Support device for identifying the cause of winding failures

Abstract

This invention provides a winding defect cause identification support device that helps even inexperienced operators or electrical maintenance personnel quickly identify the cause of winding defects that occur in a stepped manner in a coil. [Solution] The cause identification support device comprises a laser sensor that measures the amount of widthwise displacement of the end face of the coil for each lap, a data storage device that stores the actual data, a data processing device, and a display device. The data processing device is configured to virtually unfold the coil for each lap, display a virtual steel plate formed by connecting each unfolded lap on the display device, associate the amount of widthwise displacement with each lap of the virtual steel plate, edit each actual data into constant length data corresponding to the virtual steel plate, and align the leading edge of the virtual steel plate to which the amount of widthwise displacement is associated with the starting point of the constant length data, and display the constant length data together with the virtual steel plate.

Description

Technical Field

[0001] The present disclosure relates to a device for assisting in identifying the cause of winding defects. More specifically, when a stepped winding defect occurs in a coil formed by winding a strip-shaped steel plate with a winder, it relates to assisting in the task of identifying the cause of its occurrence.

Background Art

[0002] It is known, for example, from Patent Document 1 that a stepped winding defect occurring in a coil can lead to cracks and fractures. In this Patent Document 1, the displacement gauge scans the end face of the coil to measure the magnitude of the unevenness of the end face (i.e., the amount of deviation in the width direction). When the measured amount of deviation in the width direction exceeds the allowable range, it is generally determined as a winding defect.

[0003] In order to suppress such winding defects, various parameters such as the winding speed and tension of the winder, the position and pressure of the pinch roll, and the position and pressure of the side guide are set.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Incidentally, when a winding failure occurs, the operator or electrical maintenance staff needs to identify the cause of the failure from among the various parameters mentioned above. However, the time required for such identification depended on the skill level of the operator or electrical maintenance staff. In other words, inexperienced operators or electrical maintenance staff had the problem of taking a long time to identify the cause. Furthermore, Patent Document 1 mentioned above does not disclose any method for identifying the cause of a winding failure when it occurs.

[0006] This disclosure was made to solve the problems described above. The purpose of this disclosure is to provide a winding defect cause identification support device that helps even inexperienced operators or electrical maintenance personnel identify the cause of a step-like winding defect in a coil in a short amount of time. [Means for solving the problem]

[0007] The first aspect of this disclosure relates to a device for identifying the cause of winding defects. The device assists in identifying the cause of winding defects when they occur in a coil made of strip-shaped steel sheets wound by a winding machine. The device includes a laser sensor that measures the amount of widthwise displacement of the end face of the coil for each wrap, a data storage device that stores the data on the amount of widthwise displacement and multiple historical data representing changes in physical quantities related to winding defects measured by sensors other than the laser sensor, a data processing device that processes the data on the amount of widthwise displacement and the multiple historical data, and a display device. The data processing device is configured to virtually unfold the coil for each wrap, display a virtual steel sheet formed by connecting each unfolded wrap on the display device, associate the amount of widthwise displacement with each wrap of the virtual steel sheet, edit each historical data into constant length data corresponding to the virtual steel sheet, and align the leading edge of the virtual steel sheet to which the amount of widthwise displacement is associated with the starting point of the constant length data, and display the constant length data together with the virtual steel sheet.

[0008] The second perspective, in addition to the first perspective, has the following further characteristics: Displaying fixed-length data on a display device includes calculating the difference between the fixed-length data and the set value corresponding to the fixed-length data, and displaying the fixed-length data for which the difference is greater than a predetermined value.

[0009] The third aspect, in addition to the first or second aspect, further includes the following features: The cause identification support device further comprises a camera that images the end face of the coil. The data processing device is configured to display the image of the coil end face captured by the camera on the display device. [Effects of the Invention]

[0010] According to this disclosure, when a step-shaped winding defect occurs in the coil, a virtual steel plate linked to the widthwise displacement of each wrap, and constant length data compiled from each actual data, are displayed on the display device. By aligning the leading edge of the virtual steel plate with the starting point of each constant length data, it becomes easy to compare the portion of the virtual steel plate with a large widthwise displacement with the timing when abnormal values ​​occur in the constant length data. Therefore, even inexperienced operators or electrical maintenance personnel can identify the cause of the defect in a short time. [Brief explanation of the drawing]

[0011] [Figure 1] This figure shows an example of a rolling line to which the winding defect cause identification support device according to the embodiment of this disclosure is applied. [Figure 2] This diagram shows the reference point for the number of coil wraps. [Figure 3] This figure shows the amount of widthwise displacement of the coil end face measured by a laser sensor. [Figure 4] This diagram shows a virtual steel plate created by virtually unfolding and connecting the coil in one-wrap increments, and the amount of axial displacement associated with the virtual steel plate. [Figure 5] This figure shows an example of fixed-length data and its starting point. [Figure 6] This figure shows an example of displaying a virtual steel plate linked to axial displacement and constant length data on the HMI. [Figure 7] This is a conceptual diagram showing an example of the hardware configuration of a device that assists in identifying the cause of winding failures. [Modes for carrying out the invention]

[0012] Embodiments of this disclosure will be described below with reference to the drawings. Common or corresponding elements in each drawing are denoted by the same reference numerals, and their descriptions are simplified or omitted.

[0013] Figure 1 shows an example of a rolling line 2 to which the winding defect cause identification support device 1 is applied. While a hot rolling line is used as an example for the rolling line 2, a cold rolling line may also be used. The rolling line 2 is equipped with the following main rolling equipment: a heating furnace 3, a roughing mill 4, a finishing mill 5, a cooling device 6, a winding machine 7, and a conveying table (not shown) for transporting steel sheets Pr. These rolling equipment are driven by an electrical system consisting of motors and actuators.

[0014] The heating furnace 3 is configured to heat the steel sheet (slab) Pr to a predetermined temperature (for example, 1200°C) before rolling. The roughing mill 4 has 1 to 3 rolling stands (1 in the example shown in Figure 1) and rolls the steel sheet (slab) Pr heated in the heating furnace 3 in multiple passes in the forward direction (from upstream to downstream of the rolling line) and in the reverse direction (from downstream to upstream of the rolling line). The finishing mill 5 is a tandem rolling mill equipped with multiple rolling stands Fi (7 in the example shown in Figure 1) arranged in parallel in the rolling direction of the steel sheet Pr. Each rolling stand Fi (i=1 to 7) is equipped with two upper and lower work rolls 51, two upper and lower backup rolls 52, and a motor 53 for rotating the rolls. The backup rolls 52 are provided with a reduction device 54, which is configured to adjust the gap between the upper and lower work rolls 51. The rolling load of each rolling stand F1 to F7 is measured by a rolling load sensor 55. The current Am of the motor 53 of each rolling stand F1 to F7 is measured by a current measuring instrument 56. The cooling device 6 cools the steel strip Pr by injecting water into the steel strip Pr via a cooling bank.

[0015] The winding machine (also called a "mandrel") 7 winds the cooled steel plate Pr into a coil. A pinch roll 71 is provided to guide the leading end of the steel plate Pr into the winding machine 7 and to press the steel plate Pr in order to apply tension to the trailing end of the steel plate Pr. In addition, side guides 72 are provided on both sides of the steel plate Pr in the width direction to center the steel plate Pr in the width direction. Although not shown in the figure, the winding machine 7 is also provided with a wrapper roll to assist in winding.

[0016] Various sensors are installed as measuring instruments at key points along the rolling line 2. These key points include, for example, the exit side of the heating furnace 3, the exit side of the roughing mill 4, the exit side of the finishing mill 5, and the entry side of the winding machine 7. Various sensors may also be installed between the rolling stands F1 to F7 of the finishing mill 5. The various sensors include a shape detector 81 capable of measuring the shape of the steel sheet Pr at the exit side of the roughing mill 4, a thermometer 82 for measuring the surface temperature of the steel sheet Pr at the inlet side of the finishing mill 5, a speed detector 83 for measuring the speed Va of the steel sheet Pr at the exit side of the finishing mill 5, a thickness / width meter 84 for measuring the thickness and width of the steel sheet Pr at the exit side of the finishing mill 5, a thermometer 85 for measuring the surface temperature of the steel sheet Pr at the inlet side of the winding machine 7, a laser sensor 87 for measuring the widthwise displacement of the end face of the coil Co in the vicinity of the winding machine 7 with each lap, the rolling load sensor 55, and the current measuring instrument 56. Since known sensors can be used, a detailed explanation is omitted. The various sensors sequentially measure the state of the steel sheet Pr and each rolling equipment. The actual data measured by the various sensors is time-series data transmitted moment by moment to the control computer 101. The time-series data includes waveform data of the measured values. Additionally, a camera 88 is installed near the winding machine 7 to image the end face of the coil.

[0017] The rolling line 2 is operated (operated) by a control system using a computer having a hierarchical structure. The computer includes a control computer 101 and a host computer 102 that are connected to each other via a network. The control computer 101 is connected to the support device 1 via a network. The control computer 101 has a controller for control such as a PLC (Programmable Logic Controller). An HMI (Human Machine Interface) 103 is connected to the control computer 101 via a network. The HMI 103 presents data of the monitoring target (rolling equipment), and is configured so that an operator or an electrical maintenance person (not shown) can monitor or operate (control) the rolling equipment that is the monitoring target. When a rolling plan is input to the host computer 102, rolling information is sent from the host computer 102 to the control computer 101. The rolling information includes a target sheet thickness, a target sheet width, a target temperature, and the like. The control computer 101 receives the input of the rolling information from the host computer 102, calculates setting data including setting values of each rolling equipment that is a control target, and transmits the calculated design data to the rolling line 2, thereby executing the control of each rolling equipment constituting the rolling line 2.

[0018] In addition, the control computer 101 acquires (collects) actual data measured by various sensors. The control computer 101 sends design data including setting values of each rolling equipment and the collected actual data to a winding defect cause identification support device (hereinafter also referred to as "support device") 1 via a network. The support device 1 also receives and acquires image data and video data of the coil Co imaged by the camera 88 via the network. Note that the support device 1 may be configured to acquire video data of the coil Co and generate and acquire image data from the acquired video data.

[0019] The support device 1 collects design data, performance data, and image data that are exchanged between each rolling equipment on the rolling line 2 and the control computer 101. The support device 1 displays, on the HMI 103, a virtual steel plate associated with the amount of lateral displacement of each wrap of the coil, and fixed-length data obtained by editing each performance data, as will be described later. This supports the work of the operator or the electrical maintenance personnel to identify the cause of the occurrence when a winding defect occurs in the coil Co formed by winding the strip-shaped steel plate Pr on the winder 7. The HMI 103 corresponds to the "display device" in the claims. A display device (not shown) provided separately from the HMI 103 may be configured to display a virtual steel plate associated with the amount of lateral displacement of each wrap of the coil, and fixed-length data obtained by editing each performance data.

[0020] The support device 1 includes a data storage device 11 and a data processing device 12. The data storage device 11 stores the design data, performance data, and image data received from the control computer 101 in the database DB.

[0021] The data processing device 12 executes the following processes using the design data, performance data, and image data stored in the data storage device 11.

[0022] FIG. 2 is a diagram showing a reference point of the number of wraps of the coil Co. FIG. 3 is a diagram showing the amount of lateral displacement of the coil end face measured by the laser sensor 87. FIG. 4 is a diagram showing a virtual steel plate obtained by virtually unfolding and connecting the coil for each wrap, and the amount of lateral displacement associated with the virtual steel plate. FIG. 5 is a diagram showing an example of fixed-length data and its starting point. FIG. 6 is a diagram showing a display example of a virtual steel plate associated with the amount of axial displacement and fixed-length data on the HMI.

[0023] As shown in Figure 2, coil Co is composed of multiple wraps. In the example shown in Figure 2, if the upper end of coil Co is set to 0°, the position of the tail end is 150°, and the reference points W0, W1, ..., W10 of each wrap are set to 90°. Wi (i=0,1, ...,11) also represents the number of turns. The length of the wrap from the tail end of coil Co to the reference point W0 is X1, the length of one wrap from the reference point W0 to W1 is X2, and so on. In Figure 2, for the sake of illustration simplicity, each wrap is shown as a concentric circle. In this embodiment, the reference points W0, W1, ..., W10 are set at a position of 90°, which is θ (=60°) away from the tail end position, but θ is not limited to 60° and can be set to a stable position considering the shape of the tail end and the amount of tail end cut.

[0024] As shown in Figure 3, the widthwise displacement of each wrap X1 to X11 is measured by irradiating the right end face of the coil Co in the width direction with laser light from the laser sensor 87 and analyzing the reflected light. Taking the center Pc of the steady section of the coil Co (wraps X4 to X9) as the reference (0 mm), the radially outer wraps X1 to X3 experience a displacement to the right (+ side) in the width direction. On the other hand, the radially inner wraps X10 and X11 experience a displacement to the left (- side) in the width direction. The widthwise displacement of each wrap X1 to X11 is stored as actual data in the data storage device 11. The data processing device 12 reads the widthwise displacement of each wrap X1 to X11 from the data storage device 11 and determines that there is a winding defect if the displacement falls outside a predetermined allowable range.

[0025] If such a winding defect occurs, the data processing device 12 virtually unfolds each of the wraps X1 to X11 that make up the coil Co, one wrap at a time, and displays a virtual steel sheet Vpr, formed by connecting the unfolded wraps X1 to X11, on the HMI 103. The virtual steel sheet Vpr corresponds to the steel sheet Pr before winding.

[0026] Here, when unfolding each wrap X1 to X11, pressure extension information for each wrap is required. If the diameter of coil Co is Di (mm) (see Figure 2), the thickness of steel plate Pr is t (mm), and the number of windings is W (0, 1, ..., 11), then the length of wrap X1 can be calculated by (Di - t × W) × π × 60 / 360, and the lengths of each wrap X2 to X11 can be calculated by (Di - t × W) × π.

[0027] Next, the data processing device 12 associates the displacement amounts, which are hatched in Figure 4, with each wrap X1 to X11 of the virtual steel plate Vpr. That is, as shown in Figure 4, the virtual steel plate Vpr, in which the widthwise displacement amounts of each wrap X1 to X11 are reflected in a stepped manner, is displayed on the HMI 103. Upon receiving this display, operators and electrical maintenance personnel can easily and quickly grasp the direction and magnitude of the displacement amount for each wrap of the coil Co.

[0028] Next, the data processing device 12 displays the actual data of the rolling equipment measured by various sensors on the HMI 103, alongside the virtual steel plate Vpr to which the displacement amount is linked. Examples of actual data include, but are not limited to, the winding speed and tension of the winding machine (mandrel) 7, the position and pressure of the pinch rolls, the position and pressure of the side guides, the position and pressure of the wrapper rolls, and the steel plate temperature, as shown in Figure 5.

[0029] Here, the data processing device 12 edits each actual data into fixed-length data corresponding to the length from the leading edge to the trailing edge of the virtual steel plate Vpr, so that it can be compared with the displacement amount of the virtual steel plate Vpr. The starting point of the fixed-length data is the timing shown in Figure 5, and these are also stored in the data storage device 11 as actual data. For example, fixed-length data related to pinch roll pressure can be obtained by cutting the actual data related to pinch roll pressure at the timing when the steel plate Pr enters the pinch roll. The data processing device 12 calculates the difference between the fixed-length data and the set value corresponding to the fixed-length data, and displays the fixed-length data where the difference is greater than a predetermined value.

[0030] As shown in Figure 6, the data processing device 12 displays constant length data Dc1 related to pinch roll pressure and constant length data Dc2 related to side guide position so that they can be compared with a virtual steel plate Vpr to which the widthwise displacement is linked. That is, the leading edge of the virtual steel plate Vpr and the starting points of both constant length data Dc1 and Dc2 are aligned and displayed together on the HMI 103. Operators and electrical maintenance personnel who receive this display can easily compare the timing of winding defects with the timing of rolling equipment malfunctions. In the example shown in Figure 6, the pinch roll pressure can be identified as the cause of the displacement of laps X10 to X11, and the side guide position can be identified as the cause of the displacement of laps X1 to X3. As a result, the time required to identify the cause can be shortened.

[0031] As explained above, according to this embodiment, when a step-shaped winding defect occurs in the coil Co, a virtual steel plate Vpr, to which the widthwise displacement amount of each wrap X1 to X11 is linked, and constant length data Dc1 and Dc2, which are edited from the actual data, are displayed on the HMI103. Here, by aligning the leading edge of the virtual steel plate Vpr with the starting point of each constant length data Dc1 and Dc2, it becomes easy to compare the portion of the virtual steel plate Vpr with a large widthwise displacement amount with the timing when abnormal values ​​occur in the constant length data Dc1 and Dc2. Therefore, even inexperienced operators or electrical maintenance personnel can identify the cause of the problem in a short time.

[0032] Figure 7 shows an example of the hardware configuration of the winding failure cause identification support device 1. Each of the functions of the support device 1 described above can be realized by the processing circuit 10 shown in Figure 7. This processing circuit 10 may be dedicated hardware 10a. This processing circuit 10 may include a processor 10b and memory 10c. This processing circuit 10 may be partially formed as dedicated hardware 10a and further include a processor 10b and memory 10c. In the example shown in Figure 7, a part of the processing circuit 10 is formed as dedicated hardware 10a, and the processing circuit 10 also includes a processor 10b and memory 10c. The processing circuit 10 may include at least one dedicated hardware 10a. In this case, the processing circuit 10 may be, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC, an FPGA, or a combination thereof. The processing circuit 10 may include at least one processor 10b and at least one memory 10c. In this case, each function of the support device 1 is realized by software, firmware, or a combination of software and firmware. The software and firmware are written as programs and stored in memory 10c. The processor 10b realizes each function of the support device 1 by reading and executing the programs stored in memory 10c. The processor 10b is also called a CPU (Central Processing Unit), processing unit, arithmetic unit, microprocessor, microcomputer, or DSP. Memory 10c is a storage device such as a non-volatile or volatile semiconductor memory, such as RAM, ROM, flash memory, EPROM, or EEPROM. Memory 10c can also serve as a database DB. In this way, the processing circuit 10 can realize each function of the support device 1 through hardware, software, firmware, or a combination thereof.

[0033] Although embodiments of the present disclosure have been described above, the present disclosure is not limited to the embodiments described above, and can be implemented in various modified forms without departing from the spirit of the present disclosure. In the above embodiments, the case in which the HMI 103, which is a display device, is provided outside the support device 1 was described as an example, but the HMI 103 may be provided inside the support device 1.

[0034] In the above embodiment, two constant length data sets Dc1 and Dc2 are displayed along with the virtual steel plate Vpr to which the amount of deviation is linked. However, an image of the coil Co captured by the camera 88 can also be displayed. By providing an image of the coil Co to operators and electrical maintenance personnel who have difficulty understanding the state of winding defects from the virtual steel plate Vpr with the coil Co unfolded, it becomes possible to easily understand the state of winding defects, and the work of identifying the cause can be made even more efficient. Furthermore, the number of constant length data sets to be displayed is not limited to two; one constant length data set may be displayed, or three or more constant length data sets may be displayed. In addition, when displaying multiple constant length data sets, they may be configured to be displayed in order from the one with the greatest degree of abnormality (amount of deviation from the set value).

[0035] Furthermore, when referring to the number, quantity, amount, range, etc., of each element in the embodiments described above, this disclosure is not limited to the number referred to, unless otherwise explicitly stated or clearly defined in principle. Also, the structures, etc., described in the embodiments described above are not necessarily essential to this invention, unless otherwise explicitly stated or clearly defined in principle. [Explanation of Symbols]

[0036] 1...Support device for identifying the cause of winding defects, 11...Data storage device, DB...Database, 12...Data processing device, 2...Rolling line, 87...Laser sensor, 88...Camera, 101...Control computer, 102...Supercomputer, 103...HMI (Display device), Co...Coil, Dc1, Dc2...Constant length data, Pr...Steel plate, Vpr...Virtual steel plate, X1~X11...Wrap

Claims

1. A device for assisting in identifying the cause of winding failures, In a system that assists in identifying the cause of a winding defect that occurs when a coil is wound from a strip of steel plate using a winding machine, A laser sensor that measures the amount of widthwise displacement of the end face of the coil for each wrap, A data storage device that stores data on the widthwise displacement and a plurality of actual data representing changes in physical quantities related to the winding defect measured by sensors other than the laser sensor, A data processing device that processes the data on the widthwise displacement and the plurality of actual data, A display device, The aforementioned data processing device is The coil is virtually unfolded one wrap at a time, and the virtual steel plate formed by connecting each unfolded wrap is displayed on the display device. Each of the aforementioned laps of the virtual steel plate is associated with the aforementioned widthwise displacement amount, The process involves editing each performance data into constant length data corresponding to the aforementioned virtual steel plate, Align the leading edge of the virtual steel plate to which the widthwise displacement amount is linked with the starting point of the constant length data, and display the constant length data together with the virtual steel plate. A device configured to perform the following to help identify the cause of winding failures.

2. A device for identifying the cause of winding defects as described in claim 1, Displaying the aforementioned fixed-length data on the display device means The difference between the constant length data and the setting value corresponding to the constant length data is calculated, Displaying the constant-length data where the difference is greater than a predetermined value, A device to assist in identifying the cause of winding defects, including those mentioned above.

3. A device for identifying the cause of winding defects according to claim 1 or claim 2, The system further includes a camera for imaging the end face of the coil, The data processing device is configured to display an image of the end face of the coil captured by the camera on the display device, and is a winding defect cause identification support device.

Images