Rolling recording device, rolling recording method, and rolling recording program

Abstract

This rolling recording device stores: a plurality of camera images acquired by a plurality of cameras for imaging a plurality of rolling mills; control signals to be inputted to the respective rolling mills; actual measurement values of rolling states acquired by a plurality of sensors provided on a rolling line; HMI screen information for creating an HMI screen in which the rolling line is exemplified; and time point information including an acquisition time point for each of the plurality of camera images, an input time point for each of the control signals, and an update time point for the HMI screen information. In addition, the rolling recording device executes: update processing for updating the HMI screen information on the basis of at least the actual measurement values regarding the rolling states; generation processing for generating an output display screen including a display screen for a target camera image, a display screen for a control signal, and the HMI screen which are synchronized on the basis of the time point information; display processing for displaying the output display screen on a monitor; saving processing for saving the output display screen; and reproduction processing for reproducing the history of the output display screens in response to a request.

Description

Rolling recording device, rolling recording method, and rolling recording program

[0001] The present disclosure relates to techniques for recording the state of a rolling line.

[0002] Patent Document 1 discloses a material quality recording device that records the material quality of rolled material. The material quality recording device records material data obtained by measuring the material quality of the rolled material with a sensor, process data obtained by measuring the rolling process with a sensor, and image data obtained by capturing the state of the rolled material with a camera. The material quality recording device reads out the various recorded data (material quality data, process data, image data) and displays the data continuously or partially. This makes it easy to identify the cause even if an abnormality occurs in the material.

[0003] Japanese Patent Application Publication No. 2007-083300

[0004] Consider a case where an abnormality occurs in a rolling line having multiple rolling mills. In this case, the various data shown in Patent Document 1 alone does not allow an operator to immediately determine which rolling mill has the abnormality, and it may take a considerable amount of time to determine the cause. On the other hand, an HMI screen that shows a simplified image of the rolling line is used by operators to operate the rolling line. Therefore, there is a need for an improved system that allows operators to easily understand the rolling status of the rolling line by utilizing not only sensor-acquired information and camera image information but also the HMI screen. This is expected to enable operators to smoothly determine the cause when an abnormality occurs.

[0005] One object of the present disclosure is to provide a technology that allows an operator to easily grasp the rolling status of a rolling line by using information including an HMI screen.

[0006] A first aspect of the present disclosure relates to a rolling recording device that records the rolling state of a rolling line in which multiple rolling mills are arranged in sequence from the upstream side. The rolling recording device includes one or more processors and one or more storage devices. The one or more storage devices store multiple camera images acquired by multiple cameras that photograph the multiple rolling mills, control signals input to the rolling mills, actual measurement values ​​of the rolling state acquired by multiple sensors provided on the rolling line, HMI screen information for creating an HMI screen that schematically depicts the rolling line, and time information including the acquisition times of the multiple camera images, the input times of the control signals, and the update times of the HMI screen information. The one or more processors execute an update process that updates the HMI screen information based on at least the actual measurement values ​​of the rolling state, a generation process that generates an output display screen that includes a display screen of a target camera image, a display screen of the control signals, and the HMI screen that are synchronized based on the time information, a display process that displays the output display screen on a monitor, a storage process that saves the output display screen, and a playback process that plays back a history of the output display screen upon request.

[0007] A second aspect of the present disclosure has the following feature in addition to the first aspect: The generation process includes a process of synchronizing the timing of each of the second information and the third information, which are different from the first information, with the timing of the first information corresponding to the latest time among the acquisition time of the target camera image, the input time of the control signal, and the update time of the HMI screen information.

[0008] A third aspect of the present disclosure has the same features as the first aspect, but further includes the following: when a camera screen corresponding to a rolling mill in which an abnormality has been detected is selected as the target camera image in the display processing, the one or more processors highlight the display screen of the target camera image.

[0009] A fourth aspect of the present disclosure has the following characteristics in addition to the first aspect: In the playback process, the one or more processors superimpose a symbol indicating a playback position on a display screen of the control signal.

[0010] A fifth aspect of the present disclosure relates to a rolling recording method for recording the rolling state of a rolling line in which a plurality of rolling mills are lined up in order from the upstream side. The rolling recording method includes acquiring a plurality of camera images taken by a plurality of cameras that photograph the plurality of rolling mills, acquiring control signals input to the rolling mills, acquiring actual measurement values ​​of the rolling state acquired by a plurality of sensors provided on the rolling line, updating HMI screen information for creating an HMI screen that schematically depicts the rolling line based on at least the actual measurement values ​​of the rolling state, acquiring time information including the acquisition times of the plurality of camera images, the input times of the control signals, and the update times of the HMI screen information, generating an output display screen that includes a display screen of the target camera image, a display screen of the control signals, and the HMI screen that are synchronized based on the time information, displaying the output display screen on a monitor, saving the output display screen, and replaying a history of the output display screen upon request.

[0011] A sixth aspect of the present disclosure relates to a rolling recording program for recording the rolling state of a rolling line in which a plurality of rolling mills are lined up in order from the upstream side. The rolling recording program causes a computer to execute the following operations: acquiring a plurality of camera images taken by a plurality of cameras that photograph the plurality of rolling mills, acquiring control signals input to the rolling mills, acquiring actual measured values ​​of the rolling state taken by a plurality of sensors provided on the rolling line, updating HMI screen information for creating an HMI screen that schematically depicts the rolling line based on at least the actual measured values ​​of the rolling state, acquiring time information including the acquisition times of the plurality of camera images, the input times of the control signals, and the update times of the HMI screen information, generating an output display screen that includes a display screen of the target camera image, a display screen of the control signals, and the HMI screen that are synchronized based on the time information, displaying the output display screen on a monitor, saving the output display screen, and replaying a history of the output display screen upon request.

[0012] According to the present disclosure, an output display screen is generated that includes a display screen of a target camera image, a display screen of a control signal, and an HMI screen that are synchronized based on time information including the acquisition times of multiple camera images, the input time of a control signal input to a rolling mill, and the update time of HMI screen information for creating an HMI screen that schematically illustrates the rolling line. Then, a process is executed to save the output display screen displayed on the monitor, and a process is executed to play back the history of the output display screen upon request. This allows workers to easily grasp the rolling status of the rolling line. Therefore, workers can smoothly investigate the cause of an abnormality and perform maintenance when it occurs.

[0013] It is a diagram for explaining an outline of a rolling recording system. It is a block diagram showing an example of the configuration of a rolling recording device according to an embodiment. It is a block diagram showing an example of rolling recording processing according to an embodiment. It is an explanatory diagram showing a specific example of synchronization processing according to an embodiment. It is an explanatory diagram showing a specific example of reproduction processing according to an embodiment.

[0014] A rolling recording device, a rolling recording method, and a rolling recording program according to embodiments of the present disclosure will be described with reference to the accompanying drawings. In addition, common elements in the drawings will be assigned the same reference numerals and redundant explanations will be omitted.

[0015] 1. Overview of the Rolling Recording System Fig. 1 is a diagram for explaining the overview of the rolling recording system 1. The rolling recording system 1 records the rolling state of a rolling line 2. The rolling line 2 is, for example, a hot rolling line or a cold rolling line. The rolling line 2 is equipped with a plurality of rolling mills 4 arranged side by side along the conveyance direction of the material 3 to be rolled. In other words, the rolling line 2 is made up of a plurality of rolling mills 4 arranged in order from the upstream side.

[0016] The rolling line 2 further includes a plurality of cameras 5 and a plurality of sensors 6. The plurality of cameras 5 photograph the plurality of rolling mills 4. The plurality of cameras 5 are installed, for example, so as to be able to photograph the plurality of rolling mills 4 from a predetermined direction. The plurality of cameras 5 may be provided for each rolling mill 4, or for each group of rolling mills 4. A group of rolling mills 4 means two or more rolling mills 4 that are included in the angle of view of the camera 5. The plurality of camera images acquired by the plurality of cameras 5 are input into a rolling recording device 10.

[0017] The multiple sensors 6 measure the rolling state of the material to be rolled 3. The multiple sensors 6 may be provided, for example, on the input side of the first (most upstream) rolling mill 4 in the conveying direction of the material to be rolled 3, or on the output side of the last (most downstream) rolling mill 4 in the conveying direction of the material to be rolled 3, or may be provided between rolling mills 4. In other words, the multiple sensors 6 may be disposed in various locations. Examples of the multiple sensors 6 include a plate speed meter, a plate thickness meter, etc. Information acquired by the multiple sensors 6 is input to a controller 8.

[0018] Each of the plurality of rolling mills 4 includes an actuator 7 and is driven by the actuator 7. An actuator 7 is provided for each rolling mill 4. The actuator 7 performs drive control in accordance with a control signal output from a controller 8. The control signal output from the controller 8 is, for example, a parameter input to the actuator 7. Examples of the parameter include the rotation speed of the rolls included in the rolling mill 4 and the opening degree of the rolls. The parameter input to the actuator 7 may be generated by the controller 8 or may be generated by the rolling recording device 10.

[0019] The rolling recording system 1 includes the above-mentioned rolling line 2 , a controller 8 , a rolling recording device 10 , and a monitor 11 .

[0020] The controller 8 executes various processes. Specifically, the controller 8 executes sequence control of the control signals input to the actuators 7 and control of transmitting predetermined information to the rolling recording device 10. The predetermined information includes sensor-acquired information (also referred to as actual measured values ​​of the rolling state) acquired by the sensors 6. Furthermore, the predetermined information may include information related to the control signals (information on the control signals input to the actuators 7, the input times of the control signals, etc.).

[0021] The controller 8 may include, for example, one or more processors (not shown) and one or more storage devices (not shown), or may include one or more dedicated hardware (not shown). As a specific example, the controller 8 is a PLC (Programmable Logic Controller).

[0022] The rolling recording device 10 records the rolling state of the rolling line 2 as an image. Specifically, the rolling recording device 10 generates an output display screen to be displayed on the monitor 11. The output display screen includes a plurality of display screens.

[0023] 1, the output display screen is made up of a first display screen, a second display screen, and a third display screen. For example, the first display screen displays a target camera image from among multiple camera images acquired by multiple cameras 5, the second display screen displays an HMI screen, and the third screen displays a control signal input to the rolling mill 4 (actuator 7). Note that each of the multiple display screens may be displayed on the same monitor 11, or may be displayed on each monitor 11.

[0024] The HMI screen is a schematic representation of the rolling line 2. The HMI screen displays, for example, actual measured values ​​of the rolling state acquired by a plurality of sensors 6. The HMI screen is displayed, for example, by executing a program generated by a dedicated HMI tool. The HMI screen is updated based on at least the actual measured values ​​of the rolling state.

[0025] Then, the rolling recorder 10 displays (outputs) the generated output display screen on the monitor 11. A specific example of the rolling recorder 10 will be described in detail below.

[0026] 2. Examples of Rolling Recording Devices 2-1. Configuration Example FIG. 2 is a block diagram showing a configuration example of a rolling recording device 10 according to an embodiment.

[0027] The rolling recording device 10 includes one or more processors 20 (hereinafter simply referred to as processors 20) and one or more storage devices 30 (hereinafter simply referred to as storage devices 30). The processor 20 executes the rolling recording process. An example of the processor 20 is a CPU (Central Processing Unit). The storage device 30 stores various information required for processing by the processor 20. Examples of the storage device 30 include a volatile memory, a non-volatile memory, an HDD (Hard Disk Drive), an SSD (Solid State Drive), etc. The rolling recording process executed by the processor 20 will be described in detail below.

[0028] The rolling record program (not shown) is a computer program executed by the processor 20. The processor 20 may execute the rolling record program to realize various functions of the rolling record device 10. The rolling record program is stored in the storage device 30. Alternatively, the rolling record program may be recorded in a computer-readable storage medium.

[0029] The various types of information stored in the storage device 30 include camera image information 31 , sensor acquisition information 32 , control signal information 33 , HMI screen information 34 , and time information 35 .

[0030] As described above, the camera image information 31 is camera images taken by each of the multiple cameras 5 .

[0031] As described above, the sensor-acquired information 32 is actual measurement values ​​of the rolling state acquired by a plurality of sensors 6 provided on the rolling line 2 .

[0032] As described above, the control signal information 33 includes the control signals input to each of the plurality of rolling mills 4 (actuators 7).

[0033] The HMI screen information 34 is information for creating an HMI screen that schematically illustrates the rolling line 2. The HMI screen information 34 is, for example, a program generated by a dedicated HMI tool.

[0034] The time information 35 includes the acquisition times of the multiple camera images, the input times of control signals input to the rolling mill 4 (actuators 7), and the update times of the HMI screen information 34. The update times of the HMI screen information 34 are, for example, the times when updating of the HMI screen information 34 is completed. The HMI screen information 34 is updated based on at least the sensor acquired information 32 (actual measured values ​​of the rolling state).

[0035] 3 is a block diagram showing an example of the rolling record processing according to the embodiment. The rolling record processing executed by the processor 20 includes an HMI screen update processing 21, a display target selection processing 22, a synchronization processing 23, an output display screen generation processing 24, a monitor display processing 25, an output display screen save processing 26, and an output display screen history playback processing 27.

[0036] The processor 20 executes the following processes in this order, for example: HMI screen update process 21, display target selection process 22, synchronization process 23, output display screen generation process 24, monitor display process 25, output display screen storage process 26, and output display screen history playback process 27. Each process will be described in detail below.

[0037] In the HMI screen update process 21, the processor 20 updates the HMI screen information 34 based on at least the sensor acquired information 32 (actual measured values ​​of the rolling state, etc.).

[0038] In the display target selection process 22, the processor 20 selects a target camera image to be displayed on the output display screen from among multiple camera images based on camera image information 31. The number of target camera images may be one or more. Then, based on control signal information 33, the processor 20 selects a control signal to be input to the rolling mill 4 (actuator 7) that corresponds to the target camera image. Furthermore, the processor 20 selects a screen to be displayed on the monitor 11. At least three of the screens to be displayed on the monitor 11 are selected: the target camera image, the control signal, and the updated HMI screen. The control signal to be displayed on the monitor 11 may be only the control signal corresponding to the target camera image.

[0039] In synchronization process 23, processor 20 acquires the acquisition time (first time) of the target camera image, the input time (second time) of the control signal, and the update time (third time) of the HMI screen based on time information 35. Then, processor 20 synchronizes the target camera image, the control signal, and the updated HMI screen based on the first time, the second time, and the third time. Details of synchronization process 23 will be described later.

[0040] In the output display screen generation process 24, the processor 20 generates output display screens including a display screen for the target camera image (first display screen), a display screen for the control signal (second display screen), and an HMI screen (third display screen). Note that the second and third display screens are each encoded to be converted into the same format as the first display screen.

[0041] In the monitor display process 25, the processor 20 displays (outputs) the output display screen on the monitor 11. Specifically, the output display screen is converted into a frame rate compatible with the monitor 11 and then output to the monitor 11.

[0042] In the output display screen saving process 26, the processor 20 captures the output display screen output on the monitor 11 based on an operation by the worker. The captured image of the output display screen is called the output display screen history. The output display screen history is saved in the storage device 30. The time period during which the output display screen is captured is determined by an operation by the worker.

[0043] In the output display screen history playback process 27, the processor 20 plays back the output display screen history based on an operation from the operator. The output display screen history playback process 27 will be described in detail later.

[0044] 4 is an explanatory diagram showing a specific example of the synchronization process 23 according to the embodiment. Consider the synchronization process 23 based on the camera image acquisition time, the control signal input time, and the HMI screen information 34 update time, all of which are included in the time information 35.

[0045] The time at which the camera image is acquired depends, for example, on the distance between the camera 5 and the rolling recording device 10. In this case, the shorter the distance, the earlier the time at which the camera image is acquired, and the longer the distance, the later the time at which the camera image is acquired.

[0046] The input time of the control signal depends, for example, on the distance between the rolling mill 4 and the rolling recording device 10 and the waiting time from when the control signal is generated until when it is input to the rolling mill 4. In this case, the shorter the distance, the earlier the input time of the control signal, and the longer the distance, the later the input time of the control signal. Furthermore, the shorter the waiting time, the earlier the input time of the control signal, and the longer the waiting time, the later the input time of the control signal. The waiting time is determined by the sequence control of the controller 8.

[0047] Consider the update time of the HMI screen information 34. The HMI screen is updated based on the sensor acquired information 32 (actual measured values ​​of the rolling state). Therefore, the update time of the HMI screen information depends, for example, on the distance between the sensor 6 and the rolling recording device 10 and the time required to update the HMI screen. In this case, the shorter the distance, the earlier the update time of the HMI screen information 34, and the longer the distance, the later the update time of the HMI screen information 34. Furthermore, the shorter the time required to update the HMI screen, the earlier the update time of the HMI screen information 34, and the longer the time required to update the HMI screen, the later the update time of the HMI screen information 34.

[0048] As described above, the timing of the target camera image displayed on the first display screen of the output display screen, the control signal displayed on the second display screen, and the HMI screen displayed on the third display screen are all different, so it is necessary to synchronize the target camera image, the control signal, and the HMI screen to match the timing of one of them.

[0049] According to this embodiment, the rolling recording device 10 (processor 20) synchronizes the timing of the second information and the third information, which are different from the first information, with the timing of the information (first information) corresponding to the latest time among the time of acquisition of the target camera image, the time of input of the control signal, and the time of update of the HMI screen information, based on the time information 35.

[0050] Specifically, the processor 20 extracts the first information corresponding to the latest time among the acquisition time of the target camera image, the input time of the control signal, and the update time of the HMI screen information. The processor 20 then subtracts the time of the first information from the time of the second information, and subtracts the time of the first information from the time of the third information. Furthermore, the processor 20 delays the timing of each of the second information and the third information based on the time obtained by the subtraction.

[0051] In the example shown in Figure 4, the control signal input time, the target camera image acquisition time, and the HMI screen update time are acquired in this order. In this case, the timing of the control signal and the target camera image are synchronized with the timing of the HMI screen corresponding to the latest time. This allows all information displayed on the output display screen to be synchronized.

[0052] 2-4. Example of Playback Processing Fig. 5 is an explanatory diagram showing a specific example of playback processing 27 of the history of the output display screen according to the embodiment. The rolling recording device 10 (processor 20) plays back the history of the output display screen based on an instruction from the operator using the operation buttons. A playback screen is used to play back the history of the output display screen. The playback screen may include only the output display screen, or may include two screens, the output display screen and the control button screen, as shown in Fig. 5. The control button screen may also be a touch panel display that can be operated by the operator. Examples of operation buttons include a play button, a reverse play button, a stop button, a pause button, a slow play button, a fast forward button, a fast rewind button, a repeat button, etc.

[0053] Consider the display method of the control signal displayed on the third display screen of the output display screen when the output display screen history playback process 27 is executed. For example, as shown in FIG. 5, if the control signal on the third display screen is displayed as a graph, the operator cannot grasp where on the graph the playback position is. Therefore, the processor 20 superimposes a symbol indicating the playback position on the third display screen. The playback position means the current frame. This allows the operator to grasp where on the graph the playback position is.

[0054] 3. Modifications 3-1. First Example In the example shown in FIG. 3 described above, after the synchronization process 23 is executed, the output display screen generation process 24 generates a display screen for the target camera image (first display screen), a display screen for the control signal (second display screen), and an HMI screen (third display screen). However, this is not limiting. For example, in the output display screen generation process 24, the synchronization process 23 may be executed between the generation of the first display screen, the second display screen, and the third display screen and the generation of the output display screen. In other words, the output display screen generation process 24 may include the synchronization process 23.

[0055] 3-2. Second Example While the output display screen is being displayed, the camera image displayed on the display screen for the target camera image (first display screen) may be switched to another camera image. In this case, the processor 20 newly executes the display target selection process 22, synchronization process 23, output display screen generation process 24, and monitor display process 25 described above.

[0056] 3-3. Third Example When a camera screen corresponding to a rolling mill 4 in which an abnormality has been detected is selected as the target camera image, the display screen (first display screen) of the target camera image may be highlighted. This allows the worker to shift their gaze to the highlighted image. Therefore, it is possible to easily identify the rolling mill 4 in which an abnormality has been detected.

[0057] 4. Effects According to the rolling recording device 10 of the embodiment, an output display screen is generated that includes a display screen of a target camera image, a display screen of a control signal, and an HMI screen that are synchronized based on time information including the acquisition times of multiple camera images, the input time of a control signal input to the rolling mill, and the update time of HMI screen information for creating an HMI screen that schematically illustrates the rolling line. Then, a process is executed to save the output display screen displayed on the monitor, and a process is executed to play back the history of the output display screen upon request. This allows workers to easily grasp the rolling status of the rolling line. Therefore, workers can smoothly investigate the cause of an abnormality and perform maintenance when it occurs.

[0058] 1...Rolling recording system, 2...Rolling line, 3...Rolled material, 4...Rolling mill, 5...Camera, 6...Sensor, 7...Actuator, 8...Controller, 10...Rolling recording device, 11...Monitor, 20...Processor, 21...HMI screen update processing, 22...Display object selection processing, 23...Synchronization processing, 24...Output display screen generation processing, 25...Monitor display processing, 26...Output display screen saving processing, 27...Output display screen history playback processing, 30...Storage device, 31...Camera image information, 32...Sensor acquisition information, 33...Control signal information, 34...HMI screen information, 35...Time information

Claims

1. A rolling recording device for recording the rolling state of a rolling line in which a plurality of rolling mills are arranged in sequence from the upstream side, comprising one or more processors and one or more storage devices, wherein the one or more storage devices store: a plurality of camera images acquired by a plurality of cameras photographing the plurality of rolling mills; control signals input to the rolling mills; actual measured values ​​of the rolling state acquired by a plurality of sensors provided on the rolling line; HMI screen information for creating an HMI screen that simplifies the rolling line; and time information including the acquisition times of the plurality of camera images, the input time of the control signals, and the update time of the HMI screen information, wherein the one or more processors perform: an update process for updating the HMI screen information based on at least the actual measured values ​​of the rolling state; a generation process for generating an output display screen including a display screen of a target camera image, a display screen of the control signals, and the HMI screen, which are synchronized based on the time information; a display process for displaying the output display screen on a monitor; and a storage process for saving the output display screen. a reproducing process for reproducing the history of the output display screen in response to a request.

2. A rolling recording device as described in claim 1, characterized in that the generation process includes a process of synchronizing the timing of second information and third information, which are different from the first information, with the timing of first information corresponding to the latest time among the time of acquisition of the target camera image, the time of input of the control signal, and the time of update of the HMI screen information.

3. A rolling recording device as described in claim 1, characterized in that the one or more processors are configured in the display processing to highlight the display screen of the target camera image when a camera screen corresponding to a rolling mill in which an abnormality has been detected is selected as the target camera image.

4. A rolling recorder as claimed in claim 1, characterized in that the one or more processors are configured to, during the playback process, superimpose a symbol indicating the playback position on the display screen of the control signal.

5. A rolling recording method for recording the rolling state of a rolling line in which a plurality of rolling mills are lined up in sequence from the upstream side, comprising: acquiring a plurality of camera images taken by a plurality of cameras photographing the plurality of rolling mills; acquiring control signals input to the rolling mills; acquiring actual measured values ​​of the rolling state acquired by a plurality of sensors provided in the rolling line; updating HMI screen information for creating an HMI screen that simplifies the rolling line based on at least the actual measured values ​​of the rolling state; acquiring time information including the acquisition times of the plurality of camera images, the input time of the control signals, and the update time of the HMI screen information; generating an output display screen including a display screen of a target camera image, a display screen of the control signals, and the HMI screen, which are synchronized based on the time information; displaying the output display screen on a monitor; saving the output display screen; and reproducing a history of the output display screen upon request.

6. A rolling record program for recording the rolling state of a rolling line in which a plurality of rolling mills are lined up in sequence from the upstream side, characterized in that the rolling record program is configured to cause a computer to execute the following: acquiring a plurality of camera images taken by a plurality of cameras photographing the plurality of rolling mills; acquiring control signals input to the rolling mills; acquiring actual measured values ​​of the rolling state acquired by a plurality of sensors provided on the rolling line; updating HMI screen information for creating an HMI screen that simplifies the rolling line based on at least the actual measured values ​​of the rolling state; acquiring time information including the acquisition times of the plurality of camera images, the input time of the control signals, and the update time of the HMI screen information; generating an output display screen including a display screen of a target camera image, a display screen of the control signals, and the HMI screen, which are synchronized based on the time information; displaying the output display screen on a monitor; saving the output display screen; and reproducing the history of the output display screen upon request.

Images