Operation support device, operation support method, and operation support program

Abstract

To provide an operation support device, an operation support method, and an operation support program that can appropriately manage and operate materials and equipment used in a casting bed of continuous casting equipment without requiring much labor.SOLUTION: An operation support device 22, which is one embodiment of the present invention, is equipped with a calculation processing unit 221 that reads information regarding the use conditions of items corresponding to the manufacturing conditions of the product to be manufactured from management information that indicates the relationship between the manufacturing conditions of the product and the use conditions of multiple types of items used in manufacturing the product, controls the manufacturing process of the product in accordance with the read information, and performs notification about information for prompting the replacement of items at a predetermined timing.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to an operation support device, an operation support method, and an operation support program that support management of materials and equipment used in the casthouse of a continuous casting facility. [Background technology]

[0002] Traditionally, the management of materials and equipment used in the casthouse of continuous casting equipment, such as immersion nozzles, long nozzles, and mold powder, has been done manually. Specifically, the operators manually record the usage history of materials and equipment on paper. Furthermore, the timing of equipment replacement based on production plans and service life was determined by the operators' manual calculations and judgment. For example, the timing of changing the immersion depth of immersion nozzles and long nozzles to match the casting schedule, and the selection of immersion nozzles and mold powder to match the steel type, such as the molten steel composition, were determined by the operators' schedule calculations before the start of casting. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 8-174170 [Patent Document 2] Japanese Patent Application Laid-Open No. 2004-202538 Summary of the Invention [Problem to be solved by the invention]

[0004] When the management of materials and equipment used in the casthouse of continuous casting equipment is performed manually, it requires a lot of labor, and human errors such as incorrect entries or calculations can prevent the proper management and operation of materials and equipment, which can lead to operational problems such as incorrect use of materials and damage due to exceeding their service life. For this reason, there has been a demand for technology to assist in the management of materials and equipment. Note that Patent Documents 1 and 2 disclose technology related to control methods for continuous casting equipment, but do not disclose or suggest technology to assist operators in the management of materials and equipment.

[0005] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide an operation support device, an operation support method, and an operation support program that can appropriately manage and operate the materials and equipment used in the casthouse of a continuous casting facility without requiring much effort. [Means for solving the problem]

[0006] The operation support device according to the present invention includes a processing unit that reads information relating to the use conditions of an item corresponding to the manufacturing conditions of the product to be manufactured from management information indicating the relationship between the manufacturing conditions of the product and the use conditions of multiple types of items used in manufacturing the product, controls the manufacturing process of the product in accordance with the read information, and notifies information prompting the replacement of the item at a predetermined timing.

[0007] The product may be a steel product, and the article may be equipment used in the cast floor of a continuous casting facility.

[0008] The calculation processing unit may refer to the management information to determine the brand of mold powder to be used depending on the steel type and size of the steel product to be manufactured, set the immersion depth and service life of the immersion nozzle depending on the determined brand of mold powder, and control the operation of the continuous casting equipment according to the set information.

[0009] When the number of charges using the long nozzle reaches a set value, the calculation processing unit may notify information urging replacement of the long nozzle.

[0010] The operation support method according to the present invention includes the steps of reading information relating to the use conditions of an item corresponding to the manufacturing conditions of the product to be manufactured from management information indicating the relationship between the manufacturing conditions of the product and the use conditions of multiple types of items used in manufacturing the product, controlling the manufacturing process of the product in accordance with the read information, and notifying information prompting replacement of the item at a predetermined timing.

[0011] The operation support program of the present invention reads information regarding the use conditions of an item corresponding to the manufacturing conditions of the product to be manufactured from management information indicating the relationship between the manufacturing conditions of the product and the use conditions of multiple types of items used in manufacturing the product, controls the manufacturing process of the product in accordance with the read information, and notifies information prompting the replacement of the item at a predetermined timing. [Effects of the Invention]

[0012] According to the operation support device, the operation support method, and the operation support program of the present invention, it is possible to appropriately manage and operate the materials and equipment used in the casthouse of a continuous casting facility without requiring much effort. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a schematic diagram showing the configuration of a casthouse of a continuous casting facility that is the object of management of an operation support device according to one embodiment of the present invention. [Figure 2] FIG. 2 is a block diagram showing the configuration of an operation system according to one embodiment of the present invention. [Figure 3] FIG. 3 is a block diagram showing the configuration of the operation support device shown in FIG. [Figure 4] FIG. 4 is a flowchart showing the flow of the operation of the operation support device when controlling the immersion depth of the immersion nozzle. [Figure 5] FIG. 5 is a diagram illustrating an example of an immersion nozzle management table. [Figure 6] FIG. 6 is a diagram showing an example of a service life table for immersion nozzles. [Figure 7] FIG. 7 is a diagram showing an example of table data showing the relationship between the immersion pattern of the immersion nozzle and the immersion depth of each stage. [Figure 8] FIG. 8 is a diagram for explaining a method for calculating the usage time of each stage of the immersion nozzle. [Figure 9] FIG. 9 is a diagram showing an example of a casting schedule setting table. [Figure 10] FIG. 10 is a flowchart showing the flow of the operation of the operation support device when controlling the immersion depth of the long nozzle. [Figure 11] FIG. 11 is a diagram showing an example of the long nozzle management table. [Figure 12] FIG. 12 is a diagram showing an example of an immersion depth pattern table for a long nozzle. [Figure 13] FIG. 13 is a flowchart showing the flow of the operation of the operation support device when controlling the amount of mold powder charged. [Figure 14] FIG. 14 is a diagram showing an example of a mold powder management table. [Figure 15] FIG. 15 is a diagram illustrating an example of the hopper management table. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, the configuration and operation of an operation support device according to one embodiment of the present invention will be described with reference to the drawings.

[0015] [Casthouse configuration] First, with reference to FIG. 1, the configuration of a casthouse of a continuous casting facility that is the object of management of an operation support device according to one embodiment of the present invention will be described.

[0016] FIG. 1 is a schematic diagram showing the configuration of a casthouse of a continuous casting facility that is a target of management by an operation support device according to an embodiment of the present invention. As shown in FIG. 1 , the casthouse of the continuous casting facility 1 that is a target of management by an operation support device according to an embodiment of the present invention includes a ladle 11, a long nozzle (L / N) 12, a tundish (T / D) 13, an immersion nozzle (I / N) 14, and a mold (M / D) 15. In this casthouse, molten steel in the ladle 11 is supplied to an intermediate vessel, the T / D 13, via the L / N 12 attached to the bottom of the ladle 11. The molten steel supplied to the T / D 13 is then supplied to the M / D 15 via the I / N 14 attached to the bottom of the T / D 13. The molten steel supplied to the M / D 15 is then cooled and withdrawn as a slab SA from the bottom of the M / D 15 in the pouring direction. The slab SA withdrawn from the M / D 15 is then transported by rolls (not shown) to a cutting machine (not shown) where it is cut into a slab.

[0017] In order to prevent oxidation of the surface of the molten steel supplied into T / D 13, T / D flux is added to the molten steel in T / D 13. In addition, in order to prevent oxidation of the surface of the molten steel supplied into M / D 15 and seizure between M / D 15 and the cast slab SA, M / D powder is added to the molten steel in M / D 15. L / N 12, T / D 13, I / N 14, and M / D powder correspond to the materials and equipment according to the present invention.

[0018] [Configuration of operation support device] Next, the configuration of an operation support device according to one embodiment of the present invention will be described with reference to FIGS.

[0019] FIG. 2 is a block diagram showing the configuration of an operation system according to one embodiment of the present invention. As shown in FIG. 2, the operation system 2 according to one embodiment of the present invention is a system that manages and controls the operational status of the continuous casting equipment 1 shown in FIG. 1 and includes a production management computer 21, an operation support device 22, and a subordinate control system 23. The production management computer 21 is configured with an information processing device such as a business computer that manages the production plan of the continuous casting equipment 1 and is connected to the operation support device 22 via a telecommunications line. The detailed configuration of the operation support device 22 will be described later. The subordinate control system 23 is configured with an information processing device such as a personal computer and is connected to the operation support device 22 via a telecommunications line. The subordinate control system 23 controls the operation of the continuous casting equipment 1 in accordance with various signals and information output from the operation support device 22.

[0020] FIG. 3 is a block diagram showing the configuration of the operation support device 22 shown in FIG. 2. As shown in FIG. 3, the operation support device 22 is configured with an information processing device such as a process computer. The operation support device 22 controls the operation of the lower-level control system 23 according to information acquired from the production management computer 21 and supports the management of materials and equipment used in the casthouse of the continuous casting equipment 1. In this embodiment, the operation support device 22 includes a processor 221 such as a CPU and a memory 222 such as a ROM, and the memory 222 stores an operation support program 222a and table data 222b. The processor 221 executes the operation support program 222a, which is a computer program, to realize the functions (operations) described below using the table data 222b. The table data 222b includes an immersion nozzle management table described below.

[0021] An input device 31 and an output device 32 are also connected to the operation support device 22. The input device 31 is a device for inputting various types of information into the operation support device 22, and is composed of operation input devices such as a keyboard, mouse pointer, and touch panel, as well as a communication device for receiving various types of information via a telecommunication line. The output device 32 is a device for outputting various types of information in accordance with control signals from the operation support device 22, and is composed of output devices such as a display and printer, as well as a communication device for transmitting various types of information via a telecommunication line.

[0022] The operation support device 22 having such a configuration supports the management of materials and equipment used in the casthouse of the continuous casting equipment 1 by executing the processes described below. Below, the operation of the operation support device 22 when supporting the management of materials and equipment used in the casthouse of the continuous casting equipment 1 will be described using as examples the control of the immersion depth of the I / N 14, the control of the immersion depth of the L / N 12, and the control of the amount of M / D powder added. Note that the scope of application of the operation support device 22 is not limited to this example, and it can also be applied to, for example, the control of the temperature (preheating, heat-up) of the T / D 13, management of the number of uses, etc.

[0023] [Controlling the immersion depth of the immersion nozzle] First, the operation of the operation support device 22 when controlling the immersion depth of the I / N 14 will be described with reference to FIGS.

[0024] FIG. 4 is a flowchart showing the flow of operations performed by the operation support device 22 when controlling the immersion depth of the I / N 14. As shown in FIG. 4, when controlling the immersion depth of the I / N 14, the operation support device 22 first acquires an operation schedule from the production management computer 21 via a telecommunications line, the operation schedule including information such as the steel type (e.g., composition, carbon equivalent), thickness, casting time, and number of casting charges (ch) of the slab to be produced (step S1). Next, the operation support device 22 references the immersion nozzle management table shown in FIGS. 5(a) and 5(b) and selects a brand of I / N 14 corresponding to the steel type and thickness of the slab included in the acquired operation schedule (step S2). This prevents the operator from selecting the wrong brand of I / N 14.

[0025] The immersion nozzle management tables shown in Figures 5(a) and 5(b) are composed of a registration table (Figure 5(a)) in which the relationship between the brand of I / N 14 and the steel grade and thickness of the slab is registered in advance, and a performance table (Figure 5(b)) in which the actual usage history of I / N 14 is recorded. The registration table shown in Figure 5(a) pre-registers the number of stages used, the lower and upper limits of the heating temperature, the discharge angle, the number of holes, the target steel grade, and the slab thickness for each usable I / N 14. If the I / N 14 is for testing, a unique identification number corresponding to that I / N 14 is registered in the "Experiment" column. The performance table shown in Figure 5(b) records actual data for the I / N 14, including the date and time of use, the brand, the M / D powder brand, the duration of use, the number of channels used, the number of stages used, the date and time of heating, the heating time, and the steel grade of the first charge, by the operation support device 22.

[0026] Next, the operation support device 22 reads out information about the M / D powder brand corresponding to the slab steel type and thickness included in the acquired operation schedule from table data created in advance that shows the relationship between the slab steel type and thickness and the M / D powder brand to be used.The operation support device 22 then refers to a service life table shown in Fig. 6 that shows the relationship between the I / N 14 and M / D powder brands and the service life of each I / N 14 stage, and reads out information about the service life of each I / N 14 stage that corresponds to the I / N 14 and M / D powder brand to be used (step S3).

[0027] Next, the operation support device 22 reads information on the immersion pattern of the I / N 14 corresponding to the brand of the I / N 14 to be used and the thickness of the slab to be produced from table data created in advance, which shows the relationship between the brand of the I / N 14, the slab thickness, and the I / N 14 immersion pattern. Then, the operation support device 22 reads information on the immersion depth of each stage corresponding to the read immersion pattern from table data shown in FIG. 7, which shows the relationship between the I / N 14 immersion pattern and the immersion depth of each stage. The operation support device 22 also calculates the usage time of each stage corresponding to the read immersion pattern (step S4). Specifically, as shown in FIG. 8, the operation support device 22 calculates and sets the usage time per stage by multiplying the casting time acquired from the production management computer 21 by a coefficient (immersion time coefficient (variable value)) and dividing the result by the number of stages used. The coefficient is a value that takes into account the extension of the casting time. This prevents operators from making calculation errors in the usage time.

[0028] By processing steps S1 to S4, the operation support device 22 automatically inputs set values ​​into the columns of the corresponding charge steel type, thickness, casting time, I / N brand, number of I / N stages used, M / D powder brand, and usage time for each stage in the casting schedule setting table shown in Figures 9(a) and 9(b). By outputting this casting schedule setting table to the output device 32, the operator can confirm the I / N 14 and M / D powder brands, the number of I / N 14 stages used, and the usage time for each stage that correspond to the steel type and size of the slab to be produced. Note that if an identification number is set in the I / N experiment flag and M / D powder experiment flag columns in the casting schedule setting table, the operation support device 22 selects the I / N 14 and M / D powder brands for the experiment that correspond to the set identification number in the processing of steps S2 and S3.

[0029] Next, when slab production starts, the operation support device 22 records operational performance data of the continuous casting equipment 1 in the corresponding table data. The operation support device 22 also measures the usage time of each stage of the I / N 14 and monitors whether the measured time exceeds the usage time set in the processing of step S4 (step S5). If the measured time exceeds the set usage time, alarm information is sent to the lower-level control system 23. Upon receiving the alarm information, the lower-level control system 23 notifies the operator that the usage time of the I / N 14 has exceeded the set time. This allows the operator to recognize the appropriate timing for replacing the I / N 14.

[0030] [Controlling the immersion depth of long nozzles] Next, the operation of the operation support device 22 when controlling the immersion depth of the L / N 12 will be described with reference to FIGS.

[0031] Fig. 10 is a flowchart showing the flow of the operation of the operation support device 22 when controlling the immersion depth of the L / N 12. As shown in Fig. 10, when controlling the immersion depth of the L / N 12, the operation support device 22 first obtains an operation schedule including information such as the steel type, thickness, casting time, and number of casting charges of the slab to be manufactured from the production management computer 21 via a telecommunications line (step S11). Note that if the operation schedule has already been obtained through another control, the processing of step S11 can be omitted.

[0032] Next, the operation support device 22 refers to the long nozzle management table shown in FIG. 11 and selects a brand of L / N 12 corresponding to the steel grade of the slab included in the acquired operation schedule (step S12). This prevents the operator from selecting the wrong brand of L / N 12. The long nozzle management table shown in FIG. 11 is composed of columns for each usable brand of L / N 12, including the number of stages used, pitch, start position, allowable erosion amount, number of stages used, maximum number of charges, set heat-up temperature, length, neck outer diameter, slag line outer diameter, remaining thickness threshold, regular / emergency flag, experimental flag, whether in use, and remarks, and settings are pre-registered in each column. Next, the operation support device 22 reads out information on the immersion depth pattern corresponding to the selected brand of L / N 12 from the immersion depth pattern table shown in FIG. 12, which indicates the immersion depth of each stage for each brand of L / N 12. Then, the operation support device 22 sets the read immersion depth pattern as the immersion depth pattern for the selected brand of L / N12 (step S13).

[0033] By processing steps S11 to S13, the operation support device 22 automatically inputs set values ​​into the corresponding charge steel type, thickness, casting time, L / N brand, and L / N immersion depth columns of the casting schedule setting table shown in Figures 9(a) and 9(b). At this time, information about the T / D 13 related to the L / N 12 (T / D flux, T / D car, etc.) may also be input. By outputting this casting schedule setting table to the output device 32, the operator can confirm the brand and immersion depth of the L / N 12 corresponding to the steel type of the slab to be produced. The operator registers a unique identification number assigned to the L / N 12 in the L / N Identification No. column in the casting schedule setting table. The operator also registers information indicating the L / N 12 status (discard, reuse, etc.) in the L / N Status column.

[0034] Next, when slab production begins, the operation support device 22 records operational performance data of the continuous casting equipment 1 in the corresponding table data. The operation support device 22 also monitors the number of charges of L / N 12 used (step S14). When the number of charges used reaches the maximum number of charges registered in the long nozzle management table, alarm information is transmitted to the lower-level control system 23. Upon receiving the alarm information, the lower-level control system 23 notifies the operator that the number of charges of L / N 12 used has reached the maximum number of charges. This allows the operator to recognize the appropriate timing for replacing L / N 12 according to the number of charges used. The operation support device 22 may also monitor the remaining thickness of L / N 12, and transmit alarm information to the lower-level control system 23 when the remaining thickness falls below the remaining thickness threshold registered in the long nozzle management table. This allows the operator to recognize the appropriate timing for replacing L / N 12 according to the remaining thickness.

[0035] [Control of the amount of mold powder added] Finally, the operation of the operation support device 22 when controlling the amount of M / D powder charged will be described with reference to FIGS.

[0036] Fig. 13 is a flowchart showing the flow of the operation of the operation support device 22 when controlling the amount of M / D powder charged. As shown in Fig. 13, when controlling the amount of M / D powder charged, the operation support device 22 first acquires an operation schedule including information such as the steel type, thickness, casting time, and number of casting charges of the slab to be manufactured from the production management computer 21 via an electric communication line (step S21). Note that if the operation schedule has already been acquired through another control, the processing of step S21 can be omitted.

[0037] Next, the operation support device 22 refers to the M / D powder management table shown in Figures 14(a) and (b) and selects the brand of M / D powder corresponding to the steel type and thickness of the slab included in the acquired operation schedule (step S22). This prevents the operator from selecting the wrong M / D powder brand. The M / D powder management table shown in Figures 14(a) and (b) is composed of a registration table (Figure 14(a)) in which the relationship between the M / D powder brand and the steel type and thickness of the slab is registered in advance, and a performance table (Figure 14(b)) in which the actual usage of M / D powder is recorded.

[0038] The registration table shown in Figure 14(a) pre-registers the steel type, slab thickness, slab width, set consumption amount, I / N immersion time coefficient, lower limit consumption amount, set molten layer thickness, lower limit molten layer thickness, upper limit molten layer thickness, hopper number, year, crystallization temperature, powder input coefficient, and powder or granule type for each brand of usable M / D powder.The operation support device 22 records the actual data of the casting date, sorting number, steel number, specification, steel type, slab thickness, slab width, actual consumption amount, molten layer thickness in M / D 15 (corner portion, 1 / 4 width portion, 1 / 2 width portion), set hopper number, and actual hopper number in the performance table shown in Figure 14(b).

[0039] Next, the operation support device 22 selects a hopper containing the selected M / D powder by referring to a hopper management table, such as that shown in FIG. 15, which is created in advance and shows the relationship between the hoppers that supply the M / D powder and the brands of the M / D powder contained in the hoppers. This prevents the operator from selecting the wrong hopper. The hopper management table shown in FIG. 15 is pre-registered with the hopper number, brand, lot number, capacity, and storage amount. The operation support device 22 then controls the subordinate control system 23 to supply the M / D powder from the selected hopper. The subordinate control system 23 may supply the M / D powder to the entire M / D 15, or may monitor the M / D 15 with a thermoviewer and supply the M / D powder selectively to areas where there is a shortage of M / D powder. The operation support device 22 then records operational performance data (such as the amount of M / D powder used) of the continuous casting equipment 1 in the corresponding table data.

[0040] As is clear from the above explanation, the operation support device 22, one embodiment of the present invention, reads information on the use conditions of materials and equipment corresponding to the production conditions of the slab to be produced from management information showing the relationship between the slab production conditions and the use conditions of multiple types of materials and equipment used at the casthouse of the continuous casting equipment 1, controls the slab production process according to the read information, and issues information prompting the replacement of materials and equipment at predetermined times. This makes it possible to appropriately manage and operate the materials and equipment used at the casthouse of the continuous casting equipment 1 without requiring much effort.

[0041] Although the present invention has been described above as an embodiment, the present invention is not limited to the descriptions and drawings that form part of the disclosure of the present invention. In other words, other embodiments, examples, and operational techniques that can be made by those skilled in the art based on the present invention are all included in the scope of the present invention. [Explanation of symbols]

[0042] 1. Continuous casting equipment 2 Operational System 11 Ladle 12 Long nozzle (L / N) 13 Tundish (T / D) 14 Immersion nozzle (I / N) 15 Mold (M / D) 21 Production control computer 22 Operation support equipment 23 Lower-level control system 31 Input Devices 32 Output Devices 221 Processing unit 222 Storage section 222a Operational Support Program 222b Table Data SA billet

Claims

1. An operation support device comprising: a processing unit that reads information relating to the use conditions of an article corresponding to the manufacturing conditions of a product to be manufactured from management information indicating the relationship between the manufacturing conditions of the product and the use conditions of multiple types of articles used in manufacturing the product; controls the manufacturing process of the product in accordance with the read information; and notifies information prompting the replacement of the article at a predetermined timing.

2. 2. The operation support device according to claim 1, wherein the product is a steel product and the article is equipment used in a casthouse of a continuous casting facility.

3. 3. The operation support device according to claim 2, wherein the calculation processing unit determines a brand of mold powder to be used depending on a steel type and a size of a steel product to be manufactured by referring to the management information, sets an immersion depth and a service life of an immersion nozzle depending on the determined brand of mold powder, and controls an operation of the continuous casting equipment according to the set information.

4. 3. The operation support device according to claim 2, wherein the calculation processing unit issues information urging replacement of the long nozzle when the number of charges using the long nozzle reaches a set value.

5. An operation support method including the steps of reading information relating to the use conditions of an article corresponding to the manufacturing conditions of a product to be manufactured from management information indicating the relationship between the manufacturing conditions of the product and the use conditions of multiple types of articles used in manufacturing the product, controlling the manufacturing process of the product in accordance with the read information, and notifying information prompting replacement of the article at a predetermined timing.

6. An operation support program that causes a computer to execute a process of reading information regarding the use conditions of an article corresponding to the manufacturing conditions of a product to be manufactured from management information that indicates the relationship between the manufacturing conditions of the product and the use conditions of multiple types of articles used in manufacturing the product, controlling the manufacturing process of the product in accordance with the read information, and notifying information prompting the replacement of the article at a predetermined timing.

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