CN109047683B - Continuous casting billet intelligence basis weight scale on-line control system - Google Patents
Continuous casting billet intelligence basis weight scale on-line control system Download PDFInfo
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- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
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Abstract
The invention relates to an intelligent weight and length fixing online control system for a continuous casting billet, which comprises an input module, a data acquisition module, a data storage module, a communication module, a core calculation module, an output module, an execution module and a monitoring interface module. The data acquisition module is used for acquiring information such as real-time production process data of the continuous casting billet, the return deviation of the cutting machine, the weighing of the continuous casting billet and the like, the data storage module is used for storing the data, the core calculation module is used for performing data calculation processing by adopting a multi-model continuous casting billet weight control method, an optimal continuous casting billet sizing set value is output and is issued to the sizing system to be executed, and the continuous casting billet weight precision is improved. The system takes the communication module as a link for realizing basic data interaction by using the control system, and can realize data communication between the data acquisition module and the production management MES system and data communication between the data acquisition module and the basic automation PLC system. The interface monitoring module realizes the visualization of the production process in the form of 'number and table', and intuitively and clearly reflects various important information.
Description
Technical Field
The invention relates to the technical field of ferrous metallurgy, in particular to an intelligent weight and length fixing online control system for a continuous casting billet.
Background
In the continuous casting process flow of steel enterprises, most continuous casting machines of steel plants are fixed in weight by fixed length (the length of a continuous casting billet), namely, a fixed length system is adopted to produce the continuous casting billet with the weight required by steel rolling in the next process, but the weight of the continuous casting billets with the same length is large in difference due to the influences of crystallizer abrasion, pulling speed change, superheat degree change and molten steel component change in the actual production process, and the actual weight of the continuous casting billet is not the weight required by the steel rolling. The overweight of the continuous casting billet causes too much excess material after rolling, if the excess material is too light, the defective quantity is increased, and the precision of the weight of the continuous casting billet affects the rolled steel yield.
In order to improve the weight precision of continuous casting billets, some enterprises apply a continuous casting billet fixed-weight fixed-length online feedback control technology which is controlled based on a camera fixed-length and weighing feedback compensation mode, namely in the production process, a rolling mill provides the weight of billets to a steel mill as a target weight according to finished product specifications, a system automatically sets the length of the billets according to the target weight to cut the billets, then the cut billets are weighed, the weighed weight is compared with the target weight to obtain a deviation, the length of the next secondary cut billets is compensated, and the steps are sequentially circulated (continuous weighing and continuous adjustment), gradually approached (different adjustment coefficients are adopted under different working conditions), so that the billets produced by a continuous casting machine are different in appearance and size but have the same weight, and stable billets are provided for the next working procedure. However, the control mode can only compensate for the fixed length deviation caused by equipment factors such as the abrasion of a crystallizer copper pipe and the like, does not consider the influence of the drawing speed change, the superheat degree change and the molten steel component change of the continuous casting billet, and can obtain better precision only when the constant drawing speed, the constant temperature and the molten steel component fluctuation of the continuous casting machine are small.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides an intelligent weight and length fixing online control system for a continuous casting billet. The system integrates production process data tracking, a weighing system, machine learning and intelligent control, comprehensively considers the influence of factors of crystallizer abrasion equipment and the influence of production process parameter changes such as fluctuation of working conditions (pulling speed change, superheat degree change and molten steel component change), can realize accurate fixed weight cutting of continuous casting billets, provides stable, little-fluctuation and accurate-weight blanks for the next process, reduces rolled excess materials for steel rolling, reduces metal loss, reduces the proportion of random scale materials, finally improves production technical indexes such as rolling yield and yield, and generates considerable economic benefits for enterprises. This technique also makes things convenient for more, the information of every billet after the accurate acquisition cutting, including stove number, weighing data etc. makes things convenient for the steel mill to carry out real time monitoring and inquiry to the information of continuous casting billet, knows the production steady state, in time guides production, and the very big production management that makes things convenient for. Meanwhile, by utilizing the network communication technology, the settlement data from a steel mill to a steel rolling mill can be more reasonable and complete, the basis is more sufficient, the metering precision is improved, and human factor errors are avoided.
The continuous casting billet intelligent weight and length fixing online control system is integrated with an input module, a data acquisition module, a data storage module, a communication module, a core calculation module, an output module, an execution module and a monitoring interface module. The input module can modify the initial setting of the control system and make some adjustments to the control system according to actual conditions and needs. The data acquisition module continuously acquires the current production process history information of the continuous casting billet and transfers the acquired production process history information to the data storage module and the core calculation module. The data storage module is the basis of the control system and stores the received data transmitted by the data acquisition module and the communication module. The communication module is a link of the Control system, realizes data interaction with a basic automation PLC system through OPC (OLE for Process Control, namely OLE for process Control, which is an industrial standard) communication, realizes data interaction with a production management MES (manufacturing execution system) system through database modes (Oracle, SQLServer, MySQL and the like), and simultaneously reduces manual participation links and improves the intelligent degree of the Control system by adopting L1-level and L2 cascading lock protection measures and free switching and emergency switching functions. The core calculation module is the core of the whole control system, receives the real-time working condition data of the data acquisition module and the production process tracking data in the data storage module, and adopts an advanced control strategy of multiple models to comprehensively set the cutting fixed length of the continuous casting billet after data diagnosis and processing. The core calculation module comprises a fixed-length prediction module and a compensation module, wherein the prediction module carries out online real-time prediction on the weight and the fixed length of the continuous casting blank by referring to production process information corresponding to the continuous casting blank, and the compensation module carries out compensation value calculation on the fixed length according to the weighing data of the continuous casting blank and the return deviation detection of the cutting machine. The output module outputs the result of the core calculation module to the execution module. And the execution module realizes the fixed-length cutting of the continuous casting billet according to the result of the core calculation module transmitted by the output module. The monitoring interface module is a window of the control system, so that the control system can display data from the data acquisition module, the data storage module, the communication module, the core calculation module and the output module in a 'number and table' form, the visualization of the production process is realized, and the important information such as the pouring plan, the production process, the production parameters, the fixed length, the weighing weight, the predicted weight, the fixed length and the like of each casting flow can be conveniently, intuitively and clearly known by operation or process personnel.
The data acquisition module continuously acquires the information such as the process data tracking information of the continuous casting billet in the real-time production process, the homing deviation of the cutting machine, the weighing after the continuous casting billet is cut, the production management MES system data and the like through the communication module, and the information acquired by the data acquisition module is transmitted to the data storage module and the core calculation module; data storage is carried out through a data storage module; the communication module is used as a link for realizing basic data interaction by using the control system, and data communication between the data acquisition module and the production management MES system and the basic automation PLC system is realized; the core calculation module obtains real-time working condition data from the data acquisition module and course tracking data from the data storage module, and performs data diagnosis and calculation processing; outputting the result of the core calculation module to an execution module through an output module; and the execution module realizes the fixed-length cutting of the continuous casting billet according to the result of the core calculation module transmitted by the output module. The communication module adopts two-stage interlocking protection measures to realize free switching and emergency switching functions.
In the production process, a data acquisition module of the continuous casting billet intelligent fixed-weight fixed-length control system can automatically acquire signals of casting start, casting tail, casting stop and the like, after the system is started according to the current production signal, a casting plan is acquired from a production management MES (manufacturing execution system) system, the current casting conditions (steel ladle molten steel weight, middle ladle molten steel weight, pulling speed, molten steel temperature, crystallizer water quantity, temperature difference and the like) are acquired from a basic automation level PLC system, after a cutting signal or a weighing signal is acquired, actual weighing data are automatically acquired, a prediction model and a compensation model in a core calculation module are started in combination with production process tracking data, the next cutting fixed-length is comprehensively calculated, and then the next cutting fixed-length is issued to a fixed-length system through an output module (PLC system).
The calculation formula of the continuous casting billet quality M is as follows:
M＝ρV＝ρ*S*L。
in the formula:
rho is the density of the continuous casting billet and the unit is Kg/m3The density of the continuous casting blank is changed with the steel grade and the temperature of the casting blank. The steel grade is influenced by the composition of molten steel, and the temperature of a continuous casting billet is influenced by cooling of a crystallizer (primary cooling), secondary cooling, a throwing speed and the temperature of molten steel in a tundish.
V is the volume of the continuous casting billet, and V is S L and unit m3。
L is the continuous casting billet length, unit m. The continuous casting billet sizing is mainly affected by the system error of a sizing system and the error of a cutting machine system.
S is the area of the cross section of the continuous casting billet and the unit m2. The continuous casting billet mold wear degree is different, and the actual section sizes of the continuous casting billets are slightly different under the condition of the same specification. In addition, when the withdrawal speed is higher, the shell of the crystallizer for continuously cast billet is thinner, the bulging tendency exists, the actual section size of the continuously cast billet can be influenced, the density of the continuously cast billet is changed, and therefore the influence can be comprehensively considered by the influence of the density of the continuously cast billet.
Through the analysis of the influence factors of the weight of the continuous casting billet, the actual production process is combined, and the weight determining precision of the continuous casting billet can be analyzed from the following technical paths:
1) for the influence of the continuous casting billet density on the weight, the process parameters of the production process can be collected in real time, the process parameters are comprehensively analyzed in a continuous casting billet density mathematical modeling or machine learning mode, and a fixed weight and fixed length control model based on the process information of the production process is established;
2) to the influence of cutting machine system to the actual scale of continuous casting billet, can adopt laser rangefinder's mode to carry out real-time detection to conticaster cutting origin position, propose the continuous casting billet scale compensation model based on cutting machine system. For the influence of the system error of the sizing system on the sizing of the continuous casting billet, a high-precision sizing system can be adopted, such as a non-contact sizing cutting technology of a camera sizing system or a laser sizing system.
3) For the influence of equipment such as crystallizer abrasion on the actual section size of the continuous casting billet, the continuous casting billet can be weighed on line, and a fixed-length compensation model based on continuous casting billet weight feedback is established;
4) in order to meet the requirement of continuous casting billet weight-fixed online real-time control, a mode of real-time communication with an MES system and a PLC system can be adopted, and a continuous casting billet weight-fixed and length-fixed online intelligent control system is integrated.
Therefore, in order to realize accurate fixed weight cutting of the continuous casting billet, the continuous casting billet intelligent fixed weight and fixed length online control system comprehensively adopts a continuous casting billet process data course information tracking method to collect continuous casting billet process data, and adopts a continuous casting billet fixed weight control method based on multiple models and fusing a continuous casting billet feed-forward fixed weight control sub-model and a continuous casting billet feed-back control sub-model to improve the continuous casting billet fixed weight and fixed length control accuracy, as shown in fig. 4 and 5, wherein the feed-back control sub-model adopts a length compensation control sub-model based on an online weighing system, and the feed-forward control sub-model can adopt a continuous casting billet fixed weight compensation model based on cutting machine homing deviation detection, a control sub-model based on continuous casting billet density characteristics and various sub-models containing structural modes of 'sample data + training' (such as a control sub-model based on neural network method prediction, a, A control submodel predicted by a GBDT method based on Scikit-lern, a control submodel predicted by a random forest method based on Scikit-lern, a continuous casting billet fixed weight prediction model predicted by machine learning based on a Tensorflow method prediction control submodel and the like) and the like or a feedforward control method model set constructed by all feedforward control methods. The following is a detailed introduction of a new method and a model related to the continuous casting billet intelligent weight and length fixing online control system:
(1) continuous casting billet process data process information tracking method
The problem primarily solved by machine learning is the correct data sample, i.e. the weight of the continuous casting billet and the completely corresponding continuous casting billet history data information. In order to obtain continuous and complete continuous casting billet process data information, the continuous casting billet is virtually divided into a plurality of unit blocks according to a certain length along the running direction of the continuous casting billet, see fig. 6, each unit block is taken as an independent information unit, information data borne by each unit block is continuously tracked and monitored from the solidification starting point of molten steel according to a certain period, and is recorded to the control ending point to form a complete corresponding dynamic tracking data file of the continuous casting billet. The method can regard a molten steel solidification starting point (generally taking a crystallizer meniscus) as a unit block birth point, regard a control end point as a unit block vanishing point, regard the running time of the unit block from the birth point to the vanishing point along the running direction of the continuous casting billet as the service life of the unit block, and the control end point is customized by a user and generally takes the position of the maximum fixed-length tail end point after the continuous casting billet is cut.
As the preferred scheme, the lengths of all the unit blocks virtually divided for the continuous casting billet are equal, and the length of the unit block is less than 10mm, so that the uniformity and the density of process data acquisition and recording are ensured, and the reliability of data use and analysis is enhanced.
Each unit block is an independent information unit, and the information data carried by the unit block as an independent information unit includes but is not limited to the attributes of the unit block itself, the production condition data attribute, the production signal attribute and the production event attribute.
In the actual production process, each unit block starts tracking process information from birth, the unit block grows according to a data recording period, corresponding data is recorded according to the position of the unit block every growth, and the unit block is recorded in a cyclic and reciprocating manner until the unit block reaches the end point (end point) of a control area. In a data recording period, if the forward moving distance of the continuous casting billet is greater than or equal to the length of a unit block, a new unit block is generated at the solidification starting point (birth point) of molten steel, the unit block in the control area grows in an advancing way, the unit block disappears at the end point (end point) of the control area, and the whole production process is continuous; on the contrary, if the forward moving distance of the continuous casting slab is less than a unit block length in one data recording period, a new unit block is not generated at the solidification starting point (birth point) of molten steel until the accumulated running distance is greater than or equal to the unit block length. When the unit block moves forward in the continuous casting billet running direction within a period of time, the distance is not larger than the length of the unit block in the continuous casting billet running direction, and the information of the unit block is ensured to be recorded at least once on each length node. The information of the cell block reaching the end point of the control area comprises all process data history information of the cell block in the growing process, and at the moment, the quality or weight of the continuous casting blank can be analyzed without carrying out continuous casting blank production process data backtracking on the data information.
(2) Length compensation control submodel based on online weighing system
The length compensation control submodel based on the online weighing system belongs to a feedback control submodel, and is a model for measuring the weight of a cut continuous casting billet on line and determining whether the fixed size of the next cutting is adjusted or not according to the comparison condition of obtained data and a standard value. The reliability of the weighing data is the premise of establishing a weight-based scale compensation model and is also the basis for verifying the accuracy of the intelligent scale control model on line. The continuous casting billet on-line weighing device mainly has structural forms such as a hanging frame lifting type and a frame jacking type, and as the weighing system works in a roller way area with high temperature and high humidity, the weighing system can stand the change of temperature and humidity for a long time and can accept the impact of the weighing frame for a long time, the field environment is very severe, the environment adaptability of the weighing system is required to be strong, the reliability is high, and the failure rate is low. Therefore, the weighing system adopts a cylindrical weighing sensor with better high temperature resistance, and is provided with a water cooling protection measure and a weighing hanging frame deflection prevention measure. The weighing precision of the weighing system is not more than +/-1 kg.
The weight of using above-mentioned continuous casting billet weighing system actual weighing can compensate the continuous casting billet next time cutting scale to eliminate the influence of equipment factors such as crystallizer wearing and tearing to continuous casting billet weight, the continuous casting billet scale compensation quantity computational formula based on weighing system is:
△Lm1＝Ki(Li(G0-Gi)/Gi)
in the formula:
△Lm1-next cutting of the casting blank to a specified length compensation value of mm;
Li-sizing the casting blank for this cutting;
G0-casting blank basis weight;
Gi-actual casting blank weight;
Ki-a length correction factor.
Length correction factor KiThe value function of (A) is shown in FIG. 7, and the calculation formula is as follows:
when only one effective weighing is carried out KiThe value can be automatically set according to the requirement of an approach rate, wherein the value is 0.6-0.8;
when effective weighing is carried out more than twice
In the formula:
x is a variable of the weight deviation amount,
unit per mill;
a0、b0a, b and x1、x2The constant parameters are set by the craftsman according to the approaching speed requirement, but a0、b0A, b and x1、x2The setting must satisfy: 1.0. gtoreq.b0＞a0≥0。x1And x2Selecting according to the weight deviation control requirement, wherein x is more than or equal to 01＜x2Less than or equal to 5; when x is equal to x1When ax + b is a0When x is equal to x2When ax + b is equal to b0. When a is0、b0、x1、x2After the determination, a and b can be obtained.
When the weight of the current weighing is larger than the allowable deviation of the reference weight, the previous sizing is carried out;
when the weight of the current weighing is larger than the reference weight and the weight of the last weighing is smaller than the reference weight, taking the weight close to the reference weight and the corresponding length as the actually measured weight Gi and length Li;
when the prediction model participates in the control, the calculation formula of the fixed-length compensation model is as follows:
in the formula:
ΔLmi-controlling the predicted equipment factor compensation value, mm, of the model Mi;
k is the effective weighing times and the effective prediction times, namely when the deviation of the weighing value and the predicted value and the deviation of the weighing value and the reference value meet the allowable error, the weighing is considered to be effective. When k is 0, Δ LmiMaintaining the last value;
Lmijthe casting blank weighed in the jth time is actually sized to be mm;
Gmij-the casting blank weight predicted value, kg, weighed for the jth time;
Gjthe actual weight of the casting blank weighed in the jth time is kg;
(3) continuous casting billet sizing compensation model based on cutting machine homing deviation detection
Determining a base point in the moving direction of the continuous casting cutting machine, installing a laser distance meter at the position of the base point, determining the reference distance between the base point and the original point of the cutting machine, and setting the reference distance in a PLC system; before preparing cutting work, determining that the cutting machine is reset; measuring the distance (relative to a base point) of the actual position of the cutting machine after the cutting machine is returned by using a laser range finder, and transmitting the measurement data to a PLC system by using the laser range finder; calculating a deviation value of the measured distance of the cutting machine to the base point and the reference distance by the PLC system; and judging whether the calculated deviation value exceeds the cutting allowable deviation range of the continuous casting billet or not, if so, compensating the stroke of the cutting machine by the deviation value when the cutting machine advances before cutting the continuous casting billet. If the deviation value does not exceed the cutting allowable deviation range of the continuous casting billet, the stroke of the cutting machine does not need to be compensated, and the figure 8 shows that the deviation value does not exceed the cutting allowable deviation range of the continuous casting billet.
Origin detection for continuous casting cutting machineThe device is shown in figure 9 and comprises a cutting machine (1), a running track (3), a cutting machine (1) positioned on the running track (3), a cutting gun (2) arranged on the cutting machine (1), a laser range finder (4), a laser range finder support frame (9), a range finding target (5), a PLC system (10) and a sizing system (11), wherein the laser range finder (4) is fixed on the laser range finder support frame (9), the laser range finder support frame (9) is positioned at one end of the running track (3), the range finding target (5) is arranged on the cutting machine (1) just opposite to the laser range finder (4), the laser range finder (4) is connected with the PLC system (10), the PLC system (10) is connected with the sizing system (11), the laser range finder (4) transmits the measured range of the cutting machine (1) after being reset to the PLC system (10), and the range of the range is out of the range after the cutting machine (1) is reset, the PLC system (10) transmits the deviation value to the sizing system (11) to compensate the sizing set value. A reference distance value S from a base point of the laser distance meter (4) when the cutting machine (1) stops at the origin is set in the PLC system (10)0The cutting allowance deviation delta S and other parameters of the continuous casting billet, under the normal condition, cutting machine (1) is completed each time and all should return to the original point, when cutting the continuous casting billet during operation, fixed length system (11) control cutting machine (1) is from the original point along orbit (3) and continuous casting billet (8) synchronous motion to cut continuous casting billet (8) with burning torch (2), after the cutting is accomplished, cutting machine (1) moves the return to the original point, in order to prepare next cutting action. When the cutting machine (1) is reset, the cutting machine cannot return to the original position due to the influence of various factors, and has a certain deviation with the original position. Therefore, in actual work, after the cutting machine (1) is reset, the laser distance measuring instrument (4) emits laser, and the distance S between the cutting machine (1) and the base point of the laser distance measuring instrument (4) is measured through the feedback of the distance measuring target (5) to the laser1Measuring the distance S1Transmitting the distance deviation value delta L to a PLC system, and calculating the distance deviation value delta L through a calculation model set in the PLC systemM2The deviation value DeltaLM2Cutting tolerance range delta L of continuous casting billet0Comparing, judging whether the length exceeds the preset length, and if the length exceeds the preset length, compensating a delta L for the set length of the continuous casting billet of the sizing system (11)M2The value is obtained. E.g. reference scale L0Setting a length value for the continuous casting billet; when Δ LM2Is greater than the allowable measurement control accuracy DeltaL0Then, the reference fixed length L is combined0And (3) performing compensation calculation on the set fixed length L: l ═ L0+ΔLM2And taking the compensated L value as the length set value of the next continuous casting billet.
The fixed-length compensation quantity calculation formula based on the homing deviation of the cutting machine is as follows:
ΔLM2＝S1-S0
in the formula:
ΔLM2-next cutting of the casting blank to a specified length compensation value of mm;
S1-the cutter returns to the final stop position, mm;
S0-cutting machine reference origin position, mm;
(4) sub-model with structure mode of' sample data + training
A feedforward control model of a sub-model in a structural mode of 'sample data + training' belongs to a prediction model, after a data sample is established by using process information acquired by a continuous casting billet process data process information tracking method, the data sample is respectively input into an established fixed-length training model and a fixed-weight training model for self-learning, after parameter optimization is performed by multiple learning, the fixed-length model and the fixed-weight model are stored and then integrated into the fixed-weight fixed-length prediction model, in the actual production process, the prediction model calls the corresponding fixed-length model or the fixed-weight model according to the process data information of the continuous casting billet in real time, online real-time prediction is respectively performed on the fixed length and the fixed weight of the continuous casting billet, the continuous casting billet with abnormal weight is found in time, the fixed-weight precision is improved, and the diagram shown in.
The training model can adopt a model with a structural mode of 'sample data + training', including but not limited to a control submodel predicted based on a neural network method, a control submodel predicted based on a GBDT method of Scikit-lern, a control submodel predicted based on a random forest method of Scikit-lern, a continuous casting billet fixed weight prediction model predicted by machine learning based on a Tensorflow method prediction control submodel and the like, and the model is stored after the training of the fixed size model and the fixed weight model is finished so as to facilitate the direct calling of the model by the fixed weight and fixed size prediction model in the later period.
When the fixed-length fixed-weight prediction is carried out on line, the production process data of the continuous casting billet is collected in real time, when a cutting signal appears, the process data are analyzed and sorted according to the data format of the training model, the input data of the predicted weight and the predicted fixed-length are respectively obtained, and then the corresponding fixed-weight/fixed-length model is called. On one hand, the weight of the continuous casting billet cut this time is predicted, and if the weight is out of tolerance, a warning is sent out in time; and on the other hand, the next cutting sizing for obtaining the expected weight is predicted and issued to the sizing system, so that the weight of the casting blank can meet the blank weight requirement through each cutting.
In order to realize the intelligent control of the continuous casting billet fixed weight and fixed length, the process control of the continuous casting billet intelligent fixed weight and fixed length control system adopts multi-level control, all control levels are mutually independent, and a standard communication protocol is applied. The communication of the continuous casting intelligent weight and length fixing control system adopts an industrial standard OPC technology to realize data interaction with a production line basic level PLC system, and adopts a database mode to realize data interaction with a production management level MES system.
Compared with the prior art, the invention has the beneficial effects that: based on a continuous casting billet process data process information tracking method and a system multi-stage control thought, an intelligent fixed-weight fixed-length online control system of a continuous casting billet is integrated, a mathematical model is used for tracking the production process data of the casting billet in real time, the influence of continuous casting machine equipment factors and production working condition data on the weight of the continuous casting billet is comprehensively considered according to the production process data and actual weighing data in real time, an advanced strategy of multi-model control is adopted, the cutting fixed length of the continuous casting billet is optimized, and better continuous casting billet fixed-weight precision control is realized.
Drawings
FIG. 1 is a structural component of the present invention;
FIG. 2 is a network topology of the present invention;
FIG. 3 is a parameter I/O relationship according to the present invention;
FIG. 4 is a diagram of a multi-model control architecture;
FIG. 5 is a diagram of the composition of a set of multiple models;
fig. 6 is a schematic illustration of a division of a cell block as a separate information carrier;
FIG. 7 shows the length correction factor KiA value function graph of (a);
FIG. 8 is a flow chart of a continuous casting billet sizing compensation method based on the detection of the return deviation of the cutting machine;
FIG. 9 is a structural diagram of a continuous casting billet sizing compensation device based on the detection of the return deviation of a cutting machine;
FIG. 10 is a flow chart of a continuous casting billet weight and length fixed online prediction method;
FIG. 11 is a flowchart illustrating the calculation of a main routine according to the present invention;
FIG. 12 is a monitoring interface of the present invention at a steel mill;
FIG. 13 is a comparative graph of the metallurgical effect of the practical application of the present invention.
In fig. 4: u-controller output; e-model error; y-result output
In fig. 9: 1. cutting machine 2, burning torch 3, orbit 4, laser range finder 5, range finding mark 6, laser range finder support 7, fixed frame 8, continuous casting 9, laser range finder support frame 10, PLC system 11, scale system
Detailed Description
The invention is further described below with reference to the accompanying drawings.
The intelligent on-line control system for continuous casting blank in fixed weight and fixed length integrates weighing system, production process data tracking, machine learning, mathematical model and intelligent control. As shown in fig. 1, the present invention is mainly composed of an input module, a data acquisition module, a data storage module, a communication module, a core calculation module, an output module, an execution module, and a monitoring interface module. The data acquisition module is connected with the data storage module and the core calculation module, the data acquisition module continuously acquires information such as real-time production process history information of the continuous casting billet, homing deviation of the cutting machine, weighing of the continuous casting billet after cutting and the like, and the information acquired by the data acquisition module is transferred to the data storage module and the core calculation module; the data storage module acquires production management MES system data and production process data through the communication module and stores the data; the communication module is used as a link for realizing basic data interaction by using the control system, and data communication between the data acquisition module and the production management MES system and the basic automation PLC system is realized; the core calculation module obtains real-time working condition data from the data acquisition module and historical data from the data storage module, and performs data diagnosis and calculation processing; outputting the result of the core calculation module to an execution module through an output module; and the execution module realizes the fixed-length cutting of the continuous casting billet according to the result of the core calculation module transmitted by the output module.
The communication module adopts two-stage interlocking protection measures to realize free switching and emergency switching functions. In order to realize the intelligent control of the fixed weight and the fixed length of the continuous casting billet, the process control of the invention adopts multi-level control, each control level is mutually independent, and a standard communication protocol is applied. As shown in fig. 2, the present invention belongs to the L2 stage, and exists independently from the L1 stage and the L3 stage, and is used for completing complex calculations which cannot be completed by a simple mathematical model of the L1 stage. The data interaction communication between the production line basic PLC system and the production line basic PLC system is realized by adopting an industrial standard OPC technology, and the data interaction between the production line basic PLC system and the production management MES system is realized by adopting a database mode. In the automatic control process, the L2 level obtains a production plan from the L3 level system, acquires actual data of the current production working condition from the L1 level PLC, performs optimization calculation on the set data by applying a core calculation model, and then issues the data to the PLC for executing an instruction of optimizing the data.
The input and output relationship of the invention is shown in figure 3, the main program calculation flow chart of the invention is shown in figure 11, the invention automatically obtains signals of casting start, casting tail, casting stop and the like from a PLC system, after the system is started according to the current production signal, the invention automatically obtains a casting plan (ladle furnace number, time to set, steel type name, molten steel component, casting blank reference weight, casting blank reference length/fixed length, fixed weight, section size and the like) from an MES system, and simultaneously, the invention automatically obtains current production parameters (ladle molten steel weight, tundish molten steel weight, billet drawing speed, tundish molten steel temperature, crystallizer cooling water quantity, crystallizer cooling water inlet and outlet temperature difference, actual water quantity of each loop of a secondary cooling zone, actual fixed length, actual weight, cutting machine origin position and the like) from the PLC system and tracks the process information of production data; and when the cutting signal or weighing signal is acquired, the production process data is automatically analyzed, the prediction calculation model and the compensation length calculation model are started, and the next cutting fixed length after comprehensive analysis and calculation is transmitted to the fixed length system through the PLC system.
Taking actual production of a certain steel mill as an example, the monitoring interface of the continuous casting billet intelligent fixed-weight fixed-length online control system is shown in fig. 12, the control system displays production process data and model optimization data in a number and table mode, and technologists can visually and clearly know important information such as pouring plans, production process data, real-time working condition parameters, continuous casting billet fixed-length, continuous casting billet weighing weight, predicted continuous casting billet weight and optimized cutting fixed-length of each casting flow. For example, the section of a steel mill produced at a certain time is 160mm multiplied by 160mm, the grade of produced steel is HRB400-E, the standard size is L0-10500 mm, and the standard weight is G0-2354 kg. The actual cut length is Li 10514mm and the actual weight is Gi 2348 kg. The cutter reference origin S0 is 500mm, and the cutter return stop bit is S1 is 503 mm. The control model analyzes production process data, a multi-model control strategy is applied to optimize calculation to obtain that the next cutting fixed length is Li (10553 mm), and the cut continuous casting blank is weighed by a weighing system to obtain the actual casting blank weight is Gi (2354 kg). Therefore, the casting blank weight control method can achieve a better control effect in the casting blank weight control.
FIG. 13 is a comparison of the control effect of the conventional control technique based on the scale compensation of the weighing system (shown by the dotted line in the figure) and the actual continuous casting slab weight control effect of the intelligent scale online control system (shown by the solid line in the figure) in a certain casting number of a certain steel mill. The basis weight of the continuous casting billet is 2203kg, the weight deviation of the continuous casting billet is +/-8 kg by adopting the traditional sizing compensation control technology, and the control calculation of the invention is adopted, the weight deviation of the continuous casting billet is +/-3 kg, so that the continuous casting billet weight precision can be stably controlled by adopting the continuous casting billet intelligent weight and sizing online control system, and the economic benefit of enterprises is improved.
Claims (10)
1. The utility model provides an online control system of continuous casting billet intelligence basis weight scale which characterized in that: the system comprises an input module, a data acquisition module, a data storage module, a communication module, a core calculation module, an output module and an execution module; setting parameters of the control system through an input module; the data acquisition module is connected with the data storage module and the core calculation module, the data acquisition module continuously acquires process data tracking information, cutting machine homing deviation, weighing after cutting of the continuous casting billet and production management MES system data information in the real-time production process of the continuous casting billet through the communication module, and the information acquired by the data acquisition module is transmitted to the data storage module and the core calculation module; data storage is carried out through a data storage module; the communication module is used as a link for realizing basic data interaction by using the control system, and data communication between the data acquisition module and the production management MES system and the basic automation PLC system is realized; the core calculation module obtains real-time working condition data from the data acquisition module and course tracking data from the data storage module, and performs data diagnosis and calculation processing; outputting the result of the core calculation module to an execution module through an output module; the execution module realizes the fixed-length cutting of the continuous casting billet according to the result of the core calculation module transmitted by the output module,
the core calculation module adopts a continuous casting billet constant weight control method based on multiple models, a local model set is constructed by a continuous casting billet feed-forward control sub-model and a continuous casting billet feed-back control sub-model, the sub-models form corresponding sub-model adaptive controllers, the sub-model adaptive controllers coordinate to realize sub-model adaptive control, and the weighting output by the multiple sub-model adaptive controllers and the realization of sub-model switching control on continuous casting billet constant weight are adopted;
the continuous casting billet feedback control sub-model is a length compensation control sub-model based on an online weighing system, and the calculation formula is as follows:
△Lm1＝Ki(Li(G0-Gi)/Gi)
in the formula:
△Lm1-next cutting of the casting blank to a specified length compensation value of mm;
Li-sizing the casting blank for this cutting;
G0-casting blank basis weight;
Gi-actual casting blank weight;
Ki-a length correction factor;
length correction factor KiThe calculation formula of (2) is as follows:
when only one effective weighing is carried out Ki＝0.6～0.8，KiSetting according to an approaching rate;
when effective weighing is carried out more than twice
In the formula:
x is a variable of the weight deviation amount,
unit per mill;
a0、b0a, b and x1、x2Is constant, set according to the rate of approximation, but a0、b0A, b and x1、x2The setting should satisfy: 1.0. gtoreq.b0＞a0≥0；
x1And x2Selecting according to the weight deviation control requirement, wherein x is more than or equal to 01＜x2≤5；
When x is equal to x1When ax + b is a0When x is equal to x2When ax + b is equal to b0；
From a to a0、b0、x1、x2And determining a and b.
2. The continuous casting billet intelligent weight and length fixing online control system according to claim 1, characterized in that: the continuous casting billet intelligent weight and length on-line control system further comprises a monitoring interface module, wherein the monitoring interface module displays data from the data acquisition module, the data storage module, the communication module, the core calculation module and the output module in a number and table mode, and visualization of a production process is achieved.
3. The continuous casting billet intelligent weight and length fixing online control system according to claim 1, characterized in that: the communication module adopts two-stage interlocking protection measures to realize free switching and emergency switching functions.
4. The continuous casting billet intelligent weight and length fixing online control system according to claim 1, characterized in that: the data acquisition module adopts a continuous casting billet process data history information tracking method, virtually divides the continuous casting billet into a plurality of unit blocks along the running direction of the continuous casting billet, takes each unit block as an independent information unit, continuously tracks and monitors information data borne by each unit block according to a certain period from the beginning point of molten steel solidification, records the information data to the end point of control, and forms complete corresponding dynamic tracking data of the continuous casting billet.
5. The continuous casting billet intelligent weight and length fixing online control system according to claim 4, characterized in that: the control end point is arranged at the tail end of the maximum fixed length after the continuous casting billet is cut, and the information data borne by the cell block as an independent information unit comprises the self attribute of the cell block, the production working condition data attribute, the production signal attribute and the production event attribute.
6. The continuous casting billet intelligent weight and length fixing online control system according to claim 1, characterized in that: the data acquisition module adopts a continuous casting billet sizing compensation method based on cutting machine homing deviation detection, a base point is determined in the moving direction of a continuous casting billet cutting machine, a laser distance meter is installed at the position of the base point, the reference distance between the base point and the original point of the cutting machine is determined, and the reference distance is set in a PLC system; before preparing cutting work, determining that the cutting machine is reset; measuring the actual position distance of the cutting machine relative to the base point after the cutting machine is returned by using a laser range finder, and transmitting measurement data to a PLC system by using the laser range finder; calculating a deviation value of the measured distance of the cutting machine to the base point and the reference distance by the PLC system; and judging whether the calculated deviation value exceeds the cutting allowable deviation range of the continuous casting billet or not, if so, compensating the stroke of the cutting machine by the deviation value when the cutting machine advances before cutting the continuous casting billet.
7. The continuous casting billet intelligent weight and length fixing online control system as claimed in claim 6, characterized in that: the utility model discloses a cutting machine, including cutting machine, operation track, the cutting machine is located operation track (3), there is the burning torch on the cutting machine, still include laser range finder, laser range finder support frame, the range finding mark target, PLC system and scale system, laser range finder fixes on the laser range finder support frame, the laser range finder support frame is located operation track's one end, the range finding mark target is just setting up on the cutting machine to laser range finder, laser range finder and PLC headtotail, the PLC system is connected with scale system, laser range finder gives the PLC system to the distance transmission after the cutting machine playback that records, after the cutting machine playback the distance deviation value surpasss the scope, then the PLC system gives the deviation value for scale system compensation scale setting value.
8. The continuous casting billet intelligent weight and length fixing online control system according to claim 1, characterized in that: the continuous casting billet feedforward control submodel comprises a length compensation control submodel based on the detection of the homing deviation of the cutting machine, and the calculation formula is as follows:
△Lm2＝S1-S0
in the formula:
△Lm2-next cutting of the casting blank to a specified length compensation value;
S1-the cutter returns to the final stop position;
S0-cutter reference origin position.
9. The continuous casting billet intelligent weight and length fixing online control system according to claim 1, characterized in that: the continuous casting billet feedforward control sub-model further comprises a control sub-model based on the continuous casting billet density characteristic.
10. The continuous casting billet intelligent weight and length fixing online control system according to claim 1, characterized in that: the continuous casting feed-forward control sub-model also comprises a sub-model constructed in a structural mode of 'sample data + training'.
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| CN110756749A (en) * | 2019-10-31 | 2020-02-07 | 联峰钢铁（张家港）有限公司 | Billet length measuring method |
| CN111168028B (en) * | 2020-01-21 | 2022-04-29 | 宝钢湛江钢铁有限公司 | Self-adaptive control method for slab weight based on continuous casting thick plate |
| CN113523217B (en) * | 2020-04-21 | 2022-09-06 | 上海梅山钢铁股份有限公司 | Method for calibrating continuous casting ladle scale and tundish scale |
| CN111872337A (en) * | 2020-07-24 | 2020-11-03 | 刘少华 | Method and system for calculating length of steel |
| CN111872336A (en) * | 2020-07-24 | 2020-11-03 | 刘少华 | Method and system for calculating weight of steel |
| CN112427624B (en) * | 2020-11-04 | 2021-11-09 | 中国科学院重庆绿色智能技术研究院 | Casting and forging double-control forming system based on digital twinning and parameter optimization method |
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