Multi-strand copper bar horizontal continuous casting flow speed coordinated control method

Abstract

The application is suitable for the technical field of copper bar production, and particularly relates to a multi-head copper bar horizontal continuous casting flow speed coordination control method, which comprises the following steps: calculating an equivalent resistance index; comparing the equivalent resistance index of the current period of each flow with the corresponding historical moving average value to obtain a relative deviation, and obtaining a corresponding deterioration discrimination result of each flow according to the size of the relative deviation; executing a corresponding compensation strategy on each flow according to the deterioration discrimination result of each flow; and recalculating the equivalent resistance index and the actual drawing displacement of each flow within a preset number of drawing periods after the compensation strategy is executed. The multi-head copper bar horizontal continuous casting flow speed coordination control method provided by the application can improve the problems of the existing technology, such as the uncoordinated drawing speed of each flow of the multi-head copper bar horizontal continuous casting caused by the differentiated gradual change of resistance, the inconsistent quality of each bar, and the problems of the traditional fixed speed control mode, such as the stress mutation of the solidified shell and the drawing leakage accident.

Description

Technical Field

[0001] This application belongs to the field of copper rod production technology, and in particular relates to a method for coordinated control of the billet pulling speed of each stream in horizontal continuous casting of multi-head copper rods. Background Technology

[0002] Horizontal continuous casting is the core process for copper bar production. Multi-head horizontal continuous casting machines are usually equipped with 4 to 16 parallel drawing units, sharing the tundish liquid supply and each flow is equipped with an independent crystallizer and drawing mechanism. The intermittent drawing process of "draw-stop-push" is used to achieve continuous solidification and forming of copper liquid. Under ideal working conditions, the drawing speed and displacement of each flow are consistent, which can ensure uniform product quality and stable output.

[0003] However, in actual production, under the equipment architecture of "shared source, independent flow", there are systematic and gradual differences in the wear rate of the drawing rollers, the lubrication status of the crystallizer, the cooling heat exchange efficiency and the copper liquid inlet parameters of each flow. As the equipment service cycle continues to accumulate, it will form a significant differentiation in the equivalent drawing resistance. In addition, copper alloys have large solidification shrinkage and strong hot brittleness. The intermittent drawing process is extremely sensitive to the resistance difference. The flow with greater resistance is prone to roller slippage and insufficient actual displacement, causing the solidified shell thickness to deviate from the optimal range, resulting in internal shrinkage porosity and surface defects. Moreover, the stress concentration at the moment of "drawing-stopping" is more likely to induce microcracks or even drawing leakage accidents. Summary of the Invention

[0004] This application provides a method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars. This method can improve the problems in the prior art, such as the incoordination of casting speed and the inconsistent quality of each bar caused by the gradual change of resistance difference in each stream of horizontal continuous casting of multi-head copper bars, as well as the problems that the traditional fixed speed control mode is prone to causing sudden stress change in the solidified shell and the failure of the casting.

[0005] In a first aspect, embodiments of this application provide a method for coordinated control of the billet pulling speed of each stream in multi-head horizontal continuous casting of copper bars, applied to a multi-head horizontal continuous casting apparatus. The multi-head horizontal continuous casting apparatus includes a billet pulling unit with multiple streams arranged in parallel. Each billet pulling unit has a billet pulling drive motor, each stream shares a tundish and has an independent crystallizer, and each stream adopts an intermittent pulling process of pulling, stopping, and pushing. The control method includes: Using the single intermittent billet drawing cycle of each flow billet drawing unit as the basic time unit, at the end of each billet drawing cycle, the net effective mechanical work of the billet drawing drive motor acting on the billet during that cycle is calculated, and the equivalent resistance index is calculated in combination with the actual net billet drawing displacement of that cycle. The equivalent resistance index of each flow in the current cycle is compared with the corresponding historical moving average to obtain the relative deviation. The corresponding degradation judgment result of each flow is obtained according to the magnitude of the relative deviation. The degradation judgment result is one of healthy flow, slightly degraded flow, and severely degraded flow. Based on the degradation assessment results of each flow, corresponding compensation strategies are implemented for each flow; if the degradation assessment result of a flow is slightly degraded, a strategy combining resistance feedforward compensation and displacement gradual recovery is implemented; if the degradation assessment result of a flow is severely degraded, a strategy combining local safety degradation and global output collaborative averaging is implemented. Within a preset number of drawing cycles after the compensation strategy is executed, the equivalent resistance index and actual drawing displacement of each flow are recalculated to obtain verification results reflecting the compensation effect, and the parameters of the compensation strategy are dynamically adjusted based on the verification results.

[0006] The technical solutions described in this application embodiment have at least the following technical effects: Using a single intermittent billet drawing cycle of each flow drawing mill as the basic time unit, the net effective mechanical work of the drawing drive motor acting on the billet during that cycle is calculated at the end of each drawing cycle, and the equivalent resistance index is obtained by combining this with the actual net drawing displacement of that cycle, reflecting the drawing resistance state of each flow in real time; by comparing the equivalent resistance index of each flow in the current cycle with the corresponding historical sliding average to obtain the relative deviation, three types of degradation judgment results—healthy flow, slightly deteriorated flow, and severely deteriorated flow—are obtained, distinguishing the degree of degradation of each flow to match differentiated compensation schemes; resistance feedforward compensation is performed for slightly deteriorated flow. By combining a gradual displacement recovery strategy with a strategy of local safety degradation and global production balancing for severely deteriorated flows, the problem of inconsistent billet drawing speeds caused by the gradual variation in resistance of each flow can be alleviated, maintaining the balance of billet drawing status and production of each flow. At the same time, the gradual displacement adjustment and graded degradation can reduce the risk of sudden stress changes in the solidified shell. By recalculating the equivalent resistance index and actual billet drawing displacement of each flow within a preset number of drawing cycles after the compensation strategy is implemented, the verification results reflecting the compensation effect are obtained. Based on the verification results, the parameters of the compensation strategy are dynamically adjusted to adapt to the dynamic changes in resistance of each flow, improve the uniformity of copper rod quality of each flow, and reduce the probability of drawing leakage accidents.

[0007] Secondly, embodiments of this application provide a coordinated control system for the casting speed of each stream in a multi-head copper bar horizontal continuous casting process, comprising: The resistance sensing unit is used to calculate the net effective mechanical work of the billet drive motor on the billet during the cycle at the end of each billet drawing unit, taking the single intermittent billet drawing cycle of each flow drawing unit as the basic time unit, and calculate the equivalent resistance index in combination with the actual net billet drawing displacement of the cycle. The degradation discrimination unit is used to compare the equivalent resistance index of each flow in the current cycle with the corresponding historical moving average to obtain the relative deviation, and to obtain the degradation discrimination result corresponding to each flow based on the magnitude of the relative deviation; wherein, the degradation discrimination result is one of healthy flow, slightly degraded flow, and severely degraded flow; The differential compensation unit is used to execute corresponding compensation strategies for each flow based on the degradation judgment results of each flow. If the degradation judgment result of the flow is slightly degraded, a strategy of resistance feedforward compensation combined with displacement gradual recovery is executed. If the degradation judgment result of the flow is severely degraded, a strategy of local safety degradation combined with global output collaborative averaging is executed. The verification and adjustment unit is used to recalculate the equivalent resistance index and actual billet displacement of each flow within a preset number of billet pulling cycles after the compensation strategy is executed, to obtain verification results reflecting the compensation effect, and to dynamically adjust the parameters of the compensation strategy based on the verification results.

[0008] Thirdly, embodiments of this application provide a multi-head copper bar horizontal continuous casting apparatus, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the method described in any one of the first aspects above.

[0009] Fourthly, embodiments of this application provide a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any one of the first aspects above.

[0010] Fifthly, embodiments of this application provide a computer program product that, when running on a multi-head copper bar horizontal continuous casting device, causes the multi-head copper bar horizontal continuous casting device to execute the multi-head copper bar horizontal continuous casting process described in any of the first aspects above, the method for coordinated control of the billet pulling speed of each stream in multi-head copper bar horizontal continuous casting.

[0011] It is understood that the beneficial effects of the second to fifth aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a schematic flowchart of a method for coordinated control of the billet pulling speed of each stream in horizontal continuous casting of multi-head copper bars provided in an embodiment of this application; Figure 2 This is a flowchart illustrating step S100 in the method for coordinated control of the billet pulling speed of each stream in horizontal continuous casting of multi-head copper bars provided in an embodiment of this application. Figure 3This is a flowchart illustrating step S200 in the method for coordinated control of the billet pulling speed of each stream in horizontal continuous casting of multi-head copper bars provided in an embodiment of this application. Figure 4 This is a schematic diagram of the structure of the multi-head copper bar horizontal continuous casting process with coordinated drawing speed of each stream provided in an embodiment of this application; Figure 5 This is a schematic diagram of the structure of a multi-head copper bar horizontal continuous casting device provided in an embodiment of this application. Detailed Implementation

[0014] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0015] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0016] To address the issues of inconsistent casting speeds and bar quality caused by gradual changes in resistance among different streams in multi-head horizontal continuous casting of copper bars, as well as the problems of sudden stress changes in the solidified shell and casting leakage accidents easily caused by traditional fixed-speed control modes, this application provides a method for coordinated control of casting speed among different streams in multi-head horizontal continuous casting of copper bars. This method uses a single intermittent casting cycle of each stream casting unit as the basic time unit. At the end of each casting cycle, the net effective mechanical work performed by the casting drive motor on the billet during that cycle is calculated, and combined with the actual net casting displacement of that cycle, an equivalent resistance index is obtained to reflect the casting resistance status of each stream in real time. By comparing the equivalent resistance index of each stream in the current cycle with the corresponding historical sliding average, a relative deviation is obtained, leading to three categories of degradation judgment results: healthy stream, slightly degraded stream, and severely degraded stream. This distinguishes the degree of degradation of each stream to match differentiated compensation schemes. For slightly degraded streams, a resistance feedforward compensation combined with a displacement gradual recovery strategy is implemented. The strategy of implementing local safety degradation combined with global production balancing for severely degraded flows can alleviate the problem of inconsistent billet drawing speeds caused by the gradual variation in resistance of each flow, maintain the balance of billet drawing status and output of each flow, and reduce the risk of sudden stress changes in the solidified shell by gradually adjusting displacement and grading degradation. By recalculating the equivalent resistance index and actual billet drawing displacement of each flow within a preset number of drawing cycles after the compensation strategy is implemented, the verification results reflecting the compensation effect are obtained. Based on the verification results, the parameters of the compensation strategy are dynamically adjusted to adapt to the dynamic changes in resistance of each flow, improve the uniformity of copper rod quality of each flow, and reduce the probability of drawing leakage accidents.

[0017] The method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars provided in this application embodiment can be applied to a horizontal continuous casting device for multi-head copper bars. In this case, the horizontal continuous casting device for multi-head copper bars is the main body for executing the method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of horizontal continuous casting device for multi-head copper bars.

[0018] For example, a multi-head copper bar horizontal continuous casting device may include multiple billet drawing units, tundishes, and multiple crystallizers. The multiple billet drawing units are arranged side-by-side, each uniquely corresponding to one production flow. Each billet drawing unit is equipped with an independent billet drawing drive motor, driving independently for each flow. The billet drawing units can be roller-type clamping billet drawing units, crawler-type continuous clamping billet drawing units, etc. The tundish is used to receive molten copper from the upstream smelting furnace and to stabilize, stabilize, and uniformly distribute the molten copper, delivering it to the inlet of the crystallizer corresponding to each flow. For example, the tundish can be an integrated refractory casting tundish, a modular assembly tundish, etc. Each crystallizer corresponds to a specific flow and is used to rapidly cool the incoming high-temperature molten copper, ensuring the copper... The surface layer preferentially solidifies to form a semi-solidified copper billet with a complete solid shell, and the formed copper billet is continuously transported to the drawing unit of the corresponding flow channel. For example, the crystallizer can be a water-cooled graphite crystallizer, a copper sleeve liner crystallizer, etc.; the drawing drive motor can be a servo drive motor, a variable frequency stepper motor, etc.; the billet unit receives the semi-solidified copper billet sent by the crystallizer, and continuously pulls the copper billet backward according to the pull-stop-push intermittent action. The drawing drive motor of the drawing unit provides continuous power output for the complete single-flow drawing, stopping, and reverse pushing intermittent action, ensuring that the phase nodes of the pull-stop-push process are stable and controllable. By adjusting the motor running speed and running time, the single-cycle set drawing displacement and the actual net drawing displacement are controlled to determine the single-flow unit capacity output.

[0019] To better understand the method for coordinated control of the drawing speed of each stream in horizontal continuous casting of multi-head copper bars provided in this application, the specific implementation process of the method for coordinated control of the drawing speed of each stream in horizontal continuous casting of multi-head copper bars provided in this application will be described by way of example below.

[0020] Figure 1 This paper presents a schematic flowchart of a method for coordinated control of the drawing speed of each stream in horizontal continuous casting of multi-head copper bars, according to an embodiment of this application. The method includes: S100 uses the single intermittent billet drawing cycle of each flow billet drawing unit as the basic time unit. At the end of each billet drawing cycle, the net effective mechanical work of the billet drawing drive motor on the billet during that cycle is calculated, and the equivalent resistance index is calculated in combination with the actual net billet drawing displacement of that cycle.

[0021] It can be understood that each flow drawing unit refers to a complete set of execution units arranged in parallel in a multi-head copper bar horizontal continuous casting device, which is responsible for independently completing the drawing operation of a single copper bar. For example, the drawing unit may include clamping rollers, a gearbox, a drawing drive motor, and a displacement encoder.

[0022] A single intermittent casting cycle refers to the time unit in the intermittent casting process of casting, stopping and pushing to complete one casting, pausing and reverse pushing process. For example, the single cycle time of common horizontal continuous casting of copper bars can be set to the range of 3 to 8 seconds.

[0023] A billet pulling drive motor refers to a power device that provides power output to the billet pulling rollers and drives the billet to move forward or backward according to process requirements. For example, a billet pulling drive motor can be a servo motor with a matching encoder.

[0024] A cast billet refers to a copper rod that has undergone preliminary solidification in a crystallizer but has not yet completed all cooling processes.

[0025] Net effective mechanical work refers to the algebraic sum of the work done by the billet pulling drive motor in a single cycle, which is actually applied to the billet during forward pulling and reverse pushing, minus the losses of the transmission system itself.

[0026] The actual net billet displacement refers to the total displacement of the billet along the billet moving direction within a single billet pulling cycle. For example, the actual net billet displacement can be directly acquired by an encoder installed on the driven roller.

[0027] The equivalent resistance index is a quantitative indicator used to characterize the average resistance experienced by the billet during casting, reflecting the comprehensive resistance status of the crystallizer, drawing rollers, and other components.

[0028] The net effective mechanical work of the billet-drawing drive motor acting on the billet during the cycle can be calculated by staged integration, performing time integration on the product of motor torque and speed during the drawing and reverse-pushing stages respectively, and then subtracting the corresponding no-load losses before summing the algebraic values. For example, assuming that the effective work done during the drawing stage is 120 joules and the effective work done during the reverse-pushing stage is 25 joules, the corresponding net effective mechanical work = 120 - 25 = 95 joules. Alternatively, the power time-domain accumulation method can be used, collecting the instantaneous effective power output of the motor at a fixed sampling step and accumulating it point by point. For example, the effective power value of the entire cycle can be accumulated at a sampling step of 1 millisecond, and the corresponding net effective mechanical work can be obtained by summing the values.

[0029] The equivalent resistance index can be calculated using a single-cycle direct ratio, where the net effective mechanical work in a single cycle is divided directly by the actual net casting displacement in the corresponding cycle. For example, if the net effective mechanical work in a certain cycle is 95 joules and the actual net casting displacement is 0.05 meters, then the equivalent resistance index = 95 / 0.05 = 1900 Newtons. Alternatively, a multi-cycle moving average correction ratio can be used, which compares the average net effective mechanical work over several consecutive cycles with the average actual net casting displacement. For example, if the average net effective mechanical work over three consecutive cycles is 285 joules and the average actual net casting displacement is 0.15 meters, then the equivalent resistance index = 285 / 0.15 = 1900 Newtons is calculated.

[0030] In one possible implementation, please refer to Figure 2 In S100, the equivalent resistance index is calculated, including: S110, for the i-th flow, during the P-th drawing cycle, the real-time torque and real-time speed of the drawing drive motor in the drawing stage and the reverse pushing stage are collected respectively, and the mechanical work output by the motor in the drawing stage and the reverse pushing stage is calculated.

[0031] It can be understood that the i-th flow refers to any one of the N parallel drawing mills in the multi-head copper bar horizontal continuous casting device, and i is the sequential number used to distinguish different flow channels.

[0032] The Pth billet drawing cycle refers to the Pth cycle in the billet drawing cycle of a certain flow billet drawing unit arranged in chronological order, where P is a positive integer used to mark the cycle timing.

[0033] The billet pulling stage refers to the process stage in which the motor drives the billet forward within a single intermittent billet pulling cycle. For example, in a single 5-second billet pulling cycle, the duration of the billet pulling stage can be set to 2 seconds, 2.2 seconds, etc.

[0034] The reverse push stage refers to the process stage in which the motor drives the billet to retreat slightly backward within a single intermittent billet pulling cycle. For example, in a single 5-second billet pulling cycle, the duration of the reverse push stage can be set to 0.5 seconds or 0.7 seconds.

[0035] Real-time torque refers to the instantaneous output torque value collected at a fixed sampling frequency during the operation of the billet drawing drive motor. Real-time speed refers to the instantaneous rotational speed value collected at a fixed sampling frequency during the operation of the billet drawing drive motor.

[0036] The mechanical work output by the motor refers to the total mechanical energy output by the motor driving the billet, which includes both the transmission system losses and the effective work done on the billet.

[0037] The real-time torque and speed of the drawing drive motor during the drawing and reverse stages can be collected by using the built-in sampling of the motor driver to directly read the internal operating data of the servo driver that is matched with the drawing drive motor. For example, the real-time torque and speed values ​​can be read through the communication interface of the servo driver at a sampling period of 1 millisecond. Alternatively, the motor driver can use built-in sampling and external sensor independent sampling. A torque and speed sensor can be installed at the motor output shaft to collect operating parameters. For example, a photoelectric torque and speed sensor can be installed to collect real-time torque and speed signals.

[0038] The mechanical work output of the motor corresponding to the drawing stage and the reverse stage can be calculated by continuous-time integration, which integrates the product of the real-time torque and real-time speed of the motor over the stage duration. For example, if the integral result of the product of torque and speed in a certain drawing stage is 130 joules, then the mechanical work output of the motor in that stage is 130 joules. Alternatively, discrete sampling and accumulation can be used, which multiplies the product of torque and speed at each sampling point by the sampling step size and then sums them point by point. For example, the calculated values ​​of all sampling points in the reverse stage can be accumulated with a sampling step size of 1 millisecond to obtain the mechanical work output of the motor in the corresponding reverse stage.

[0039] By collecting motor operating parameters during the billet pulling and reverse pushing stages respectively, the characteristics of staged work in the intermittent billet pulling process are matched; by calculating the mechanical work output by the motor in stages, basic data can be provided for the subsequent conversion of the effective work acting on the billet, supporting the calculation of the equivalent resistance index.

[0040] For example, suppose the real-time torques of the drawing drive motor during the drawing stage and the reverse stage are respectively , The real-time speed of the wheel drive motor during the wheel pulling and reverse pushing stages is: , The mechanical power output of the motor during the throwing stage is then... The mechanical power output of the motor during the reverse propulsion phase .

[0041] S120, the corresponding no-load loss work of the transmission system based on no-load test calibration is deducted from the mechanical work output of the motor corresponding to the billet pulling stage and the reverse pushing stage, respectively, to obtain the effective mechanical work acting on the billet during the billet pulling stage and the reverse pushing stage.

[0042] It is understandable that no-load test calibration refers to the calibration process of testing and recording the operating loss parameters of the transmission system under the no-load state of the billet drawing unit without clamping the billet and without external load.

[0043] The no-load loss power of the transmission system refers to the portion of the mechanical work output by the drawing drive motor that is used to overcome the frictional losses of the transmission components such as the gearbox, bearings, and drawing rollers.

[0044] Effective mechanical work refers to the portion of the mechanical work output by the motor that is actually applied to the billet after deducting the no-load loss. It is divided into two categories: effective mechanical work in the billet pulling stage and effective mechanical work in the reverse pushing stage. For example, if the mechanical work output by the motor in a certain billet pulling stage is 130 joules, after deducting the calibrated no-load loss of 10 joules, the effective mechanical work in the billet pulling stage is 130 - 10 = 120 joules.

[0045] By subtracting the no-load loss work of the transmission system from the loss value calibrated based on the no-load test, the interference of the transmission link's own loss on the work calculation is eliminated; by obtaining the effective mechanical work acting on the billet in stages, more accurate basic data for the subsequent calculation of net effective mechanical work is provided for the actual resistance.

[0046] S130, taking the forward direction of the billet pulling as the positive direction, the effective mechanical work of the billet pulling stage is counted as a positive value, and the effective mechanical work of the reverse pushing stage is counted as a negative value. The effective mechanical work of the billet pulling stage and the effective mechanical work of the reverse pushing stage are added together to obtain the net effective mechanical work of a single cycle.

[0047] It can be understood that the direction of billet forward movement refers to the direction in which the billet moves from the outlet of the crystallizer towards the subsequent cooling process, and is the main direction of movement in horizontal continuous casting billet pulling operations.

[0048] The net effective mechanical work per cycle refers to the algebraic sum of the effective mechanical work of the billet pulling stage and the reverse pushing stage within a single billet pulling cycle, according to the sign rule. It reflects the total effective work done to drive the billet forward movement within a single cycle. For example, if the effective work done in a certain cycle is 120 joules for billet pulling and 25 joules for reverse pushing, the corresponding net effective mechanical work per cycle is 120 - 25 = 95 joules.

[0049] By unifying the rules for setting the work symbols with the direction of billet movement as the positive direction, the physical direction attributes of the work done in different stages are aligned; by algebraically summing the effective mechanical work in the two stages, the net effective mechanical work in a single cycle is obtained, which intuitively reflects the total effective work done on the billet in a single cycle.

[0050] S140 records the actual net billet displacement during the P-th billet pulling cycle using a displacement detection device that does not slide relative to the billet, and defines the ratio of the net effective mechanical work per cycle to the actual net billet displacement as the equivalent resistance index.

[0051] It can be understood that the displacement detection device refers to the measuring device used to collect the displacement data of the billet. This method adopts the detection type that does not have relative sliding with the billet. For example, the displacement detection device can be a driven roller encoder that is in close contact with the billet, or a non-contact laser velocimeter to achieve displacement measurement without relative sliding.

[0052] By recording the actual net billet displacement, the displacement measurement deviation caused by roller slippage is reduced; by defining the equivalent resistance index by the ratio of the net effective mechanical work in a single cycle to the actual net billet displacement, a quantitative index reflecting the change in billet resistance is constructed.

[0053] For example, assuming the net effective mechanical work in a single cycle is 95 joules and the actual net casting displacement is 0.05 meters, the corresponding equivalent resistance index is 95 / 0.05 = 1900 Newtons.

[0054] S200 compares the equivalent resistance index of each flow in the current cycle with the corresponding historical moving average to obtain the relative deviation, and obtains the corresponding degradation judgment result for each flow based on the magnitude of the relative deviation; wherein, the degradation judgment result is one of healthy flow, slightly degraded flow, and severely degraded flow.

[0055] It is understandable that the degradation judgment result refers to the judgment conclusion given on the degree of degradation of the resistance of each flow drawing based on the relative deviation of the equivalent resistance.

[0056] The method for obtaining the corresponding degradation judgment result for each flow based on the magnitude of the relative deviation can be a fixed threshold classification, where all flows use a unified first preset threshold and a second preset threshold to complete the three-level judgment. For example, the first preset threshold is set to 5% and the second preset threshold is set to 15%. A flow with a relative deviation of 3% is judged as a healthy flow, a relative deviation of 12% is judged as a slightly degraded flow, and a relative deviation of 18% is judged as a severely degraded flow. Alternatively, a dynamic threshold classification can be used, which means matching differentiated thresholds to each flow based on the copper rod specifications, process parameters, etc., to complete the judgment. For example, a large-diameter copper rod flow corresponds to a first preset threshold of 4% and a second preset threshold of 12%, while a small-diameter copper rod flow corresponds to a first preset threshold of 6% and a second preset threshold of 18%. Each flow obtains a degradation judgment result according to its corresponding threshold, and so on.

[0057] By matching the magnitude of the relative deviation with the corresponding degradation judgment results, the degradation degree of each flow resistance can be classified and identified, providing a basis for the subsequent implementation of differentiated compensation strategies.

[0058] In one possible implementation, please refer to Figure 3 In S200, the degradation judgment results corresponding to each flow are obtained based on the magnitude of the relative deviation, including: S210, calculate the historical sliding average value of the equivalent resistance index of the i-th flow within the preset sliding window length. The historical sliding average value is the average value of all equivalent resistance indices within the window up to the previous drawing cycle.

[0059] It is understandable that the preset sliding window length refers to the number of consecutive drawing cycles that are pre-set for calculating the historical sliding average. For example, the sliding window length can be set to 5 or 10, that is, the equivalent resistance index of the most recent 5 or 10 cycles is used to participate in the average value calculation.

[0060] The historical sliding average refers to the average of all historical equivalent resistance indicators within the sliding window. It only includes historical data up to the previous billet pulling cycle and does not include the value of the current cycle. For example, when the window length is 3, the historical sliding average corresponding to the 10th cycle is the average of the equivalent resistance indicators of the 7th, 8th and 9th cycles.

[0061] By setting a preset sliding window length to select a historical data range, interference caused by fluctuations in single-cycle data is filtered out; by calculating the historical sliding average value up to the previous billet-pulling cycle, a stable historical benchmark is provided for comparing the resistance state of the current cycle.

[0062] For example, assuming the preset sliding window length is 3, the equivalent resistance indicators corresponding to the three historical periods are 1800 N, 1900 N, and 2000 N, respectively. Then the historical sliding average value = (1800 + 1900 + 2000) / 3 = 1900 N.

[0063] S220, calculate the relative deviation of the equivalent resistance index of the current period relative to the historical moving average; where the relative deviation is the ratio of the absolute value of the difference between the equivalent resistance index of the current period and the historical moving average to the historical moving average.

[0064] It can be understood that relative deviation is a quantitative value used to characterize the degree to which the current cycle equivalent resistance index deviates from the historical benchmark. It is calculated by dividing the absolute value of the difference between the current value and the historical average by the historical average. For example, assuming the historical average is 1900 N and the current value is 2090 N, the relative deviation = (2090-1900) / 1900 = 0.1 = 10%.

[0065] By calculating the relative deviation between the current cycle equivalent resistance index and the historical moving average, the impact of benchmark magnitude differences on degradation judgment is reduced; by defining the relative deviation by using the ratio of the absolute value of the difference to the historical average, the degradation judgment scale of different flow channels is unified, adapting to scenarios where the initial resistance of each flow is inconsistent.

[0066] S230, if the relative deviation is less than the first preset threshold, the i-th flow is determined to be a healthy flow; if the relative deviation is greater than or equal to the first preset threshold and less than the second preset threshold, the i-th flow is determined to be a slightly degraded flow; if the relative deviation is greater than or equal to the second preset threshold, the i-th flow is determined to be a severely degraded flow.

[0067] It is understandable that the first preset threshold is a relative deviation threshold used to distinguish between healthy flow and slightly deteriorated flow. For example, the first preset threshold can be set to 5%, 6%, etc., and the flow channel with a relative deviation below this value is judged to be in a healthy state.

[0068] The second preset threshold is a relative deviation threshold used to distinguish between slightly degraded flow and severely degraded flow. For example, the second preset threshold can be set to 15%, 16%, etc. Flow channels with a relative deviation higher than or equal to this value are judged to be in a severely degraded state.

[0069] A healthy flow channel is defined as a flow channel whose relative deviation of equivalent resistance is below the first preset threshold and whose billet pulling resistance is within the normal fluctuation range. A slightly deteriorated flow channel is defined as a flow channel whose relative deviation of equivalent resistance is between the first and second preset thresholds and whose billet pulling resistance shows a slight abnormal increase. A severely deteriorated flow channel is defined as a flow channel whose relative deviation of equivalent resistance is above or equal to the second preset threshold and whose billet pulling resistance shows a significant abnormal increase.

[0070] The first and second preset thresholds can be determined by using historical data statistics. The relative deviation fluctuation range under normal production conditions can be statistically analyzed, and the corresponding quantile can be used as the threshold. For example, statistical data on the relative deviation of 30 days of normal production can be collected, and the 95th quantile value of 5% can be used as the first preset threshold, and the 99th quantile value of 15% can be used as the second preset threshold.

[0071] By setting two preset thresholds to classify three levels of degradation, the degree of degradation of each flow resistance can be graded and distinguished. By matching different flow channel status labels to different degradation levels, a judgment basis is provided for the execution of subsequent differentiated compensation strategies.

[0072] S300: Based on the degradation judgment results of each flow, implement corresponding compensation strategies for each flow; if the degradation judgment result of the flow is slightly degraded, implement a strategy of resistance feedforward compensation combined with displacement gradual recovery; if the degradation judgment result of the flow is severely degraded, implement a strategy of local safety degradation combined with global output collaborative averaging.

[0073] It is understandable that the compensation strategy refers to the differentiated billet drawing parameter adjustment scheme adopted for flow channels with different degrees of deterioration, in order to alleviate the displacement deviation and quality risks caused by resistance deterioration.

[0074] The drag feedforward compensation combined with the displacement gradual recovery strategy is a compensation scheme for slightly deteriorated flow. It offsets the new drag by torque feedforward and gradually makes up the displacement gap. For example, after a slight increase in the drag of a certain flow, the compensation torque is first superimposed, and then the displacement deviation is gradually made up in the following 5 cycles.

[0075] The strategy of combining local safety degradation with global production synergy and sharing is a compensation scheme for severely degraded flows. First, the billet load of the degraded flow is reduced to ensure safety, and then the production shortfall is distributed to the other healthy flows. For example, after a certain flow is severely degraded, the single-cycle displacement is reduced by 20%, and the reduced production is shared equally by the other 5 healthy flows.

[0076] The strategy of combining resistance feedforward compensation with gradual displacement recovery can be implemented by prioritizing torque compensation, first adding sufficient feedforward torque and then gradually restoring displacement. For example, if the resistance of a flow increases by 10%, the first cycle adds 10% compensation torque, and then the displacement gap is filled in 6 cycles. Alternatively, displacement compensation can be prioritized, first slightly increasing the displacement and then gradually increasing the torque compensation. For example, if the resistance of a flow increases by 10%, the first cycle fills in 20% of the displacement gap, and then the torque is gradually increased until the resistance deviation falls back.

[0077] The strategy of combining local safety degradation with global production coordination and amortization can be implemented by displacement reduction amortization. After reducing the single-cycle displacement of the degraded flow, the production gap is converted into the displacement increment of the healthy flow for amortization. For example, if the single-cycle displacement of the degraded flow is reduced by 1 mm, the corresponding production gap is amortized by increasing the displacement of each of the 5 healthy flows by 0.2 mm. Alternatively, rate adaptation amortization can be used. The degraded flow displacement is kept unchanged and the dwell time is extended. The production gap is converted into the cycle displacement increment of the healthy flow per unit time for amortization. For example, if the cycle of the degraded flow is extended by 10%, the corresponding production gap is gradually amortized by the healthy flow over the cycle.

[0078] By matching the deterioration judgment results, a differentiated compensation strategy is implemented to adapt to different levels of resistance deterioration scenarios. By setting two types of schemes, namely slight deterioration compensation and severe deterioration compensation, the impact on output and billet quality is minimized while ensuring the safety of billet pulling.

[0079] In one possible implementation, please refer to Figure 3 In S300, based on the strategy of combining resistance feedforward compensation with displacement asymptotic recovery, it includes: S311 defines the difference between the current cycle's equivalent resistance index and the historical moving average as the resistance increment.

[0080] It can be understood that the resistance increment refers to the change in the current cycle equivalent resistance index relative to the historical moving average, reflecting the short-term fluctuation range of the resistance during billet pulling. For example, when the historical moving average is 1900 N and the current value is 2090 N, the resistance increment = 2090 - 1900 = 190 N.

[0081] The resistance increment is obtained by calculating the difference between the current equivalent resistance index and the historical sliding average value, which quantifies the change in billet pulling resistance within a single cycle and provides a basis for the subsequent calculation of feedforward compensation torque.

[0082] S312, the product of the preset feedforward gain coefficient and the resistance increment is confirmed as the resistance feedforward compensation torque, and in the drawing stage of the next drawing cycle, the resistance feedforward compensation torque is superimposed on the basic torque command of the flow.

[0083] It is understandable that the preset feedforward gain coefficient refers to the preset parameter used to adjust the conversion ratio of resistance increment to compensation torque. It can be determined according to the inertia matching characteristics of the billet pulling drive system and the steady-state convergence rate of the historical compensation response curve. For example, the preset feedforward gain coefficient can be set to 0.8 or 0.5, that is, 80% or 85% of the resistance increment is converted into compensation torque.

[0084] The resistance feedforward compensation torque refers to the additional torque command value added to offset the increased resistance during billet pulling. It is calculated from the resistance increment and the feedforward gain coefficient. For example, when the resistance increment is 200 N and the gain coefficient is 0.8, the resistance feedforward compensation torque = 200 N. 0.8 = 160 Nm.

[0085] The basic torque command refers to the preset reference torque value of the motor during the billet drawing stage under normal operating conditions, and it is the basis for the superposition of compensation torque.

[0086] The preset feedforward gain coefficient can be determined by transmission characteristic calibration, which involves testing the torque-resistance relationship of the transmission system under no-load and loaded conditions to determine the gain value. For example, if the test shows that each 1 Newton of resistance increment corresponds to 0.8 Nm of torque compensation, then the preset feedforward gain coefficient is set to 0.8. Alternatively, adaptive iterative adjustment can be used, dynamically adjusting the gain coefficient based on the compensation effect. For example, assuming the default preset feedforward gain coefficient is 0.7, if the displacement deviation is still too large after three consecutive cycles of compensation, then the gain coefficient is increased by 0.1, etc.

[0087] The method of superimposing the resistance feedforward compensation torque onto the basic torque command of the flow can be to superimpose a fixed value of compensation torque throughout the entire drawing stage; or to limit the torque value within the rated ratio range, etc.

[0088] By superimposing the resistance feedforward compensation torque onto the basic torque command of the flow, a fixed value of compensation torque can be directly superimposed throughout the entire drawing stage. For example, if the basic torque command is 500 Nm, after superimposing 100 Nm of compensation torque, the total torque during the drawing stage will be 600 Nm. Alternatively, the compensation torque can be gradually increased to the target value in the early stage of the drawing stage and gradually decreased at the end of the drawing stage. For example, if the basic torque command is 500 Nm, the compensation torque of 100 Nm can be increased to the target value in 5 steps with a 20% gradient to avoid sudden torque changes.

[0089] The resistance feedforward compensation torque is calculated by pre-setting the feedforward gain coefficient and the resistance increment. The resistance change is converted into a motor control parameter that can be directly executed. In the next drawing cycle, the compensation torque is superimposed on the basic torque command to offset the impact of the new resistance in advance and alleviate the expansion of displacement deviation.

[0090] S313, the difference between the single-cycle set billet displacement and the actual net billet displacement is identified as the single-cycle displacement gap, and the displacement gap of the current cycle is accumulated into the displacement gap accumulator configured for the flow.

[0091] It is understandable that the single-cycle setting of billet displacement refers to the preset target displacement value of the billet's forward movement within a single billet pulling cycle. For example, the single-cycle setting of billet displacement can be set to 5 mm, 5.5 mm, etc.

[0092] The single-cycle displacement gap refers to the difference between the set billet displacement and the actual net billet displacement within a single cycle. It reflects the extent to which the current cycle displacement has not met the standard. For example, if the set displacement is 5 mm and the actual displacement is 4.7 mm, then the single-cycle displacement gap = 5 - 4.7 = 0.3 mm.

[0093] The displacement gap accumulator is a storage unit used to store the accumulated unfilled displacement gaps in each cycle. Each stream has an independent accumulator.

[0094] The single-cycle displacement gap is obtained by calculating the difference between the set displacement and the actual displacement. The displacement gap is accumulated to the corresponding accumulator to record the total amount of unfilled displacement deviation, providing a data basis for subsequent gradual recovery.

[0095] S314, reconstruct the set displacement for the next cycle as the sum of the base displacement set value and the displacement compensation amount; wherein, the displacement compensation amount is the product of the value in the displacement gap accumulator and the exponential decay factor based on the smoothing time constant.

[0096] It is understandable that the basic displacement setting value refers to the single-cycle billet displacement reference value uniformly adopted by all streams under normal and healthy working conditions. For example, the basic displacement setting value can be set to 5 mm, 5.5 mm, etc.

[0097] The smoothing time constant is a preset parameter used to adjust the recovery speed of the displacement notch. The smaller the time constant, the faster the recovery speed. It can be determined by the cycle length of the billet pulling process and the allowable time for displacement recovery. For example, the smoothing time constant can be set to 3 cycles, 4 cycles, etc.

[0098] Displacement compensation refers to the additional displacement value added within a single cycle to make up for the displacement gap, which is extracted proportionally from the displacement gap accumulator.

[0099] The exponential decay factor is a decay coefficient calculated based on a smoothed time constant, used to control the proportion of displacement compensation extracted per cycle. The exponential decay factor can be calculated as follows: ,in, The total duration of a single throwing cycle. The smoothing time constant is used to smooth the material. A smaller smoothing time constant results in a smaller exponential decay factor, a higher proportion of displacement compensation extracted per drawing cycle, and a faster recovery speed for the displacement notch. For example, when the smoothing time constant is set to 3 drawing cycles, after 3 drawing cycles (i.e., ...) =3), and the calculated exponential decay factor is: = ≈0.368, at this point the remaining value in the displacement gap accumulator is about 36.8% of the original value, which means that the displacement gap has recovered by about 63.2%.

[0100] By superimposing displacement compensation on the basic displacement setpoint to reconstruct the next cycle set displacement, the displacement gap is gradually filled; by using an exponential decay factor to calculate the displacement compensation, the displacement recovery rate is controlled to avoid excessive stress in the solidified shell caused by sudden displacement changes.

[0101] For example, assuming the basic displacement setting is 5 mm and the displacement compensation is 0.2 mm, then the displacement setting for the next cycle after reconstruction is 5 + 0.2 = 5.2 mm; assuming the displacement gap accumulator value is 0.9 mm and the exponential decay factor is one-third, then the displacement compensation is 0.9 / 3 = 0.3 mm.

[0102] S315, update the displacement gap accumulator to the original accumulator value minus the displacement compensation amount, and maintain the set displacement of all healthy flows as the base displacement set value unchanged.

[0103] It is understandable that the way to update the displacement gap accumulator is to directly subtract the displacement compensation amount from the original accumulator value to obtain the new accumulator value. For example, if the original accumulator value is 0.9 mm and the displacement compensation amount is 0.3 mm, the updated accumulator value is 0.9 - 0.3 = 0.6 mm.

[0104] The displacement gap accumulator is updated by deducting the compensated displacement amount, and the total amount of remaining displacement gap to be filled is recorded. The set displacement of all healthy flows remains unchanged as the base value, avoiding frequent fluctuations in healthy flow parameters and ensuring the production stability of normal flow channels.

[0105] S316, during the compensation process, the phase nodes of the pull-stop-push process are kept synchronized with those of the healthy flow and the slightly deteriorated flow. The displacement adjustment is achieved by fine-tuning the speed amplitude of the pulling stage, without changing the total duration of a single cycle.

[0106] It can be understood that the phase node of the pull-stop-push process refers to the start and end time nodes of the three stages of pulling, stopping and pushing. For example, if all streams start the pulling stage at second 0 and enter the stopping stage at second 2, the corresponding time is the phase node.

[0107] The speed amplitude refers to the maximum speed at which the billet moves during the billet pulling stage. Adjusting this value can change the total displacement of the billet pulling without changing the duration. For example, if the duration of the billet pulling stage is 2 seconds and the speed amplitude is 2.5 mm, then the total displacement per second is 5 mm.

[0108] The total duration of a single cycle refers to the total time to complete one complete pull-stop-push process, including the duration of the three stages of pulling, stopping, and pushing.

[0109] To maintain synchronization of the pull-stop-push process phase nodes for healthy and slightly deteriorated flows, a unified clock trigger can be used, where the pull-stop-push phase switching for all flows is triggered by the same controller clock signal. For example, the controller sends a cycle start signal every 5 seconds, and all flows start the pulling stage synchronously. Alternatively, phase deviation correction can be used, where the phase deviation of each flow is detected every cycle and the stage duration is finely adjusted. For example, if the phase deviation of a certain flow is 0.05 seconds, the pause stage duration is finely adjusted by 0.05 seconds to pull back to synchronization.

[0110] The speed amplitude during the casting stage can be adjusted in several ways. One way is to keep the speed constant during the casting stage and only adjust the speed magnitude to change the total displacement. For example, if the casting stage lasts for 2 seconds and the speed amplitude is increased from 2.5 mm / s to 2.6 mm / s, the single-cycle displacement increases from 5 mm to 5.2 mm. Another way is to keep the acceleration and deceleration slopes constant during the casting stage and only adjust the speed amplitude during the constant speed segment to change the total displacement. For example, if the speed during the constant speed segment is increased from 2.5 mm / s to 2.6 mm / s while keeping the acceleration and deceleration duration constant, the total displacement will increase accordingly.

[0111] By synchronizing the process phase nodes of the healthy flow and the slightly deteriorated flow, the overall cycle time consistency of multi-flow casting is maintained, adapting to the liquid supply characteristics of the shared tundish; displacement adjustment is achieved by fine-tuning the speed amplitude of the casting stage without changing the total cycle time, thus adjusting the displacement without disrupting the process rhythm and reducing interference with the solidification process.

[0112] In one possible implementation, please refer to Figure 3 In the S300, the strategy of combining local security degradation with global output sharing includes: S321, perform local safety degradation on severely degraded flow k; wherein, local safety degradation includes at least one method of reducing the single-cycle set displacement. If the local safety degradation adopts the method of reducing the single-cycle set displacement, the corresponding safety displacement is the product of the basic displacement set value and the safety degradation coefficient.

[0113] It can be understood that "severely degraded flow k" refers to a designated degraded flow channel in a multi-head copper bar horizontal continuous casting device where the relative deviation is greater than or equal to the second preset threshold and the billet pulling resistance shows a significant abnormal increase. k is the number of the flow that is judged to be severely degraded.

[0114] Local safety degradation refers to a parameter degradation control method that is performed separately for severely degraded flow. It only adjusts the process parameters of the target degraded flow and does not directly change the operating parameters of other flow channels. For example, the single-cycle set displacement of severely degraded flow k is reduced from 5 mm to 4 mm.

[0115] The safety degradation factor refers to the preset proportional coefficient used to calculate the safety displacement, which reflects the degree of local safety degradation. For example, the safety degradation factor can be set to 0.8, 0.7, etc.

[0116] Safe displacement refers to the compliant billet displacement value allowed for operation in a single cycle after a severely degraded flow undergoes local safety degradation.

[0117] By performing local safety degradation treatment on severely degraded flow k separately, the risk of billet operation in flow channels with abnormally high resistance is reduced; by calculating the safety displacement by multiplying the basic displacement setpoint and the safety degradation coefficient, safe process parameters adapted to the degraded flow are provided to mitigate the equipment and billet quality hazards caused by abnormal operating conditions.

[0118] For example, assuming the basic displacement setting is 5 mm and the fixed safety degradation factor is 0.8, then the safety displacement = 5 mm. 0.8 = 4 millimeters.

[0119] S322, calculate the global production gap caused by the local safety degradation of the severely degraded flow k within a single cycle; where, if the local safety degradation adopts the method of lowering the single-cycle set displacement, the global production gap is the product of the cross-sectional area of ​​the copper rod and the difference between the basic displacement set value and the safety displacement.

[0120] It is understandable that the global production gap refers to the reduction in copper rod output of the entire continuous casting production line within a single cycle after a severely degraded flow implements local safety downgrades.

[0121] The cross-sectional area of ​​a copper rod refers to the cross-sectional area of ​​a copper rod produced by horizontal continuous casting. It is determined by the specifications and dimensions of the copper rod. The cross-sectional area of ​​a copper rod can be obtained by receiving data output after manual measurement, or by reading the cross-sectional area of ​​the copper rod specified in the production plan.

[0122] The difference between the basic displacement setpoint and the safe displacement refers to the difference in single-cycle billet displacement before and after severe flow degradation, reflecting the amount of single-cycle displacement reduction.

[0123] By locating the displacement difference before and after the severely degraded flow degradation, the displacement reduction rate in a single cycle is quantified; by combining the cross-sectional area of ​​the copper rod to calculate the global production gap, the displacement loss is transformed into an intuitive production loss value, providing a basis for subsequent multi-flow production coordinated and averaging control.

[0124] Two methods for calculating the global production gap and examples For example, assuming the cross-sectional area of ​​the copper rod is 78.5 square millimeters, the basic displacement setting is 5 millimeters, and the safety displacement is 4 millimeters, then the global production gap = 78.5. (5-4) = 78.5 cubic millimeters.

[0125] S323, the global production gap is distributed among all healthy streams by fine-tuning the billet displacement setting value; for each healthy stream j, the single-stream distributed displacement increment is calculated, which is the global production gap divided by the product of the copper bar cross-sectional area and the number of healthy streams; if the single-stream distributed displacement increment exceeds the preset maximum allowable displacement increment threshold, it is truncated to the maximum allowable displacement increment threshold; the setting displacement of the healthy stream j in the next cycle is updated to the sum of the basic displacement setting value and the single-stream distributed displacement increment after the limit is applied.

[0126] It can be understood that healthy flow j refers to any healthy flow channel in a multi-head copper bar horizontal continuous casting device where the relative deviation is less than the first preset threshold and the billet pulling resistance is within the normal fluctuation range, and j is the label of the flow that is determined to be healthy flow.

[0127] The single-flow average displacement increment refers to the additional billet displacement required for a single healthy flow in a single cycle, used to compensate for the production gap caused by the degradation of the deteriorated flow.

[0128] The number of healthy flow channels refers to the total number of channels that are currently in normal and healthy operation and can participate in the production gap sharing.

[0129] The maximum allowable displacement increment threshold refers to the upper limit of the allowable increase in billet displacement within a single healthy flow cycle. It is used to limit the single-flow control amplitude and avoid the risk of excessive parameter adjustment. For example, if the maximum allowable displacement increment threshold is 0.2 mm, and the calculated single-flow increment is 0.25 mm, then it is directly truncated to 0.2 mm.

[0130] The single-stream amortized displacement increment after limiting refers to the effective displacement increment value used for parameter updates after the single-stream amortized displacement increment has been corrected by threshold truncation.

[0131] The method for updating the set displacement of the healthy flow j for the next cycle can be to directly superimpose the single-flow amortized displacement increment after the current cycle to update the parameters of the next cycle. For example, if the base displacement setting is 5 mm and the single-flow amortized displacement increment after the limit is 0.2 mm, then the set displacement after the update is 5.2 mm. Alternatively, the total increment can be split into multiple cycles and gradually superimposed on each cycle. For example, if the total increment is 0.2 mm, it can be split into 2 cycles, with 0.1 mm superimposed in each cycle. The set displacement for the first update cycle is 5.1 mm, etc.

[0132] By distributing the global production shortfall to all healthy flows to achieve production compensation, the impact of single-flow degradation on overall capacity is mitigated; by setting a maximum allowable displacement increment threshold to limit and correct the increment, excessive adjustment of healthy flow displacement parameters is avoided, ensuring the stability and safety of multi-flow production.

[0133] For example, assuming a global production deficit of 78.5 cubic millimeters, a copper rod cross-sectional area of ​​78.5 square millimeters, and a healthy flow quantity of 5 flows, then the flow-averaged displacement increment = 78.5 / (78.5) 5) = 0.2 mm.

[0134] In one possible implementation, please refer to Figure 3 In S300, based on the degradation assessment results of each flow, corresponding compensation strategies are implemented for each flow, including: S310 When multiple severely degraded flows exist simultaneously, local safety degradation is performed sequentially according to the relative deviation of each flow from largest to smallest, and the single-flow amortized displacement increment of the remaining healthy flow is recalculated after each degradation.

[0135] It is understandable that multiple severely degraded flows refer to the simultaneous existence of two or more degraded flows with relative deviations greater than or equal to the second preset threshold in a multi-head copper bar horizontal continuous casting device within the same production cycle.

[0136] The remaining healthy flow refers to the set of channels that are still in a healthy operating state and can participate in the production gap sharing after a single local safety degradation operation is completed.

[0137] The methods for degrading and recalculating the increment of severely degraded flows can be as follows: First, degrade the flows one by one according to their relative deviations, from largest to smallest. After each flow is degraded, immediately recalculate the average displacement increment of the single flow based on the number of remaining healthy flows. For example, if the device originally has 6 flows, including 2 severely degraded flows, prioritize degrading the flow with a deviation of 22%, recalculate the increment for the remaining 4 healthy flows, then degrade the flow with a deviation of 16%, and recalculate the increment for the remaining 3 healthy flows. Alternatively, severely degraded flows with similar relative deviations can be grouped into the same batch for simultaneous degradation. After the batch is completed, the increment is recalculated uniformly. For example, two degraded flows with deviations of 22% and 21% can be grouped into a batch for simultaneous degradation. After the batch operation is completed, the average displacement increment parameters are updated uniformly based on the remaining healthy flows.

[0138] By sorting and performing multi-flow local safety degradation based on the relative deviation values, priority can be given to processing flow channels with higher degradation and greater operational risks. After each degradation is completed, the amortization parameters of the remaining healthy flow are recalculated to adapt to dynamically changing flow channel conditions, so that the output amortization result matches the real-time production status.

[0139] S320: When multiple slightly deteriorated flows exist simultaneously, each flow independently executes a strategy that combines resistance feedforward compensation with displacement asymptotic recovery.

[0140] It is understandable that multiple slightly deteriorated flows refer to two or more deteriorated flow channels in the same production cycle of a multi-head copper bar horizontal continuous casting device, where the relative deviation is greater than or equal to the first preset threshold and less than the second preset threshold.

[0141] The strategy of combining resistance feedforward compensation with displacement gradual recovery means that the compensation and control processes of each slightly deteriorated flow do not interfere with or link with each other, and each flow matches parameters independently based on its own resistance deterioration state.

[0142] By allowing each slightly deteriorated flow to independently execute a resistance feedforward compensation combined with a displacement gradual recovery strategy, the system adapts to the different small resistance deterioration states of each flow and slightly adjusts the operating parameters of each flow to fit the optimal operating conditions.

[0143] S330: When the single-stream average displacement increment after limiting is still unable to fully cover the global production gap, a production alarm is triggered, and the displacement setting value of the healthy stream is no longer increased.

[0144] It is understandable that the production alarm refers to the working condition prompt mechanism triggered when the production gap of the production line cannot be made up by fine-tuning the health flow parameters, and is used to remind staff to pay attention to abnormal production status.

[0145] By detecting the compensation effect after the limit is evenly distributed, the production gap coverage is judged, abnormal operating conditions of insufficient capacity compensation are identified, production alarms are triggered and the operating parameters of each flow are locked, so as to avoid the operational risks caused by excessive adjustment of healthy flow parameters and ensure the overall safe and stable operation of the production line.

[0146] S400 recalculates the equivalent resistance index and actual billet displacement of each flow within a preset number of billet pulling cycles after the compensation strategy is executed, obtains verification results reflecting the compensation effect, and dynamically adjusts the parameters of the compensation strategy based on the verification results.

[0147] It is understandable that the preset number of drawing cycles refers to the fixed period of observation used to observe the compensation effect after the compensation strategy is executed. It can be set according to the production process requirements. For example, the preset number can be set to 10 drawing cycles or 15 drawing cycles.

[0148] The verification results refer to the comprehensive judgment data calculated based on the flow operation parameters after compensation, which are used to reflect the effect of the compensation strategy and can reflect the improvement status of displacement deviation and resistance deviation.

[0149] The parameters of the compensation strategy refer to various adjustable process parameters involved in the compensation control, which may include control parameters such as safety degradation coefficient, feedforward gain coefficient, and displacement attenuation factor.

[0150] The equivalent resistance index and actual billet displacement of each flow can be calculated to obtain verification results reflecting the compensation effect. One method is to take the average value of parameters of all billet pulling cycles of a preset number to calculate the equivalent resistance index and actual billet displacement, and generate verification results based on the average data. Another method is to select multiple sets of parameters for steady-state operation in the second half of the observation cycle to calculate the index, remove the fluctuation data in the early stage of compensation, calculate the equivalent resistance index and actual billet displacement, and generate verification results.

[0151] The method of dynamically adjusting the parameters of the compensation strategy based on the verification results can be to slightly increase or decrease the compensation parameters according to the magnitude of the deviation improvement. For example, if the deviation improvement after compensation is small, the preset feedforward gain coefficient can be finely adjusted from 0.8 to 0.85. Alternatively, the corresponding parameter level can be matched according to the deviation range of the verification results. For example, if the deviation is in the range of 5% to 10%, the medium displacement attenuation factor can be used, and if the deviation is less than 5%, the low displacement attenuation factor can be used.

[0152] By reserving a fixed observation period after the compensation strategy is executed, stable and effective subsequent operation data are collected; compensation verification results are obtained based on measured parameters, and parameters are dynamically iterated and adjusted to adapt the compensation strategy to the dynamic changes in the flow channel conditions, thereby gradually optimizing the billet pulling compensation control effect.

[0153] In one possible implementation, please refer to Figure 3 S400, within a preset number of drawing cycles after the compensation strategy is executed, recalculate the equivalent resistance index and actual drawing displacement of each flow to obtain verification results reflecting the compensation effect, and dynamically adjust the parameters of the compensation strategy based on the verification results, including: S410, after executing the compensation strategy, recalculates the equivalent resistance index and actual billet displacement of each compensated flow after a preset number of billet drawing cycles.

[0154] It is understandable that the compensated flow refers to a single or multi-channel flow that has previously undergone compensation strategies such as resistance feedforward compensation, displacement asymptotic recovery, or safety degradation.

[0155] The post-compensation observation period refers to a preset period interval specifically used to observe the recovery state of the compensated flow parameters.

[0156] The equivalent resistance index and actual billet displacement of each compensated flow can be recalculated by calculating the equivalent resistance index and actual billet displacement separately for each cycle within a preset observation period, such as calculating the resistance index and displacement data for each of the 10 observation cycles; or by integrating all sampled data within a preset period and uniformly calculating the average equivalent resistance index and average actual billet displacement, such as integrating the data from 10 cycles and calculating the average resistance index and average actual displacement for that observation interval.

[0157] By reserving a preset number of drawing cycles to allow the compensation strategy to take effect stably, computational interference caused by parameter fluctuations in the early stages of strategy execution is avoided; by recalculating the operating parameters of the compensated flow in a targeted manner, the actual operating status after single-flow compensation is obtained, providing data support for subsequent effect judgment.

[0158] S420, if the displacement gap of the compensated flow is reduced to within the preset accuracy range and the relative deviation is reduced to below the preset threshold, then the compensation is deemed effective and the current strategy parameters are maintained.

[0159] It is understandable that the preset accuracy range refers to the range of small deviations that the displacement gap can tolerate. It is a quantitative standard for determining whether the displacement recovery meets the standard. For example, the preset accuracy range can be set to 0 mm to 0.1 mm, 0 mm to 0.08 mm, etc.

[0160] The preset threshold value refers to the qualified critical value of the relative deviation of the compensated flow. If the deviation is lower than this value, it can be determined that the resistance state has returned to normal. For example, the preset threshold value can be set to 5%, 4%, etc.

[0161] The methods for determining the preset accuracy range and preset compliance threshold can be as follows: parameters can be set based on the process experience of stable on-site production. For example, based on the fluctuation range of normal production, the preset accuracy range of displacement can be set to 0 mm to 0.1 mm and the preset compliance threshold can be set to 5%. Alternatively, parameters can be determined by statistically analyzing the fluctuation range of long-term healthy flow operation data. For example, if the maximum fluctuation of displacement in healthy flow over 30 days is 0.08 mm and the maximum fluctuation of relative deviation is 4%, the corresponding displacement accuracy range can be set to 0 mm to 0.08 mm and the compliance threshold can be set to 4%.

[0162] By setting a standard for judging the accuracy of displacement gaps, the degree of perfection of displacement recovery is quantified. Combined with the relative deviation threshold of resistance, the effectiveness of compensation is comprehensively judged, realizing multi-dimensional judgment of compensation effect and ensuring the stable operation of subsequent strategy parameters.

[0163] S430, if the displacement gap shrinks but does not shrink to the preset accuracy range, the compensation part is deemed effective, and the strength of the resistance feedforward compensation is increased or the displacement recovery rate is accelerated before continuing execution.

[0164] It is understandable that the effective compensation part refers to the intermediate operating state where the working conditions are slightly improved after the compensation strategy is implemented, but have not fully reached the qualified standard.

[0165] The strength of resistance feedforward compensation refers to the force of feedforward torque compensation, which is determined by the preset feedforward gain coefficient. The larger the gain coefficient, the higher the compensation strength. For example, a gain coefficient of 0.8 is the normal strength, and 0.9 is the enhanced strength.

[0166] The displacement recovery rate refers to the rate at which the cumulative value of the displacement gap is made up. It is determined by the smoothing time constant and the exponential decay factor. The larger the decay factor, the faster the displacement recovery rate.

[0167] Increasing the strength of resistance feedforward compensation or accelerating the displacement recovery rate can be achieved by increasing the preset feedforward gain coefficient to increase the torque compensation strength, for example, increasing the original gain coefficient from 0.8 to 0.85; or by decreasing the smoothing time constant to increase the exponential decay factor and accelerate the displacement gap filling speed, for example, adjusting the original smoothing time constant from 5 cycles to 3 cycles to accelerate the displacement recovery rate.

[0168] By identifying intermediate working conditions where compensation is effective, the system covers transitional scenarios where compensation is insufficient; by specifically increasing the compensation intensity or accelerating the displacement recovery speed, the compensation effect is slightly enhanced, and the compensated flow conditions are gradually restored to the qualified range.

[0169] S440 If the displacement gap remains unchanged or increases, or the corresponding equivalent resistance index continues to rise, the compensation is deemed invalid, triggering a process alarm requesting manual intervention.

[0170] It is understandable that ineffective compensation refers to an abnormal operating condition in which the displacement deviation and resistance deviation of the compensated flow do not improve or even worsen after the compensation strategy is implemented.

[0171] By monitoring the inverse relationship between the displacement gap and the equivalent resistance index, abnormal operating conditions where compensation control fails can be identified, triggering process alarms and requesting manual intervention. This allows for the timely termination of ineffective automatic control and avoids production risks caused by the continuous deterioration of operating conditions.

[0172] In one possible implementation, please refer to Figure 3 The billet pulling displacement setting value is limited between a minimum displacement limit value and a maximum displacement limit value; wherein, the minimum displacement limit value is a preset minimum proportion of the basic displacement setting value, and the maximum displacement limit value is a preset maximum proportion of the basic displacement setting value; the absolute value of the change in the set displacement between adjacent cycles is limited to a maximum rate of change limit value; wherein, the maximum rate of change limit value is a preset rate of change of the basic displacement setting value; the resistance feedforward compensation torque is limited to a preset torque proportion of the rated torque of the billet pulling drive motor, and the method further includes: S500: When the relative deviation of a certain flow exceeds the emergency threshold, or when a sudden increase in torque and a sudden drop in speed of the billet drive motor are detected, the flow is triggered to stop casting and the corresponding stopper bar in the tundish is closed. The remaining flows then re-execute the global production coordination and averaging strategy.

[0173] It can be understood that the minimum displacement limit value refers to the lowest allowable downward adjustment of the billet displacement setting value, used to prevent excessive downward adjustment of displacement from causing production abnormalities. For example, if the basic displacement setting value is 5 mm and the preset minimum ratio is 0.7, then the corresponding minimum displacement limit value is 5 mm. 0.7 = 3.5 millimeters.

[0174] The maximum displacement limit refers to the highest allowable upward adjustment of the billet displacement setting. It is used to constrain the upward adjustment range of healthy flow displacement compensation. For example, if the basic displacement setting is 5 mm and the preset maximum ratio is 1.2, the corresponding maximum displacement limit is 5 mm. 1.2 = 6 millimeters.

[0175] The absolute value of the change in displacement between adjacent cycles refers to the positive value of the difference between the displacement settings of two consecutive billet drawing cycles, which is used to characterize the adjustment range of the displacement parameter in a single cycle.

[0176] The maximum rate of change limit refers to the maximum allowable change in displacement between adjacent periods. It is used to prevent sudden changes in displacement parameters. For example, if the basic displacement setting is 5 mm and the preset change ratio is 0.05, the corresponding maximum rate of change limit is 5 mm. 0.05 = 0.25 millimeters.

[0177] The preset torque ratio refers to the proportional parameter used to limit the upper limit of the feedforward compensation torque. It is based on the rated torque of the billet drive motor and is used to avoid the risk of torque overload. For example, if the rated torque is 200 Nm and the preset torque ratio is 0.15, the corresponding upper limit of the compensation torque is 30 Nm.

[0178] The emergency threshold is a critical relative deviation value used to determine if a flow channel has experienced a high-risk or deteriorated chemical condition. The value is higher than the conventional deterioration threshold and serves as the basis for triggering emergency protection actions. It can be determined based on the statistical analysis of the equipment's safe operating margin and historical leakage precursor data (taking the minimum deviation data of historical leakage accident precursors as a reference benchmark). For example, the emergency threshold can be set to 30%, 35%, etc.

[0179] Emergency shutdown refers to the emergency shutdown and material cut-off protection operation executed when a high-risk fault precursor is detected in a single flow, used to avoid major quality risks to equipment and billets.

[0180] The stopper rods corresponding to the tundish refer to the flow control components on the tundish corresponding to each flow channel, which can control the flow state of molten steel in a single stream through opening and closing actions.

[0181] The preset minimum and maximum ratios can be determined based on the normal production process fluctuation range. For example, if the displacement fluctuation range in normal production is 70% to 120% of the base value, then the preset minimum ratio is set to 0.7 and the preset maximum ratio is set to 1.2. Alternatively, the ratios can be matched based on the upper and lower limits of the displacement that the billet pulling equipment can stably bear. For example, if the minimum stable operating displacement of the equipment is 65% of the base value and the maximum stable displacement is 125% of the base value, then after reserving a safety margin, the preset minimum ratio is set to 0.68 and the preset maximum ratio is set to 1.22, etc.

[0182] The preset change ratio can be determined by statistically analyzing the maximum displacement fluctuation of adjacent cycles in normal production as the preset change ratio. For example, if the maximum displacement fluctuation of a single cycle in long-term steady-state production is 4% of the base displacement, then the preset change ratio is set to 0.04. Alternatively, the ratio parameter can be adapted according to the dynamic response speed of the system. For example, if the system response speed is fast, the preset change ratio is set to 0.06, and if the system response speed is slow, the preset change ratio is set to 0.03 to avoid parameter adjustment lag or overshoot.

[0183] The preset torque ratio can be determined by retaining a safety margin of the motor's rated torque. For example, to ensure long-term stable operation of the motor, if an 85% basic load margin is retained, the preset torque ratio is set to 0.15. Alternatively, it can be matched according to the maximum compensation requirement under slightly degraded operating conditions. For example, if the maximum compensation torque requirement under multi-flow, slightly degraded operating conditions is 12% of the rated torque, then after reserving a margin, the preset torque ratio is set to 0.14, etc.

[0184] The remaining streams can re-implement the global production coordination and allocation strategy in the following ways: after an emergency shutdown of a single stream, the entire production gap generated by that stream is evenly distributed to all remaining healthy streams. For example, if an emergency shutdown of stream 1 in a 6-stream production line generates a production gap of 100 cubic millimeters, the remaining 5 streams each receive the displacement increment corresponding to a gap of 20 cubic millimeters. Alternatively, the allocation weight can be set according to the equipment operating status and process margin of each remaining stream. Streams with more stable conditions will bear more compensation. For example, if 3 of the remaining 5 streams are in stable condition and 2 are in normal condition, the stable streams will each receive a gap of 25 cubic millimeters, and the normal streams will each receive a gap of 12.5 cubic millimeters.

[0185] By setting upper and lower limits for displacement and limits for the rate of change of periodic displacement, the adjustment range and speed of the billet displacement parameters are constrained, thus avoiding operational disturbances caused by large fluctuations in parameters. By setting limits for the proportional ratio of resistance feedforward compensation torque, the upper limit of motor output is constrained, reducing the probability of motor overload operation. By identifying high-risk deviations and signs of leakage, single-flow emergency protection is triggered and multi-flow production is restarted, thus maintaining the stability of the entire production line's capacity as much as possible while dealing with sudden failures.

[0186] In one possible implementation, the method also includes: While performing cycle-level collaborative control, the S600 uploads the equivalent resistance index of each flow in each drawing cycle to the edge computing node.

[0187] It can be understood that cycle-level coordinated control refers to the coordinated adjustment of multiple flow parameters executed on a single billet drawing cycle basis, including the conventional coordinated control logic such as production distribution, displacement compensation, and torque correction mentioned above.

[0188] Edge computing nodes refer to terminal computing devices that can perform data processing and analysis.

[0189] By uploading the equivalent resistance index of each flow cycle to the edge computing node, continuous and complete basic data support can be provided for upper-layer time series modeling, trend analysis and other processes.

[0190] S700 uses a time-series prediction model to perform trend analysis on the time series of the equivalent drag index of each flow, and fits the long-term drift slope of the corresponding flow's equivalent drag index.

[0191] It is understandable that time series forecasting models refer to analytical models built for time series data, which can uncover the potential patterns of data changes over time and are suitable for trend analysis scenarios of continuous industrial sampling data. For example, linear time series fitting models and exponential smoothing time series forecasting models can be used.

[0192] The equivalent resistance index time series refers to the data set of equivalent resistance index that is continuously collected and arranged in the order of the billet pulling cycle, and includes information on resistance fluctuations and long-term changes over multiple cycles.

[0193] Long-term drift slope refers to a quantitative slope parameter that characterizes the long-term overall trend of the equivalent resistance index. It can reflect the steady-state change pattern of the resistance index as it slowly rises or falls, and can weaken the interference of short-term random fluctuations.

[0194] The long-term drift slope of the corresponding flow equivalent drag index can be obtained by fitting the time series prediction model using least squares linear fitting, which constructs a linear equation based on multi-period time series data to solve for the optimal slope; or it can be obtained by using Sen slope robust estimation, which solves for the trend slope by the median of the differences between multiple sets of data, thus weakening the influence of abnormal noise.

[0195] By using a time-series prediction model to conduct trend analysis on the time-series data of resistance indicators, the interference caused by single-cycle random fluctuations is eliminated. By fitting and solving the long-term drift slope corresponding to each flow, the long-term deterioration trend of the resistance of each flow is quantified, providing a quantitative basis for predicting future deterioration conditions.

[0196] For example, the equivalent resistance index values ​​of the previous 50 drawing cycles are used to construct the time-series input sequence. Based on the wheel-throwing cycle number These are time features, constituting the input feature pairs. Based on this feature, a univariate linear regression model is constructed. Where the slope parameter 'a' is the long-term drift slope and the intercept 'b' is the baseline resistance term, the result is achieved by minimizing the sum of squared residuals. Solving for optimal parameters After the fitting is completed, the rolling cycle number corresponding to the preset future duration (e.g., 20 cycles) will be assigned. Substitute into the linear model to calculate the predicted value of the equivalent drag index for this flow. ,when When the equivalent resistance index value corresponding to the second preset threshold is reached or exceeded, it is determined that the flow will enter a severely deteriorated state within 20 drawing cycles, and the determination coefficient of the fitted model is calculated at the same time. To verify the goodness of fit, when the determination coefficient When the coefficient is below a preset goodness-of-fit threshold, the linear trend is determined to be insignificant, and no prediction is triggered. When the predicted value is greater than or equal to the preset goodness-of-fit threshold, calculate the predicted value. ,like If the equivalent resistance index value corresponding to the second preset threshold is reached or exceeded, it is determined that the flow will enter a severely degraded state within the preset future time period.

[0197] S800 When it is predicted that the equivalent resistance index of a certain flow will reach the severe deterioration threshold within a preset time period in the future, a preventive maintenance work order is generated and issued, and the control mode of the flow is switched from the collaborative optimization mode to the safe production mode. In the safe production mode, the flow performs a derated billet setting, no longer participates in the global production collaborative allocation, and increases the monitoring frequency of the equivalent resistance index.

[0198] It is understandable that the future preset duration refers to the future time interval used to predict the deterioration trend. It can be determined by the confidence interval width of the long-term drift slope and the response margin of the billet pulling process. For example, the future preset duration can be set to 20 billet pulling cycles, 30 billet pulling cycles, etc.

[0199] Collaborative optimization mode refers to the control mode of normal production line operation, which aims to balance multi-flow capacity and optimize parameter collaboration, and performs global output collaborative allocation and parameter adaptive compensation.

[0200] The safety and production protection mode refers to a dedicated control mode activated in response to anticipated high-risk and deteriorating flows. It prioritizes the safe and stable operation of equipment while appropriately sacrificing capacity optimization.

[0201] The derated billet setting refers to the low-load billet setting used in the safe production mode. It reduces the operating load of the equipment by lowering the single-cycle billet displacement, for example, reducing the basic displacement from 5 mm to 4 mm.

[0202] Monitoring frequency refers to the number of times parameters are collected and detected per unit time or unit cycle. Increasing the monitoring frequency can obtain more intensive operating condition data, making it easier to capture abnormal changes in a timely manner.

[0203] For example, the process for generating and issuing preventive maintenance work orders can be as follows: when the time series prediction model determines that the equivalent resistance index of a certain flow will reach the severe degradation threshold within a preset time period in the future, the control device automatically generates a preventive maintenance work order. The work order content includes at least the predicted degradation flow channel number, the current equivalent resistance index value, the number of remaining cycles before the predicted severe degradation threshold is reached, the recommended maintenance action type matched according to the degradation trend characteristics (such as crystallizer status inspection, cooling water circuit cleaning, billet drive component replacement, tundish stopper rod seal inspection, etc.), and the suggested maintenance window time. After the work order is generated, it can be synchronously issued to the manufacturing execution system through the communication interface and pushed to the field operation terminal display screen, while triggering the audible and visual prompt signals of the control device to remind the on-duty personnel, etc.

[0204] For example, the switching logic and execution steps between the collaborative optimization mode and the safe production mode can be as follows: The judgment logic adopts a three-level gradient triggering mechanism. When the predicted number of remaining cycles for a certain flow is less than or equal to the first preset cycle threshold (e.g., 10 cycles), the mode switching is triggered immediately. When the number of remaining cycles is greater than the first preset cycle threshold but less than or equal to the second preset cycle threshold (e.g., 30 cycles), the mode switching is triggered after the current billet pulling cycle ends, ensuring that the mode switching does not interrupt the billet pulling action being executed. When the number of remaining cycles is greater than the second preset cycle threshold, only a preventive maintenance work order is generated, and the control mode is not switched temporarily, maintaining the operation of the collaborative optimization mode. The execution steps are as follows: Step 1, freeze the current collaborative optimization parameters of the flow and record the current displacement setting value; Step 2, execute the derated billet setting, reduce the displacement setting value according to the preset derated ratio and lock it so that it no longer participates in adaptive adjustment; Step 3, remove the flow from the participating flow set of global production collaborative allocation, and recalculate the single-flow allocated displacement increment of the remaining healthy flows; Step 4, increase the monitoring frequency of the equivalent resistance index of the flow from once per cycle to twice or three times per cycle to obtain more intensive operating condition data; Step 5, highlight the safe production operation status indicator of the flow on the human-machine interface of the control device, and prompt the operator that the flow has exited collaborative optimization and entered independent safe operation mode, etc.

[0205] By relying on time-series prediction results to anticipate future deterioration conditions, potential faults can be identified and addressed in advance. By switching the control mode of high-risk flow channels and matching control logics such as derating, exemption from amortization, and high-frequency monitoring, the overall stable operation of the production line can be maintained while ensuring the safe operation of equipment, thus reducing production disturbances caused by sudden failures.

[0206] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0207] Corresponding to the multi-head copper bar horizontal continuous casting speed coordination control method of the above embodiments, this application embodiment also provides a multi-head copper bar horizontal continuous casting speed coordination control system, each unit of the system can realize each step of the multi-head copper bar horizontal continuous casting speed coordination control method. Figure 4 The diagram shows a structural block diagram of the multi-head copper bar horizontal continuous casting stud speed coordination control system provided in the embodiment of this application. For ease of explanation, only the parts related to the embodiment of this application are shown.

[0208] Reference Figure 4 The system includes: The resistance sensing unit is used to calculate the net effective mechanical work of the billet drive motor on the billet during the cycle at the end of each billet drawing unit, taking the single intermittent billet drawing cycle of each flow drawing unit as the basic time unit, and calculate the equivalent resistance index in combination with the actual net billet drawing displacement of the cycle.

[0209] The degradation discrimination unit is used to compare the equivalent resistance index of each flow in the current cycle with the corresponding historical moving average to obtain the relative deviation, and obtain the corresponding degradation discrimination result of each flow based on the magnitude of the relative deviation; wherein, the degradation discrimination result is one of healthy flow, slightly degraded flow, and severely degraded flow.

[0210] The differential compensation unit is used to execute corresponding compensation strategies for each flow based on the degradation judgment results of each flow. If the degradation judgment result of the flow is slightly degraded, a strategy of resistance feedforward compensation combined with displacement gradual recovery is executed. If the degradation judgment result of the flow is severely degraded, a strategy of local safety degradation combined with global output collaborative averaging is executed.

[0211] The verification and adjustment unit is used to recalculate the equivalent resistance index and actual billet displacement of each flow within a preset number of billet pulling cycles after the compensation strategy is executed, to obtain verification results reflecting the compensation effect, and to dynamically adjust the parameters of the compensation strategy based on the verification results.

[0212] It should be noted that the information interaction and execution process between the above-mentioned units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.

[0213] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the system can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units and modules in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0214] This application also provides a multi-head copper bar horizontal continuous casting device. Figure 5 This is a schematic diagram of the structure of a multi-head copper bar horizontal continuous casting apparatus provided in one embodiment of this application. Figure 5 As shown, the multi-head copper bar horizontal continuous casting apparatus of this embodiment also includes a control device 6. The control device 6 includes at least one processor 60. Figure 5 Only one is shown in the image), at least one memory 61 ( Figure 5 (Only one is shown in the image) and a computer program 62 stored in the at least one memory 61 and executable on the at least one processor 60. When the processor 60 executes the computer program 62, it causes the multi-head copper bar horizontal continuous casting device to implement the steps in any of the above embodiments of the multi-head copper bar horizontal continuous casting flow drawing speed coordinated control method, or causes the multi-head copper bar horizontal continuous casting device to implement the functions of each unit in the above embodiments of the system.

[0215] For example, the computer program 62 may be divided into one or more modules / units, which are stored in the memory 61 and executed by the processor 60 to complete this application. The one or more modules / units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 62 in the control device 6.

[0216] The control device 6 can be an industrial programmable logic controller (PLC), an embedded motion controller, a desktop computer, an industrial server, or other computing device. The control device 6 may include, but is not limited to, a processor 60 and a memory 61. Those skilled in the art will understand that... Figure 5This is merely an example of a multi-head horizontal continuous casting device for copper bars and does not constitute a limitation on such devices. It may include more or fewer components than shown in the figure, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0217] The processor 60 can be a Central Processing Unit (CPU), or it can be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0218] In some embodiments, the memory 61 may be an internal storage unit of the control device 6, such as a hard disk or memory of the control device 6. In other embodiments, the memory 61 may be an external storage device of the control device 6, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the control device 6. Furthermore, the memory 61 may include both internal storage units and external storage devices of the control device 6. The memory 61 is used to store operating systems, applications, bootloaders, data, and other programs, such as the program code of computer programs. The memory 61 can also be used to temporarily store data that has been output or will be output.

[0219] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A method for coordinated control of the billet pulling speed of each stream in horizontal continuous casting of multi-head copper bars, characterized in that, This invention relates to a multi-spindle horizontal continuous casting apparatus for copper bars, comprising a multi-strand parallel-arranged billet-drawing unit. Each billet-drawing unit has a billet-drawing drive motor, and each strand shares a tundish and has an independent crystallizer. Each strand employs an intermittent drawing process involving pulling, stopping, and pushing. The control method includes: Using the single intermittent billet drawing cycle of each flow billet drawing unit as the basic time unit, at the end of each billet drawing cycle, the net effective mechanical work of the billet drawing drive motor acting on the billet during that cycle is calculated, and the equivalent resistance index is calculated in combination with the actual net billet drawing displacement of that cycle. The equivalent resistance index of each flow in the current cycle is compared with the corresponding historical moving average to obtain the relative deviation. The corresponding degradation judgment result of each flow is obtained according to the magnitude of the relative deviation. The degradation judgment result is one of healthy flow, slightly degraded flow, and severely degraded flow. Based on the degradation assessment results of each flow, corresponding compensation strategies are implemented for each flow; if the degradation assessment result of a flow is slightly degraded, a strategy combining resistance feedforward compensation and displacement gradual recovery is implemented; if the degradation assessment result of a flow is severely degraded, a strategy combining local safety degradation and global output collaborative averaging is implemented. Within a preset number of drawing cycles after the compensation strategy is executed, the equivalent resistance index and actual drawing displacement of each flow are recalculated to obtain verification results reflecting the compensation effect, and the parameters of the compensation strategy are dynamically adjusted based on the verification results.

2. The method for coordinated control of the billet pulling speed of each stream in horizontal continuous casting of multi-head copper bars as described in claim 1, characterized in that, The calculation of the equivalent resistance index includes: For the i-th flow, during the P-th drawing cycle, the real-time torque and real-time speed of the drawing drive motor in the drawing stage and the reverse push stage are collected respectively, and the mechanical work output by the motor in the drawing stage and the reverse push stage is calculated. The effective mechanical work of the billet being applied to the billet is obtained by subtracting the corresponding no-load loss of the transmission system based on no-load test calibration from the mechanical work output of the motor corresponding to the billet pulling stage and the reverse pushing stage. Taking the forward direction of the billet pulling as the positive direction, the effective mechanical work of the billet pulling stage is counted as a positive value, and the effective mechanical work of the reverse pushing stage is counted as a negative value. The effective mechanical work of the billet pulling stage and the effective mechanical work of the reverse pushing stage are added together to obtain the net effective mechanical work of a single cycle. The actual net billet displacement during the P-th billet pulling cycle is recorded by a displacement detection device that does not slide relative to the billet, and the ratio of the net effective mechanical work per cycle to the actual net billet displacement is defined as the equivalent resistance index.

3. The method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars as described in claim 2, characterized in that, The step of obtaining the degradation judgment result corresponding to each flow based on the magnitude of the relative deviation includes: Calculate the historical sliding average value of the equivalent resistance index of the i-th flow within a preset sliding window length. The historical sliding average value is the average value of all equivalent resistance indices within the window up to the previous drawing cycle. Calculate the relative deviation of the equivalent resistance index of the current period relative to the historical moving average; wherein the relative deviation is the ratio of the absolute value of the difference between the equivalent resistance index of the current period and the historical moving average to the historical moving average. If the relative deviation is less than the first preset threshold, the i-th flow is determined to be the healthy flow; if the relative deviation is greater than or equal to the first preset threshold and less than the second preset threshold, the i-th flow is determined to be the slightly degraded flow; if the relative deviation is greater than or equal to the second preset threshold, the i-th flow is determined to be the severely degraded flow.

4. The method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars as described in claim 3, characterized in that, The execution resistance feedforward compensation combined with displacement asymptotic recovery strategy includes: The difference between the equivalent resistance index of the current period and the historical moving average is identified as the resistance increment. The product of the preset feedforward gain coefficient and the resistance increment is determined as the resistance feedforward compensation torque, and in the drawing stage of the next drawing cycle, the resistance feedforward compensation torque is superimposed on the basic torque command of the flow. The difference between the single-cycle set billet displacement and the actual net billet displacement is identified as the single-cycle displacement gap, and the displacement gap of the current cycle is accumulated into the displacement gap accumulator configured for the corresponding flow. The set displacement for the next cycle is the sum of the set base displacement and the displacement compensation amount; wherein the displacement compensation amount is the product of the value in the displacement gap accumulator and the exponential decay factor based on the smoothing time constant. The displacement gap accumulator is updated to the original accumulator value minus the displacement compensation amount, while maintaining the set displacement of all healthy flows as the base displacement set value unchanged; During the compensation process, the phase nodes of the pull-stop-push process of the healthy flow and the slightly deteriorated flow are kept synchronized. The displacement adjustment is achieved by fine-tuning the speed amplitude of the drawing stage, without changing the total duration of a single cycle.

5. The method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars as described in claim 3, characterized in that, The strategy of combining local security degradation with global output sharing includes: Perform local safety degradation on severely degraded flow k; wherein, the local safety degradation includes at least one method of reducing the single-cycle set displacement, and if the local safety degradation adopts the method of reducing the single-cycle set displacement, the corresponding safety displacement is the product of the base displacement set value and the safety degradation coefficient; Calculate the global production gap caused by the severe deterioration flow k performing local safety degradation within a single cycle; wherein, if the local safety degradation adopts the reduction of the single-cycle set displacement, the global production gap is the product of the copper rod cross-sectional area and the difference between the basic displacement set value and the safety displacement; The global production gap is distributed among all healthy flows by fine-tuning the billet displacement setting value. For each healthy flow j, the single-flow distributed displacement increment is calculated, which is the global production gap divided by the product of the copper rod cross-sectional area and the number of healthy flows. If the single-flow distributed displacement increment exceeds the preset maximum allowable displacement increment threshold, it is truncated to the maximum allowable displacement increment threshold. The set displacement of the healthy flow j in the next cycle is updated to be the sum of the base displacement setting value and the single-flow distributed displacement increment after the limit.

6. The method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars as described in claim 5, characterized in that, The step of implementing corresponding compensation strategies for each flow based on the degradation assessment results of each flow also includes: When multiple severely degraded flows exist simultaneously, local safety degradation is performed sequentially in descending order of the relative deviation of each flow, and the amortized displacement increment of the remaining healthy flow is recalculated after each degradation. When multiple slightly deteriorated flows exist simultaneously, each flow independently executes the resistance feedforward compensation combined with the displacement asymptotic recovery strategy. When the single-stream average displacement increment after the limit is still insufficient to fully cover the global production gap, a production alarm is triggered, and the displacement setting value of the healthy stream is no longer increased.

7. The method for coordinated control of the billet pulling speed of each stream in horizontal continuous casting of multi-head copper bars as described in claim 4, characterized in that, Within a preset number of drawing cycles after the compensation strategy is executed, the equivalent resistance index and actual drawing displacement of each flow are recalculated to obtain verification results reflecting the compensation effect. Based on these verification results, the parameters of the compensation strategy are dynamically adjusted, including: After the compensation strategy is executed, after the preset number of drawing cycles, the equivalent resistance index and actual drawing displacement of each compensated flow are recalculated. If the displacement gap of the compensated flow is reduced to within the preset accuracy range and the relative deviation is reduced to below the preset threshold, the compensation is deemed effective and the current strategy parameters are maintained. If the displacement gap shrinks but does not shrink to the preset accuracy range, the compensation is deemed effective, and the strength of the resistance feedforward compensation is increased or the displacement recovery rate is accelerated before continuing execution. If the displacement gap remains unchanged or increases, or the corresponding equivalent resistance index continues to rise, the compensation is deemed invalid, triggering a process alarm and requesting manual intervention.

8. The method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars as described in claim 5, characterized in that, The billet pulling displacement setting value is limited between a minimum displacement limit value and a maximum displacement limit value; wherein, the minimum displacement limit value is a preset minimum proportion of the basic displacement setting value, and the maximum displacement limit value is a preset maximum proportion of the basic displacement setting value; the absolute value of the change in the set displacement between adjacent cycles is limited to a maximum rate of change limit value; wherein, the maximum rate of change limit value is a preset rate of change of the basic displacement setting value; the resistance feedforward compensation torque is limited to a preset torque proportion of the rated torque of the billet pulling drive motor; When the relative deviation of a certain flow exceeds the emergency threshold, or when a sudden increase in torque and a sudden drop in speed of the billet drive motor are detected, the flow is triggered to stop casting urgently and the corresponding stopper bar in the tundish is shut off. The remaining flows then re-execute the global production coordination and averaging strategy.

9. The method for coordinated control of the casting speed of each stream in horizontal continuous casting of multi-head copper bars as described in any one of claims 1 to 8, characterized in that, Also includes: While performing cycle-level collaborative control, the equivalent resistance index of each flow in each billet drawing cycle is uploaded to the edge computing node; The time series of equivalent drag indices for each flow were analyzed using a time series prediction model, and the long-term drift slope of the corresponding flow equivalent drag indices was obtained by fitting. When it is predicted that the equivalent resistance index of a certain flow will reach a severe deterioration threshold within a preset time period in the future, a preventive maintenance work order is generated and issued, and the control mode of the flow is switched from the collaborative optimization mode to the safe production mode. In the safe production mode, the flow performs a derated billet setting, no longer participates in the global production collaborative allocation, and the monitoring frequency of the equivalent resistance index is increased.

10. A multi-head copper bar horizontal continuous casting apparatus, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method as described in any one of claims 1 to 9.

Images