Rolled product quality defect analysis support system

Abstract

This quality defect analysis assistance system for a rolled product is provided with a plurality of recording devices, a conversion device, and a search device. A first recording device records steel sheet time-unit information, rolling facility time-unit information, and manual operation time-unit information in a time-axis performance database in association with a product ID of the steel sheet. The conversion device converts each of the steel sheet time-unit information, the rolling facility time-unit information, and the manual operation time-unit information into length-unit information. A second recording device records each information converted by the conversion device in a product-unit database in association with the product ID. A third recording device records a rolling plan of the rolling plant and an error occurrence record of the rolling facility in the product-unit database. The search device uses the product ID of the steel sheet determined to be a defective product as a search key to extract information on the defective product from the time-axis performance database, the product-unit database, a machine-unit database, and an electricity-unit database.

Description

[Technical field]

[0001] The present disclosure relates to a quality defect analysis support system for rolled products, and more particularly to a system that supports analysis of quality defects when a steel plate manufactured in a rolling plant is determined to be of defective quality. [Background technology]

[0002] In a rolling plant such as a hot rolling plant, physical quantities such as the thickness and width of a steel plate, flatness in the width direction, flatness in the longitudinal direction, and temperature during rolling are measured by various sensors arranged in the rolling line, and the measured values ​​are stored as performance data. For example, a computer determines whether the performance data is within a predetermined target range, and determines that the quality of the steel plate is poor if the performance data is out of the target range. Various determination methods, including target ranges and determination formulas for determining whether the quality of a steel plate is good or bad, have been proposed in the past.

[0003] Patent Document 1 below discloses a product quality analysis support system. In this system, physical quantities measured by various sensors are used as actual data, sampling data for each predetermined length of the steel plate is created from the actual data, the sampling data is divided into a leading end portion, a central portion, and a trailing end portion, and the quality of each portion is judged based on the divided sampling data. If the quality is judged to be poor, the waveform pattern of the sampling data for each portion is registered in a database together with an ID. After registration, if the quality of the steel plate is judged to be poor, a similar waveform pattern is identified from among the registered waveform patterns, an ID corresponding to the identified waveform pattern is determined, and countermeasure information corresponding to the determined ID is presented. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2021-192915 Summary of the Invention [Problem to be solved by the invention]

[0005] The product quality analysis support system for presenting countermeasure information in the above Patent Document 1 aims to present the countermeasure information to rolling line operators. The rolling line operators can maintain the quality of the steel sheet by manually intervening (manually operating) the rolling mill based on the presented countermeasure information.

[0006] Incidentally, for example, when manual intervention is frequently performed, it is necessary to change the rolling plan, which is an operation plan created by a host computer. However, since the product quality analysis support system of the above Patent Document 1 does not present information to the designer of the rolling plan, it takes a long time for the designer to start changing the rolling plan. That is, even if a change in the rolling plan is necessary, the necessity is hidden (does not surface) due to the manual intervention of the operator, and as a result, the steel plate is manufactured in an unstable state for a long time. Similarly, when there is a defect in the maintenance by the maintenance operator, the defect is hidden due to the manual intervention, and the steel plate may be manufactured in an unstable state for a long time.

[0007] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a quality defect analysis support system for rolled products that can shorten the time for which steel sheets are manufactured in an unstable state even when there are defects in rolling plans or maintenance. [Means for solving the problem]

[0008] The first aspect relates to a quality defect analysis support system for rolled products that supports an analysis of quality defects when the quality of a steel plate manufactured in a rolling plant is determined to be defective. The quality defect analysis support system includes a first recording device, a conversion device, a second recording device, a third recording device, a fourth recording device, a fifth recording device, and a search device. The first recording device records, in a time axis performance database, steel plate time unit information including a plate thickness and a temperature of the steel plate in a rolling time unit, rolling equipment time unit information including a rolling load of a rolling equipment installed in the rolling plant, and time unit information of manual operation by an operator of the rolling plant, in association with a product ID of a steel plate manufactured in the past. The conversion device converts the steel plate time unit information, the rolling equipment time unit information, and the time unit information of manual operation into information in length units, respectively. The second recording device records each piece of information converted by the conversion device in a product unit database in association with a product ID. The third recording device records the rolling plan of the rolling plant and the error occurrence record of the rolling equipment in the product unit database. The fourth recording device records mechanical system maintenance information of the rolling equipment in the machine unit database in association with the product ID. The fifth recording device records electrical system maintenance information of the rolling equipment in association with the product ID in the electrical unit database. The search device uses the product ID of the steel plate determined to be defective as a search key to extract information related to the defective product from the time axis performance database, product unit database, machine unit database and electrical unit database.

[0009] The second aspect has the following features in addition to those of the first aspect: The search device extracts information about good products as well as information about defective products from the time axis performance database, the product unit database, the machine unit database and the electric unit database using a product ID as a search key. The quality defect analysis support system further includes a difference detection device that detects a difference between the information about defective products extracted by the search device and the information about good products. Effect of the Invention

[0010] According to the present disclosure, by recording not only the thickness and temperature of the steel plate but also the rolling plan of the rolling plant and the maintenance information of the rolling equipment in the database in association with the product ID, it is possible to extract the rolling plan and the maintenance information related to the defective product using the product ID as a search key. This allows the designer of the rolling plan who receives the extraction result to change the rolling plan promptly. Also, the maintenance operator who receives the extraction result can perform maintenance promptly to eliminate the defect. In this way, it is possible to provide a quality defect analysis support system for rolled products that can shorten the time for manufacturing steel plates in an unstable state by bringing to light defects in the rolling plan and maintenance that were hidden by manual operations. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a diagram illustrating an example of a rolling plant. [Diagram 2] 1 is a block diagram showing a quality defect analysis support system for a rolled product according to a first embodiment. [Diagram 3] 3 is a diagram illustrating an example of the operation of the quality defect analysis support system for rolled products illustrated in FIG. 2. [Figure 4] FIG. 1 is a diagram illustrating an example of a hardware configuration of a quality defect analysis support system for a rolled product. [Diagram 5] FIG. 11 is a block diagram showing a quality defect analysis support system for a rolled product according to a second embodiment. [Figure 6] 6 is a diagram illustrating an example of the operation of the quality defect analysis support system for rolled products illustrated in FIG. 5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, with reference to the drawings, a rolled product quality defect analysis support system according to an embodiment of the present invention will be described, taking as an example a case where an analysis work for quality defects is supported when the quality of a steel plate, which is a rolled product manufactured in a hot rolling plant (hereinafter referred to as a "rolling plant"), is judged to be defective. Note that elements common to each drawing are given the same reference numerals and duplicated explanations will be omitted.

[0013] Embodiment 1 [Rolling plant] Fig. 1 is a diagram showing an example of a rolling plant 1. In the rolling plant 1, as main rolling equipment, a heating furnace 2, a roughing mill 3, a crop shear 4, a finishing mill 5 as a hot rolling mill, a cooling device 6, and a winder 7 are installed. In the rolling plant 1, a conveying table (not shown) for conveying the steel sheet Pr between the rolling equipment is installed. These rolling equipment are driven by an electric system including electric motors and actuators.

[0014] The heating furnace 2 is configured to heat the steel plate (slab) Pr before rolling to a predetermined temperature (for example, 1200°C). The roughing mill 3 has at least one rolling stand (usually 1 to 3 stands) and rolls the steel plate (slab) Pr heated in the heating furnace 2 in a forward direction (from upstream to downstream of the rolling line) and a reverse direction (from downstream to upstream of the rolling line) for multiple passes. The crop shear 4 cuts off defective parts of the shape at the front or tail end of the steel plate Pr with upper and lower blades based on the shape measured by a shape detector 81 described later. The finishing mill 5 is a tandem rolling mill equipped with, for example, seven rolling stands F1 to F7 arranged in parallel in the rolling direction of the steel plate Pr. Each of the rolling stands F1 to F7 is equipped with two work rolls 51, one above and one below, two backup rolls 52, and an electric motor 53 for rotating the rolls. The backup rolls 52 are provided with a screw down device 54, which is configured to be able 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 cooling device 6 cools the steel sheet Pr by injecting water onto the steel sheet Pr using a cooling bank. The cooled steel sheet Pr is wound into a coil by a winder 7.

[0015] Various sensors are installed as measuring instruments at key points in the rolling plant 1. Key points in the rolling plant 1 include, for example, the exit side of the heating furnace 2, the exit side of the roughing mill 3, the exit side of the finishing mill 5, and the entry side of the winder 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 3, a thermometer 82 that measures the surface temperature of the steel sheet Pr at the entry side of the finishing mill 5, a speed detector 83 that measures the speed Va of the steel sheet Pr at the exit side of the finishing mill 5, and a speed detector 84 that measures the plate thickness and plate speed of the steel sheet Pr at the exit side of the finishing mill 5. width The various sensors include a plate thickness / plate width meter 84 that measures the thickness, width, and thickness of the steel plate Pr, a thermometer 85 that measures the surface temperature of the steel plate Pr at the inlet side of the winder 7, and the rolling load sensor 55. The various sensors sequentially measure the state of the steel plate Pr and the state of each rolling facility.

[0016] The rolling plant 1 is operated by a control system using computers having a hierarchical structure. The computers include a process control computer 11 at level 1 and a host computer 12 at level 2, which are connected to each other via a network. The process control computer 11 and the host computer 12 are connected to a quality defect analysis support system for rolled products, which will be described later, via the network. The process control computer 11 has a control controller such as a PLC (Programmable Logic Controller). An interface screen 13, which is an operation screen on which manual operations are performed by an operator of the rolling plant 1, is connected to the process control computer 11 via the network. When a rolling plan is input to the host computer 12 by a rolling plan designer, the rolling plan is sent from the host computer 12 to the process control computer 11. In addition to the rolling plan, slab information such as the thickness, width, length, steel type, etc. of the slab, which is the material to be rolled M before rolling, and coil target information such as the target thickness, target width, target temperature, etc. of the coil, which is the material to be rolled M after rolling, are input from the host computer 12 to the process control computer 11. The process control computer 11 receives the input from the host computer 12 and executes setting calculations and control of the control objects in a series of rolling processes.

[0017] [Support system for quality defect analysis of rolled products] 2 is a block diagram showing a quality defect analysis support system 20 for rolled products according to embodiment 1. The quality defect analysis support system 20 is applied when the quality of the steel sheet Pr manufactured in the rolling plant 1 is determined to be defective, but can also be applied to other rolling plants.

[0018] The quality defect analysis support system 20 includes five recording devices (registration devices) 21 to 25 and a conversion device 26. The recording devices 21 to 25 may be integrated into a single recording device.

[0019] The first recording device 21 records the steel plate time unit information, the rolling equipment time unit information, and the manual operation time unit information input from the process control computer 11 in a time axis performance database (DB) 31 in association with the product ID of the steel plate Pr manufactured in the past. The steel plate time unit information includes, for example, the thickness, width, temperature, and waveforms thereof of the steel plate Pr in the rolling time unit during rolling. The rolling equipment time unit information is information during rolling of the rolling equipment installed in the rolling plant 1, and includes the rolling load of each stand F1 to F7 of the finishing rolling mill 5, the temperature of the heating furnace 2, and waveforms thereof. The manual operation time unit information is information on manual operations such as button operations and lever operations performed on the operation screen 13 by the operator of the rolling plant 1.

[0020] Each piece of time unit information recorded in the time axis performance database 31 is also input from the process control computer 11 to the conversion device 26. The conversion device 26 converts the steel plate time unit information, rolling equipment time unit information, and manual operation time unit information into information on the length unit in the rolling direction of the steel plate Pr (hereinafter referred to as "steel plate length unit information", "rolling equipment length unit information", and "manual operation length unit information"). As a method of converting from time unit to length unit can be a known method, a detailed explanation will be omitted here.

[0021] The second recording device 22 records the steel plate length unit information, rolling equipment length unit information, and manual operation length unit information converted by the conversion device 26 in the product unit database 32 in association with the product ID.

[0022] The third recording device 23 records the rolling plan of the rolling plant 1 input from the host computer 12 and the error occurrence record of the rolling equipment in the product unit database 32 in association with the product ID. The rolling plan includes the product size, steel type, rolling schedule, plate threading time, information on the slabs used, etc. The error occurrence record of the rolling equipment includes the limit violation of the reduction device 54 that occurred during the production of the steel plate Pr, the type and location of the alarm that occurred during the production, and the countermeasure (operation) method.

[0023] The fourth recording device 24 records the mechanical maintenance information of the rolling facility in association with the product ID in the machine unit database 33. The mechanical maintenance information includes the date and time and details of the care such as maintenance and adjustment.

[0024] The fifth recording device 25 records the electrical system maintenance information of the rolling equipment in association with the product ID in the electrical unit database 34. The electrical system maintenance information includes the date and time and details of maintenance such as maintenance, repair, calibration, and adjustment.

[0025] The product ID of the steel sheet Pr determined to be defective is automatically or manually inputted into the search device 27. The search device 27 uses the inputted product ID as a search key to extract information on the defective product from the time axis performance database 31, the product unit database 32, the machine unit database 33 and the electric unit database 34. The search device 27 outputs the information extracted from each of the databases 31 to 34. The output method includes not only a method of displaying on a display device (not shown) but also an output in a report format. When displayed on a display device, for example, the information is displayed on a monitor (not shown) of the host computer 12 to be displayed to a designer of a rolling plan. In addition, the information can be displayed on the operation screen 13 to be displayed to an operator performing manual operation.

[0026] Next, a description will be given of the operation of the quality defect analysis support system 20. FIG.

[0027] When the product ID of a product in which a defect has occurred is input to the search device 27 of the quality defect analysis support system 20, the search device 27 uses the input product ID as a search key and searches for the product ID that has the defect. time An inquiry is made to the axis performance database 31 to obtain information on each time unit (step S1).

[0028] In parallel with the above step S1, the search device 27 queries the product unit database 32 using the product ID as a search key to acquire each length unit information (step S2). In this step S2, together with each length unit information, the rolling plan and the rolling equipment error occurrence record are acquired.

[0029] In parallel with steps S1 and S2, the search device 27 queries the machine unit database 33 and the electric unit database 34 using the product ID as a search key to obtain mechanical maintenance information and electric maintenance information (steps S3 and S4).

[0030] The search device 27 displays the information acquired in the above steps S1 to S4 to the designer of the rolling plan (step S5).

[0031] FIG. 4 is a diagram showing an example of a hardware configuration of the quality defect analysis support system 20. Each of the above-mentioned functions of the quality defect analysis support system 20 can be realized by a processing circuit shown in FIG. 4. The processing circuit 20 may be dedicated hardware 20a. The processing circuit may include a processor 20b and a memory 20c. The processing circuit may be partially formed as the dedicated hardware 20a and further include a processor 20b and a memory 20c. In the example of FIG. 4, a part of the processing circuit 20 is formed as the dedicated hardware 20a, and the processing circuit 20 also includes a processor 20b and a memory 20c. The processing circuit 20 may be at least one dedicated hardware 20a. In this case, the processing circuit 20 corresponds to, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC, an FPGA, or a combination of these. The processing circuit 20 may include at least one processor 20b and at least one memory 20c. In this case, each function of the quality defect analysis support system 20 is realized by software, firmware, or a combination of software and firmware. The software and firmware are written as a program and stored in the memory 20c. The processor 20b reads out and executes the program stored in the memory 20c to realize the functions of the recording devices 21 to 25, the conversion device 26, the search device 27, and the difference detection device 28 of the second embodiment described later. The processor 20b is also called a CPU (Central Processing Unit), a central processing unit, a processing device, an arithmetic unit, a microprocessor, a microcomputer, or a DSP. The memory 20c corresponds to, for example, a non-volatile or volatile semiconductor memory such as a RAM, a ROM, a flash memory, an EPROM, or an EEPROM. In this way, the processing circuit 20 can realize the functions of the quality defect analysis support system 20 by hardware, software, firmware, or a combination of these.

[0032] As described above, according to this embodiment, by recording not only time unit information and length unit information such as the thickness and temperature of the steel plate in association with the product ID, but also the rolling plan of the rolling plant 1 and the maintenance information of the rolling equipment in the databases 31 to 34, it is possible to extract these rolling plans and maintenance information related to defective products using the product ID as a search key. As a result, the rolling plan designer who receives the display of the extraction result can quickly change the rolling plan. In addition, the rolling plan designer who receives the display of the extraction result can notify the maintenance operator and quickly perform maintenance to eliminate the defect. In this way, it is possible to surface defects in the rolling plan and maintenance that were previously hidden by the manual operation of the operator, so it is possible to provide a rolled product quality defect analysis support system 20 that makes it possible to shorten the time for manufacturing the steel plate Pr in an unstable state.

[0033] Embodiment 2 Next, a second embodiment of the present invention will be described with reference to Figures 5 and 6. The differences from the first embodiment will be mainly described, and the same or corresponding parts will be denoted by the same reference numerals and description thereof will be omitted.

[0034] FIG. 5 is a block diagram showing a quality defect analysis support system for rolled products according to the second embodiment. In the quality defect analysis support system 20 shown in FIG. 5, each of the recording devices 21-25 records not only information on defective products but also information on non-defective products in each of the databases 31-34. That is, information on both defective products and non-defective products is recorded in each of the databases 31-34. The search device 27 can extract not only information on defective products but also information on non-defective products from each of the databases 31-34 using the product ID as a search key. Here, since the amount of information on non-defective products is enormous compared to the amount of information on defective products, it is preferable to list the information on non-defective products and configure the system so that necessary information on non-defective products can be selected from the non-defective product list, thereby filtering out unnecessary information on non-defective products. This makes it possible to narrow down the necessary information on non-defective products.

[0035] The quality defect analysis support system 20 further includes a difference detection device 28. The difference detection device 28 detects the difference between the information on the defective product and the information on the non-defective product input from the search device 27. The difference detection device 28 outputs the detected difference. As an output method, the same method as the output method from the search device 27 can be used. Note that, although the example shown in Fig. 5 is configured with a single difference detection device 28, it may also be configured by dividing it into multiple devices.

[0036] Next, there will be described an operation of the quality defect analysis support system 20. Fig. 6 is a diagram showing an example of an operation of the quality defect analysis support system for rolled products shown in Fig. 5.

[0037] As in the first embodiment, when the product ID of a product in which a defect has occurred is input to the search device 27, the search device 27 searches for the product ID by using the input product ID as a search key. time The search device 27 queries the shaft performance database 31 to obtain each time unit information (step S11). In parallel with the above step S11, the search device 27 queries the product unit database 32 using the product ID as a search key to obtain each length unit information (step S12). In this step S12, the search device 27 obtains the rolling plan and the rolling equipment error occurrence record together with each length unit information. In parallel with the above steps S11 and S12, the search device 27 queries the machine unit database 33 and the electric unit database 34 using the product ID as a search key to obtain mechanical system maintenance information and electric system maintenance information, respectively (steps S13 and S14).

[0038] In these steps S11 to S14, both the information on defective products and the information on non-defective products are acquired. When acquiring the information on non-defective products, the non-defective product information can be filtered by selecting the necessary non-defective product information from the list of the non-defective product information.

[0039] The information on defective products and non-defective products acquired in steps S11 to S14 is input to a difference detection device 28. The difference detection device 28 detects the difference between the information on defective products and the information on non-defective products for each piece of information, and displays the detected difference to the designer of the rolling plan (step S15). Note that in step S15, the search device 27 may display the information on defective products acquired in the above steps S11 to S14 to the designer of the rolling plan.

[0040] As described above, according to this embodiment, a configuration is adopted in which the difference between information on defective products and information on non-defective products is detected by the difference detection device 28 and displayed to the designer of the rolling plan, so that information useful for examining the necessity of changing the rolling plan can be presented to the designer of the rolling plan.

[0041] Although the embodiments of the present invention have been described above, the present invention is not limited to the above-mentioned embodiments, and various modifications can be made without departing from the spirit of the present invention. In the above-mentioned embodiments, when the number, quantity, amount, range, etc. of each element is mentioned, the present invention is not limited to the mentioned numbers, unless otherwise specified or clearly specified in principle. Furthermore, the structures, etc. described in the above-mentioned embodiments are not necessarily essential to the present invention, unless otherwise specified or clearly specified in principle.

[0042] In the above embodiment, the information on non-defective products is filtered, but the system may be configured to further include a defect occurrence frequency calculation device that acquires information on all non-defective products without filtering and calculates the occurrence frequency of defective products. This makes it possible to present more useful information to the designer of the rolling plan. [Explanation of symbols]

[0043] Reference Signs List 1...Rolling plant, 20...Rolled product quality defect analysis support system, 21...First recording device, 22...Second recording device, 23...Third recording device, 24...Fourth recording device, 25...Fifth recording device, 26...Conversion device, 27...Search device, 28...Difference detection device, 31...Time axis performance database, 32...Product unit database, 33...Machine unit database, 34...Electrical unit database

Claims

1. A quality defect analysis support system for rolled products that supports analysis of quality defects when the quality of steel plates manufactured in a rolling plant is determined to be defective, a first recording device that records, in a time axis performance database, steel plate time unit information including a plate thickness and a temperature of the steel plate for each rolling time unit, rolling equipment time unit information including a rolling load of a rolling equipment installed in the rolling plant, and time unit information of manual operation by an operator of the rolling plant, in association with a product ID of a steel plate manufactured in the past; The steel plate time unit information, the rolling equipment time unit information, and the manual operation time unit information, A conversion device for converting each of the information into length unit information; a second recording device that records each piece of information converted by the conversion device in a product unit database in association with the product ID; a third recording device that records a rolling plan of the rolling plant and an error occurrence record of the rolling equipment in the product unit database in association with the product ID; A fourth recording device that records mechanical maintenance information of the rolling equipment in a machine unit database in association with the product ID; a fifth recording device that records electrical system maintenance information of the rolling equipment in an electrical unit database in association with the product ID; a search device that extracts information about the defective product from the time axis performance database, the product unit database, the machine unit database, and the electrical unit database by using the product ID of the steel plate determined to be defective as a search key; A quality defect analysis support system for rolled products.

2. the search device extracts information about the defective products and information about the non-defective products from the time axis performance database, the product unit database, the machine unit database, and the electrical unit database using the product ID as a search key; The quality defect analysis support system for rolled products according to claim 1 , further comprising a difference detection device that detects a difference between the information about the defective products extracted by the search device and the information about the non-defective products.

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