A method for automatically adjusting the weight of a continuous casting billet

Abstract

The application discloses a continuous casting billet weight setting automatic adjustment method, comprising the following steps: obtaining a preset target weight of a casting billet and an initial reference cutting length; obtaining a current casting speed of a continuous casting machine and an actual weighing weight of a produced casting billet in real time; based on a deviation between the actual weighing weight and the target weight and a change of the current casting speed relative to a historical casting speed, according to a preset adjustment judgment rule, deciding whether to adjust a cutting length of a subsequent casting billet and calculating an adjustment amount; and outputting a control instruction according to a decision result to adjust a fixed-length length of a cutting mechanism. The application realizes automatic adjustment of the weight setting of the casting billet based on data intelligent decision from manual experience adjustment, and improves weight control precision, stability and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of continuous casting equipment control technology, and in particular to an automatic method for adjusting the constant weight of continuously cast billets. Background Technology

[0002] Currently, continuous casting weight adjustment is mainly done manually. The adjustment is based on weighing the billet before it enters the furnace on the roller conveyor. This weight is then collected and processed in the background, and the changes in weight for each casting run are displayed in real-time on mobile devices and the main control screen using information technology software. On-site operators use the previous weight, current casting speed changes, tundish temperature changes, and steel grade as reference conditions, and rely on experience to judge the amount of adjustment needed for the next casting run before making the necessary changes. Whether the weight adjustment is satisfactory is entirely determined manually. The accuracy of manual adjustment is greatly affected by the individual operator's skill level. Differences in adjustment ability among different operators can lead to large fluctuations in billet weight, affecting product quality. Furthermore, manual adjustment is prone to operator fatigue and lack of concentration, which can result in untimely or excessive adjustments, further exacerbating billet weight instability. Summary of the Invention

[0003] In order to overcome the above-mentioned shortcomings of the prior art, the purpose of this invention is to provide an automatic adjustment method for the fixed weight of continuously cast billets.

[0004] The technical solution adopted by this invention to solve its technical problem is: an automatic adjustment method for the fixed weight of continuously cast billets, comprising the following steps: Obtain the preset target weight of the billet and the initial reference cutting length; Real-time acquisition of the current casting speed of the continuous casting machine and the actual weighing weight of the produced billets; Based on the deviation between the actual weighed weight and the target weight, and the change of the current casting speed relative to the historical casting speed, a decision is made on whether to adjust the cutting length of the subsequent casting billet and the adjustment amount is calculated according to the preset adjustment judgment rules. Based on the decision results, control commands are output to adjust the fixed length of the cutting mechanism.

[0005] As a further improvement of the present invention: the preset adjustment judgment rule includes a weight feedback adjustment sub-rule, which performs the following sub-steps: Calculate the average actual weighing weight of the most recent consecutive produced billets in the current flow, and use it as a dynamic reference weight; Calculate the weight difference between the actual weighing weight of the latest billet and the dynamic reference weight; Whether to trigger the cutting length adjustment is determined based on the threshold range in which the absolute value of the weight difference falls and the number of times it occurs consecutively.

[0006] As a further improvement of the present invention: the step of determining whether to trigger the adjustment based on the absolute value of the weight difference includes: If the absolute value of the weight difference is less than or equal to the first threshold, it is determined to be qualified and no adjustment is triggered. If the absolute value of the weight difference is greater than the first threshold but less than the second threshold, then the continuous trigger judgment process is initiated. If the absolute value of the weight difference is greater than or equal to the second threshold, the cutting length adjustment is triggered immediately.

[0007] As a further improvement of the present invention: the continuous triggering judgment process includes: Record the current weight difference status as the first non-compliance. When the absolute value of the weight difference corresponding to the next billet is still greater than the first threshold and less than the second threshold, it is determined that the continuous triggering condition is met, and the cutting length adjustment is triggered for the next billet.

[0008] As a further improvement of the present invention: when it is determined that the cutting length adjustment is triggered, the adjustment amount is calculated by multiplying the weight difference by a preset weight-length conversion factor.

[0009] As a further improvement of the present invention: the preset adjustment judgment rule also includes a sub-rule for adjusting the pulling speed change, which performs the following sub-steps: Calculate the difference between the current pulling speed and a historical reference pulling speed to obtain the change in pulling speed; If the absolute value of the change in pulling speed is less than or equal to the third threshold, then the length adjustment component caused by the pulling speed is calculated based on the change in pulling speed.

[0010] As a further improvement of the present invention, the length adjustment component is calculated by multiplying the change in pulling speed by a preset pulling speed-length adjustment coefficient, wherein the coefficient is negative when the pulling speed increases and positive when the pulling speed decreases.

[0011] As a further improvement of the present invention: after performing a cutting length adjustment, a post-adjustment verification and reset step is also included. Obtain the actual weighing weight of the first cast billet produced after adjustment; If the deviation between the actual weighing weight of the billet and the target weight falls within the acceptable range, the cutting length will be reset to the length before this adjustment.

[0012] As a further improvement of the present invention, it also includes a disturbance-resistant continuous control step: If a weight deviation-based adjustment is triggered for a billet, and the weight deviation of the next billet still exceeds the acceptable range, then no new adjustment will be triggered. Continue to obtain the weight deviation of subsequent castings for judgment. If the deviation continues to exceed the qualified range, an adjustment is triggered again.

[0013] As a further improvement of the present invention: after the weight of the billet is stabilized within the qualified range by adjustment, the cutting length of the currently stable output is updated to the new initial reference cutting length.

[0014] Compared with the prior art, the beneficial effects of the present invention are: This invention constructs an automatic decision-making system based on real-time weight deviation and casting speed change data, replacing the traditional adjustment method that relies on manual experience. It can process production data in real time, automatically judge and calculate the adjustment amount and timing of cutting length according to preset precise rules, thereby achieving high-precision and high-consistency automatic control of billet weight, effectively overcoming the problems of response lag, accuracy fluctuation and easy fatigue that exist in manual adjustment. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the process of the present invention.

[0016] Figure 2 This is a flowchart illustrating an embodiment of the present invention. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0018] In order to solve the technical problems in the prior art, the present invention will now be further described in conjunction with the accompanying drawings and embodiments: like Figure 1 As shown in the figure, an embodiment of the present invention discloses an automatic adjustment method for the fixed weight of continuously cast billets, including the following steps: S1: Obtain the preset target weight of the billet and the initial reference cutting length; S2: Real-time acquisition of the current casting speed of the continuous casting machine and the actual weighing weight of the produced billets; S3: Based on the deviation between the actual weighed weight and the target weight, and the change of the current casting speed relative to the historical casting speed, decide whether to adjust the cutting length of the subsequent casting billet according to the preset adjustment judgment rules and calculate the adjustment amount. In some implementations, the preset adjustment judgment rule includes a weight feedback adjustment sub-rule, which performs the following sub-steps: Calculate the average actual weighing weight of the most recent consecutive produced billets in the current flow, and use it as a dynamic reference weight; Calculate the weight difference between the actual weighing weight of the latest billet and the dynamic reference weight; Whether to trigger the cutting length adjustment is determined based on the threshold range in which the absolute value of the weight difference falls and the number of times it occurs consecutively.

[0019] Specifically, the average weight of the most recent multiple cast billets is used as a dynamic and adaptive reference benchmark, rather than a fixed theoretical weight, to closely reflect the fluctuations in actual continuous production.

[0020] Furthermore, determining whether to trigger an adjustment based on the absolute value of the weight difference includes: If the absolute value of the weight difference is less than or equal to the first threshold, it is determined to be qualified and no adjustment is triggered. If the absolute value of the weight difference is greater than the first threshold but less than the second threshold, then the continuous trigger judgment process is initiated. If the absolute value of the weight difference is greater than or equal to the second threshold, the cutting length adjustment is triggered immediately.

[0021] Specifically, the continuous weight deviation range is divided into a "qualified zone," an "observation / delayed trigger zone," and an "immediate action zone." By setting thresholds, a tiered response is achieved, avoiding overreaction of the system to small fluctuations (qualified zone) and improving stability; a delayed judgment is introduced for medium deviations (observation zone) to prevent misadjustment; and a rapid response is provided for large deviations (action zone) to ensure timely control and achieve refined and intelligent decision-making.

[0022] In some implementations, the continuous triggering judgment process includes: Record the current weight difference status as the first non-compliance. When the absolute value of the weight difference corresponding to the next billet is still greater than the first threshold and less than the second threshold, it is determined that the continuous triggering condition is met, and the cutting length adjustment is triggered for the next billet.

[0023] Specifically, a rule is designed for the "observation / delay trigger zone" that triggers only after two consecutive exceedances. This effectively distinguishes between random fluctuations and trend deviations, confirming that an adjustment is truly necessary only when the deviation has a certain degree of persistence, greatly reducing the probability of incorrect adjustments caused by noise from a single measurement or random interference.

[0024] In some implementations, when it is determined that the cutting length adjustment is triggered, the adjustment amount is calculated by multiplying the weight difference by a preset weight-length conversion factor.

[0025] Establish a linear (or proportional) conversion relationship between weight deviation and cutting length adjustment, transforming the weight control problem into a more direct length control problem.

[0026] S4: Output control commands based on the decision results to adjust the fixed length of the cutting mechanism.

[0027] In some implementations, the preset adjustment judgment rule further includes a sub-rule for adjusting the pulling speed, which performs the following sub-steps: Calculate the difference between the current pulling speed and a historical reference pulling speed to obtain the change in pulling speed; If the absolute value of the change in pulling speed is less than or equal to the third threshold, then the length adjustment component caused by the pulling speed is calculated based on the change in pulling speed.

[0028] Specifically, the feedforward disturbance factor of "casting speed variation" is independently identified and addressed. Casting speed variation directly affects the amount of casting per unit time and is one of the important causes of weight deviation. Before the weight feedback lags, the impact of casting speed variation is predicted and compensated for in advance, accelerating the system's response speed and improving the lag of simple feedback control. Furthermore, the length adjustment component is calculated by multiplying the change in pulling speed by a preset pulling speed-length adjustment coefficient, wherein the coefficient is negative when the pulling speed increases and positive when the pulling speed decreases. The quantitative relationship and directionality between the change in pulling speed and the length compensation amount are defined (length decreases as pulling speed increases).

[0029] In some implementations, after performing a cutting length adjustment, a post-adjustment verification and reset step is also included: Obtain the actual weighing weight of the first cast billet produced after adjustment; If the deviation between the actual weighing weight of the billet and the target weight falls within the acceptable range, the cutting length will be reset to the length before this adjustment.

[0030] Specifically, after each adjustment, a "verification-reset" step is added. This checks the immediate effect of the adjustment; if the effect is excellent (immediately satisfactory), the adjustment is reversed. This includes a negative feedback stabilization mechanism to prevent over-adjustment or oscillation, ensuring that the system will not introduce a reverse deviation due to a single adjustment, even if the operating condition may have already recovered on its own. Some implementations also include a disturbance rejection continuous control step: If a weight deviation-based adjustment is triggered for a billet, and the weight deviation of the next billet still exceeds the acceptable range, then no new adjustment will be triggered. Continue to obtain the weight deviation of subsequent castings for judgment. If the deviation continues to exceed the qualified range, an adjustment is triggered again.

[0031] Specifically, an intermittent adjustment strategy of "adjustment-wait-reassessment" is designed. After one adjustment, the next cycle is skipped for observation, giving the process sufficient response time and avoiding intensive continuous adjustments under high-frequency interference or high inertia.

[0032] In some implementations, once the billet weight is stabilized within acceptable limits through adjustments, the currently stable cutting length is updated to the new initial reference cutting length.

[0033] This invention acquires a preset target weight and initial cutting length for the cast billet; it collects real-time data on the current casting speed of the continuous casting machine and the actual weighing weight of the produced billets; based on the deviation between the actual weight and the target weight, and the change in the current casting speed relative to historical casting speeds, it automatically decides whether to adjust the cutting length of subsequent cast billets and calculates the adjustment amount according to preset adjustment judgment rules; finally, it outputs control commands based on the decision results to adjust the fixed length of the flame cutter. This realizes the automatic adjustment of the cast billet weight setting from manual experience to data-driven intelligent decision-making, improving weight control accuracy, stability, and production efficiency.

[0034] Implementation Case 1: like Figure 1 and Figure 2 As shown, this embodiment discloses an automatic method for adjusting the fixed weight of continuously cast billets. It is built upon the existing programmable logic controller (PLC) of the continuous casting production line. This PLC communicates with an encoder that measures the casting speed, a pre-furnace scale that weighs the billets, and a cutting machine that performs the cutting. Before the method begins, the operator sets the target unit weight of the billet (e.g., 2000 kg) and an initial cutting length (e.g., 9.5 m) via a human-machine interface (HMI). The system stores the target unit weight and initial cutting length as reference parameters.

[0035] The automatic weight feedback adjustment process is as follows: The system operates continuously during the continuous casting process. First, the system acquires the actual weight of the cut billets from the scale before they enter the furnace. Due to signal transmission and process distance, this weight feedback is delayed by approximately three billets relative to the cutting point. Starting from the actual weight of the third billet, the system continuously calculates the moving average of the most recent three billet weights and uses this average as a "reference weight" for dynamic comparison. For example, if the most recent three billet weights are 1998 kg, 2003 kg, and 2001 kg, then the reference weight is 2000.67 kg.

[0036] The system calculates the difference between the actual weight of the latest cast billet (e.g., the nth billet) and this reference weight. Different logic is executed depending on the specific value of this difference: Case A (Slight Deviation): If the difference is within ±2 kg, the system determines that the weight is qualified and does not send any adjustment instructions. The fire cutter cuts the next billet according to the current length.

[0037] Scenario B (Medium Deviation): If the deviation is +12 kg (positive value, and within the range of +10 to +15 kg), the system records this state but does not immediately adjust. Until the deviation of the next (n+1) billet is still +11 kg (still within the same range), the system determines that the "continuous triggering condition" is met and decides to adjust the length of the next billet (n+2). The adjustment amount is calculated according to preset rules: for example, if the rule is set to "adjust the cutting length by 0.5 cm for every 1 kg deviation," then for a deviation of +12 kg, the calculated adjustment amount is a shortening of 6 cm.

[0038] Case C (Large Deviation): If the difference exceeds ±15 kg, an adjustment is triggered immediately, and the adjustment amount is calculated in the same way as in Case B.

[0039] The real-time compensation process for changes in pulling speed is as follows: This process runs in parallel with the weight feedback process. The system records the pulling speed value once per second and calculates the difference between the current pulling speed and the baseline pulling speed recorded two seconds ago.

[0040] If the difference in drawing speed is within ±0.5 m / min (for example, if the drawing speed increases by 0.2 m / min), the system will compensate accordingly. The compensation rule is set as follows: for every 0.1 m / min increase in drawing speed, the cutting length decreases by 0.5 mm. Therefore, for an increase of 0.2 m / min, the system will calculate an additional length adjustment component: shortening by 1.0 mm.

[0041] If the pulling speed changes by more than ±0.5 m / min, the system considers the change too drastic and will not perform automatic compensation to avoid over-adjustment.

[0042] The decision synthesis and execution are adjusted as follows: The system adds the adjustment amount (which may be 0) calculated by the weight feedback process to the adjustment component calculated by the casting speed change compensation process to form the final total adjustment amount. For example, if the weight feedback requires a reduction of 6 cm and the casting speed compensation requires a reduction of 1 mm, then the final adjustment instruction is: reduce the cutting length of the next casting billet by 61 mm from the existing length. The PLC sends this instruction to the flame cutter for execution.

[0043] The adjusted verification and status reset are as follows: After the system performs an active length adjustment, it enters the verification phase. It focuses on monitoring the weight of the first billet produced after the adjustment (i.e., the billet that accepts the new length cutting).

[0044] If the deviation between the billet weight and the target weight returns to the acceptable range of ±2 kg, the system determines that the adjustment has overreacted or the operating condition has returned to normal, and initiates a "reset" operation to restore the cutting length to the value before the adjustment.

[0045] If the weight of the billet is still unacceptable, the system activates a "continuous control strategy": skipping the adjustment for the next billet (giving the system a response cycle) and continuing to monitor the weight of the next billet after that. If the weight still exceeds the limit, a new round of adjustment calculations is initiated. This strategy helps avoid adjustment oscillations under fluctuating operating conditions.

[0046] Once the billet weight stabilizes again within the acceptable range after adjustment, the system will update the currently stable cutting length to a new "initial reference cutting length" for subsequent deviation calculation.

[0047] Implementation Case 2: like Figure 2 As shown, this embodiment discloses an automatic weight adjustment method for continuously cast billets. It utilizes the existing S7_300 series PLC control system and a fire-cutting machine system equipped with encoders to support length cutting of the billets. Based on changes in casting speed and the feedback weight, the length of the billet is automatically adjusted to achieve a weight within the acceptable range. Since the continuous casting machine cutting system is far from the furnace weighing system, there is a delay of three billets in the weighing feedback. Therefore, the automatic billet adjustment involves multiple judgments. Specific technical details are as follows: 1. Before production, if the billet meets the input conditions, the standard weight adjustment needs to be manually entered. During production, when automatic length adjustment is activated, the standard length is based on the length entered on the current screen. 2. Under normal circumstances, the weight of the billet before it enters the furnace is used as the basis for adjustment. If the difference between the weight of the first billet and the standard (calculated after the third billet by comparing the average weight of the three most recent billets in the current flow) is within +2 to -2, no adjustment is made. If the difference is within +10 to +15, no adjustment is made either, until the next billet is still within +10 to +15, then adjustment is made. If it exceeds the range, zero is used as the standard point, and 0.5cm is adjusted for every 1kg difference. If the next billet is unqualified, no adjustment is made. If the next billet is qualified, the adjustment is returned to the previous length. Otherwise, if the difference is still outside the range by the fourth billet, adjustment continues until it is within the standard range. If the difference is within the standard range, the current length is used as the benchmark, and readjustment is made again when the next billet is unqualified. 3. When the casting machine speed changes, the billet should be adjusted immediately: increase the speed by 0.1 m / min, decrease the length by 0.5 mm, and decrease the speed by 0.1 m / min, increase the length by 0.5 mm (no adjustment is needed for speed changes less than -0.5 m / min or greater than 0.5 m / min). 4. If the weight deviation exceeds 10 kg when the casting speed remains constant, it is considered inaccurate weighing, and no weight adjustment is made.

[0048] By collecting, organizing, and statistically analyzing equipment data, a specific adjustment logic is constructed based on patterns to achieve automatic weight adjustment. This method effectively controls the weight of the cast billet, ensuring quality stability and consistency. The automatic adjustment system precisely controls the billet weight, avoiding weight fluctuations caused by human error or equipment variations. Furthermore, the automatic adjustment system can quickly respond and adjust the billet weight, reducing manual intervention and thus improving production efficiency. This method can also reduce unnecessary energy consumption and material waste by controlling the billet length, thereby achieving the goal of cost reduction.

[0049] This embodiment can effectively control the weight of the cast billet, ensuring the stability and consistency of its quality. The automatic adjustment system precisely controls the billet weight, avoiding weight fluctuations caused by human error or equipment variations. Furthermore, the automatic adjustment system can quickly respond and adjust the billet weight, reducing manual intervention and thus improving production efficiency. This method can also reduce unnecessary energy consumption and material waste by controlling the billet length, thereby achieving the goal of cost reduction.

[0050] 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 automatic adjustment of the fixed weight of continuously cast billets, characterized in that, Includes the following steps: Obtain the preset target weight of the billet and the initial reference cutting length; Real-time acquisition of the current casting speed of the continuous casting machine and the actual weighing weight of the produced billets; Based on the deviation between the actual weighed weight and the target weight, and the change of the current casting speed relative to the historical casting speed, a decision is made on whether to adjust the cutting length of the subsequent casting billet and the adjustment amount is calculated according to the preset adjustment judgment rules. Based on the decision results, control commands are output to adjust the fixed length of the cutting mechanism.

2. The method for automatic adjustment of continuous casting billet weight according to claim 1, characterized in that, The preset adjustment judgment rule includes a weight feedback adjustment sub-rule, which executes the following sub-steps: Calculate the average actual weighing weight of the most recent consecutive produced billets in the current flow, and use it as a dynamic reference weight; Calculate the weight difference between the actual weighing weight of the latest billet and the dynamic reference weight; Whether to trigger the cutting length adjustment is determined based on the threshold range in which the absolute value of the weight difference falls and the number of times it occurs consecutively.

3. The method for automatic adjustment of continuous casting billet weight according to claim 2, characterized in that, The method of determining whether to trigger an adjustment based on the absolute value of the weight difference includes: If the absolute value of the weight difference is less than or equal to the first threshold, it is determined to be qualified and no adjustment is triggered. If the absolute value of the weight difference is greater than the first threshold but less than the second threshold, then the continuous trigger judgment process is initiated. If the absolute value of the weight difference is greater than or equal to the second threshold, the cutting length adjustment is triggered immediately.

4. The method for automatic adjustment of continuous casting billet weight according to claim 3, characterized in that, The continuous triggering judgment process includes: Record the current weight difference status as the first non-compliance. When the absolute value of the weight difference corresponding to the next billet is still greater than the first threshold and less than the second threshold, it is determined that the continuous triggering condition is met, and the cutting length adjustment is triggered for the next billet.

5. A method for automatic adjustment of the fixed weight of continuously cast billets according to any one of claims 2 to 4, characterized in that, When it is determined that the cutting length adjustment is triggered, the adjustment amount is calculated by multiplying the weight difference by a preset weight-length conversion factor.

6. The method for automatic adjustment of the fixed weight of continuously cast billets according to claim 1, characterized in that, The preset adjustment judgment rule also includes a sub-rule for adjusting the pulling speed, which executes the following sub-steps: Calculate the difference between the current pulling speed and a historical reference pulling speed to obtain the change in pulling speed; If the absolute value of the change in pulling speed is less than or equal to the third threshold, then the length adjustment component caused by the pulling speed is calculated based on the change in pulling speed.

7. The method for automatic adjustment of the fixed weight of continuously cast billets according to claim 6, characterized in that, The length adjustment component is calculated by multiplying the change in pulling speed by a preset pulling speed-length adjustment coefficient, wherein the coefficient is negative when the pulling speed increases and positive when the pulling speed decreases.

8. The method for automatic adjustment of continuous casting billet weight according to claim 1, characterized in that, After performing a cutting length adjustment, the process also includes a post-adjustment verification and reset step. Obtain the actual weighing weight of the first cast billet produced after adjustment; If the deviation between the actual weighing weight of the billet and the target weight falls within the acceptable range, the cutting length will be reset to the length before this adjustment.

9. The method for automatic adjustment of the fixed weight of continuously cast billets according to claim 1, characterized in that, It also includes disturbance rejection continuous control steps: If a weight deviation-based adjustment is triggered for a billet, and the weight deviation of the next billet still exceeds the acceptable range, then no new adjustment will be triggered. Continue to obtain the weight deviation of subsequent castings for judgment. If the deviation continues to exceed the qualified range, an adjustment is triggered again.

10. The method for automatic adjustment of the fixed weight of continuously cast billets according to claim 1, characterized in that, Once the billet weight is stabilized within the acceptable range through adjustments, the currently stable cutting length is updated to the new initial reference cutting length.

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