Winding Control System

Abstract

A winding control system according to one embodiment comprises: a motor drive control device that controls the driving of a motor which rotationally drives a mandrel for winding a rolled material around a coil; a tail end sensor that detects one point of the rolled material to thereby output a detection signal indicating that the rolled material passes through a tail end; a winding control device that tracks the position of the tail end; a first camera that is provided between the finishing roll mill and the mandrel and captures images for first image data including information about the shape of the tail end; and an image analysis device that performs image analysis on the first image data at a timing at which the detection signal is emitted, generates a correction value for correcting the position of the tail end on the basis of a result of the image analysis of the image data, and outputs the correction value to the winding control device. The winding control device corrects the position of the tail end by using the correction value.

Description

[Technical Field]

[0001] An embodiment of the present invention relates to a rolled material winding control system. [Background technology]

[0002] In a rolling line such as a hot rolling line, a process of winding a rolled material into a coil is provided. Such a process is automated, and winding control is performed to wind the tail end of the rolled material at an appropriate position. In the winding control, the position of the tail end of the rolled material in a coiled state is controlled by tracking the position of the tail end.

[0003] A cold metal detector (CMD) is used to detect the tail end of the rolled material. The CMD monitors one point on the pass line on the discharge side of the finishing mill and detects the passage of the tail end by determining whether or not there is any rolled material being transported along the pass line.

[0004] In the winding control, the tail end position is tracked and a winding speed pattern is set according to the tail end position. By winding the rolled material onto a coil using the set speed pattern, the tail end of the rolled material is controlled to be at a desired position on the coil when winding is completed.

[0005] Since the CMD detects one point in the width direction of the rolled material, if the shape of the tail end of the rolled material is not a straight line perpendicular to the conveying direction, the position of the tail end cannot be detected accurately. Therefore, if the tail end position is tracked by the CMD, the tail end position may deviate from the appropriate position at the end of winding. If the tail end position after winding deviates from the appropriate position, the tail end may sag from the coil, causing problems when placing the coil.

[0006] If the tail end position is misaligned after winding is complete, an operator on-site must visually check the position of the tail end and rotate the mandrel to adjust the position of the tail end. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent Application No. 2013-94798 Summary of the Invention [Problem to be solved by the invention]

[0008] The embodiment of the present invention has been made to address such problems, and aims to provide a winding control system that corrects the position of the tail end according to the shape of the tail end and winds it at the appropriate tail end position. [Means for solving the problem]

[0009] A winding control system according to an embodiment of the present invention comprises: an electric motor drive control device that controls the drive of an electric motor that rotates a mandrel that winds the rolled material discharged from a finishing rolling mill into a coil on the discharge side of the finishing rolling mill; a tail end sensor that is provided on the discharge side of the finishing rolling mill and detects a point on the rolled material to output a detection signal indicating the passage of the tail end of the rolled material; a winding control device that tracks the position of the tail end as a rotation angle of the mandrel; a first camera that is provided between the finishing rolling mill and the mandrel and outputs first image data including information on the shape of the tail end; and an image analyzer that performs image analysis of the first image data when the detection signal is issued, and generates a correction value to correct the position of the tail end based on the results of the image analysis of the first image data and outputs the correction value to the winding control device. Upon receiving the detection signal, the winding control device starts tracking the position of the tail end as a tentative tail end position, and generates a first speed command value that sets the rotation speed of the mandrel based on the tentative tail end position, the correction value, and a predetermined target angle, and outputs the first speed command value to the motor drive control device. [Effects of the Invention]

[0010] According to an embodiment of the present invention, a winding control system is provided that corrects the position of the tail end according to the shape of the tail end and winds the tail end at an appropriate position. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic block diagram illustrating a winding control system according to an embodiment. [Figure 2] 1 is a schematic diagram illustrating a hot rolling process to which a winding control system according to an embodiment is applied; [Figure 3A] 1 is an example of the shape of the tail end of a rolled material. [Figure 3B] 1 is an example of the shape of the tail end of a rolled material. [Figure 3C] 1 is an example of the shape of the tail end of a rolled material. [Figure 4] FIG. 2 is a schematic block diagram illustrating a winding control device and an image analysis device according to an embodiment. [Figure 5A] FIG. 3B is a schematic diagram illustrating a method for determining a target tail tip position by image analysis based on the shape of the tail tip in FIG. 3A. [Figure 5B] FIG. 3C is a schematic diagram illustrating a method for determining a target tail tip position by image analysis based on the shape of the tail tip in FIG. 3B. [Figure 5C] FIG. 3D is a schematic diagram illustrating a method for determining a target tail tip position by image analysis based on the shape of the tail tip of FIG. 3C. [Figure 6] 10 is an example of a definition formula for determining a target tail end position. [Figure 7A] FIG. 10 is a schematic diagram for explaining the adjustment of the tail end position after the coiling of the rolled material is completed. [Figure 7B] FIG. 10 is a schematic diagram for explaining the adjustment of the tail end position after the coiling of the rolled material is completed. [Figure 8] 10 is an example of a flowchart for explaining an operation of controlling winding of a rolled material at a target tail end position. [Figure 9] 10 is an example of a flowchart for explaining an operation for correcting the tail end position after the coiling of the rolled material is completed. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the size ratio between parts, etc. are not necessarily the same as those in reality. Furthermore, even when the same part is shown, the dimensions and ratios may be different depending on the drawing. In the present specification and the drawings, elements similar to those described above with reference to the previous drawings are designated by the same reference numerals, and detailed descriptions thereof will be omitted as appropriate.

[0013] FIG. 1 is a schematic block diagram illustrating a winding control system according to an embodiment. As shown in Fig. 1, a winding control system 100 according to the embodiment includes a winding control device 10, an image analysis device 20, a camera 25a, a tail end sensor 30, and a motor drive control device 60. In this example, the winding control device 10 and the image analysis device 20 are communicatively connected via a control network 102. A camera 25a is connected to the image analysis device 20. The camera 25a is provided on the discharge side of the rolled material 1 of a finishing mill 201 shown in Fig. 2 (described later) so as to capture an image of the shape of the tail end of the rolled material 1 discharged from the finishing mill 201.

[0014] The winding control system 100 according to the embodiment may further include a camera 25b. The camera 25b is disposed to the side of the coil wound around the mandrel 80 shown in Fig. 2. The camera 25b is provided so as to capture an image of the position of the tail end of the rolled material after winding is completed.

[0015] The image analysis device 20 performs image analysis on the image data generated and output based on the images captured by the cameras 25a and 25b, and transmits the image data to the winding control device 10 via the control network 102. The image data includes image data including the shape of the tail end of the rolled material 1 and the position of the tail end of the rolled material 1.

[0016] The winding control device 10 is communicatively connected to the tail end sensor 30 via a remote IO panel 40. The tail end sensor 30 is provided to detect the presence or absence of a rolled material being transported on the pass line on the discharge side of the finishing rolling mill. The tail end sensor 30 is a CMD, and, for example, outputs an active detection signal to the winding control device 10 when it detects the tail end of the rolled material. The tail end sensor 30 may be a type that remains active until it detects the tail end of the rolled material 1, and outputs a detection signal that becomes inactive upon detecting the tail end. In the following, unless otherwise specified, it is assumed that the tail end sensor 30 outputs an active detection signal when it detects the tail end of the rolled material.

[0017] The winding control device 10 is connected to the motor drive control device 60 via the remote IO panel 50. The motor drive control device 60 is connected to an electric motor 70 mechanically coupled to a mandrel 80. The electric motor drive control device 60 receives a speed command value output from the winding control device 10 and an actual measurement value of the rotation speed of the electric motor 70 detected by a speed sensor provided in the electric motor 70. The electric motor drive control device 60 drives the electric motor 70 so that the actual measurement value of the speed of the electric motor 70 follows the speed command value. The electric motor drive control device 60 and the electric motor 70 are not limited to such sensor-based speed control, and of course, sensorless speed control may also be used.

[0018] The winding control device 10 calculates a correction value for the target angle based on image data (first image data) including the shape of the tail end of the rolled material acquired by the camera 25a. The target angle is an angle obtained by winding the rolled material around a mandrel as a coil and converting the position of the tail end on the circumference of the coil after winding into a rotation angle of the mandrel.

[0019] The rewinding control device 10 corrects the preset target angle using the calculated correction value for the target angle. The rewinding control device 10 generates a speed command value so that the rotation angle representing the tail end position detected by the tail end sensor 30 coincides with the corrected target angle, and outputs the speed command value to the motor drive control device 60. The motor drive control device 60 drives and rotates the mandrel 80 in accordance with the speed command value so that the tail end is at the desired position.

[0020] The winding control device 10 is, for example, a programmable logic controller (PLC). The PLC may be implemented by hardware, or may be a virtual PLC implemented by software installed in a computer device. The functions of each unit constituting the winding control device 10, which will be described later, are implemented by one or more steps of a program or software that runs on the winding control device 10, which is a PLC. The program or software that operates the winding control device 10 is stored, for example, in a storage device connected inside or outside the winding control device 10. The winding control device 10 appropriately reads out the program or software stored in the storage device to implement the functions of each unit, which will be described later.

[0021] The image analysis device 20 is, for example, a computer device. The functions of each part that realizes the image analysis device 20, which will be described later, are realized by one or more steps of programs and software that constitute the image analysis device 20, which is a computer device. The programs and software that operate the image analysis device 20 are stored, for example, in a storage device connected inside or outside the image analysis device 20. The image analysis device 20 reads out the programs and software stored in the storage device as appropriate to realize the functions of each part that will be described later.

[0022] The winding control device 10 and the image analysis device 20 are not limited to being implemented in different PLCs and computer devices, respectively, but may also be realized by implementing all or some of these components in a single computer device, for example.

[0023] FIG. 2 is a schematic view illustrating a hot rolling process to which the winding control system according to the embodiment is applied. As shown in Fig. 2, in the hot rolling process, a mandrel 80 is provided on the discharge side of a finishing mill 201. The rolled material 1 is transported from the finishing mill 201 toward the mandrel 80, as indicated by the thick solid arrow going from right to left in Fig. 2. The rolled material 1 is wound around the mandrel 80 as a coil 1a while the tension is adjusted by a pinch roll R1 provided before the mandrel 80. The dashed line drawn continuously with the rolled material 1 in Fig. 1 indicates the pass line along which the rolled material 1 has been transported.

[0024] The winding end angle θf can be defined with reference to the winding point Pw. The winding point Pw is the point where the conveyed rolled material 1 starts to be wound around the coil 1a. The reference position of the winding end angle θf can be a straight line connecting the winding point Pw and the rotation center of the mandrel 80. When the tail end position at the end of winding is on the circumference of the coil 1a, the angle formed by a line connecting the tail end position Pf and the rotation center of the mandrel 80 from the reference position is defined as the winding end angle θf. Note that, for simplicity, the above description is based on the assumption that the rolling process is on a two-dimensional plane as shown in FIG. 2. In reality, the winding point Pw is a straight line perpendicular to the plane of FIG. 2, and the rotation center of the mandrel 80 is the central axis of rotation of the mandrel 80, which is also a straight line perpendicular to the plane of FIG. 2. In other words, the winding end angle θf represents the angle within two planes. The angle at the end of winding will also be explained in the same manner in connection with FIGS. 7A and 7B below.

[0025] In the coiling control system 100 according to the embodiment, a tail end sensor 30 and a camera 25a are provided on the discharge side of the finishing rolling mill 201. The tail end sensor 30 is provided to detect the presence or absence of the rolled material 1 being transported on the pass line. The tail end sensor 30 is arranged, for example, at approximately the center of the length of the rolled material 1 in the width direction so as to detect the presence or absence of the rolled material 1. The camera 25a is arranged to capture an image of the entire shape of the tail end of the rolled material 1.

[0026] The tail end of the rolled material 1 is detected by the tail end sensor 30, and the movement distance of the tail end from the detection point to the winding point Pw can be found by integrating the transport speed of the rolled material 1. The transport speed of the rolled material 1 is calculated as the product of the rotation speed of the mandrel 80 and the radius of the coil 1a. Therefore, by controlling the rotation speed of the mandrel 80, the rolled material 1 can be wound so that the tail end of the rolled material 1 is in an appropriate position.

[0027] 3A to 3C, the tentative tail end position P1, which is the detected position of the tail end detected by the tail end sensor 30, may be located further forward in the conveying direction than the actual tail end position P2, which is the actual position of the tail end, depending on the shape of the tail end. In other words, if the winding position on the mandrel 80 is determined by tracking the tentative tail end position P1 detected by the tail end sensor 30, this may deviate from the winding end position Pf, which corresponds to the winding end angle θf, which is the originally desired target angle, depending on the shape of the tail end.

[0028] Therefore, in the winding control system 100 according to the embodiment, the shape of the tail end of the rolled material 1 is captured by the camera 25a, and the position of the tail end is corrected based on image data generated from the captured image including the shape of the tail end. The winding control system 100 uses the correction value for the tail end position to control the rotation angle of the mandrel 80 so that the tail end is at the desired position Pf at the end of winding.

[0029] Examples of the shape of the tail end of the rolled material and the position of the tail end for each shape will be described below. 3A to 3C show examples of the shape of the tail end of the rolled material. 3A to 3C, the conveying direction of the rolled material 1 is the X-axis, and the width direction of the rolled material 1 is the Y-axis. The rolled material 1 is conveyed in the negative direction of the X-axis. The tail end sensor 30 is placed at a position that is 1 / 2 the width W of the rolled material 1. In these examples, the edge of the rolled material 1 on the work side is the negative side of the Y-axis, and the edge of the rolled material 1 on the drive side is the positive side of the Y-axis.

[0030] Hereinafter, the term "tail end" refers to the end between two edges along the conveyance direction of the rolled material, opposite the leading end, i.e., the leading end. In the winding control system 100 according to the embodiment, the position of the tail end that is tracked to control the winding position onto the coil is expressed in XY coordinates and referred to as the tail end position. The tail end position detected by the tail end sensor 30 is referred to as the tentative tail end position P1. The tail end position of the tail end is referred to as the actual tail end position P2, and the tail end position at the end of winding onto the coil is referred to as the target tail end position P3. The target tail end position P3 may be a position between the tentative tail end position P1 and the actual tail end position P2, or may coincide with the actual tail end position P2. In the XY coordinate system defined above, the origin (0,0) is the tentative tail end position P1, and the tentative tail end position P1 is the reference position.

[0031] As shown in FIGS. 3A to 3C, the shape of the tail end of the rolled material 1 discharged from the finishing mill 201 varies depending on the thickness and temperature of the rolled material 1, variations in the roll-down control of the rolling mill, and the like.

[0032] In the shape of the tail end shown in Figure 3A, the portion near the center of the rolled material 1 extends longer in the positive direction of the X axis, i.e., in the direction opposite to the direction in which the rolled material 1 is transported, than the portions on the work side edge and drive side edge of the rolled material 1. In this case, the tentative tail end position P1 is approximately the same as the actual tail end position P2 to be tracked. The actual tail end position P2 is expressed as (0,0) in XY coordinates.

[0033] The tail end shape shown in Figure 3B is such that the work side edge portion and the drive side edge portion of the rolled material 1 extend further in the positive direction of the X axis, i.e., in the direction opposite to the direction in which the rolled material 1 is transported, than the portion near the center of the rolled material 1. In this case, the temporary tail end position P1 is on the positive side of the X axis than the actual tail end position P2 to be tracked. The actual tail end position P2 can be expressed in XY coordinates as (Xb, Yb), where Xb > 0. The tail end shape shown in Figure 3B is called a fishtail.

[0034] In the tail end shape shown in Figure 3C, the portion on the drive side of the rolled material 1 extends further in the positive direction of the X axis, i.e., in the opposite direction to the direction in which the rolled material 1 is transported, than the portion near the center of the rolled material 1 and the portion on the work side edge. Furthermore, the portion near the center of the rolled material 1 is longer in the opposite direction to the direction in which the rolled material 1 is transported, than the portion on the work side edge. In this case, the tentative tail end position P1 is on the positive side of the X axis than the actual tail end position P2 to be tracked. The actual tail end position P2 can be expressed in XY coordinates as (Xc, Yc), where Xc > 0.

[0035] 3B and 3C, the actual tail end position P2 is wound later than the tentative tail end position P1, so if the winding position is controlled by tracking the tentative tail end position P1, some of the material will be left unwound. In the winding control system 100 according to the embodiment, the tail end position to be tracked is corrected according to the shape of the tail end, making it less likely that some of the material will be left unwound.

[0036] Specific configuration examples of the winding control device 10 and the image analysis device 20 will be described in detail. FIG. 4 is a schematic block diagram illustrating the winding control device and the image analysis device according to the embodiment. First, the configuration of the winding control device 10 will be described. As shown in FIG. 4, the take-up control device 10 includes a tail end detection switch 11, a rotation angle conversion unit 12, a target angle setting unit 14, a speed command calculation unit 15, and a tail end position correction switch 16.

[0037] A pulse signal is input to the tail end detection switch 11 from a pulse generator 82 provided on the mandrel 80. The pulse generator 82 is indicated as "PG" in FIG. 4. The pulse generator 82 outputs a pulse signal according to the rotation angle of the mandrel 80. When the tail end detection switch 11 is closed, the pulse signal is output from the tail end detection switch 11 to the rotation angle conversion unit 12.

[0038] The tail end detection switch 11 is opened and closed by the detection of the tentative tail end position P1 by the tail end sensor 30. When the tail end sensor 30 detects the tail end of the rolled material 1 and outputs an active detection signal, the tail end detection switch 11 is closed. When the tail end detection switch 11 is closed, a pulse signal is output to the rotation angle conversion unit 12.

[0039] The rotation angle conversion unit 12 integrates the input pulse signals to calculate the movement distance of the tentative tail end position P1 and tracks the tentative tail end position P1. The rotation angle conversion unit 12 converts the tentative tail end position P1 into a rotation angle [rad] of the mandrel 80 and outputs the detected value θs of the rotation angle of the mandrel 80 to the speed command calculation unit 15.

[0040] Speed ​​command calculation unit 15 inputs the difference Δθ between the detected value θs of the rotation angle of mandrel 80 output from rotation angle conversion unit 12 and the target angle θg0, and calculates a speed command value N* so that the input difference Δθ becomes 0. Speed ​​command calculation unit 15 outputs the calculated speed command value N* to motor drive control device 60. Speed ​​command calculation unit 15 is, for example, a PI calculator, which performs proportional integral calculation on the input data and outputs the result.

[0041] In this example, the target angle θg0 is set in advance in the target angle setting unit 14. The target angle setting unit 14 may be set in a storage unit within the winding control device 10 or in an external storage device. The target angle θg0 may be set as a fixed value in a program that realizes the winding control device 10. The fixed value set in the program may be, for example, data specified by a host computer for each steel grade of the rolled material 1.

[0042] The tail tip position correction switch 16 inputs a correction value θc [rad] for the tail tip position based on the shape of the tail tip. The correction value θc is calculated by the image analysis device 20 and output from the image analysis device 20. Once the correction value θc for the tail tip position is determined by the image analysis device 20, the tail tip position correction switch 16 is closed and outputs the correction value θc.

[0043] The target angle θg0 is corrected by adding a correction value θc in the calculator 17. The corrected target angle θg is output to the calculator 13. The calculator 13 outputs the difference Δθ between the detected value θs of the rotation angle of the mandrel 80 and the target angle θg corrected in accordance with the tail end shape.

[0044] In the winding control system 100 according to the embodiment, the winding control device 10 can further include a tail edge position correcting unit 18. The tail edge position correcting unit 18 functions by the above-described components of the winding control device 10 after winding of the rolled material 1 is completed. The tail edge position correcting unit 18 generates and outputs a speed command value so as to obtain an appropriate tail edge position based on image data of the tail edge position of the coil after winding is completed, which is acquired by the image analyzing device 20. The appropriate tail edge position for the state of the coil after winding is completed is set in advance. The tail edge position correcting unit 18 includes, for example, a PI controller, and the PI controller of the tail edge position correcting unit 18 generates and outputs a speed command value so as to set the difference from the rotation angle of the appropriate tail edge position to zero.

[0045] The winding control device 10 switches between the output of the speed command calculation unit 15 and the output of the tail edge position correction unit 18 using a changeover switch 19. In the case of a normal winding operation in which the tail edge is tracked, the changeover switch 19 outputs the speed command value generated by the speed command calculation unit 15. The changeover switch 19 switches the connection from the output of the speed command calculation unit 15 to the output of the tail edge position correction unit 18 in accordance with a switching signal generated by the image analysis device 20 after winding of the rolled material 1 is completed. The winding control device 10 outputs the speed command value generated by the tail edge position correction unit 18 by switching the changeover switch 19.

[0046] The tail end position corrector 18 can appropriately adjust the position of the tail end in the coiled state after winding is completed, thereby eliminating the need for manual adjustment work.

[0047] Next, the configuration of the image analysis device 20 will be described. Image analysis device 20 includes first image analysis unit 21 and angle correction calculation unit 22. Image analysis device 20 inputs image data generated and output from an image captured by camera 25a to first image analysis unit 21. First image analysis unit 21 performs image analysis on the image data to determine the corrected position of the tail tip. Angle correction calculation unit 22 uses the data of the corrected tail tip position to calculate and output a correction value θc for the rotation angle.

[0048] In order to use the tentative tail tip position P1 as the reference for the rotation angle correction value θc, the first image analysis unit 21 must reliably acquire image data capturing the tentative tail tip position P1. For example, the image analysis unit 21 acquires multiple image data captured at times before and after the timing at which the tentative tail tip position P1 is detected by the tail tip sensor 30. The tentative tail tip position P1 is detected from the multiple image data using a method described below and set as the reference position. The image data acquired by the image analysis unit 21 from the camera 25a can be, for example, video data. For example, the image analysis unit 21 stores video data captured several seconds (e.g., 3 seconds) before and after the timing at which the tentative tail tip position P1 is detected by the tail tip sensor 30, and determines the tentative tail tip position P1 from the acquired video data.

[0049] An example of a method for determining the tentative tail tip position P1 by the image analysis unit 21 and an example of a specific method for correcting the tail tip position will be described. 5A to 5C are schematic diagrams illustrating a method for determining the shape of the tail end of FIGS. 3A to 3C by image analysis. In the image data of Figures 5A to 5C, the X-axis (first axis) is set in advance as a virtual reference axis. The X-axis is set to match the position of the tail end sensor 30. For example, the X-axis is set to a position that is approximately half the width of the rolled material 1. The position of the X-axis may be calibrated in advance to match the position of the tail end sensor 30. The camera 25a acquires image data that includes the tail end or edge of the rolled material 1 as image brightness information. The first image analysis unit 21 can identify the edge or tail end of the rolled material 1 by determining changes in brightness of the image data. The image analysis unit 21 overlays the acquired image data on the preset X-axis and sets the point where the brightness of the image changes as a tentative tail end position P1, which is set as the reference position. The Y-axis (second axis) is also set as a virtual reference axis so as to pass through the reference position. The image data is divided into multiple sections in both the positive and negative directions of the Y-axis from the reference position.

[0050] If the tail end sensor 30 is an optical sensor that includes a light-emitting element and a light-receiving element and detects the presence or absence of a rolled material by receiving light emitted from the light-emitting element with the light-receiving element, the following method may be used. In this case, the camera 25a needs to capture image data of the location on the rolled material 1 where the light is irradiated. The camera 25a captures continuous images or videos including the location of the light emitted from the light-emitting element of the tail end sensor 30. The camera 25a continuously captures images of the light irradiated on the transported rolled material 1 along with the rolled material 1, and acquires data including the timing at which the trajectory of the light in the continuous images intersects with the tail end. The first image analysis unit 21 sets the point where the tail end of the rolled material 1 intersects with the trajectory of the light from the tail end sensor 30 as the provisional tail end position P1 and as the reference position. In this case, the trajectory of the light is the X-axis, and the Y-axis that intersects with the X-axis at the provisional tail end position P1 is set. As in the above example, the image data is divided into a plurality of sections in both the positive and negative directions of the Y axis from the reference position.

[0051] 5A to 5C, in this example, the image data DT is divided into four sections α, β, γ, and δ in the Y-axis direction. The lengths of the sections α, β, γ, and δ in the Y-axis direction can be set arbitrarily, and in this example, the lengths in the Y-axis direction are the same. In other words, in the image data DT, each section is set at equal intervals.

[0052] The image analysis unit 21 further divides each section into a plurality of subsections, and determines the section tail end position of each section using the X coordinate of each subsection. The section tail end position represents the position of the tail end of each section. The length of the subsections in the Y axis direction can be set arbitrarily, for example, to be equal intervals between each section. The section tail end position is found by calculating the arithmetic mean of the X coordinates of the subsections.

[0053] In the example shown in Figure 5A, the tail end position of section α is αa, the tail end position of section β is βa, the tail end position of section γ is γa, and the tail end position of section δ is δa. In the example shown in Figure 5B, the tail end position of section α is αb, the tail end position of section β is βb, the tail end position of section γ is γb, and the tail end position of section δ is δb. In the example shown in Figure 5C, the tail end position of section α is αc, the tail end position of section β is βc, the tail end position of section γ is γc, and the tail end position of section δ is δc.

[0054] The first image analysis unit 21 stores the calculated section tail end position for each section. The first image analysis unit 21 uses the stored section tail end positions to determine the target tail end position P3. In this example, the target tail end position P3 is set to a position between the tentative tail end position P1 and the actual tail end position P2. For example, in the case of a slender fishtail-shaped tail end, setting the target tail end position P3 to the actual tail end position P2 is a preferable setting when the length of the ineffective portion of the rolled material 1 to be wound becomes long. Depending on the attributes of the steel material, etc., the target tail end position P3 may be set to an arbitrary appropriate position and set to the actual tail end position P2. The first image analysis unit 21 determines the target tail end position P3 using a definition equation for determining the target tail end position P3.

[0055] FIG. 6 shows an example of a definition formula for determining the target tail end position. In the example of table 21T in Figure 6, combinations ranked by the size of the segment tail end position of each segment are arranged in the row direction. In this example, the segment tail end position of segment α is α1, the segment tail end position of segment β is β1, the segment tail end position of segment γ is γ1, and the segment tail end position of segment δ is δ1. In table 21T, the ranking of the size of the segment tail end position is represented by a number. In this example, the smaller the number, the larger the size of the segment tail end position.

[0056] For example, in the combination of the first row, the magnitude of the segment tail end position is α1>β1>γ1>δ1. In the combination of the second row, the magnitude of the segment tail end position is α1>β1>δ1>γ1. Table 21T stores all combinations of the magnitude of the segment tail end position. Although not shown in the figure, combinations where the magnitude of multiple segment tail end positions is equal are also covered.

[0057] The rightmost column of table 21T stores definition formulas for setting the target tail end position P3 for combinations of the size of the segment tail end position. For example, in the combinations of rows 1 to 6, the average value of α1 and β1 is set as the target tail end position P3, and in the combinations of rows 7 and 8, α1 is set as the target tail end position P3.

[0058] The image analysis unit 21 references the stored values ​​of the section tail end positions α1, β1, γ1, and δ1 and extracts a corresponding combination from the table 21T. The image analysis unit 21 sets the target tail end position P3 using a definition formula for the extracted combination and outputs it to the angle correction calculation unit 22. As in this example, if combinations of section tail end positions are set in advance in a table or the like, the target tail end position P3 can be determined by searching for and extracting the corresponding combination, which reduces the calculation burden and enables the target tail end position P3 to be determined quickly. Another advantage is that when bundling the coil after it has been wound, the sections can be changed depending on the bundling method.

[0059] The angle correction calculation unit 22 converts the target trailing end position P3 into the rotation angle of the mandrel 80, and outputs it to the winding control device 10 as a correction value θc for the target angle θg0.

[0060] The image analysis device 20 can further include a second image analysis unit 23. The second image analysis unit 23 acquires image data generated from an image including the position of the trailing end at the end of winding captured by the camera 25b.

[0061] The method for defining and determining the target trailing end position P3 is not limited to the above, and is appropriately set according to the type of steel material and the like. For example, the sectional trailing end position with the largest value may be used as the target trailing end position P3, or as described above, the actual trailing end position P2 may be used as the target trailing end position P3. Let the number of sections be a sufficiently large n, and the value at the center of the Y-axis of each section be the sectional trailing end value. Then, k1 times (0 < k1 < 1) of the maximum value of the sectional trailing end values may be used as the target trailing end position P3, or k2 times (0 < k2 < 1) of the difference between the minimum value and the maximum value of the sectional trailing end values may be used as the target trailing end position P3.

[0062] FIG. 7A and FIG. 7B are schematic diagrams for explaining the correction of the trailing end position after the winding of the rolled material. As shown in FIGS. 7A and 7B, the camera 25b is arranged on the side of the coil 1a wound around the mandrel 80, and images the position of the trailing end at the end of winding.

[0063] FIG. 7A shows an example where the position of the trailing end is not appropriate. The position of the trailing end is represented by, for example, the rotation angle (first end angle) θ1 [rad] from the reference position. The reference position can be arbitrarily set, and in this example, the straight line directed vertically downward from the center of the mandrel 80 is used as the reference position.

[0064] FIG. 7B shows an example in which the tail tip position is appropriate. The second image analysis unit 23 has information regarding the appropriate tail tip position. The information regarding the appropriate tail tip position is set in advance. It is set in advance as a rotation angle (second end angle) θ0 [rad] from the reference position. For example, the rotation angle θ0 from the reference position may be set as a target angle θg0.

[0065] As shown in FIG. 7A, if the tail end is not positioned properly after winding is completed, the tail end may hang down away from the coil 1a. The second image analysis unit 23 has a database of the relationship between the tail end hanging state and the rotation angle θ1 at that time. The second image analysis unit 23 refers to the database and determines the magnitude of the rotation angle θ1 from the state of the tail end in the acquired image data (second image data). The second image analysis unit 23 calculates the difference between the rotation angle θ1 and a preset rotation angle θ0, and outputs the result to the winding control device 10.

[0066] As described above, the winding control device 10 generates a speed command value so as to make the difference in rotation angle zero.

[0067] A series of operations of the winding control system 100 according to the embodiment will be described with reference to a flowchart. FIG. 8 is an example of a flowchart for explaining the operation of controlling the winding of the rolled material at the target tail end position. As shown in FIG. 8, in step S1, the winding control device 10 detects the provisional tail end position P1.

[0068] In step S2, the image analyzing device 20 acquires image data including the tail end of the rolled material 1. The image analyzing device 20 sets a reference position and determines a target tail end position P3 based on the acquired image data.

[0069] In step S3, the target tail end position P3 is converted into a rotation angle, and is output to the reel control device 10 as a correction value θc of the rotation angle.

[0070] In step S4, the winding control device 10 calculates the movement distance of the temporary tail end position P1 by integrating the pulse signals output from the pulse generator 82, and converts it into a detected value θs of the rotation angle of the mandrel 80.

[0071] In step S5, the take-up control device 10 corrects the target angle θg0 with the correction value θc to calculate the corrected target angle θg.

[0072] In step S6, the take-up control device 10 generates a speed command value N* so that the difference Δθ between the detected rotation angle value θs and the target angle θg0 becomes zero, and outputs the speed command value N* to the motor drive control device 60.

[0073] By carrying out the above steps, the rolled material 1 is wound around the mandrel 80 as a coil.

[0074] The winding control system 100 according to the embodiment can operate regardless of the order of the above-described steps S1 to S6. For example, step S4 may be performed before step S2, or may be performed simultaneously with step S2.

[0075] When adjusting the position of the tail end after winding onto the coil is completed, the following operations are further carried out. FIG. 9 is an example of a flowchart for explaining the operation of correcting the tail end position after the coiling of the rolled material is completed. Once the winding of the rolled material 1 is completed and the mandrel 80 stops, the second image analysis unit 23 starts operating. As shown in Fig. 9, in step S11, the second image analysis unit 23 acquires image data of the side surface of the coil 1a.

[0076] In step S12, the image analyzer 20 performs image analysis on the input image data, determines the rotation angle θ1 corresponding to the position of the tail end based on the database, and outputs the rotation angle θ1 to the reel-up control device 10.

[0077] In step S13, the take-up control device 10 calculates the difference between the rotation angle θ1 output from the image analysis device 20 and the reference rotation angle θ0 using the calculator 24. In the take-up control device 10, the tail end position correction unit 18 generates a speed command value so that the difference in rotation angle (θ1-θ0) becomes 0, and outputs the generated speed command value to the motor drive control device 60.

[0078] In this way, the winding control system 100 according to the embodiment can position the coil at an appropriate tail end.

[0079] In the above description, the winding control device 10 tracks the detected value θs of the rotation angle based on the tentative tail end position P1 and controls the rotation angle of the mandrel so that the detected value θs becomes the target angle θg corrected based on the shape of the tail end, but this is not limiting. For example, the detected value θs based on the tentative tail end position P1 may be corrected based on the shape of the tail end, and the rotation angle of the mandrel may be controlled so that the corrected rotation angle becomes the predetermined target angle θg.

[0080] The effects of the winding control system 100 according to the embodiment will be described. The winding control system 100 according to the embodiment includes an image analyzer 20 connected to a camera 25a that is provided to capture an image of the shape of the tail end of the rolled material 1. The shape of the tail end can be appropriately determined by analyzing the image data with the image analyzer. In the winding control system 100 according to the embodiment, the winding control device can correct the position of the tail end detected by the tail end sensor 30 based on the shape of the tail end determined by the image analyzer 20 and control the rotation angle of the mandrel 80 so that the position becomes a target angle. Therefore, even in the case of various tail end shapes, winding can be completed at an appropriate winding position.

[0081] In the winding control system 100 according to the embodiment, the image analyzer 20 can determine the position of the tail end of the coil after winding is completed. The winding control device 10 can set the position of the tail end after winding is completed, determined by the image analyzer 20, to a predetermined appropriate position. This eliminates the need for additional visual inspection by an operator, which has been required in the past, and improves productivity in the rolling process.

[0082] In this way, a winding control system is realized that corrects the position of the tail end according to the shape of the tail end and winds the tail end at an appropriate position.

[0083] Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as set forth in the claims. Furthermore, the above-described embodiments can be implemented in combination with each other. [Explanation of symbols]

[0084] 1...rolled material, 1a...coil, 10...winding control device, 11...tail end detection switch, 12...rotation angle conversion unit, 14...target angle setting unit, 15...speed command calculation unit, 16...tail end position correction switch, 18...tail end position correction unit, 20...image analysis device, 21...first image analysis unit, 22...angle correction calculation unit, 23...second image analysis unit, 25a, 25b...camera, 30...tail end sensor, 60...motor drive control device, 70...electric motor, 80...mandrel, 82...pulse generator, 100...winding control system, 102...control network

Claims

1. an electric motor drive control device that controls the drive of an electric motor that rotates a mandrel that winds the rolled material discharged from the finishing rolling mill into a coil on the discharge side of the finishing rolling mill; a tail end sensor provided on the discharge side of the finishing rolling mill, which detects one point of the rolled material and outputs a detection signal indicating the passage of the tail end of the rolled material; a winding control device that tracks the position of the tail end as a rotation angle of the mandrel; a first camera provided between the finishing rolling mill and the mandrel, the first camera outputting first image data including information on the shape of the tail end; an image analyzer that performs image analysis of the first image data at the timing when the detection signal is issued, and generates a correction value for correcting the position of the tail end based on the result of the image analysis of the first image data, and outputs the correction value to the winding control device; Equipped with The winding control device includes: Upon receiving the detection signal, the position of the tail tip is set as a tentative tail tip position and tracking is started. a winding control system that generates a first speed command value for setting a rotation speed of the mandrel based on the provisional tail end position, the correction value, and a target angle that is an angle between a predetermined reference position on the mandrel and a predetermined position on the mandrel as the tail end position at the end of winding, and outputs the first speed command value to the motor drive control device, the image analysis device has a first axis serving as a virtual reference having a direction parallel to the conveyance direction of the rolled material, The image analysis device The first image data recognizes the shape of the tail end including the provisional tail end position as information on the boundary between light and dark luminance, The intersection of the information on the boundary between light and dark of the first image data and the first axis is set as a reference position corresponding to the provisional tail end position; the image analysis device has a virtual second axis perpendicular to the first axis, The image analysis device Dividing the first image data into a plurality of sections at predetermined intervals in the direction of the second axis; The positions of the plurality of sections are defined as a distance from the reference position along the first axis and a distance from the section along the second axis, determining a shape of the tail end based on a spacing distance along the first axis and a spacing distance along the second axis of each of the plurality of sections; A winding control system that determines the position of the tail end based on the determined shape of the tail end.

2. an electric motor drive control device that controls the drive of an electric motor that rotates a mandrel that winds the rolled material discharged from the finishing rolling mill into a coil on the discharge side of the finishing rolling mill; a tail end sensor provided on the discharge side of the finishing rolling mill, which detects one point of the rolled material and outputs a detection signal indicating the passage of the tail end of the rolled material; a winding control device that tracks the position of the tail end as a rotation angle of the mandrel; a first camera provided between the finishing rolling mill and the mandrel, the first camera outputting first image data including information on the shape of the tail end; an image analyzer that performs image analysis of the first image data at the timing when the detection signal is issued, and generates a correction value for correcting the position of the tail end based on the result of the image analysis of the first image data, and outputs the correction value to the winding control device; Equipped with The winding control device includes: Upon receiving the detection signal, the position of the tail tip is set as a tentative tail tip position and tracking is started. a winding control system that generates a first speed command value for setting a rotation speed of the mandrel based on the provisional tail end position, the correction value, and a target angle that is an angle between a predetermined reference position on the mandrel and a predetermined position on the mandrel as the tail end position at the end of winding, and outputs the first speed command value to the motor drive control device, a second camera that outputs second image data including a side surface of the coil after the winding of the rolled material is completed; the image analysis device determines a first end angle of a tail end of the rolled material on a side surface of the coil based on the second image data; The winding control system includes a winding control device that generates a second speed command value to set the first end angle to a preset second end angle and outputs the second speed command value to the electric motor drive control device.

Images