Rolling emulation device, rolling emulation program, and rolling control system

Abstract

This rolling emulation device executes: processing for acquiring a control signal used for control of a plurality of rolling machines from a controller for controlling the plurality of rolling machines via a communication interface; processing for emulating conveyance of a material subject to rolling by inputting the control signal to a rolling conveyance model simulating conveyance of a material subject to rolling in a rolling line; processing for generating simulation sensor signals simulating sensor signals output from a plurality of sensors provided on the rolling line on the basis of the result of the emulation by the rolling conveyance model; processing for acquiring actual sensor signals output from the plurality of sensors; learning processing for causing the rolling conveyance model to reflect a model correction value for reducing the difference between a simulation sensor signal and an actual sensor signal; and abnormality determination processing for determining, if the difference is equal to or greater than a first threshold value, that an abnormality has occurred in one of the plurality of rolling machines.

Description

Rolling emulation device, rolling emulation program, and rolling control system

[0001] The present disclosure relates to techniques for simulating a rolling line.

[0002] Patent Literature 1 discloses a rolling simulation device that simulates the state of a rolling line. Specifically, the rolling simulation device uses a model formula that simulates each process in the rolling line to calculate a target value for rolling a metallic material and a predicted state value of the rolled material when the process is changed. Furthermore, the rolling simulation device updates the parameters of the model formula based on a comparison value obtained by comparing the predicted state value of the rolled material with the control target value of the actuator used to drive the rolling line. This updates parameters that change over time, and the prediction accuracy of the model formula can be improved.

[0003] International Publication No. 2016 / 038705

[0004] The rolling state of a rolling line is reflected in the actual measurement values ​​of sensors installed in the rolling line. One possible cause of the actual measurement values ​​of the rolling state being inappropriate is an abnormality occurring in one of the rolling mills constituting the rolling line. In such a case, it is sufficient to notify an operator that an abnormality has occurred in the rolling mill without changing the model simulating the rolling line. However, the rolling simulation device shown in Patent Document 1 determines that the change is due to aging deterioration of the rolling mill and updates the model formula. This may result in the rolling line continuing to operate without interruption despite the occurrence of an abnormality.

[0005] Furthermore, an inappropriate setting value of the control signal input to the rolling mill can also be a cause of the actual measured value of the rolling state being inappropriate. In this case, too, the rolling simulation device shown in Patent Document 1 updates the model formula without detecting an abnormality in the rolling state of the rolling line.

[0006] One object of the present disclosure is to provide a technology that can detect abnormalities in the rolling state of a rolling line while improving the accuracy of a model that simulates a rolling line.

[0007] A first aspect of the present disclosure relates to a rolling emulation device simulating a rolling line in which multiple rolling mills are lined up in order from the upstream side. The rolling emulation device includes a processor connected to a controller that controls the multiple rolling mills via a communication interface, and a storage device that stores a rolling conveyance model that simulates the conveyance of a material to be rolled in the rolling line. The processor executes the following operations: acquiring control signals used to control the multiple rolling mills from the controller; inputting the control signals into the rolling conveyance model to emulate the conveyance of the material to be rolled; generating simulated sensor signals that simulate sensor signals output from multiple sensors provided in the rolling line based on the emulation results using the rolling conveyance model; acquiring actual sensor signals output from the multiple sensors; learning that reflects model correction values ​​that reduce the difference between the simulated sensor signals and the actual sensor signals in the rolling conveyance model; and, if the difference is equal to or greater than a first threshold, determining that an abnormality has occurred in one of the multiple rolling mills.

[0008] A second aspect of the present disclosure relates to a rolling control system for controlling a rolling line in which multiple rolling mills are lined up in order from the upstream side. The rolling control system includes a controller for controlling the multiple rolling mills via a communication interface, a host device connected upstream of the controller and generating setting values ​​for control signals to be input to the multiple rolling mills via the controller, and a rolling emulation device provided in parallel between the multiple rolling mills and the controller and emulating the transportation of a material to be rolled using a rolling transportation model that simulates the transportation of the material to be rolled in the rolling line. When the multiple rolling mills and the controller are disconnected and the multiple sensors provided in the rolling line are disconnected from the controller, the rolling emulation device executes the following processes: acquiring control signals used to control the multiple rolling mills from the controller; inputting the control signals into the rolling transportation model to emulate the transportation of the material to be rolled; generating simulated sensor signals that simulate sensor signals output from the multiple sensors based on the emulation results using the rolling transportation model; and outputting the simulated sensor signals to the controller. Furthermore, the higher-level device executes a determination process based on the simulated sensor signal to determine whether the rolling state of the rolling line is within an appropriate range.

[0009] The above-described operations of the processor may be realized by the processor executing a rolling emulation program.

[0010] According to a first aspect of the present disclosure, a control signal used to control a plurality of rolling mills arranged in sequence from the upstream side in a rolling line is acquired from a controller that controls the plurality of rolling mills. The control signal is input to a rolling conveyance model that simulates the conveyance of the rolled material in the rolling line, and the conveyance of the rolled material is emulated. Then, based on the emulation results using the rolling conveyance model, a simulated sensor signal is generated that simulates sensor signals output from a plurality of sensors provided in the rolling line. In parallel with the generation of the simulated sensor signal, actual sensor signals output from the plurality of sensors are acquired. Then, a model correction value for reducing the difference between the simulated sensor signal and the actual sensor signal is reflected in the rolling conveyance model, thereby learning the rolling conveyance model. However, if the difference is equal to or greater than a first threshold, it is determined that an abnormality has occurred in one of the plurality of rolling mills. This makes it possible to detect abnormalities in the rolling state of the rolling line while further improving the accuracy of the rolling conveyance model through learning based on the difference between the simulated sensor signal and the actual sensor signal.

[0011] According to a second aspect of the present disclosure, when a plurality of rolling mills are disconnected from a controller and a plurality of sensors provided in a rolling line are disconnected from the controller, control signals used to control the plurality of rolling mills are acquired from the controller. The control signals are input to a rolling conveyance model that simulates the conveyance of the material to be rolled in the rolling line, and the conveyance of the material to be rolled is emulated. Then, simulated sensor signals that simulate the sensor signals output from the plurality of sensors are generated based on the emulation results using the rolling conveyance model. Thereafter, based on the simulated sensor signals, it is determined whether the rolling state of the rolling line is within an appropriate range. As a result, if the rolling state of the rolling line 2 becomes inappropriate, it is possible to detect an abnormality in the rolling state of the rolling line and to confirm whether the set values ​​of the control signals are appropriate. Furthermore, when a part of the rolling line is changed or a new rolling line is installed, operation of the rolling line is started after confirming that the set values ​​of the control signals are appropriate. Therefore, the frequency with which the set values ​​of the control signals input to the multiple rolling mills need to be adjusted while the rolling line is in operation can be reduced, and improvement in the finishing accuracy of the rolled material can be expected.

[0012] FIG. 1 is a diagram for explaining an outline of a rolling control system according to embodiment 1. FIG. 2 is a block diagram showing an example of the configuration of a rolling emulation device according to embodiment 1. FIG. 3 is a block diagram showing an example of processing by the rolling emulation device according to embodiment 1. FIG. 4 is a flowchart showing an example of processing by the rolling emulation device according to embodiment 1. FIG. 5 is a diagram for explaining an outline of a rolling control system according to embodiment 2. FIG. 6 is a block diagram showing an example of processing by the rolling control system according to embodiment 2. FIG. 7 is a flowchart showing an example of processing by the rolling control system according to embodiment 2.

[0013] A rolling control system, a rolling emulation device, and a rolling emulation program according to embodiments of the present disclosure will be described with reference to the accompanying drawings. Elements common to the drawings will be designated by the same reference numerals, and duplicated explanations will be omitted.

[0014] 1. Embodiment 1 1-1. Overview of Rolling Control System Fig. 1 is a diagram for explaining an overview of a rolling control system 1A according to Embodiment 1. The rolling control system 1A controls 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 transport 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.

[0015] The rolling line 2 further includes a plurality of sensors 6. The plurality of sensors 6 measure the rolling state of the material 3 to be rolled. The plurality of 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 3 to be rolled, or on the output side of the last (most downstream) rolling mill 4 in the conveying direction of the material 3 to be rolled, or may be provided between rolling mills 4. In other words, the plurality of sensors 6 may be disposed in various locations. Examples of the plurality of sensors 6 include a strip speed meter and a strip thickness meter. Information acquired by the plurality of sensors 6 is input to a controller 8. The information acquired by the sensors 6 is also referred to as an actual sensor signal.

[0016] 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 higher-level device 50.

[0017] The rolling recording system 1 comprises the above-mentioned rolling line 2 , a controller 8 , a rolling emulation device 10 , and a higher-level device 50 .

[0018] The controller 8 controls the multiple rolling mills 4 via a communication interface. Specifically, the controller 8 executes sequence control of control signals input to the actuators 7 and control for transmitting predetermined information to the higher-level device 50. The predetermined information includes actual sensor signals (actual measured values ​​of the rolling state, etc.) acquired by the sensors 6. Furthermore, the predetermined information may also include information related to the control signals (information on the control signals input to the actuators 7, etc.).

[0019] 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).

[0020] The host device 50 manages the rolling state of the rolling line 2. Specifically, the host device 50 generates setting values ​​(parameters) of control signals to be input to the rolling mills 4 (actuators 7). The setting values ​​of the control signals may be generated based on the results of a simulation analyzed by a dedicated tool for simulating the rolling state of the rolling line 2, or may be generated based on the difference between the predicted value of the rolling state based on the simulation results and the actual sensor signal. The setting values ​​of the control signals are also simply referred to as control signals.

[0021] The host device 50 is connected upstream of the controller 8. The host device 50 includes, for example, one or more processors (not shown) and one or more storage devices (not shown).

[0022] The rolling emulation device 10 emulates the transportation of the material 3 to be rolled in the rolling line 2. A rolling transportation model (not shown) that simulates the transportation of the material 3 to be rolled is used to emulate the transportation of the material 3 to be rolled. The rolling transportation model here is premised on a model that has undergone a certain level of learning. Based on this, for example, if the rolling state obtained from the rolling transportation model differs from the actual rolling state, the rolling emulation device 10 determines whether or not the accuracy of the rolling transportation model needs to be further improved, whether or not there is an abnormality in the rolling mill 4, etc. This makes it possible to detect abnormalities in the rolling state of the rolling line 2 while further improving the accuracy of the rolling transportation model.

[0023] An overview of the processing by the rolling emulation device 10 is as follows. The rolling emulation device 10 executes the following processes: acquiring control signals used to control the multiple rolling mills 4 from a controller 8 that controls the multiple rolling mills 4 arranged in sequence from the upstream side in the rolling line 2; emulating the transportation of the material to be rolled 3 by inputting control signals into a rolling conveyance model; generating simulated sensor signals that simulate sensor signals output from the multiple sensors 6 provided in the rolling line 2 based on the emulation results using the rolling conveyance model; acquiring actual sensor signals output from the multiple sensors 6; learning processing that reflects model correction values ​​to reduce the difference between the simulated sensor signals and the actual sensor signals in the rolling conveyance model; and abnormality determination processing that determines that an abnormality has occurred in one of the multiple rolling mills if the difference is equal to or greater than a first threshold value. Details of the processing by the rolling emulation device 10 will be described later.

[0024] Consider the location where the rolling emulator 10 is installed. The rolling emulator 10 performs a process of comparing the difference between the simulated sensor signal and the actual sensor signal. In this case, it is desirable that the difference between the time when the simulated sensor signal is generated by the rolling emulator 10 and the time when the rolling emulator 10 acquires the actual sensor signal is small. On the other hand, it is expected that the time from when the set value of the control signal is input to the rolling mill 4 to when the actual sensor signal is output by the sensor 6 is short. For this reason, it is desirable that the rolling emulator 10 is installed downstream of the controller 8, just like the rolling mill 4. Therefore, the rolling emulator 10 is installed in parallel between a plurality of rolling mills 4 and the controller 8.

[0025] 1-2. Example of Rolling Emulation Apparatus 1-2-1. Configuration Example FIG. 2 is a block diagram showing a configuration example of the rolling emulation apparatus 10 according to the first embodiment.

[0026] The rolling emulation 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 processors 20 execute various processes. An example of the processor 20 is a CPU (Central Processing Unit). The storage devices 30 store various information required for processing by the processor 20. Examples of the storage devices 30 include volatile memory, non-volatile memory, HDD (Hard Disk Drive), SSD (Solid State Drive), etc.

[0027] The various information stored in the storage device 30 includes a rolling conveyance model 31 and a rolling emulation program. As described above, the rolling conveyance model 31 is a model that simulates the conveyance of the material 3 to be rolled on the rolling line 2. The rolling emulation program (not shown) is a computer program executed by the processor 20. The processor 20 may execute the rolling emulation program to realize various functions of the rolling emulation device 10. Note that the rolling emulation program is not limited to being stored in the storage device 30, and may also be recorded in a computer-readable storage medium.

[0028] 1-2-2. Processing Example Fig. 3 is a block diagram showing a processing example of the rolling emulator 10 according to the embodiment.

[0029] Specifically, the rolling emulation device 10 (more specifically, the processor 20) receives a control signal output from the controller 8. Then, the rolling emulation device 10 executes an emulation process 11 that emulates the transportation of the material to be rolled 3 based on the control signal. In the emulation process 11, a process is performed to read a rolling transportation model 31 stored in the storage device 30. Furthermore, in the emulation process 11, the rolling emulation device 10 generates simulated sensor signals that simulate the sensor signals output from the plurality of sensors 6 based on the emulation results using the rolling transportation model 31.

[0030] Furthermore, the rolling emulation device 10 acquires actual sensor signals output from the multiple sensors 6. Then, the rolling emulation device 10 performs difference determination processing 12 based on the simulated sensor signals and the actual sensor signals. In difference determination processing 12, the rolling emulation device 10 determines whether or not the difference between the simulated sensor signals and the actual sensor signals is less than a first threshold value. If the difference is less than the first threshold value, the rolling emulation device 10 performs model correction value generation processing 13 to generate a model correction value to reduce the difference. After executing the model correction value generation processing 13, the rolling emulation device 10 executes learning processing to reflect the model correction value in the rolling transportation model 31. This makes it possible to further improve the accuracy of the rolling transportation model 31.

[0031] If the difference is small, it is considered that the rolling transportation model has a certain level of accuracy or higher. In this case, the rolling emulation device 10 may not reflect the difference in the rolling transportation model. Therefore, in the learning process, if the difference is less than the first threshold value and is equal to or greater than a second threshold value that is smaller than the first threshold value, the rolling emulation device 10 may reflect the model correction value in the rolling transportation model 31.

[0032] On the other hand, if the difference is equal to or greater than the first threshold value, the rolling emulation device 10 executes an abnormality determination process in difference determination process 12 to determine that an abnormality has occurred in one of the plurality of rolling mills 4. In this case, the rolling emulation device 10 notifies the higher-level device 50 via the controller 8 that an abnormality has occurred in a rolling mill 4. This makes it possible to detect an abnormality in the rolling state of the rolling line 2. Note that an abnormality in a rolling mill 4 means, for example, that the amount of change in a parameter indicating the state of the rolling mill 4 is equal to or greater than a predetermined value. Examples of factors that can cause the amount of change in the parameter to be equal to or greater than the predetermined value include aging deterioration of the rolling mill 4 and a breakdown of the rolling mill 4.

[0033] Furthermore, after executing the difference determination process 12, the rolling emulator 10 may perform a storage process 14 for storing the difference value between the simulated sensor signal and the actual sensor signal and the states of the various sensor signals. This makes it possible to check the history of the difference value and the states of the various sensor signals when a cause for the rolling state of the rolling line 2 becoming inappropriate occurs. Therefore, it becomes easy to identify the cause for the rolling state of the rolling line becoming inappropriate.

[0034] FIG. 4 is a flowchart showing an outline of an example of processing by the rolling emulation device 10.

[0035] In step S100, the rolling emulator 10 acquires various information. Then, the process proceeds to step S110. The various information includes a control signal output from the controller 8 and actual sensor signals output from the multiple sensors 6.

[0036] In step S110, the rolling emulator 10 emulates the transportation of the material to be rolled 3 using the rolling transportation model 31. Thereafter, the process proceeds to step S120.

[0037] In step S120, the rolling emulator 10 generates simulated sensor signals that simulate the sensor signals output from the plurality of sensors 6, based on the results of the emulation by the rolling transportation model 31. Thereafter, the process proceeds to step S130.

[0038] In step S130, the rolling emulator 10 calculates the difference between the simulated sensor signal and the actual sensor signal, after which the process proceeds to step S140.

[0039] In step S140, the rolling emulator 10 determines whether the difference between the simulated sensor signal and the actual sensor signal is less than a threshold value. If it is determined that the difference is less than the threshold value (step S140; Yes), the process proceeds to step S150. Otherwise (step S140; No), the process proceeds to step S170.

[0040] In step S150, the rolling emulator 10 generates a model correction value to reduce the difference, after which the process proceeds to step S160.

[0041] In step S160 , the rolling emulator 10 performs a learning process to reflect the model correction value in the rolling transportation model 31 .

[0042] As described above, if the difference is less than the first threshold value and is equal to or greater than a second threshold value that is smaller than the first threshold value, the rolling emulation device 10 may reflect the model correction value in the rolling conveying model 31.

[0043] In step S170, the rolling emulator 10 determines that an abnormality has occurred in one of the rolling mills 4. Thereafter, the process proceeds to step S180.

[0044] In step S180, the rolling emulator 10 notifies the higher-level device 50 via the controller 8 that an abnormality has occurred in the rolling mill 4.

[0045] 1-3. Effects According to this embodiment, control signals used to control the multiple rolling mills 4 are acquired from a controller 8 that controls the multiple rolling mills 4 arranged in sequence from the upstream side in the rolling line 2. The control signals are input to a rolling conveyance model 31 that simulates the conveyance of the material 3 to be rolled in the rolling line 2, and the conveyance of the material 3 to be rolled is emulated. Then, based on the results of the emulation by the rolling conveyance model 31, simulated sensor signals are generated that simulate the sensor signals output from the multiple sensors 6 provided in the rolling line 2. In parallel with the generation of the simulated sensor signals, actual sensor signals output from the multiple sensors 6 are acquired. Then, a model correction value for reducing the difference between the simulated sensor signals and the actual sensor signals is reflected in the rolling conveyance model 31, thereby allowing the rolling conveyance model 31 to learn. However, if the difference is equal to or greater than a first threshold, it is determined that an abnormality has occurred in one of the multiple rolling mills 4. This makes it possible to further improve the accuracy of the rolling conveyance model 31 through learning based on the difference between the simulated sensor signal and the actual sensor signal, while also detecting abnormalities in the rolling state of the rolling line 2.

[0046] 2. Second Embodiment 2-1. Overview of the Rolling Control System FIG. 5 is a diagram for explaining the overview of a rolling control system 1B according to a second embodiment. For example, consider a case where the cause of the inappropriate rolling state of the rolling line 2 is not the accuracy of the rolling transport model or an abnormality in the rolling mills 4, but rather the set values ​​of the control signals input to the rolling mills 4. In this case, the rolling emulation device 10 of the rolling control system 1A according to the first embodiment described above cannot identify the cause. Therefore, in the rolling control system 1B, when the rolling state of the rolling line 2 is inappropriate, it is determined whether the set values ​​of the control signals input to the plurality of rolling mills 4 are appropriate.

[0047] The basic configuration of the rolling control system 1B is the same as that of the above-mentioned rolling control system 1A. The differences from the rolling control system 1A include the fact that, as shown in Fig. 5 , the plurality of rolling mills 4 and the controller 8 are in a non-connected state (first non-connected state), the plurality of sensors 6 and the controller 8 are in a non-connected state (second non-connected state), and the fact that simulated sensor signals generated by the rolling emulation device 10 are output to the controller 8.

[0048] The first non-connection state is, for example, a state in which the wiring between the plurality of rolling mills 4 and the controller 8 is cut off, a state in which the use of control signals input to the rolling mills 4 (actuators 7) is restricted, etc. The second non-connection state is, for example, a state in which the wiring between the plurality of sensors 6 and the controller 8 is cut off, a state in which the output of sensor signals from the sensors 6 is restricted, etc.

[0049] Switching between the rolling control system 1A and the rolling control system 1B is controlled by the higher-level device 50. For example, when the operation mode of the rolling line 2 is the operation mode, the rolling control system 1A is selected, and when the operation mode of the rolling line 2 is the inspection mode, the rolling control system 1B is selected. Furthermore, when the rolling control system 1B is selected, switching to the first non-connection state and switching to the second non-connection state are performed.

[0050] An overview of the processing by the rolling control system 1B is as follows: When the plurality of rolling mills 4 and the controller 8 are not connected and the plurality of sensors 6 and the controller 8 are not connected, the rolling control system 1B executes the following processes: acquiring control signals used to control the plurality of rolling mills 4 from the controller 8 that controls the plurality of rolling mills 4; inputting control signals to a rolling conveyance model 31 to emulate the conveyance of the material to be rolled 3; generating simulated sensor signals that simulate sensor signals output from the plurality of sensors 6 provided in the rolling line 2 based on the emulation results by the rolling conveyance model 31; outputting the simulated sensor signals to the controller 8; and determining whether the rolling state of the rolling line 2 is within an appropriate range based on the simulated sensor signals. Details of the processing by the rolling control system 1B will be described later.

[0051] 6 is a block diagram showing a processing example of the rolling control system 1B according to embodiment 2. The processing of the rolling control system 1B includes processing by the rolling emulator device 10 and the higher-level device 50.

[0052] An example of processing by the rolling emulation device 10 will be described. Specifically, the rolling emulation device 10 (processor 20) inputs a control signal output from the controller 8. Then, the rolling emulation device 10 executes emulation processing 11 that emulates the transportation of the material to be rolled 3 based on the control signal. Furthermore, in the emulation processing 11, the rolling emulation device 10 generates simulated sensor signals that simulate sensor signals output from the multiple sensors 6 based on the emulation results using the rolling transportation model 31. Thereafter, the rolling emulation device 10 outputs the simulated sensor signals to the controller 8.

[0053] Next, an example of processing by the higher-level device 50 will be described. Specifically, the higher-level device 50 executes processing for generating a set value for a control signal (process 51 for generating a set value for a control signal). After executing processing 51 for generating a set value for a control signal, the higher-level device 50 outputs the control signal to the rolling emulator device 10 via the controller 8. Furthermore, the higher-level device 50 acquires a simulated sensor signal output from the rolling emulator device 10 via the controller 8. The higher-level device 50 then executes processing for determining whether the rolling state of the rolling line 2 is within an appropriate range (process 52 for determining a rolling state) based on the simulated sensor signal. Thereafter, if the higher-level device 50 determines that the rolling state of the rolling line 2 is not within the appropriate range, it executes processing for changing the set value of the control signal (process 53 for changing the set value of the control signal). Note that the rolling state determination processing 52 includes an abnormality determination processing, as shown in FIG. 6 . The abnormality determination processing refers to processing for determining that an abnormality has occurred in one of the plurality of rolling mills 4 if it is determined that the rolling state of the rolling line 2 is not within the appropriate range. This makes it possible to detect abnormalities in the rolling state of the rolling line 2.

[0054] FIG. 7 is a flowchart showing an outline of an example of processing by the rolling control system 1B.

[0055] In step S200, the rolling control system 1B generates a set value for the control signal, after which the process proceeds to step S210.

[0056] In step S210, the rolling control system 1B inputs a control signal to the rolling conveyance model 31 to emulate the conveyance of the material to be rolled 3. Thereafter, the process proceeds to step S220.

[0057] In step S220, the rolling control system 1B generates simulated sensor signals that simulate the sensor signals output from the plurality of sensors 6, based on the emulation results by the rolling conveyance model 31. Thereafter, the process proceeds to step S230.

[0058] In step S230, the rolling control system 1B determines whether or not the rolling state of the rolling line 2 is within an appropriate range. If it is determined that the rolling state of the rolling line 2 is within an appropriate range (step S230; Yes), the processing ends. Otherwise (step S230; No), the processing proceeds to step S240.

[0059] In step S240, the rolling control system 1B changes the set value of the control signal.

[0060] 2-3. Effects According to this embodiment, when the plurality of rolling mills 4 and the controller 8 are disconnected and the plurality of sensors 6 provided in the rolling line 2 are disconnected from the controller 8, control signals used to control the plurality of rolling mills 4 are acquired from the controller 8. The control signals are input to a rolling conveyance model 31 that simulates the conveyance of the material 3 to be rolled in the rolling line 2, and the conveyance of the material 3 to be rolled is emulated. Then, based on the results of the emulation by the rolling conveyance model 31, simulated sensor signals that simulate the sensor signals output from the plurality of sensors 6 are generated. Thereafter, based on the simulated sensor signals, it is determined whether the rolling state of the rolling line 2 is within an appropriate range. As a result, if the rolling state of the rolling line 2 becomes inappropriate, it is possible to detect an abnormality in the rolling state of the rolling line 2 and to confirm whether the set values ​​of the control signals are appropriate.

[0061] Furthermore, when a part of the rolling line 2 is changed or a new rolling line 2 is installed, it is confirmed that the set values ​​of the control signals are appropriate before starting operation of the rolling line 2. Therefore, while the rolling line 2 is in operation, the frequency of adjusting the set values ​​of the control signals input to the multiple rolling mills 4 is reduced, and improvement in the finishing accuracy of the rolled material 3 can be expected.

[0062] DESCRIPTION OF SYMBOLS 1A, 1B... Rolling control system, 2... Rolling line, 3... Rolled material, 4... Rolling mill, 6... Sensor, 7... Actuator, 8... Controller, 10... Rolling emulation device, 11... Emulation processing, 12... Difference determination processing, 13... Model correction value generation processing, 14... Storage processing, 20... Processor, 30... Storage device, 31... Rolling transport model, 32... Rolling emulation program, 50... Upper device, 51... Generation processing of control signal setting value, 52... Rolling state determination processing, 53... Change processing of control signal setting value

Claims

1. A rolling emulation device simulating a rolling line in which a plurality of rolling mills are lined up in order from the upstream side, comprising: a processor connected to a controller that controls the plurality of rolling mills via a communication interface; and a storage device that stores a rolling conveyance model that simulates the conveyance of the rolled material in the rolling line, wherein the processor is configured to execute the following processes: a process of acquiring control signals used to control the plurality of rolling mills from the controller; a process of inputting the control signals into the rolling conveyance model to emulate the conveyance of the rolled material; a process of generating simulated sensor signals that simulate sensor signals output from a plurality of sensors provided in the rolling line based on the emulation result by the rolling conveyance model; a process of acquiring actual sensor signals that are output from the plurality of sensors; a learning process of reflecting in the rolling conveyance model a model correction value that reduces the difference between the simulated sensor signal and the actual sensor signal; and an abnormality determination process of determining that an abnormality has occurred in one of the plurality of rolling mills if the difference is equal to or greater than a first threshold value.

2. A rolling emulation device as claimed in claim 1, characterized in that the processor is further configured to execute a process of notifying a higher-level device connected upstream of the controller that an abnormality has occurred in the rolling mill when the difference is equal to or greater than the first threshold value.

3. A rolling emulation device as claimed in claim 1 or 2, characterized in that the processor is configured to, in the learning process, reflect the model correction value in the rolling transport model when the difference is less than a first threshold value and is equal to or greater than a second threshold value which is smaller than the first threshold value.

4. A rolling emulation program simulating a rolling line in which a plurality of rolling mills are lined up in order from the upstream side, characterized in that the rolling emulation program is configured to cause a computer to execute the following processes: a process of acquiring control signals used to control the plurality of rolling mills from a controller connected to a controller controlling the plurality of rolling mills via a communication interface; a process of inputting the control signals into a rolling conveyance model simulating the conveyance of the rolled material in the rolling line to emulate the conveyance of the rolled material; a process of generating simulated sensor signals simulating sensor signals output from a plurality of sensors provided in the rolling line based on a result of emulation by the rolling conveyance model; a process of acquiring actual sensor signals output from the plurality of sensors; a learning process of reflecting in the rolling conveyance model a model correction value for reducing a difference between the simulated sensor signal and the actual sensor signal; and an abnormality determination process of determining that an abnormality has occurred in one of the plurality of rolling mills if the difference is equal to or greater than a first threshold value.

5. A rolling control system for controlling a rolling line in which a plurality of rolling mills are arranged in order from the upstream side, comprising: a controller for controlling the plurality of rolling mills via a communication interface; a host device connected upstream of the controller and generating setting values ​​for control signals to be input to the plurality of rolling mills via the controller; and a rolling emulation device provided in parallel between the plurality of rolling mills and the controller and emulating the transportation of the rolled material using a rolling transport model that simulates the transportation of the rolled material in the rolling line, wherein when the plurality of rolling mills and the controller are not connected and when the plurality of sensors provided in the rolling line and the controller are not connected, the rolling emulation device performs the following steps: a process for acquiring control signals used for controlling the plurality of rolling mills from the controller; a process for inputting the control signals into the rolling transport model to emulate the transportation of the rolled material; and a process for generating simulated sensor signals that simulate sensor signals output from the plurality of sensors based on the emulation results using the rolling transport model. a process of outputting the simulated sensor signal to the controller, wherein the higher-level device is configured to execute a judgment process of judging whether or not the rolling state of the rolling line is within an appropriate range based on the simulated sensor signal.

6. A rolling control system as claimed in claim 5, characterized in that the host device is configured to change the set value of the control signal when the rolling state is not within the appropriate range in the judgment process.

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