Optimization method for high-speed wire rod mill thermal simulation function

Abstract

The present application relates to the technical field of high-speed wire rolling line thermal simulation, and discloses a kind of high-speed wire rolling line thermal simulation function optimization method, including S1 rolling line segmented planning, S2 signal output optimization and S3 cross-section interference prevention and control, the S1 rolling line segmented planning includes S101 data acquisition and quantitative analysis, S102 segmented point accurate positioning and S103 two sections time consumption balanced regulation, S2 signal output optimization includes S201 signal output logic optimization, S202 output time accurate compression and S203 signal effectiveness verification, S3 cross-section interference prevention and control includes S301 signal isolation mechanism design, S302 simulation start timing planning and S303 whole-process stability verification, the method realizes, simulation efficiency is greatly improved: through the balanced segmented design of two sections of data driving, hot metal detector signal optimization and cross-section signal isolation prevention and control, single steel thermal simulation time is compressed from original 3 minutes to 50S, simulation efficiency is increased by about 72%, significantly shorten production preparation cycle, can quickly respond to the adjustment demand of production plan.

Description

Technical Field

[0001] This invention relates to the field of high-speed wire rod rolling thermal simulation technology, specifically to an optimization method for high-speed wire rod rolling thermal simulation function. Background Technology

[0002] Thermal simulation of high-speed wire rod rolling lines is a core preparatory step before formal production. Its core purpose is to simulate actual rolling conditions, verify the coordination, timing accuracy, and signal transmission stability of various equipment within the rolling line, and proactively identify potential problems such as equipment jamming and delays. This reduces the risk of steel stockpiling during initial rolling and ensures production continuity and product quality. However, existing thermal simulation technologies generally employ a one-time simulation of the entire rolling line, which has several significant drawbacks: Firstly, the simulation covers a large number of devices and has a lengthy process, with a single steel bar simulation taking up to 3 minutes, which significantly extends the production preparation cycle and makes it difficult to adapt to the needs of adjusting production plans for multiple batches and small quantities. Secondly, during the long-term simulation, the rolling mill is in a no-load idling state, which not only wastes a lot of electrical energy, but also aggravates the ineffective wear of the equipment transmission components, significantly increasing the equipment maintenance cost. Third, the signal link of the entire simulation is complex, and the risk of cross-segment signal interference is high. Once a signal abnormality occurs in a certain segment, the entire simulation process needs to be restarted, which further reduces the simulation efficiency. Fourth, the signal output logic of the hot metal detector is redundant, and the signal output of a single steel bar takes a long time, which restricts the improvement of simulation efficiency from the source. Moreover, there is no effective isolation mechanism for cross-segment signals, which can easily cause downstream equipment to be affected by residual signals from the upstream section and cause abnormal operation, affecting the accuracy of simulation verification. Summary of the Invention

[0003] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides an optimization method for the thermal simulation function of high-speed wire rod rolling, which has the advantages of significantly improved simulation efficiency and solves the problem of significantly extended production preparation cycle and difficulty in adapting to the needs of adjusting production plans for multiple batches and small quantities.

[0004] (II) Technical Solution To achieve the above-mentioned goal of significantly improving simulation efficiency, the present invention provides the following technical solution: an optimization method for the thermal simulation function of high-speed wire rod rolling, including S1 rolling line segment planning, S2 signal output optimization and S3 cross-segment interference prevention and control, wherein the S1 rolling line segment planning includes S101 data acquisition and quantitative analysis, S102 precise positioning of segment points and S103 two-segment time balance control; Among them, the S2 signal output optimization includes S201 signal output logic optimization, S202 output time precise compression and S203 signal validity verification; Among them, the S3 cross-segment interference prevention and control includes the design of the S301 signal isolation mechanism, the S302 simulated startup timing planning, and the S303 full-process stability verification.

[0005] Preferably, the S101 data acquisition and quantitative analysis involves using a professional data analysis tool (IBA) to collect multi-dimensional data on the entire process of the high-speed wire rod rolling line, covering core parameters such as equipment action sequence, signal transmission delay, simulated task volume of each section, and the proportion of single equipment operation time, to form a complete data analysis dataset.

[0006] Preferably, the S102 segmentation point is precisely located: based on the data analysis results, combined with the linkage logic of the rolling mill equipment and the core requirements of simulation verification, the optimal segmentation node with weak signal interaction and balanced simulation workload is selected to ensure that the equipment composition, action complexity and signal transmission density of the two simulation units after segmentation tend to be consistent.

[0007] Preferably, the S103 two-segment time balance control: the entire rolling line is divided into two independent simulation units. By adjusting the equipment action trigger interval and signal transmission priority parameters in each unit, the time deviation between the two simulations is controlled to not exceed 5 seconds, so as to achieve balanced matching of the two simulation times and avoid slowing down the overall efficiency due to excessive time consumption in a single segment.

[0008] Preferably, the S201 signal output logic optimization involves reconstructing the signal output logic of the hot metal detector without reducing signal detection accuracy and device recognition sensitivity. This includes adjusting the signal trigger threshold, reducing redundant signal transmission links, optimizing the signal encoding format, and reducing the transmission time occupied by invalid signals.

[0009] Preferably, the output time of S202 is precisely compressed: through repeated debugging and parameter calibration, the output signal time of the hot metal detector for a single steel piece is shortened by more than 30%, reducing the basic time consumption of each thermal simulation from the source, laying a key foundation for improving the overall simulation efficiency.

[0010] Preferably, the S203 signal validity verification involves verifying the integrity of the core features of the signal through a single-segment simulation test after signal optimization, ensuring that the device can still respond quickly and accurately to the optimized signal without affecting the validity of the device action verification during the simulation process.

[0011] Preferably, the S301 signal isolation mechanism is designed by combining hardware isolation modules with software logic constraints to construct independent signal links for the two analog units, completely interrupting the physical connection and logical association between the two analog units, and eliminating signal crosstalk.

[0012] Preferably, the S302 simulation startup timing plan clarifies the startup logic of the two simulations and sets a timing rule for starting the next simulation within 3 seconds after the previous simulation is completely finished. This ensures the continuity of the simulation process and avoids residual or delayed signals from the previous simulation from interfering with the operation of the next device.

[0013] Preferably, the S303 full-process stability verification involves: after completing the segmentation, signal optimization and isolation design, conducting a full-process thermal simulation test to verify the independent operation stability of the two simulation units, ensuring that the equipment operates without abnormalities and that signal transmission is free from interference, and ultimately achieving the goal of optimizing the thermal simulation time of a single steel bar from the original 3 minutes (180S) to within 50S.

[0014] (III) Beneficial Effects Compared with the prior art, the present invention provides an optimization method for the thermal simulation function of high-speed wire rod rolling, which has the following beneficial effects: 1. The optimization method of the thermal simulation function of the high-speed wire rod rolling line has achieved a significant improvement in simulation efficiency: through data-driven two-segment balanced segment design, hot metal detector signal optimization and cross-segment signal isolation and control, the thermal simulation time of a single steel bar is reduced from the original 3 minutes (180S) to within 50S, the simulation efficiency is improved by about 72%, the production preparation cycle is significantly shortened, and the adjustment needs of the production plan can be responded to quickly.

[0015] 2. The optimization method of the high-speed wire rod rolling line thermal simulation function has achieved significant reductions in energy and maintenance costs: the greatly shortened simulation time reduces the idle time of the equipment without load, and the energy consumption of a single simulation is reduced by more than 68% compared with the original scheme, which can save a lot of electricity resources in the long term; at the same time, the ineffective wear of the equipment is reduced, the service life of transmission components is extended, and the frequency and cost of equipment maintenance are reduced.

[0016] 3. The optimization method of the high-speed wire rod rolling thermal simulation function has achieved the following improvements: Through a cross-segment signal isolation mechanism that combines hardware isolation and software logic limitation, the interference of residual signals from the front-end simulation on the downstream equipment is completely eliminated. Combined with the signal validity verification step, the detection rate of abnormal equipment operation is increased from the original 92% to over 99%, ensuring that the simulation results can accurately reflect the actual operating status of the equipment.

[0017] 4. The optimization method of the thermal simulation function of the high-speed wire rod rolling line has been achieved, which enhances production flexibility: the efficient thermal simulation process supports the rapid rolling preparation of multi-specification wire rods, and can flexibly adapt to the production needs of different batches and specifications, thereby improving the production adaptability and market response speed of the rolling line. Detailed Implementation

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0019] This solution provides a technical approach, specifically an optimization method for high-speed wire rod rolling line thermal simulation, comprising the following methods: S1 Rolling Line Segmentation Planning: Data-Driven Balanced Segmentation Design S101 Data Acquisition and Quantitative Analysis: Using professional data analysis tools (IBA), multi-dimensional data acquisition is carried out on the entire process of high-speed wire rod rolling line, covering core parameters such as equipment action sequence, signal transmission delay, simulated task volume of each section, and the proportion of single equipment operation time, forming a complete data analysis dataset. S102 Segment Point Precise Positioning: Based on data analysis results, combined with the linkage logic of rolling mill equipment and the core requirements of simulation verification, the optimal segment nodes with weak signal interaction and balanced simulation workload are selected to ensure that the equipment composition, action complexity and signal transmission density of the two simulation units after segmentation tend to be consistent. S103 Two-Segment Time Equilibrium Control: The entire rolling line is divided into two independent simulation units. By adjusting the trigger interval of equipment actions and the signal transmission priority parameters in each unit, the time deviation between the two simulations is controlled to not exceed 5 seconds, so as to achieve balanced matching of the simulation time between the two segments and avoid slowing down the overall efficiency due to excessive time consumption in a single segment. S2 signal output optimization: Efficient signal calibration for hot metal detectors S201 signal output logic optimization: Without reducing signal detection accuracy and device recognition sensitivity, the signal output logic of the hot metal detector is reconstructed, including adjusting the signal trigger threshold, reducing redundant signal transmission links, optimizing the signal encoding format, and reducing the transmission time occupied by invalid signals. S202 output time precision compression: Through repeated debugging and parameter calibration, the output signal time of the hot metal detector for a single steel piece is shortened by more than 30%, reducing the basic time consumption of each thermal simulation from the source, laying a key foundation for improving the overall simulation efficiency; S203 Signal Validity Verification: After signal optimization, the integrity of the core signal characteristics is verified through single-segment simulation testing to ensure that the equipment can still respond quickly and accurately to the optimized signal without affecting the validity of the equipment action verification during the simulation process; S3 Cross-Segment Interference Prevention: Independent Signal Link Construction and Timing Planning S301 signal isolation mechanism design: It adopts a combination of hardware isolation modules and software logic constraints to build independent signal links for the two analog units, completely interrupting the physical connection and logical association between the two analog units, and eliminating signal crosstalk; S302 Simulation Startup Timing Planning: Clarify the startup logic of the two simulations and set a timing rule for starting the next simulation within 3 seconds after the previous simulation is completely completed. This ensures the continuity of the simulation process and avoids residual or delayed signals from the previous simulation from interfering with the operation of the next device. S303 Full-Process Stability Verification: After completing the segmentation, signal optimization and isolation design, a full-process thermal simulation test was conducted to verify the independent operation stability of the two simulation units, ensuring that the equipment operates without abnormalities and that signal transmission is free from interference. Ultimately, the goal of optimizing the thermal simulation time of a single steel bar from the original 3 minutes (180S) to within 50S was achieved. Furthermore, this method achieves a significant improvement in simulation efficiency: through data-driven two-segment balanced segmentation design, hot metal detector signal optimization, and cross-segment signal isolation and control, the thermal simulation time for a single steel bar is reduced from the original 3 minutes (180 seconds) to within 50 seconds, improving simulation efficiency by approximately 72%, significantly shortening the production preparation cycle, and enabling rapid response to adjustments in production plans. Furthermore, this method achieves a significant reduction in energy and maintenance costs: the substantial reduction in simulation time decreases the idle time of the equipment without load, and the energy consumption of a single simulation is reduced by more than 68% compared to the original scheme, which can save a lot of electricity resources in the long term; at the same time, the ineffective wear of the equipment is reduced, the service life of transmission components is extended, and the frequency and cost of equipment maintenance are reduced. Furthermore, this method achieves improved simulation reliability and accuracy: through a cross-segment signal isolation mechanism that combines hardware isolation with software logic constraints, interference from residual signals in the front-end simulation to the downstream equipment is completely eliminated. Combined with signal validity verification steps, the detection rate of abnormal equipment operation is increased from the original 92% to over 99%, ensuring that the simulation results can accurately reflect the actual operating status of the equipment. Furthermore, this method achieves enhanced production flexibility: the efficient thermal simulation process supports rapid rolling preparation for multi-specification wire rods, which can flexibly adapt to the production needs of different batches and specifications, thereby improving the production adaptability and market response speed of the rolling line.

[0020] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An optimization method for the thermal simulation function of high-speed wire rod rolling, comprising S1 rolling line segment planning, S2 signal output optimization, and S3 cross-segment interference prevention and control, characterized in that: The S1 rolling line segmentation planning includes S101 data acquisition and quantitative analysis, S102 precise positioning of segmentation points, and S103 two-segment time-balanced control. Among them, the S2 signal output optimization includes S201 signal output logic optimization, S202 output time precise compression and S203 signal validity verification; Among them, the S3 cross-segment interference prevention and control includes the design of the S301 signal isolation mechanism, the S302 simulated startup timing planning, and the S303 full-process stability verification.

2. The optimization method for high-speed wire rod rolling thermal simulation function according to claim 1, characterized in that: The S101 data acquisition and quantitative analysis: Using a professional data analysis tool (IBA), multi-dimensional data acquisition is carried out on the entire process of the high-speed wire rod rolling line, covering core parameters such as equipment action sequence, signal transmission delay, simulated task volume of each section, and the proportion of single equipment operation time, forming a complete data analysis dataset.

3. The optimization method for the thermal simulation function of high-speed wire rod rolling according to claim 1, characterized in that: The precise positioning of the S102 segmentation point: Based on the data analysis results, combined with the linkage logic of the rolling mill equipment and the core requirements of simulation verification, the optimal segmentation node with weak signal interaction and balanced simulation workload is selected to ensure that the equipment composition, action complexity and signal transmission density of the two simulation units after segmentation tend to be consistent.

4. The optimization method for the thermal simulation function of high-speed wire rod rolling according to claim 1, characterized in that: The S103 two-stage time balance control: the entire rolling line is divided into two independent simulation units. By adjusting the trigger interval of equipment actions and the signal transmission priority parameters in each unit, the time deviation between the two simulations is controlled to not exceed 5 seconds, so as to achieve a balanced match between the two simulation times and avoid slowing down the overall efficiency due to excessive time consumption in a single segment.

5. The optimization method for high-speed wire rod rolling thermal simulation function according to claim 1, characterized in that: The S201 signal output logic optimization involves reconstructing the signal output logic of the hot metal detector without reducing signal detection accuracy or device recognition sensitivity. This includes adjusting the signal trigger threshold, reducing redundant signal transmission links, optimizing the signal encoding format, and reducing the transmission time occupied by invalid signals.

6. The optimization method for the thermal simulation function of high-speed wire rod rolling according to claim 1, characterized in that: The S202 output time is precisely compressed: through repeated debugging and parameter calibration, the output signal time of the hot metal detector for a single steel piece is shortened by more than 30%, reducing the basic time consumption of each thermal simulation from the source, laying a key foundation for improving the overall simulation efficiency.

7. The optimization method for the thermal simulation function of high-speed wire rod rolling according to claim 1, characterized in that: The S203 signal validity verification: After signal optimization, the integrity of the core features of the signal is verified through single-segment simulation test to ensure that the equipment can still respond quickly and accurately to the optimized signal without affecting the validity of the equipment action verification during the simulation process.

8. The optimization method for high-speed wire rod rolling thermal simulation function according to claim 1, characterized in that: The S301 signal isolation mechanism is designed by combining hardware isolation modules with software logic constraints to construct independent signal links between the two analog units, completely interrupting the physical connection and logical association between the two analog units, and eliminating signal crosstalk.

9. The optimization method for the thermal simulation function of high-speed wire rod rolling according to claim 1, characterized in that: The S302 simulation startup timing plan clarifies the startup logic of the two simulations and sets a timing rule that the next simulation will start within 3 seconds after the previous simulation is completely finished. This ensures the continuity of the simulation process and avoids residual or delayed signals from the previous simulation from interfering with the operation of the equipment in the next simulation.

10. The optimization method for high-speed wire rod rolling thermal simulation function according to claim 1, characterized in that: The S303 full-process stability verification: After completing the segmentation, signal optimization and isolation design, a full-process thermal simulation test is carried out to verify the independent operation stability of the two simulation units, ensure that the equipment operates without abnormality and the signal transmission is free from interference, and finally achieve the goal of optimizing the thermal simulation time of a single steel bar from the original 3 minutes (180S) to within 50S.