A method for reducing sampling loss in a steel rolling system

Abstract

The application discloses a method for reducing sampling loss of a steel rolling system and relates to the technical field of steel production. The method adds a laser mid-section platform, an elevator and a robot monitoring system with sample finding and cleaning functions in an outlet sampling area. In specific implementation, after a sample plate is cut, the sample plate is grabbed by a robot to the mid-section platform, the sample plate is evenly divided and cut into a primary sample and a duplicate sample according to the coil width information issued by an L2 system and is labeled; the primary sample is sent into a primary sample hopper through the elevator, and the duplicate sample is stored into a duplicate sample hopper and the coordinates are recorded. After the primary sample is detected to be qualified and the duplicate sample is overdue, the robot automatically grabs the duplicate sample according to the recorded coordinates and cleans the sample. The application realizes one-to-two processing of a single sample plate, reduces the sampling loss and the number of sample plates by half compared with the traditional mode, effectively saves the time consumption of a production line, reduces the labor cost, and improves the yield.

Description

Technical Field

[0001] This invention relates to the field of steel rolling production technology, specifically a method for reducing sampling losses in a steel rolling system. Background Technology

[0002] In the steel manufacturing industry, steel coils, as an important industrial semi-finished product, directly affect the quality of final products in several key downstream industries such as automobile manufacturing, construction engineering, and home appliance production. To ensure that the various performance indicators of steel coils meet the usage requirements, the current quality control system generally adopts sampling and testing methods. This involves evaluating the quality of the entire coil of material by conducting mechanical property tests, chemical composition analysis, and microstructure observation on the samples.

[0003] Currently, most steel rolling production lines' export sampling systems typically require cutting two large samples from the beginning, end, or middle of the steel coil. One sample is sent for initial testing, while the other is retained as a "resample" for retesting if the initial sample fails. However, this traditional sampling method has the following significant shortcomings:

[0004] First, there is significant material waste. This destructive sampling method requires two complete, large-sized samples, resulting in substantial material waste. This waste is particularly pronounced for high-value-added steel grades, directly increasing production costs. As the steel industry transitions towards green and intelligent manufacturing, this material waste problem caused by sampling is becoming increasingly prominent.

[0005] Secondly, the process involves a high degree of human intervention and low automation efficiency. In traditional sampling processes, after the initial and duplicate samples are cut, manual handling, locating, and cleaning are often required. The duplicate samples lack intelligent location memory and management mechanisms while stored in the duplicate sample hopper. When the initial sample passes inspection and needs to be cleaned, or when the initial sample fails inspection and needs to be retrieved, manual intervention is essential for locating and handling. This not only increases labor costs and intensity but also lengthens the entire process time, hindering the improvement of overall production line efficiency.

[0006] Third, existing cost reduction solutions have limited effectiveness. Some technical solutions have attempted to address the sampling loss problem, such as adding virtual material numbers at the manufacturing system planning level and reducing the number of sampled slabs through software scheduling. However, these solutions are limited to software scheduling optimization and do not change the actual sampling equipment structure and physical operation process of the production line. They cannot fundamentally solve a series of pain points in physical operations, such as excessively large sample sizes and the need for manual intervention in sample recycling.

[0007] Therefore, developing a sampling method that can effectively reduce sampling losses, reduce human intervention, and improve the automation level of production lines from a physical process perspective is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0008] The purpose of this invention is to provide a method for reducing sampling losses in a steel rolling system, so as to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a method for reducing sampling losses in a steel rolling system, comprising the following steps:

[0010] S1: At the exit of the steel coil, a template is cut out by a shearing device;

[0011] S2: The sampling robot grabs the sample to the cutting platform and cuts the sample into two smaller pieces along the width direction according to the steel coil width information issued by the L2 system.

[0012] S3: The sampling robot affixes labels to the two small samples after cutting, and places one of the small samples as the initial sample on the lifting platform, which then transports it to the initial sample hopper; the other small sample is placed as the duplicate sample in the duplicate sample hopper for later use.

[0013] S4: When the duplicate sample is stored for more than the preset time and the initial sample is qualified, the sampling robot grabs the duplicate sample from the duplicate sample hopper and places it in the cleaning chute, so that it automatically slides down to the waste hopper to complete the cleaning.

[0014] Preferably, in step S1, after the sample is cut, it is conveyed by roller conveyor to the sampling robot's gripping position.

[0015] Preferably, in step S2, the mid-section platform is a laser cutting platform, and the average cutting is laser cutting.

[0016] Preferably, in step S3, the lifting platform is a lift, and the initial sample bucket is located on the ground floor below the lifting platform.

[0017] Preferably, the preset time is 3 days.

[0018] Preferably, in step S4, the sampling robot realizes the functions of finding duplicate samples and cleaning duplicate samples through the monitoring system; the function of finding duplicate samples includes: entering the roll number to be queried in the interface of the monitoring system, querying and selecting the target sample, and after starting the duplicate sample operation, the robot automatically searches for and takes out the target sample; the function of cleaning duplicate samples includes: selecting the duplicate sample bucket to be cleaned in the interface of the monitoring system, selecting all samples in the bucket, and after starting the cleaning operation, the robot sequentially places the samples in the duplicate sample bucket into the cleaning chute for disposal.

[0019] Preferably, this method is applied to sampling at the outlet of pickling units or cold rolling units.

[0020] Preferably, when the system malfunctions, it switches to a semi-automatic or manual control mode to perform sampling operations.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0022] 1. Reduce sampling losses and significantly improve yield. This invention optimizes the process by adding a splitting platform, reducing the need for cutting two large-sized templates to a single template that is then divided in two. This physical splitting method directly reduces the number of sampling blocks on the production line by half, significantly reducing material waste caused by destructive sampling.

[0023] 2. Reduced sampling time and improved unit production efficiency. Because this invention reduces the number of grabbing and handling operations by the sampling robot, the cycle time of the entire sampling process is optimized. In the traditional sampling mode, it takes approximately 8 seconds for the robot to handle one sample. However, this invention, by halving the number of samples, can save approximately 122 hours of production line operating time per year, effectively reducing unnecessary downtime and improving the overall throughput of the unit.

[0024] 3. Replacing manual intervention, reducing labor intensity and labor costs. This invention adds a sampling robot monitoring system with "position memory" function. Through the system's built-in "find duplicate sample" and "clean duplicate sample" logic, the robot can automatically locate the target duplicate sample in the duplicate sample bin according to the recorded coordinates, and automatically perform the cleaning of discarded duplicate samples after the initial sample inspection is qualified, completely replacing the manual operations of searching for, transporting, and disposing of waste materials in the traditional process. Based on a production line with 4 shifts and one less sample handling and cleaning personnel per shift, approximately 288,000 yuan in labor costs can be saved annually. At the same time, it greatly reduces the labor intensity of testing personnel, realizing unmanned and intelligent management of the production line sampling process.

[0025] 4. Ensure consistent testing origins and avoid quality disputes. This invention divides a single sample from the same physical location into two, ensuring a high degree of consistency between the initial sample and the duplicate sample in terms of chemical composition, metallographic structure, and mechanical properties. This effectively avoids quality disputes that may arise from differences in performance between the beginning and end of the steel coil when sampling twice, thus improving the accuracy of product quality traceability and re-inspection. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the template cutting structure;

[0027] Figure 2 for Figure 1 A three-dimensional perspective view;

[0028] Figure 3 This is a screenshot of the monitoring system's user interface.

[0029] Figure 4 This is a schematic diagram of the original process flow of the unit;

[0030] Figure 5 This is a schematic diagram of the process flow of the modified unit;

[0031] Figure 6 This is a flowchart of the sampling process after the modification.

[0032] In the diagram: 1. Roller conveyor; 2. Laser cutting platform; 3. Robot; 4. Initial sample hopper lifting platform; 5. Replica sample hopper. Detailed Implementation

[0033] 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.

[0034] This invention proposes a method for reducing sampling losses in a steel rolling system, achieved by adding specific hardware equipment and optimizing control logic to a traditional sampling production line. The main hardware components of this system include: a roller conveyor 1, a laser cutting platform 2, a sampling robot 3, a primary sample hopper lifting platform 4, and a secondary sample hopper 5. The arrangement of each component is as follows: Figure 1 As shown, the strip steel along Figure 1 Run in the direction shown.

[0035] In the specific implementation of this system, the automatic sampling workflow is carried out according to the following steps:

[0036] Step 1: Template shearing and roller conveyor

[0037] When the steel coil reaches the exit point, the unit's onboard shearing equipment cuts out a standard-sized template. After shearing, the template automatically falls into place. Figure 1 The sample is transported smoothly forward to the gripping station area of ​​the sampling robot 3 when the roller conveyor 1 is started and operated.

[0038] Step 2: Robotic gripping and mid-section cutting

[0039] After receiving the grasping command, sampling robot 3 moves above roller conveyor 1 and uses its end effector to grasp the sample. Subsequently, robot 3 carries the sample to... Figure 1 and Figure 2At the laser cutting platform 2 shown, the template is precisely placed on the cutting platform. Then, the cutting platform (i.e., laser cutting platform 2) cuts the large template into two equal-sized "small templates" along the width direction of the template, based on the current steel coil width information issued by the L2 system (Level 2 Manufacturing Execution System). These are the initial template block and the duplicate template block.

[0040] Step 3: Secondary labeling and initial sample diversion

[0041] After cutting, sampling robot 3 sequentially picks up the two small samples and uses an automatic labeling machine to affix individual traceability labels to each. Then, robot 3 uses one of the small samples as the "initial sample" and places it in... Figure 2 The initial sample bucket lifting platform 4 is shown. Figure 2 As shown in the stereoscopic view, the lifting platform 4 can be raised and lowered vertically to transport the initial sample downwards to the initial sample hopper below the platform, for subsequent retrieval and testing by the operator; simultaneously, the robot 3 places another small sample as a "duplicate sample" in the duplicate sample hopper 5 on the same platform for later use. During this process, the robot system automatically records the specific storage coordinates of the duplicate sample in the duplicate sample hopper 5.

[0042] Step 4: Retention of duplicate samples and automatic sample clearance

[0043] After the initial sample in the initial sample hopper is sent for testing, the system enters a waiting state. If the physicochemical performance test results of the initial sample show "qualified," and the retention time of the duplicate sample in the duplicate sample hopper 5 exceeds a preset time (in this embodiment, the preset time is 3 days), the mission of the duplicate sample is completed. At this time, the sampling robot 3, based on the previously recorded coordinate information, grabs the duplicate sample from the duplicate sample hopper 5 and places it on the cleaning chute. The sample automatically slides down the chute to the waste hopper at the bottom of the unit, completing the automatic cleaning of the waste sample.

[0044] Reference Figure 3 The monitoring system operation interface shown in this invention provides a monitoring system with visualization and automated operation functions for performing "find duplicate samples" and "clear duplicate samples" functions.

[0045] 1. The specific control process for the duplicate finding function:

[0046] When the system receives the instruction "Initial sample inspection failed, re-inspection needs to be initiated," the operator... Figure 3 The monitoring interface operation shown:

[0047] First, enter the steel coil number that needs to be re-inspected in the "Sample Bucket Information" query box in the middle of the interface.

[0048] After the system retrieves and locates the coordinate information of the corresponding duplicate sample in the database, it highlights the duplicate sample entry in the "Sample Bucket Information" list. The operator clicks the checkbox (small square) in front of the entry to select it.

[0049] Then, click the right arrow button located between the "Sample Information" and "Samples to be Processed" interfaces to load the selected duplicate sample information into the "Samples to be Processed" interface.

[0050] Finally, click the "Start Replication" button in the lower left corner of the interface. The system will then automatically generate the robot's movement path, and the sampling robot 3 will proceed to the replication hopper 5 to locate the target sample according to the recorded coordinates. If other samples are covering the target replica, robot 3 will execute compensation handling logic, temporarily moving the covering samples to the temporary storage area, retrieving the target replica, and transporting it to the initial sample hopper lifting platform 4 to complete the replication and inspection. After the replication is completed, the robot will automatically reset the removed samples to maintain the orderly stacking within the replication hopper.

[0051] 2. Specific control process of the clean-sampling and resample-taking function:

[0052] If the initial sample passes the test and the resample is stored for more than the preset time (3 days), the operator must clean up the discarded resample in the resample container:

[0053] In the monitoring interface, select the sample container 5 (i.e., the one that needs to be cleaned) Figure 3 (The "sample container" in the middle).

[0054] Click the "Select All" button at the bottom of the sample preparation hopper information interface to select all samples that need to be cleaned in the current sample preparation hopper.

[0055] Similarly, clicking the right arrow button will move the selected templates to the "Templates to be processed" list in batches.

[0056] Clicking the "Start Cleaning" button in the lower left corner of the interface will cause the monitoring system to automatically send a batch cleaning instruction to the sampling robot 3. The robot 3 will then sequentially grab each piece of waste sample from the sample hopper 5 and place them one by one at the entrance of the cleaning chute, allowing them to automatically slide into the waste hopper, thus achieving unmanned automatic waste cleaning.

[0057] 3. Exception Handling Mode

[0058] Under normal operating conditions, the system operates fully automatically according to the processes described in Embodiments 1 and 2 above. For example... Figure 3As shown in the "Robot Control Mode" panel in the middle, this invention has preset semi-automatic and manual modes. When alarms occur due to equipment failure, communication abnormalities, or sensor malfunctions, operators can directly switch the operating mode to "semi-automatic" or "manual" on the monitoring interface to complete emergency operations through manual intervention, ensuring that the production line does not experience prolonged downtime.

[0059] Implementation results:

[0060] This patent involves adding a mid-sectioning device, a lifting and feeding device, modifying the sample preparation hopper, making necessary modifications to the sampling area layout, and upgrading the PLC program on the basis of the original sampling process, with a total one-time modification investment of approximately RMB 1.26 million. Consumable parts used in subsequent use, such as vacuum suction cups, filters, and vacuum generators, are the same as those required by the original sampling robot, with no additional operating costs.

[0061] Through the above modifications, the workload of manual sample handling and testing in the subsequent inspection and testing system has been reduced. Taking this pickling unit with an annual output of 1.2 million tons as an example, it produces an average of about 55,000 coils per year. The original number of sample blocks was 55,000*2=110,000 blocks, and now the number of sample blocks is 55,000 blocks. Each sample takes 8 seconds, which can save 55,000*10 / 60 / 60=122 hours of production time per year. Assuming a sample weight of 9.8 kg / block and a price difference of 2,000 yuan / ton between good and scrap steel coils, the unit's yield rate is increased by 55,000*9.8 / 1000 / 1200000=0.045%, and the unit's economic benefits are increased by 55,000*9.8 / 1000*2000=1.07 million yuan / year.

[0062] By adding a sampling robot monitoring system, labor costs are reduced. Taking a four-shift system with one person per shift responsible for sample handling / cleaning as an example, labor costs can be saved by approximately: 6000 * 12 * 4 = 288,000 yuan / year.

[0063] The above total cost reduction is approximately RMB 107 + 28.8 = RMB 135.8 million per year.

[0064] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for reducing sampling losses in a steel rolling system, characterized in that, Includes the following steps: S1: At the exit of the steel coil, a template is cut out by a shearing device; S2: The sampling robot grabs the sample to the cutting platform and cuts the sample into two smaller pieces along the width direction according to the steel coil width information issued by the system. S3: The sampling robot affixes labels to the two small samples after cutting, and places one of the small samples as the initial sample on the lifting platform, which then transports it to the initial sample hopper; the other small sample is placed as the duplicate sample in the duplicate sample hopper for later use. S4: When the duplicate sample is stored for more than the preset time and the initial sample is qualified, the sampling robot grabs the duplicate sample from the duplicate sample hopper and places it in the cleaning chute, so that it automatically slides down to the waste hopper to complete the cleaning.

2. The method according to claim 1, characterized in that, In step S1, after the sample is cut, it is conveyed by roller conveyor to the sampling robot's gripping position.

3. The method according to claim 1, characterized in that, In step S2, the mid-section platform is a laser cutting platform, and the average cutting is laser cutting.

4. The method according to claim 1, characterized in that, In step S3, the lifting platform is a lift, and the initial sample bucket is located on the ground floor below the lifting platform.

5. The method according to claim 1, characterized in that, The preset time is 3 days.

6. The method according to claim 1, characterized in that, In step S4, the sampling robot realizes the functions of finding duplicate samples and cleaning duplicate samples through the monitoring system. The function of finding duplicate samples includes: entering the roll number to be queried in the interface of the monitoring system, querying and selecting the target sample, and starting the duplicate sample operation. The robot automatically searches for and takes out the target sample. The function of cleaning duplicate samples includes: selecting the duplicate sample bucket to be cleaned in the interface of the monitoring system, selecting all samples in the bucket, and starting the cleaning operation. The robot then places the samples in the duplicate sample bucket into the cleaning chute for disposal.

7. The method according to claim 1, characterized in that, This method is applied to sampling at the outlet of pickling or cold rolling mills.

8. The method according to claim 1, characterized in that, When the system malfunctions, switch to semi-automatic or manual control mode to perform sampling operations.

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