Descaling system, monitoring device and monitoring method

Abstract

The invention relates to a descaling system (100) for descaling a workpiece (1), preferably hot-rolling stock, by means of applying a high-pressure fluid to surfaces of the workpiece. The descaling system (100) comprises a high-pressure pump (7), a descaling unit (9) having nozzles (10), a fluid conveying system (4, 5, 6), sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) for measuring a plurality of operating parameters as operating parameter measurement values (Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) and a monitoring device (20) for detecting and processing the operating parameter measurement values (Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5). The monitoring device (20) is designed to determine, in real time during operation of the descaling system, at least one general and / or component-specific operational capability status and / or wear status of the descaling system by way of a combined evaluation of the detected operating parameter measurement values (Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) from at least two of the sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) for measuring different operating parameters and to output the determined operational capability status and / or wear status of the descaling system to a human-machine interface (50, 51, 52, 53, 54) coupled to the monitoring device (20). The invention further relates to a corresponding monitoring device and to a monitoring method.

Description

[0001] Descaling system, monitoring device and monitoring procedure

[0002] The present invention relates to a descaling system according to the preamble of independent claim 1. The invention also relates to a monitoring device according to the preamble of claim 11 and a monitoring method according to the preamble of claim 13.

[0003] State of the art

[0004] In today's hot rolling mills, descaling systems are used for the hydromechanical descaling of hot-rolled workpieces, such as slabs, to remove unwanted scale, i.e., iron oxide, from the workpiece surfaces prior to further processing steps, particularly rolling steps. Such descaling systems are equipped with scale washers, which, in the example of hot rolling mills, are installed downstream of the furnace and upstream of the rolling stands. Scale washers have one or more spray bars with descaling nozzles for applying a high-pressure fluid, usually water, as a spray jet(s) at a pressure of typically 100 to 400 bar to the workpiece surfaces. The scale is removed from the workpiece surfaces through sudden evaporation, thermal shock, and jet pressure.

[0005] To guarantee the descaling quality, such a descaling system must be constantly monitored with regard to its current functionality. Nowadays, functionality is monitored in such a way that individual signals or measured values ​​of the descaling system are displayed to an operator of the descaling system or the production plant on or via a human-machine interface, and that the operator recognizes critical values ​​and, if necessary, initiates an extraordinary inspection of the descaling system. In addition, the descaling system is preventively maintained at normal intervals to maintain its functionality, even in the absence of a malfunction or failure and without critical values ​​occurring. The disadvantage of this known approach is that maintenance or repairs are carried out excessively frequently at fixed intervals or in the event of a failure or malfunction of the descaling system orof the entire production plant, which in turn is associated with long downtimes of the production plant. Due to the individual signals displayed via the human-machine interface, the operator is often unable to detect excessive wear of the descaling system and / or performance losses at an early enough stage. Furthermore, the evaluation of the individual signals displayed via the human-machine interface depends on the operator's experience. Furthermore, even an experienced operator is often unable to determine from the information provided by the human-machine interface which component of the descaling system or production plant is or could be the cause of problems that are about to arise or have already occurred, meaning that targeted preventive maintenance cannot be carried out.

[0006] Disclosure of the invention

[0007] The present invention is therefore based on the object of providing a descaling system with improved monitoring of the descaling system's operability and wear. Furthermore, a descaling system is to be provided that enables targeted and timely planning and execution of maintenance of the descaling system, regardless of the skills and experience of the operating personnel. Furthermore, downtime is to be reduced and system availability increased.

[0008] The object of the present invention is achieved by a descaling system having the features of claim 1. Advantageous further developments arise from the features of the dependent claims, which can be combined as desired. The descaling system presented according to the invention is designed to descale a workpiece by exposing surfaces of the workpiece to a high-pressure fluid. The descaling system is installed in particular in a production plant, preferably a hot rolling mill with rolling stands. Accordingly, the workpiece is preferably a hot-rolled stock that is guided through the rolling stands to be rolled in the hot state. Water is preferably used as the high-pressure fluid. The descaling system has at least one high-pressure pump, at least one scale washer provided with nozzles, and a fluid line system.The at least one high-pressure pump is designed to apply high pressure to the high-pressure fluid supplied with a pre-pressure from a water supply system of the descaling system or the production plant. The high-pressure pump can be designed, for example, as a centrifugal pump or a piston pump. The fluid line system is designed to convey or forward the high-pressure fluid pressurized by the at least one high-pressure pump to the at least one scale washer. The fluid line system can contain at least one pressure accumulator for temporarily storing the high-pressure fluid under high pressure and at least one pressure regulating valve for delivering the high-pressure fluid at a predetermined minimum and / or maximum pressure value to the at least one scale washer. The at least one scale washer is provided with nozzles designed to apply the high-pressure fluid in a jet form to the workpiece to be descaled.

[0009] The at least one scale washer may have one or more nozzle receptacles arranged above a hot rolling mill, which are supplied with the high-pressure fluid on the inlet side via the fluid line system and which have the nozzles on the outlet side. The nozzle receptacles may be designed and provided in any known form without limitation and may, for example, be configured such that the nozzles are accommodated in spray bars and / or rotor heads.

[0010] The nozzles of the at least one scale washer can be divided into several nozzle zones, wherein the nozzles of the same nozzle zone can only be activated (deactivated) together, and the nozzles of the same nozzle zone are assigned a common operability status and / or wear status.

[0011] The descaling system is equipped with sensors for measuring multiple operating parameters as measured values. The sensors are designed to measure an operating parameter, such as pressure, volume flow, temperature, vibration, and / or speed. The sensors are distributed throughout the descaling system and / or a production facility coupled to the descaling system in order to measure operating parameters, such as pressure values ​​or volume flow values, at different positions within the descaling system and / or the production facility coupled to the descaling system, for example upstream and downstream of the high-pressure pump, the scale washer, and at various positions in the fluid line system.

[0012] The proposed descaling system is also equipped with a monitoring device for recording and processing the operating parameter measured values ​​from the sensors. According to the invention, the monitoring device is designed to determine, preferably in real time during operation of the descaling system, at least one general and / or component-specific operational capability status and / or wear status of the descaling system by means of a combined evaluation of the recorded and / or processed operating parameter measured values ​​from at least two of the sensors for measuring different operating parameters, and to output the determined operational capability status and / or wear status of the descaling system to a human-machine interface coupled to the monitoring device.The operational capability status and / or wear status can include a maintenance forecast for the descaling system and / or for a component of the descaling system, for example, for the at least one high-pressure pump and / or the nozzles. The feature of combined evaluation of the recorded operating parameter measured values ​​from at least two of the sensors for measuring different operating parameters means that the monitoring device uses at least two, preferably more than two, different operating parameters to determine the operational capability status and / or wear status. A measurement location is assigned to each operating parameter, which is usually predetermined by the position of the respective sensor.If the same physical parameter, such as pressure, flow rate, temperature, vibration, and / or speed, is measured at two different measuring locations, these are considered two different operating parameters. In the combined evaluation, the operational capability status and / or wear status are preferably determined in such a way that at least two of the operating parameters represent different physical parameters, i.e., not the same physical parameter.

[0013] Only if all operating parameter measured values ​​subjected to the combined evaluation exhibit respective normal operating values ​​at a given point in time does the monitoring device determine the general operating status and / or each component-specific operating status as fully functional for that point in time. A normal operating value corresponds to an operating parameter measured value measured by a sensor at a point in time when all components of the descaling system are fully functional and (virtually) wear-free. Such normal operating values, in the sense of target values, can be stored in the monitoring device as a reference and for comparison with the recorded and / or processed operating parameter measured values.

[0014] To further clarify the concept of combined evaluation, a descaling system is considered with several sensors mounted in the fluid line system and in the scale washer for measuring the fluid pressure prevailing at the respective mounting location, a temperature sensor for measuring the operating temperature of the high-pressure pump, and a speed sensor for measuring the operating speed of the high-pressure pump. The monitoring device of this descaling system is designed to evaluate the operating parameter measured values ​​of the pressure sensors, the temperature sensor, and the speed sensor in combination to determine the general or a component-specific operating condition and / or wear condition.If, for example, the measured operating temperature and the measured operating speed as well as all measured fluid pressures with the exception of the fluid pressure in the scale washer have normal operating values, the monitoring device determines by means of the combined evaluation of the operating parameter measured values ​​that the high-pressure pump is functional, the nozzles of the scale washer require maintenance (for small deviations from the usual scale washer fluid pressure value) or are defective or worn (for large deviations from the usual scale washer fluid pressure value), and that the general operational status of the descaling system is to be output to the human-machine interface as limited or defective.If, for example, the measured operating temperature is increased, the measured operating speed is reduced, and all measured fluid pressures downstream of the high-pressure pump are reduced compared to normal operating pressure values, the monitoring device determines by means of the combined evaluation of the operating parameter measured values ​​that the high-pressure pump requires maintenance (for small deviations from normal operating fluid pressure values) or is defective or worn (for large deviations from normal operating fluid pressure values), and that the general operational status of the descaling system is to be output to the human-machine interface as restricted or defective.

[0015] The monitoring device is preferably designed to determine the operational capability status and / or wear status in a qualified manner, i.e., by assigning a status attribute from a group of predefined, assignable status attributes, such as "fully functional," "still functional, maintenance required soon," and "defective." The group of predefined status attributes preferably includes more than two status attributes, i.e., not just "functional" and "defective," and in particular, a predefined status attribute for maintenance that is due soon. A quantitative value can also be added to an operational capability status and / or wear status qualified in this sense, such as, for example, an estimated remaining service life until a defect occurs.

[0016] The monitoring device preferably determines the general and / or component-specific operational status and / or wear status in such a way that this can be displayed to the operator on the human-machine interface based on the familiar traffic light colors: green (fully functional), yellow (still functional, immediate maintenance required), and red (defective, immediate repair required). This allows operators of the descaling system or production plant to easily, quickly, and reliably identify the respective operating status and maintenance requirements of components, regardless of their personal experience with the descaling system.

[0017] In a further development of the descaling system presented, the monitoring device is designed to determine at least one general or component-specific operability status and / or wear status by comparing the recorded operating parameter measured values ​​with predetermined limit value ranges.

[0018] According to this development, predefined limit value ranges are stored in the monitoring device for the respective operating parameters. For a respective operating parameter, several graduated limit value ranges, for example a narrower limit value range for full functionality and a broader limit value range for limited functionality, can be provided and stored in the monitoring device. The respective limit value ranges are predefined and stored in the monitoring device in such a way that a recorded operating parameter measured value lying outside the limit value range always indicates existing wear, for example, in the case of the aforementioned narrower limit value range, an imminent or already existing maintenance requirement and / or limited functionality, and in the case of the aforementioned broader limit value range, a defect.Only if all operating parameter measured values ​​at a given time are within the narrowest limit range specified for the respective operating parameter, the monitoring device determines the general serviceability status and / or all component-specific serviceability statuses as functional without any imminent or existing maintenance requirement.

[0019] The combined evaluation of a component-specific operational capability status or wear status described above by comparing the recorded operating parameter measured values ​​with specified limit value ranges is particularly advantageous for functional monitoring and maintenance requirement forecasting of the at least one high-pressure pump. To monitor the operational capability status and / or wear status of the at least one high-pressure pump, the monitoring device preferably performs a combined evaluation of the operating parameters pressure and volume flow downstream of the at least one high-pressure pump, for example, measured with sensors at the outlet of the at least one high-pressure pump or at the inlet of the scale washer, the rotational speed(s) of the at least one high-pressure pump, and / or calculated wear.For each of these operating parameters, critical limit value ranges have been defined which must be adhered to in order for the monitoring device to classify the at least one high-pressure pump as functional. The limit value ranges can be specified differently for the at least one high-pressure pump depending on the pump type, e.g. a centrifugal pump or a piston pump. For a high-pressure pump designed as a centrifugal pump, the pressure limit value range is, for example, 190 to 400 bar, the volume flow limit value range is a deviation of less than or equal to 10% from the setpoint, and the speed limit value range is a deviation of 100 revolutions per minute. In the case of multiple piston pumps, the pressure limit value range is, for example, 190 to 400 bar, the volume flow limit value range is a deviation of less than or equal to 10% from the setpoint, and the speed limit value range is a deviation of 10% of the setpoint between all piston pumps.In the case of a centrifugal pump, the monitoring device can also take the pump temperature into account, whereby, for example, the high-pressure pump is assessed as functional up to a deviation of 30°C from a target temperature or ambient temperature. Wear on the centrifugal pump or piston pump calculated from these operating parameters must not exceed 10% for the monitoring device to assess the high-pressure pump as functional.

[0020] In a further development of the descaling system presented, the monitoring device is designed to determine the at least one operability status and / or wear status of the descaling system by means of correlation of the recorded operating parameter measured values ​​of the sensors for measuring different operating parameters.

[0021] In this refinement, the monitoring device considers how a change in one or more operating parameters affects other operating parameters for the combined evaluation. For example, if some operating parameter measured values ​​are continuously very close to their target values, the monitoring device uses more stringent specifications as criteria for determining a currently functioning descaling system, such as specified limit ranges with narrowly defined intervals, compared to a case in which several operating parameter measured values ​​continuously exhibit a significant, but still permissible, deviation from their respective target values. Furthermore, the monitoring device evaluates the target value deviation of downstream operating parameters as a function of upstream operating parameters.For example, if the monitoring device determines that the pressure and flow rate measured at the pump outlet are within the limit range specified for evaluating the operational status of the pump(s), but are both at the lower end of this limit range, the monitoring device adjusts the nozzle pressure limit range specified for evaluating the operational status of the downstream nozzles by reducing the specified minimum pressure value of the nozzle pressure limit range and / or lowering a nozzle pressure setpoint.

[0022] In a further development of the descaling system presented, the monitoring device is designed to record and process sensor-specific measured value curves during normal production and to determine at least one operability status and / or wear status of the descaling system on the basis of the recorded and processed measured value curves.

[0023] From the measured value curves recorded over a number of operating hours, the monitoring device estimates the wear status and / or operability status of individual components or the entire descaling system.

[0024] In a further development of the descaling system presented, the monitoring device is designed to detect insufficient exposure of the surfaces of the workpiece to the high-pressure fluid in real time during operation of the descaling system and, by analyzing the recorded operating parameter measured values, to determine a component of the descaling system and / or a production system coupled to the descaling system that is responsible for the insufficient exposure and to output a message to the human-machine interface regarding the need for maintenance of the identified component.

[0025] In a further development of the proposed descaling system, the monitoring device is designed to determine a respective operability status and / or wear status for the at least one high-pressure pump, preferably individually for each high-pressure pump, the nozzles, preferably individually for individual nozzle zones and / or scale washers, and at least one bypass throttle of the descaling system and to output this to the human-machine interface. In a further development of the proposed descaling system, the monitoring device is designed to determine the at least one general and / or component-specific operability status and / or wear status of the descaling system by individually adapting the monitoring device to the monitored descaling system and to a production system coupled to the descaling system.

[0026] In a further development of the descaling system presented, the monitoring device is designed to determine at least one general and / or component-specific operability status and / or wear status of the descaling system automatically, without user interaction and without transmitting the operating parameter measured values ​​to an external evaluation device.

[0027] In a further development of the proposed descaling system, it is provided that the descaling system is equipped with or can be coupled to at least one vibration sensor. Furthermore, it is provided that the monitoring device is designed to receive sensor data from the at least one vibration sensor and to determine the at least one general and / or component-specific operability status and / or wear status of the descaling system in real time during operation of the descaling system based on the received sensor data. This further development is particularly advantageous if the at least one vibration sensor is vibrationally coupled to the at least one high-pressure pump, and the monitoring device determines the operability status or wear status of the at least one high-pressure pump based on the sensor data from the vibration sensor.

[0028] In a further development of the proposed descaling system, it is provided that the descaling system can be coupled to or is equipped with a camera system for optically inspecting the surfaces of the workpiece. Furthermore, it is provided that the monitoring device is configured to receive sensor data from the camera system and to determine the at least one general and / or component-specific operability status and / or wear status of the descaling system in real time during operation of the descaling system based on the received sensor data.

[0029] The object of the invention is also achieved by a monitoring device. The monitoring device presented is designed to determine, preferably in real time during operation of the descaling system, at least one general and / or component-specific operability status and / or wear status of the descaling system by means of a combined evaluation of recorded operating parameter measured values ​​from at least two sensors for measuring different operating parameters, and to output the determined operability status and / or wear status of the descaling system to a human-machine interface that is or can be coupled to the monitoring device.

[0030] In a further development of the presented monitoring device, the monitoring device is designed for local coupling to an existing descaling system with conventional monitoring of individual operating data measured values ​​by operating personnel. Furthermore, this monitoring device is designed for retrofitting the conventional descaling system with a maintenance forecasting functionality adapted to the descaling system, thus eliminating the need for conventional monitoring of individual measured data by operating personnel. This further development is particularly advantageous because an existing conventional descaling system can be upgraded on-site with the presented monitoring device in a system-specific manner and can be monitored and diagnosed with minimal operator effort without transmitting measured data to external units and / or without manual evaluation of measured data by experts.

[0031] The object of the invention is also achieved by a monitoring method for the descaling system presented above. According to the presented method, sensors measure a plurality of operating parameters as measured operating parameters, and a monitoring device records and processes the measured operating parameters. The monitoring device preferably determines, in real time during operation of the descaling system, at least one general and / or component-specific operability status and / or wear status of the descaling system by means of a combined evaluation of the recorded measured operating parameters from at least two of the sensors for measuring different operating parameters, and outputs the determined operability status and / or wear status of the descaling system to a human-machine interface coupled to the monitoring device.

[0032] The definitions introduced and explained for the descaling system and monitoring device according to the invention also apply to the method presented. The same advantages as the descaling system according to the invention can be realized with the method presented according to the invention.

[0033] Device features described on the basis of the proposed descaling system and one of its further developments, or any combination of these further developments, are also features of the proposed method and one of its further developments, and vice versa. Device-based features of the invention are also to be considered inventive features of the method, and vice versa. Consequently, further advantageous developments of the method according to the invention result from the described developments of the descaling system.

[0034] To clarify the proposed descaling system according to the present invention, an embodiment will now be explained with reference to the following figure:

[0035] Fig. 1 illustrates a schematic representation of an embodiment of the presented descaling system. The descaling system 100 shown in Fig. 1 is designed to descale a hot-rolled workpiece 1, which is moved relative to the descaling system in a direction x. The descaling system 100 comprises a high-pressure pump 7, a scale washer 9 provided with nozzles 10, and a fluid line system with a pump inlet section 4, a bypass section 5, and a pump outlet section 6. Via a water supply system of the descaling system and / or a production plant, a fluid, in particular water, at a pressure PV is supplied via the pump inlet section 4 to the high-pressure pump 7 and is compressed by the high-pressure pump 7 to a high-pressure fluid with an operating pressure of approximately 190 bar to 400 bar, which is typical for descaling systems.The high-pressure fluid is fed from the outlet of the high-pressure pump 7 via the pump outlet section 6 to a scale washer 9 and then exits nozzles 10 of the scale washer 9 as a nozzle-specific jet S to impinge on a surface of the workpiece 1 to be descaled at an oblique angle and to remove scale adhering to the surface. For the sake of simplicity, only one scale washer 9, one nozzle 10, and one jet S are illustrated in Fig. 1. This illustration should not be construed as a limitation of a specific design of the at least one scale washer 9 and the number of components, jets, and jet shapes illustrated. Nozzles 10 of the at least one scale washer 9 can be accommodated in at least one spray bar and / or at least one rotor head of the scale washer.

[0036] In order to allow a partial flow of the fluid to be guided past the high-pressure pump 7 designed as a centrifugal pump, the by-pass section 5 is provided with a by-pass throttle 8, which fluidically connects the pump inlet section 4 with the pump outlet section 6 only when the by-pass throttle 8 is open.

[0037] The descaling system 100 is equipped with numerous sensors 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 for measuring different operating parameters Q1, Q2, T, n, a, Q3, P3, Q4, P4 and P5 at different positions of the descaling system 100.

[0038] In the pump inlet section 4, a sensor 21 for measuring a volume flow Q1 is arranged before or upstream of the branch of the bypass section 5, and a sensor 22 for measuring a volume flow Q2 is arranged after or downstream of the branch of the bypass section 5. Similarly, in the pump outlet section 6, a sensor 26 for measuring a volume flow Q3 is arranged upstream of the inlet of the bypass section 5, and a sensor 28 for measuring a volume flow Q4 is arranged downstream of the inlet of the bypass section 5.

[0039] The high-pressure pump 7 is equipped with a sensor 23 for measuring an operating temperature T, a sensor 24 for measuring a rotational speed n, and a sensor 25 for measuring a vibration or oscillation a. The vibration sensor 25 can detect acceleration values, movement amplitude values, and / or frequency values ​​of the vibrations as measured values ​​a.

[0040] In addition, in the descaling system 100, a sensor 27 for measuring a fluid pressure P3 upstream of the inlet of the by-pass section 5, a sensor 29 for measuring a fluid pressure P4 downstream of the inlet of the by-pass section 5 and a sensor 30 for measuring a fluid pressure or nozzle pressure P5 in the scale washer are provided.

[0041] The descaling system 100 further comprises a monitoring device 20 for detecting and processing the operating parameter measured values ​​Q1, Q2, T, n, a, Q3, P3, Q4, P4 and P5 detected by the sensors 21, 22, 23, 24, 25, 26, 27, 28, 29, 30. The monitoring device 20 is designed to determine in real time during operation of the descaling system a general and three component-specific operability status or wear status of the descaling system by means of combined evaluation of the recorded operating parameter measured values ​​Q1, Q2, T, n, a, Q3, P3, Q4, P4 or P5 from at least two of the sensors 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 for measuring different operating parameters and to output the determined operability status or wear status to a human-machine interface 50 coupled to the monitoring device 20.

[0042] The monitoring device 20 of the descaling system 100 illustrated in Fig. 1 is designed to determine a general operating state and a component-specific operating state or wear state of the high-pressure pump 7, the bypass throttle 8 and the nozzles 10 by means of the combined evaluation of the recorded operating parameter measured values ​​Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5 and to transmit them to the human-machine interface 50.

[0043] The monitoring device 20 determines the operational capability states in a qualified manner and assigns to each operational capability state exactly one respective status attribute from a group of the following three assignable status attributes: “fully functional”, “still functional, maintenance required soon” and “defective”.

[0044] To determine the operational status of the high-pressure pump 7, the monitoring device 20 checks whether all operating parameter measured values ​​Q2, T, n, a, Q3, P3 are within a predefined, narrow limit range with a maximum deviation of 3% from the respective target values. If this is the case, the monitoring device 20 determines that the high-pressure pump 7 is fully functional. If, however, at least one of the operating parameter measured values ​​Q2, T, n, a, Q3, P3 exhibits a larger deviation, the monitoring device 20 checks whether all operating parameter measured values ​​Q2, T, n, a, Q3, P3 are within a predefined, broad limit range with a maximum deviation of 10% from the respective target values. If this is the case, the monitoring device 20 determines that the high-pressure pump 7 is still functional but requires maintenance.If the monitoring device 20 determines that at least one of the operating parameter measured values ​​Q2, T, n, a, Q3, P3 is outside the wider 10% limit range, the monitoring device 20 determines that the high-pressure pump 7 is defective.

[0045] To determine the operational status of the nozzles 10, the monitoring device 20 checks whether all operating parameter measured values ​​Q4, P4, P5 are within a predefined, narrow limit range with a maximum deviation of 10% from the respective setpoint values. If this is the case, the monitoring device 20 determines that the nozzles 10 are fully functional. In order to correlate with other operating parameter measured values, the monitoring device 20 is designed to lower the setpoint values ​​to be used for Q4, P4, P5 when checking the nozzles 10 if the monitoring device 20 determines that the operating parameter measured values ​​Q3, P3 measured on the output side of the high-pressure pump 7 are lower than the setpoint values ​​for Q3, P3.If all operating parameter measured values ​​Q4, P4, P5 are within a predefined, broader limit range with a maximum deviation of 12% from the respective target values, the monitoring device 20 determines that the nozzles 10 are still functional but require maintenance. If any of the operating parameter measured values ​​Q4, P4, P5 are outside the predefined, broader limit range, the monitoring device 20 determines that the nozzles 10 are defective.

[0046] To determine the operational status of the by-pass throttle 8, the monitoring device 20 checks whether all operating parameter measured values ​​Q1, Q2, Q3, Q4 are within a predefined narrow limit range with a maximum deviation of 15% from the respective setpoints. If this is the case, the monitoring device 20 determines that the by-pass throttle 8 is fully functional. If, on the other hand, at least one of the operating parameter measured values ​​Q1, Q2, Q3, Q4 shows a larger deviation from the setpoint, the monitoring device 20 checks whether all operating parameter measured values ​​Q1, Q2, Q3, Q4 are within a predefined broad limit range with a maximum deviation of 20% from the respective setpoints. If this is the case, the monitoring device 20 determines that the by-pass throttle 8 is still functional but requires maintenance.If the monitoring device 20 determines that at least one of the operating parameter measured values ​​Q1, Q2, Q3, Q4 is outside the wider 20% limit range, the monitoring device 20 determines that the by-pass throttle 8 is defective.

[0047] In the visualization example illustrated in Fig. 1, the monitoring device 20 has determined the operational status of the high-pressure pump 7 as "still functional, maintenance required soon" by means of the combined evaluation of the operating parameter measured values ​​Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5, and the human-machine interface 50 displays this result by means of an activated yellow light on a traffic light display 52. ​​In contrast, the monitoring device 20 has determined the operational status of the bypass throttle 8 and the operational status of the nozzles 10 as "fully functional" and displays this result by means of a respective activated green light on a traffic light display 53 and 54, respectively.To determine the general operational status of the descaling system, the monitoring device 20 in the example shown has determined by means of a combined evaluation of the operating parameter measured values ​​that the entire descaling system is “fully functional” and indicates this result by means of the activated green light on a larger traffic light display 51.

[0048] The descaling system 100 is also equipped with or coupled to a camera system 40 for optically inspecting the surfaces of the workpiece after descaling has been performed. The camera system 40 provides the monitoring device 20 with sensor data KS for assessing the quality of the descaling. The monitoring device 20 is configured to consider the sensor data KS, such as the operating parameter measured values ​​Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5, to determine the general or component-specific operating status.

[0049] The monitoring device 20 is installed entirely at the location of the descaling system 100 and is configured to perform the combined evaluation of the operating parameter measured values ​​described above independently, i.e., without user interaction and without recourse to data retrieved from an external source. The monitoring device 20 is also configured to perform the combined evaluation of the operating parameter measured values ​​specifically for the descaling system operating at its installation location. This means that the monitoring device 20 is operated in a system-specific manner.

[0050] List of reference symbols

[0051] 1 workpiece

[0052] 4 Pump inlet section

[0053] 5 By-pass section

[0054] 6 Pump outlet section

[0055] 7 High pressure pump

[0056] 8 By-pass throttle

[0057] 9 scale washers

[0058] 10 nozzle(s)

[0059] 20 Monitoring device

[0060] 21 Sensor for measuring volume flow Q1

[0061] 22 Sensor for measuring volume flow Q2

[0062] 23 Sensor for measuring the operating temperature T

[0063] 24 Sensor for measuring the operating speed n

[0064] 25 Sensor for measuring vibration a

[0065] 26 Sensor for measuring volume flow Q3

[0066] 27 Sensor for measuring pressure P3

[0067] 28 Sensor for measuring volume flow Q4

[0068] 29 Sensor for measuring pressure P4

[0069] 30 Sensor for measuring pressure P5

[0070] 40 camera system

[0071] 50 Human-Machine Interface

[0072] 51-54 Display of the determined operating status

[0073] 60 operators

[0074] F Detection field of the camera system

[0075] KS sensor data of the camera system

[0076] PV pressure of the water supply system

[0077] S Jet of the nozzle(s) 10 x Movement direction of the workpiece during descaling

Claims

Claims 1 . Descaling system (100) for descaling a workpiece (1), preferably a hot-rolled stock, by applying a high-pressure fluid to surfaces of the workpiece, wherein the descaling system (100) has at least one high-pressure pump (7), at least one scale washer (9) provided with nozzles (10), a fluid line system (4, 5, 6), sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) for measuring a plurality of operating parameters as operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) and a monitoring device (20) for detecting and processing the operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5), characterized in that the monitoring device (20) is trained,to determine, preferably in real time during operation of the descaling system, at least one general and / or component-specific operability status and / or wear status of the descaling system by means of combined evaluation of the recorded operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) from at least two of the sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) for measuring different operating parameters and to output the determined operability status and / or wear status of the descaling system to a human-machine interface (50, 51, 52, 53, 54) coupled to the monitoring device (20).

2. Descaling system (100) according to claim 1, characterized in that the monitoring device (20) is designed to determine the at least one operability status and / or wear status of the descaling system by comparing the recorded operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) with predetermined limit value ranges.

3. Descaling system (100) according to claim 1 or 2, characterized in that the monitoring device (20) is designed to determine the at least one operability status and / or wear status of the descaling system by means of correlation of the recorded operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) of the sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) for measuring different operating parameters.

4. Descaling system (100) according to one of the preceding claims, characterized in that the monitoring device (20) is designed to record and process sensor-specific measured value curves during normal production and to determine the at least one operability status and / or wear status of the descaling system on the basis of the recorded and processed measured value curves.

5. Descaling system (100) according to one of the preceding claims, characterized in that the monitoring device (20) is designed to detect insufficient exposure of the surfaces of the workpiece to the high-pressure fluid in real time during operation of the descaling system and, by analyzing the recorded operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5), to determine a component of the descaling system and / or of a production plant coupled to the descaling system (100) that is responsible for the insufficient exposure and to output a message (51, 52, 53, 54) to the human-machine interface (50) regarding the need for maintenance of the determined component.

6. Descaling system (100) according to one of the preceding claims, characterized in that the monitoring device (20) is designed for the at least one high-pressure pump (7), preferably individually for each individual high-pressure pump, the nozzles (10), preferably individually for individual nozzle zones and / or scale washers (9), and at least one by-pass throttle (8) of the descaling system, a respective To determine the operational status and / or wear status and to output this to the human-machine interface (50).

7. Descaling system (100) according to one of the preceding claims, characterized in that the monitoring device (20) is designed to determine the at least one general and / or component-specific operability status and / or wear status of the descaling system by individually adapting the monitoring device (20) to the monitored descaling system (100) and to a production plant coupled to the descaling system.

8. Descaling system (100) according to one of the preceding claims, characterized in that the monitoring device (20) is designed to determine the at least one general and / or component-specific operability status and / or wear status of the descaling system automatically, without user interaction and without transmitting the operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) to an external evaluation device.

9. Descaling system (100) according to one of the preceding claims, characterized in that the descaling system is equipped with or can be coupled to at least one vibration sensor (25), and in that the monitoring device (20) is designed to receive sensor data (a) from the at least one vibration sensor (25) as operating parameter measured values ​​and to determine the at least one general and / or component-specific operability status and / or wear status of the descaling system, in particular of the at least one high-pressure pump (7), in real time during operation of the descaling system, also on the basis of the received sensor data (a).

10. Descaling system (100) according to one of the preceding claims, characterized in that the descaling system can be coupled to or is equipped with a camera system (40) for optically inspecting the surfaces of the workpiece, and in that the monitoring device (20) is designed to receive sensor data (KS) from the camera system (40) and to determine the at least one general and / or component-specific operability status and / or wear status of the descaling system in real time during operation of the descaling system, taking into account the sensor data (KS) received from the camera system (40).

11. Monitoring device (20) for a descaling system (100) according to one of the preceding claims, characterized in that the monitoring device (20) is designed to determine in real time during operation of the descaling system at least one general and / or component-specific operability status and / or wear status of the descaling system by means of combined evaluation of recorded operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) from at least two sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) for measuring different operating parameters and to output the determined operability status and / or wear status of the descaling system to a human-machine interface (50) coupled or coupleable to the monitoring device (20).

12. Monitoring device (20) according to claim 11, characterized in that the monitoring device is designed for local coupling to an existing descaling system with conventional monitoring of individual operating parameter measured values ​​by operating personnel and for retrofitting this descaling system with a maintenance forecast functionality adapted to the descaling system.

13. Monitoring method for a descaling system (100) for descaling a workpiece (1), preferably a hot-rolled stock, by applying a high-pressure fluid to surfaces of the workpiece, wherein the descaling system (100) has at least one high-pressure pump (7), at least one scale washer (9) provided with nozzles (10), and a fluid line system (4, 5, 6), wherein sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) measure several operating parameters as operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5), and a monitoring device (20) records and processes the operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5), characterized in thatthat the monitoring device (20) determines in real time during operation of the descaling system at least one general and / or component-specific operability status and / or wear status of the descaling system by means of combined evaluation of the recorded operating parameter measured values ​​(Q1, Q2, T, n, a, Q3, P3, Q4, P4, P5) from at least two of the sensors (21, 22, 23, 24, 25, 26, 27, 28, 29, 30) for measuring different operating parameters and outputs the determined operability status and / or wear status of the descaling system to a human-machine interface (50, 51, 52, 53, 54) coupled to the monitoring device (20).

Images