model; the former handles explicit threshold violations, while the latter captures subtle pattern anomalies. Diagnostic results are displayed with color coding to indicate credibility and are linked to processing solutions in the knowledge base, improving fault handling efficiency.
[0071] Step Six: Operation Assistance and Automation Functions
[0072] To address the manual operation requirements of PF chains, this invention has developed a series of auxiliary functions. The system provides standardized operation wizards to guide operators through routine maintenance tasks such as hook reset and chain tensioning. For "manual hook pushing" scenarios, the system can automatically calculate the optimal pushing path and force, providing real-time guidance through an AR interface. Common operations support one-click execution, while complex operations are broken down into step-by-step processes, each with error-proofing verification. The system records all operation logs, supporting playback analysis to optimize operating procedures and improve operator skills.
[0073] The AR operation guidance system consists of a Microsoft HoloLens 2 headset and backend services. When an operator approaches the PF chain, the system uses UWB positioning technology to identify the current location and overlays virtual guide arrows, operation hotspots, and safety warnings onto the real device. For example, when dealing with a derailed hook, the AR interface will gradually display animations of loosening bolts, adjusting the position, and re-tightening. The system integrates voice recognition, supporting hands-free operation queries. This technology improves the efficiency of manual hook pushing operations by more than 40%, while significantly reducing operational risks.
[0074] Step 7: Data Visualization and Analysis Tools
[0075] This invention provides a comprehensive set of visualization tools for power PF (Power Factor) chain operation data. The system supports trend charts at multiple time scales, from real-time curves down to statistical trends spanning several months. Key parameters such as motor current and speed can be compared and analyzed side-by-side, with support for dynamic time axis zooming and annotation. Heat maps display the temperature distribution along the entire power PF chain, and bubble charts show the vibration intensity at each transmission point. All charts support interactive exploration; clicking on a data point allows viewing a snapshot of the operating conditions at that time. Analysis results can be exported as standardized reports for equipment health assessments and maintenance decisions.
[0076] The heatmap visualization is implemented using WebGL technology, mapping the entire length of the PF chain to the X-axis and the temperature values to the Y-axis. Temperature intensity is represented by a color gradient (blue-green-yellow-red). The innovation lies in introducing a time dimension; a slider control allows playback of the thermal changes over the past 24 hours, providing a clear view of abnormal patterns such as bearing overheating. The heatmap is linked to an alarm system; when the temperature in a certain area exceeds a threshold, it is automatically flagged and a diagnostic report is generated, helping to prevent problems such as PF chain signal failures.
[0077] Step 8: System Configuration and Management Platform
[0078] To simplify WinCC system maintenance, this invention develops a centralized configuration management platform. The platform provides a graphical variable management interface, supporting batch import / export and template application. Screen layout, alarm settings, user permissions, and other aspects can be managed uniformly through the configuration tool, avoiding the risks of manually modifying scripts. The system version management function records all configuration changes and supports quick rollback to any historical version. A remote diagnostic interface allows engineers to analyze problems online, reducing the need for on-site service. The platform also provides a system health monitoring panel, displaying the real-time running status and resource usage of WinCC.
[0079] The variable management interface uses a tree-structured table to display all PLC variables, supporting sorting and filtering by name, address, data type, and other columns. Its innovation lies in the bidirectional association between variables and graphic elements; clicking on a variable in the variable table locates all graphic elements using that variable, and vice versa. Variable import supports Excel templates, allowing the creation and initial value setting of hundreds of variables at once. This tool reduces the time required for optimizing WinCC parameters from several days to just a few hours.
[0080] In summary, after reading this invention document, those skilled in the art can make various other corresponding modifications to the technical solutions and concepts based on this invention without creative mental effort, and all of these modifications fall within the scope of protection of this invention.
Claims
1. A method for intelligent optimization of a high-speed wire rod reflow zone process tracking and control system, characterized in that, Includes the following steps: Construct a multi-area associated display system for monitoring information, allocate the operating status information of the PF chain and device parameters to different display areas for associated display, and adopt a display layout strategy that scales differently from the global display. Implement adaptive optimization of the display interface. Based on the acquired environmental information and the real-time running status information of the PF chain, automatically adjust the display attributes of the visual elements in the display area to optimize the overall recognizability of the interface. A visual interface reflecting the PF chain layout and device status is constructed using graphical elements associated with device semantic information and data interface information. Establish an alarm response mechanism so that when an alarm is triggered, the alarm information is associated with the corresponding graphical elements of the device in the visual interface. The system performs embedded real-time fault diagnosis, continuously acquires the operating parameters of the PF chain, performs fault analysis based on the operating parameters through the diagnostic logic integrated into the system, and provides the diagnostic results on the visual interface.
2. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 1, characterized in that, The multi-regional association display system for constructing monitoring information includes: Configure at least one main display for panoramic display of the PF chain's operating status, and at least one auxiliary display for displaying detailed equipment parameters or alarm information; based on operator interaction hotspots or preset regional importance weights, determine the importance level of each area in the monitoring screen, and use different scaling ratios for non-uniform scaling of areas of different importance to display key areas with high definition, while maintaining the continuity of the overall layout of the PF chain.
3. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 2, characterized in that, The adaptive optimization of the display interface includes: Ambient light data is collected in real time by ambient light sensors deployed in the monitoring area; based on the ambient light data and the real-time operating status of the PF chain, the preset display parameter scheme is automatically matched and invoked to dynamically adjust the overall brightness, contrast, color scheme and the size of key information characters of the monitoring screen to optimize visual recognition.
4. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 3, characterized in that, The construction of a visual interface reflecting the PF chain layout and device status includes: A vector graphic element library containing various standardized equipment symbols is created. Each graphic element embeds metadata describing its equipment type, technical parameters, and associated PLC variable address. When configuring the monitoring screen, the system calls and combines the graphic elements to build a visualization interface. The system automatically binds the graphic elements to the real-time data source based on the metadata.
5. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 4, characterized in that, The establishment of the alarm response mechanism includes: The system is equipped with a multi-level alarm mechanism that includes at least early warning, alarm, and emergency alarm. When an alarm is triggered, the system displays an alarm list in a fixed information bar on the screen, and simultaneously displays a dynamic alarm icon overlaid on the main screen of the multi-screen collaborative display system at the physical device graphic position corresponding to the alarm point, thereby achieving spatial positioning of the alarm information.
6. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 5, characterized in that, The embedded real-time fault diagnosis process includes: The system collects one or more key operating parameters from the PF chain drive motor, including current, speed, and position deviation, in real time. These operating parameters are then input into a built-in fault diagnosis engine, which integrates a rule-based reasoning module based on preset thresholds and / or a time-series anomaly detection model trained on historical data. When a fault or anomaly pattern is identified, the system automatically locates and highlights the fault point on the monitoring screen and outputs diagnostic information and processing suggestions.
7. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 2, characterized in that, The non-uniform scaling display specifically refers to the following: for key areas with high importance, a 1:1 pixel display or a low compression ratio display is used; for secondary areas with low importance, a linear compression display is used; and in the transition area between key and secondary areas, a curve smoothing algorithm is used to achieve a natural transition of image deformation.
8. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 3, characterized in that, The scheme for automatically matching display parameters based on ambient light data includes: when the ambient light intensity is higher than a first threshold, a high-contrast, bold font strong light display scheme is enabled; when the ambient light intensity is lower than a second threshold, a low-brightness, dark background weak light or night display scheme is enabled; wherein, the first threshold is greater than the second threshold.
9. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 5, characterized in that, The multi-level alarm mechanism adopts a differentiated display strategy for different alarm levels: for the warning level, a static or slowly moving icon is displayed next to the relevant parameters; for the alarm level, an alarm confirmation window automatically pops up with a flashing prompt. For emergency alarm levels, a prominent color block will be triggered to cover part or all of the main screen and activate the audible and visual alarm.
10. The method for intelligent optimization of the high-speed wire rod post-process tracking control system according to claim 6, characterized in that, The fault diagnosis engine adopts a hybrid architecture that combines rule-based reasoning with machine learning models; the rule-based reasoning module is used to handle parameter over-limit events that reach a clear threshold; the temporal anomaly detection model is used to analyze subtle parameter change patterns with complex temporal correlations that are not captured by rules; the system performs confidence weighting or logical synthesis on the diagnostic results of the two to form a final diagnostic conclusion.