CN111912856A - Plate and strip surface defect analysis system - Google Patents
Plate and strip surface defect analysis system Download PDFInfo
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Abstract
The invention discloses a plate and strip surface defect analysis system, which comprises: the system comprises an original data layer, a defect analysis layer and a result display layer; the original data layer is used for storing surface defect original data acquired from the control system; the defect analysis layer determines the selected defects and the selected coils corresponding to the selected defects and the selected units and the corresponding selected units according to the defect selection operation, and determines the corresponding defects of the selected defects when the selected coils are produced in the front unit and/or the subsequent units of the selected units according to the surface defect original data; the result display layer displays a defect paving picture of the selected plate roll in the selected unit and the production of the preorder unit and/or the subsequent unit in the first display area, and marks corresponding defects of the selected defects on the defect paving picture of the preorder unit and/or the subsequent unit; the system realizes quick association of the cross-machine set and corresponding defect tracing of the selected defect, and improves the surface quality control efficiency of the plate coil.
Description
Technical Field
The application relates to the technical field of plate and strip rolling, in particular to a plate and strip surface defect analysis system.
Background
In the field of plate and strip rolling, the control of the surface quality of plate and strip materials is always the key of the product quality, along with the high-speed development of the industry, the product homogenization competition is more intense, and the requirements of customers on the product surface quality are gradually increased. In the process of rolling and producing the plate and strip, the plate and strip usually passes through a plurality of production lines, each production line may introduce surface quality defects, and the surface quality generated by the former production line evolves in the production process of the subsequent production line, so the specific cause of the defects can be determined by analyzing the surface quality of the plate and strip products in the whole process and carrying out process improvement according to the analysis. The cold-rolled surface quality defects in the strip steel rolling process are subjected to a plurality of production lines in the front and back of the strip steel, including units such as continuous casting, hot rolling, finish rolling, cold rolling and pickling, continuous annealing, rewinding and the like, the sources of the surface defects are wide, the defects generated by the previous unit can also change in the next unit, and the defects have direct or indirect relations with raw materials, equipment, process parameters and the like, and the inspection process can relate to various aspects. The economic loss caused by the surface quality defect is extremely obvious, for example, the linear defect of the outer plate of the automobile is taken as an example, the average 1900 tons of closed coils per month can degrade 650 tons of products, the direct economic loss of product degradation caused by the linear defect per month can reach more than ten thousands yuan, and the indirect loss caused by flattening, uncoiling and re-hanging the sheet is not included; the linear defects are caused by a plurality of factors such as cold rolling scratches, hot rolling mechanical peeling, steel-making slag winding and the like, and defects are introduced due to abnormal control of a certain process, and develop into linear defects with different appearances in subsequent processes or further deteriorate.
At present, a surface quality detection system (comprising a meter detector and monitoring software) is installed on a plate and strip rolling production line to monitor the surface quality, but the existing surface quality detection system can only check the quality data of a plate and strip in the production of the current unit, the surface detection systems of different units are mutually independent and have isolated data, and can not check or trace the associated defects directly related to a certain defect in the production of a certain plate coil in the front and rear units; the whole process consumes time and labor, and depends on the professional level of a meter inspector, so that the accuracy of defect judgment cannot be ensured. Therefore, how to realize the rapid tracing and analysis of the surface defects of the plate and strip materials on different units is very important for controlling the surface quality of products.
Disclosure of Invention
The invention provides a plate and strip surface defect analysis system, which aims to solve or partially solve the technical problem that the existing surface detection system cannot trace and analyze surface defects among multiple units.
In order to solve the above technical problem, the present invention provides a system for analyzing surface defects of a sheet and a strip, comprising: the system comprises an original data layer, a defect analysis layer and a result display layer;
the original data layer is used for storing surface defect original data acquired from the control system, and the surface defect original data comprises defect data of all machine sets passed by each plate roll and plate roll manufacturing data;
the defect analysis layer determines the selected defects and the selected coils corresponding to the selected defects and the selected units and the corresponding selected units according to the defect selection operation, and determines the corresponding defects of the selected defects when the selected coils are produced in the front unit and/or the subsequent units of the selected units according to the surface defect original data;
and the result display layer displays the defect floor plan of the selected plate roll in the selected unit and the production of the preorder unit and/or the subsequent unit in the first display area, and marks the corresponding defect of the selected defect on the defect floor plan of the preorder unit and/or the subsequent unit.
Optionally, the result display layer displays the image data of the selected defect in the second display area.
Optionally, the result display layer displays, in the third display area, the roll manufacturing data of the selected roll in the selected unit, the preceding unit and/or the subsequent unit.
Optionally, the result display layer displays the position data of the selected defect of the selected roll and the corresponding position area data of the corresponding defect in the fourth display area. Optionally, the result display layer changes the selected defect according to the defect switching operation, and identifies a corresponding defect of the changed selected defect on the defect floor plan of the preceding unit and/or the subsequent unit.
As described above, the coil manufacturing data includes: all machine sets that the coil of strip passed through, the production moment of coil of strip at each machine set, the head and the tail excision volume of coil of strip at each machine set, whether the coil of strip is the head and the tail transferred, whether the coil of strip turns over from top to bottom, whether the coil of strip both sides are transferred, coil of strip length and coil of strip thickness.
Further, the defect analysis layer comprises a coiled sheet one-line production flow module, a coiled sheet position matching module and a defect matching module;
the plate roll continuous process module determines the defect data and plate roll manufacturing data of a selected plate roll corresponding to the selected defect in the selected unit, the preorder unit and/or the subsequent unit during production from the surface defect original data;
the coil position matching module determines a corresponding position area of the selected defect in the production of the preorder unit and/or the subsequent unit according to the coil manufacturing data;
and the defect matching module determines corresponding defects from the corresponding position areas according to the defect data.
Further, the defect matching module determines corresponding defects from the corresponding position areas according to at least one of defect name consistency matching, defect length-width ratio matching, defect gray matching and defect distance matching;
wherein, defect name is consistent to make the matching, specifically includes: determining the defect with the highest corresponding priority as the corresponding defect from all the defects in the corresponding position area according to the corresponding priority mapping relation between the defect name of the selected unit and the defect name of the preorder unit and/or the follow-up unit;
the defect aspect ratio matching specifically comprises: determining a second length/width ratio of the selected defect on the preceding unit and/or the subsequent unit according to a first length/width ratio of the selected defect on the selected unit and a width change rate and a length change rate of the selected coil on the preceding unit and/or the subsequent unit, and determining the defect closest to the second length/width ratio as a corresponding defect from all defects in the corresponding position area;
defect gray matching specifically comprises: acquiring the average gray value and the gray level of the selected defect; determining the defect with the same or the closest gray scale as the corresponding defect from all the defects in the corresponding position area;
defect distance matching specifically comprises the following steps: and determining theoretical position points of the selected defects in the corresponding position areas, and determining the defects with the straight line distance closest to the theoretical position points from all the defects in the corresponding position areas as the corresponding defects.
Further, the result display layer displays at least one of the data of the defect matching process and the overall defect statistical data of each unit in a fourth display area.
According to the technical scheme, the plate coil is a steel coil or a titanium coil.
Through one or more technical schemes of the invention, the invention has the following beneficial effects or advantages:
the invention provides a sheet and strip surface defect analysis system, which finds out corresponding defects of a selected sheet roll corresponding to the selected defects in a front-end unit and/or a subsequent unit by a defect analysis layer, and then simultaneously identifies the selected defects and the corresponding defects of the front-end unit and/or the subsequent unit in a result display layer, so that the selected unit generated when the selected sheet roll is produced in a certain selected unit and the corresponding defects generated when other units are produced are simultaneously displayed, the cross-process quick association and the tracing of the selected defects in the current unit, the front-end unit and/or the subsequent unit are realized, the efficiency of sheet roll surface quality control is improved, the difference in subjective judgment of different people is avoided, and the precision of product surface quality control is improved.
The foregoing description is only an overview of the technical solutions of the present invention, and the embodiments of the present invention are described below in order to make the technical means of the present invention more clearly understood and to make the above and other objects, features, and advantages of the present invention more clearly understandable.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to refer to like parts throughout the drawings. In the drawings:
FIG. 1 shows a schematic diagram of a three-level architecture of a sheet strip surface defect analysis system according to one embodiment of the present invention;
FIG. 2 illustrates a results display interface of a sheet and strip surface defect analysis system according to one embodiment of the present invention;
FIG. 3 illustrates a schematic diagram of a three-tier architecture of a web surface defect analysis system including a roll-to-roll process module, a roll position matching module, and a defect matching module, according to one embodiment of the present invention;
FIG. 4 illustrates an example of coil manufacturing data according to one embodiment of this disclosure;
FIG. 5 shows a schematic diagram of a corresponding location analysis of a corresponding defect, according to one embodiment of the invention;
FIG. 6 shows a schematic diagram of a defect matching rule according to one embodiment of the invention;
FIG. 7 illustrates 192187540 reel manufacturing data for a reel according to one embodiment of the invention;
FIG. 8 illustrates a corresponding defect matching diagram for roll 192187540, according to one embodiment of the invention.
Detailed Description
In order to make the present application more clearly understood by those skilled in the art to which the present application pertains, the following detailed description of the present application is made with reference to the accompanying drawings by way of specific embodiments. Throughout the specification, unless otherwise specifically noted, terms used herein should be understood as having meanings as commonly used in the art. Accordingly, unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. If there is a conflict, the present specification will control. Unless otherwise specifically stated, various apparatuses and the like used in the present invention are either commercially available or can be prepared by existing methods.
Based on the problem that the existing surface quality detection system cannot trace back the associated defects of the front and rear units, the application provides a new surface defect analysis system through programming development in an optional embodiment, as shown in fig. 1, and the overall idea is as follows:
a sheet and strip material surface defect analysis system comprising: the system comprises an original data layer, a defect analysis layer and a result display layer;
the original data layer 10 is used for storing surface defect original data acquired from the control system, wherein the surface defect original data comprises defect data of all machine sets passed by each plate roll and plate roll manufacturing data;
the defect analysis layer 20 determines the selected defects and the selected coils corresponding to the selected defects and the selected units to which the selected defects belong according to the defect selection operation, and determines the corresponding defects of the selected defects when the selected coils are produced in the front unit and/or the subsequent units of the selected units according to the surface defect original data;
the result display layer 30 displays the defect floor plan of the selected plate roll in the selected unit and the production of the preceding unit and/or the subsequent unit in the first display area, and identifies the corresponding defect of the selected defect on the defect floor plan of the preceding unit and/or the subsequent unit.
Specifically, the present embodiment provides a software for analyzing a surface defect of a sheet and a strip, where the analysis system establishes a communication connection with a control system of each production unit of the sheet and the strip, and obtains manufacturing data and defect data of a sheet and a roll generated in each production unit from the control system, where the defect data is derived from a surface quality detector installed on a production line site; the manufacturing data comprises the size parameters and the control parameters of the plate roll, and the corresponding defects and the corresponding positions of the defects on different machine sets can be analyzed through the analysis of the manufacturing data.
The original data layer 10 collects and manages all defect data and coil manufacturing data from the surface quality detection system and/or the secondary system, realizes the operations of data addition, deletion, modification, query and the like, and feeds back the operation result to the service logic layer; the defect data comprises image data and character data of the defect so as to describe the specific type of the defect, the position of the defect on the plate roll and other information; the defect data is derived from an on-site surface quality detector; the plate coil manufacturing data is production information data generated by the plate and strip materials in the production flow, and comprises unit production information and plate coil manufacturing information; the plate coil passes through a plurality of machine sets (continuous casting, hot rolling, cold rolling, continuous annealing hot galvanizing, recoiling and the like) in the whole production flow; the coil manufacturing data is derived from the data detected by the secondary system (the process control system of each unit), and the surface quality detection system also measures a portion of the coil manufacturing data when detecting defects. When the plate coil passes through each unit provided with the surface quality detector, defect data and plate coil manufacturing data of the plate coil on the unit are generated, and the data are uniformly stored in an original data layer;
on the other hand, a very large number of defects may occur in the production process of the plate roll, for example, the number of defects in a certain roll reaches more than 6 ten thousand, or the total amount of defect data of the plate roll is more than 4G, and the data reading, defect analysis and result display response capability of the plate and strip surface defect analysis system in this embodiment is very high in requirement. Therefore, optionally, the sheet and strip surface defect analysis system in this embodiment establishes a communication connection with the surface quality inspection systems (surface inspection systems) of each unit through the secondary local area network, and the sheet and strip surface defect analysis system can be used to query or access the databases of all the surface inspection systems at the local terminal. The corresponding defects are analyzed through the surface defect analysis system on the local terminal, and the detailed data of the corresponding defects are remotely inquired through the form inspection system, so that the defect analysis efficiency is improved, and the detailed data display effect is better.
The defect analysis layer 20 is a business logic layer of the sheet strip surface defect analysis system, reads corresponding data from an original data layer to perform logic judgment and execution operation based on the tracing and association between defects and front and rear units and other software functions, and outputs a processing result to a result display layer to be displayed; the corresponding defect determined by the defect analysis layer is a corresponding defect directly corresponding to the selected defect when the selected plate coil is produced in a previous unit or a later unit, for example, a certain selected defect is a continuous casting surface oxide inclusion which is converted into a warping defect on a corresponding position of a hot rolled plate during hot rolling, and then the hot rolling warping defect is a corresponding defect of an oxygen oxide inclusion defect of a continuous casting blank;
the result display layer 30 is a software UI interfacing with a user, and is capable of receiving an operation instruction of the user and displaying result data generated by the defect analysis layer through logical operation.
In the system for analyzing the surface defects of the sheet and strip provided by the embodiment, a user can select a sheet and a roll to be analyzed on a UI of software, and the system displays defect floor maps of all units, through which the selected sheet and roll passes during production and on which a surface quality detector is installed, according to the selection of the user; the selected plate roll is provided with at least one defect paving picture corresponding to each unit, such as a defect paving picture on the upper surface or a defect paving picture on the lower surface of the plate roll. The defect map is a plan view for visually displaying all defects on the whole plate roll in a tiled mode, each type of defect is marked by a defect symbol, and a user can drag the defect map up and down (or back and forth) to check the defects on different positions of the plate roll. When a user clicks a certain defect mark on a certain defect map, the defect becomes a selected defect, and the selected unit corresponding to the selected defect at present is also confirmed. In actual operation, a user can close some defect tiles of a preceding or subsequent unit and can reopen the defect tiles. After the selected defect is determined, the surface defect analysis system extracts the defect data and the corresponding coil manufacturing data, automatically analyzes and traces the corresponding defect (or associated defect) of the selected defect in the production of the preceding unit and/or the subsequent unit, and then identifies the corresponding defect in the corresponding defect floor plan, for example, the corresponding defect is highlighted by red circle, red frame, highlighting and the like, so that technicians can conveniently check the corresponding defect of the defect floor plan of other units directly associated with the selected defect, specifically, a 'graph display' area in fig. 2.
To facilitate the technician's review of the details of the defect, optionally, as shown in the upper left corner of fig. 2, the results presentation layer presents image data of the selected defect in a second display area. And the image data of the selected defect can be scaled according to the user operation instruction.
Optionally, as shown below the defect image of fig. 2, the result display layer displays a defect data list of the selected reel on the selected unit in the second display area. The key character class information of all defects in the current defect tile is shown in the defect data list. Optionally, the data of the selected defect can be highlighted in the defect data list by one or more combinations of highlighting, thickening, framing, and the like.
Optionally, as shown in the upper right-hand region of fig. 2, the results display layer displays, in a third display area, the roll manufacturing data for the selected roll at the selected unit, the preceding unit, and/or the subsequent unit.
Optionally, as shown below the defect map of fig. 2, the results display layer displays the location data of the selected defect and the corresponding location area data of the corresponding defect for the selected roll in a fourth display area. The corresponding position area data is a position area where the corresponding defect is located, which is determined according to the logic analysis of the defect analysis layer, and the corresponding position area data mainly comprises: the distance range between the defect and the head and the tail of the plate strip, the distance range between the defect and the nearest plate edge and the like; the data acquisition that appears in the panel strip surface defect analysis system occasionally is lost, the picture display effect is not good or corresponding defect analysis is wrong conveniently, and the technical staff can confirm according to this position region, the data in the on-the-spot surface detection system of direct inquiry.
Optionally, the result display layer changes the selected defect according to the defect switching operation, and identifies a corresponding defect of the changed selected defect on the defect floor plan of the preceding unit and/or the subsequent unit. For example, the user may determine a defect most adjacent to the original selected defect as a new selected defect using a down PageDown or up PageUp key of the keyboard and present image data of the new selected defect in the second display region; at this point, the defect analysis layer will re-analyze and identify the corresponding defect associated with the new selected defect in the defect tiling of the result presentation layer based on the changed selected defect.
The embodiment provides a sheet and strip surface defect analysis system, which finds out corresponding defects of a selected sheet roll corresponding to the selected defects in a preceding unit and/or a subsequent unit through a defect analysis layer, and then simultaneously identifies the selected defects and the corresponding defects of the preceding unit and/or the subsequent unit in a result display layer, so that the selected unit generated when the selected sheet roll is produced in a certain selected unit and the corresponding defects generated when other units are produced are simultaneously displayed, the cross-process quick association and the tracing of the selected defects in the current unit, the preceding unit and/or the subsequent unit are realized, the efficiency of sheet roll surface quality control is improved, meanwhile, the difference in subjective judgments of different people is avoided, and the precision of product surface quality control is improved.
The system for analyzing the surface defects of the sheet and strip provided in the above embodiments can be applied to a sheet rolling production line, and is particularly suitable for a sheet rolling unit of a steel coil or a titanium coil. In the following embodiments, for the sake of illustration, the strip steel rolling is taken as an application scenario, and a specific principle is explained, the rolling process of the titanium coil is very similar to that of the steel coil, and the titanium coil can be directly reused.
Based on the same inventive concept of the previous embodiment, in another alternative embodiment, the coil manufacturing data includes: all machine sets that the coil of strip passed through, the production moment of coil of strip at each machine set, the head and the tail excision volume of coil of strip at each machine set, whether the coil of strip is the head and the tail transferred, whether the coil of strip turns over from top to bottom, whether the coil of strip both sides are transferred, coil of strip length and coil of strip thickness. If the length of the plate roll detected by each unit instrument is not subjected to unified calibration, for example, the length of the plate roll detected by the secondary system has obvious deviation with the length of the plate roll detected by the meter detector, or the data acquisition of the head and tail cut-off amount of each unit is difficult, the length data of the plate roll detected by the meter detector is preferably selected, and the derivation analysis of the defect position is performed, so that the accuracy of the defect analysis layer 20 in analyzing the corresponding position data of the corresponding defect can be improved.
Specifically, the strip steel is subjected to multiple processing deformations in the rolling process, and is subjected to operations such as head and tail cutting and steering of a plurality of units, the size and position data of the strip steel directly related to the defect position information in the process can be changed correspondingly after passing through each unit, for example, the strip steel is obviously deformed in the hot rolling and cold rolling stages and is represented by the reduction ratio, and the length and the width of the strip steel are changed directly as a result; for example, the position, the shape and the type of the surface defect of the continuous casting billet are changed when the continuous casting billet is subjected to hot rolling and cold rolling, so that the corresponding defect of the defect in different units needs to be traced and selected through coil manufacturing data. The head and tail turning of the plate coil refers to that the head of the steel coil is changed into the tail and the tail is changed into the head when the steel coil is rolled by the plate coil forming machine in the next group of production; the up-down turning refers to the turning of the upper surface and the lower surface of the strip steel; the turning of the two sides of the plate coil means that when the next unit is produced, the transmission side and the operation side of the strip steel will be reversed relative to the previous unit. The above listed roll manufacturing data directly affect the location information of the selected defect on the other units corresponding to the defect.
In order to accurately find the corresponding defect of the selected defect from the roll manufacturing data, based on the same inventive concept of the previous embodiment, in yet another alternative embodiment, as shown in fig. 3, the defect analysis layer 20 includes a roll-to-roll manufacturing flow module 210, a roll position matching module 220, and a defect matching module 230;
the roll-to-roll process module 210 determines, from the surface defect raw data, defect data and roll manufacturing data of a selected roll corresponding to a selected defect in a selected unit, a pre-order unit and/or a subsequent unit during production;
the coil position matching module 220 determines the corresponding position area of the selected defect in the production of the preorder unit and/or the subsequent unit according to the coil manufacturing data;
the defect matching module 230 determines a corresponding defect from the corresponding location area according to the defect data.
Specifically, the coil-in-coil process module 210 needs to extract coil manufacturing data corresponding to the selected coil on each unit from the original data layer according to the selected coil corresponding to the selected defect, and needs to determine manufacturing information of the coil, such as the coil passing through the unit, each production time, head and tail cutting amount, head and tail turning, up and down turning, two-side turning, strip steel length, strip steel thickness, and the like. The term "consistent manufacturing" refers to integrating data of the strip steel in multiple processes to form a complete full-flow data chain. Some examples of coil manufacturing data are shown in figure 4.
After the manufacturing data of the selected coil is determined, the corresponding location area of the selected defect on the other train should then be analyzed to narrow down the area from which the corresponding defect is located. Because the size and the position of the plate roll are changed according to the factors such as the reduction rate, the head and tail cutting of the strip steel, the head and tail turning and the like when the plate roll is produced in different units, the corresponding position area where the corresponding defect is located needs to be comprehensively determined according to the manufacturing data of the plate roll in the current unit, the preorder unit and/or the subsequent unit. The method for determining the corresponding location area may be: the coil position matching module 220 determines corresponding position points of the selected defects on the pre-sequence unit and/or the subsequent unit corresponding to the defects according to the coil manufacturing data; and respectively expanding the first preset distance in the length direction of the strip steel by taking the corresponding position point as a center, and determining a rectangular area formed after expanding the second preset distance in the width direction as a corresponding position area.
Taking a steel coil as an example for explanation, as shown in fig. 5, for a steel coil number 192187540, when a D21 set (continuous annealing and galvanizing) determines that "512 # defect-warping" is a selected defect, and a defect distance is selectedThe distance between the head parts of the strip steels is XD21The distance from the WS side (the operation side of the strip) which is the nearest side is WD21Length of lap LD21The former unit is S11 (acid washing cold continuous rolling), and the latter unit is P31 (recoiling unit);
firstly, analyzing the corresponding position points of the corresponding defects on the S11 unit as follows:
distance X from headS11(D21 unit tape tail cutting amount + L)S11)*(LD21-XD21)/LD21(ii) a Wherein L isS11For selecting the finished coil length, L, of the strip on the S11 trainD21Selecting the length of a finished coil of the strip steel on a D21 unit;
nearest edge WS11Inverse WD21Here, "inverse" means that the drive side and the operation side are reversed and the distance value is equal because the strip is turned from S11 to D21 with both sides turned (drive side operation side turning) and the width is unchanged, so the side closest to the corresponding defect on S11 should be the DS side (drive side) of the strip in the S11 train and the distance value is equal to D21；
After the specific position of the corresponding position point is determined, considering the position deviation of the unit and measurement in the actual process, and taking the calculated corresponding position point as a base point, the length direction of the strip steel is expanded by delta h meters forwards and backwards, and the width direction of the strip steel is expanded by delta w millimeters left and right, so that the most possible corresponding position area of the corresponding defect is determined:
finally, on the S11 machine set, the corresponding position areas corresponding to the defects are:
tape head XS31-. DELTA.h meters and XS31C is + Δ h m, distance DS side WS11Δ W mm and WS11In the rectangular area between +. DELTA.w millimeters.
The corresponding position points of the corresponding defects on the P31 train are then analyzed as:
distance X from headP31(P31 machine set tape head cutting amount + L)P31)*(LD21-XD21)/LD21(ii) a Wherein L isP31The length of the finished coil of the strip steel on the P31 machine set;
nearest edge WP31＝WD21The reason why "reverse" is not used here is that the steel coil is not reversed on both sides from the continuous annealing hot dip galvanizing to the recoiling unit.
After the specific position of the corresponding position point is determined, considering the position deviation of the unit and measurement in the actual process, and taking the calculated corresponding position point as a base point, the length direction of the strip steel is expanded by delta h meters forwards and backwards, and the width direction of the strip steel is expanded by delta w millimeters left and right, so that the most possible corresponding position area of the corresponding defect is determined:
finally, on the P31 machine set, the corresponding position areas corresponding to the defects are:
tape head XP31-. DELTA.h meters and XP31C is + Δ h m, distance WS side WP31Δ W mm and WP31A rectangular area between +. DELTA.w millimeters.
Practice has shown that the range of the corresponding location area may be: the value range of the first preset distance delta h is 5-20 meters, and preferably 10 meters; the value range of the second preset distance delta w is 5-20 mm, preferably 10 mm; the deviation between the actual position and the theoretical position of the corresponding defect caused by errors can be well solved, and meanwhile, the number of the defects in the range is not too large, so that the type judgment of the corresponding defect is interfered.
After the corresponding location area has been determined, the corresponding defect should next be determined from the corresponding location area: further, the defect matching module 230 determines a corresponding defect from the corresponding position region according to at least one of defect name consistency matching, defect aspect ratio matching, defect gray matching, and defect distance matching;
wherein, defect name is consistent to make the matching, specifically includes: determining the defect with the highest corresponding priority as the corresponding defect from all the defects in the corresponding position area according to the corresponding priority mapping relation between the defect name of the selected unit and the defect name of the preorder unit and/or the follow-up unit;
the defect aspect ratio matching specifically comprises: determining a second length/width ratio of the selected defect on the preceding unit and/or the subsequent unit according to a first length/width ratio of the selected defect on the selected unit and a width change rate and a length change rate of the selected coil on the preceding unit and/or the subsequent unit, and determining the defect closest to the second length/width ratio as a corresponding defect from all defects in the corresponding position area;
defect gray matching specifically comprises: acquiring the average gray value and the gray level of the selected defect; determining the defect with the same or the closest gray scale as the corresponding defect from all the defects in the corresponding position area;
defect distance matching specifically comprises the following steps: and determining theoretical position points of the selected defects in the corresponding position areas, and determining the defects with the straight line distance closest to the theoretical position points from all the defects in the corresponding position areas as the corresponding defects.
The defects are changed in shape or type among different units in the rolling process of the plate coil, so that the corresponding defects are accurately determined from the corresponding position areas, a defect name matching module is designed, and the corresponding defects in the corresponding position range are locked and defined based on the result of the steel coil position matching module. The accuracy of matching the selected defects with the corresponding defects is obviously improved by the mode of independent setting or combined setting of the 4 methods.
The defect names are matched consistently, and preferential matching is carried out based on a mapping relation between the defect names made by expert experience and the priority order corresponding to the defect names of the front unit and the defect names of the rear unit. For example, the warping defect on the D21 unit is referred to as a warping defect, the corresponding defect name of the first priority on the preceding unit S11 is referred to as a warping T, the corresponding defect name of the second priority is referred to as a warping T, and the corresponding defect name of the third priority is referred to as mold powder; and if the selected steel coil has the 'warping skin' defect of the first priority in the corresponding position area at S11, determining the selected steel coil as the corresponding defect, and if only the 'covering slag' defect of the third priority exists in the corresponding position area, determining the selected steel coil as the corresponding defect. The mapping relation data corresponding to the defect names of the front and rear units can be stored in the original data layer 10 for the defect analysis layer 20 to call.
The defect length-width ratio matching is based on the deformation theory of the steel coil in the rolling length direction, and the length or the width of the plate coil changes in the rolling process. For example, when a hot-rolled raw material plate is used as a reference and a cold rolling reduction of 80% or more is applied to the hot-rolled raw material plate when the hot-rolled raw material plate passes through a cold rolling mill train, the length of a selected defect on the hot-rolled plate is extended by 5 to 6 times and the width of the selected defect is extended by 1 to 1.2 times due to cold rolling deformation during cold rolling; and based on the deformation rule, determining the defect with the highest matching degree between the length-width ratio and the theoretical value in the corresponding position area of the cold-rolled sheet, and preferentially matching the defect as the corresponding defect. The aspect ratio data of different defect types between different units can be determined in advance according to the manufacturing process and stored in the original data layer 10 for the defect analysis layer 20 to call.
Defect gray level matching: calculating according to the original gray level of the selected defect, and dividing the average gray level of 0-255 into a plurality of levels, such as 8 gray levels, according to the expert experience; and selecting a matching mode of the defects, and preferentially matching the corresponding defects in the corresponding position areas on the basis of equal gray levels or adjacent gray levels. The mapping relation data in which the defects are classified according to the gray levels may be previously stored in the original data layer.
Matching defect distance: and calculating the linear distance between the existing defect in the corresponding position area and the reference point by taking the corresponding position point of the corresponding defect obtained by the defect analysis layer as the reference point and combining a triangular calculation formula, and determining the existing defect as the corresponding defect by taking the shortest distance as the optimum.
By using the 4 matching methods separately or in combination, the corresponding defects can be matched accurately, and a schematic diagram of a rule table for defect matching is shown in fig. 6.
Further, the result display layer displays at least one of the data of the defect matching process and the overall defect statistical data of each unit in a fourth display area. By displaying the defect matching process data or the analysis data in the result display layer, technicians can master the overview of the judgment process of the system, and the judgment accuracy of the analysis system is improved subsequently.
In the following embodiment, the following description will be given taking specific implementation data as an example:
in a certain time period, the blocking rate of the warping defect of the D21 unit is increased by 10% compared with the prior art, and reason checking is required; firstly, the original data layer contains the defect information and the manufacturing information of all steel coils of all units in the whole process including D21, and data extraction is completed.
Then, a problem investigation is performed, for example, the D21 machine 192187540 volume, 512# defect-peeling defect is analyzed, and the defect data is as follows:
selecting defects: at the D21 unit 512# defect, when the coil of coil selected was produced at D21, 20 meters from the head, 50mm from the WS side edge.
Through analysis of the plate coil one-pass process module 210, the steel coil 192187540, the whole process, is subjected to the following units a11 (continuous casting) → H11 (hot rolling) → S11 (acid pickling and cold continuous rolling) → D21 (continuous annealing and zinc plating) → J21 (finishing), and steel coil manufacturing data extracted 192187540 shows that the steel coil is turned back and forth 5 times, the two operation sides and the driving side are turned, the upper surface and the lower surface are not turned over, and the steel coil manufacturing data 192187540 is shown in fig. 7.
Of the five units through which the steel coil passes, only H11, S11, D21 are equipped with surface quality detectors, so in this case, only for the preamble unit of D21: h11 and S11 were traced for defects, and the A11 and J21 units were not traced.
Next, the corresponding position area corresponding to the defect is determined according to the coil position matching module 220, the deviation Δ h is set to 10 meters, and Δ w is set to 10mm, and by analyzing the manufacturing data of the steel coil 192187540, the following results are obtained:
the corresponding position area of the S11 cold rolling unit corresponding to the defect: when the selected steel coil is expected to be produced by the S11 machine set, the selected steel coil is positioned in a rectangular range which is 2279.8 +/-10 meters away from the head part and is 50 +/-10 mm away from the DS side edge part;
corresponding position area of H11 hot rolling train corresponding defect: the selected coil is expected to be positioned within a rectangular range of 50 + -10 mm from the side of WS from the head 852.5 + -10 m when produced by the H11 machine set.
After the corresponding position area is determined, the corresponding defect is further determined through a defect matching module, wherein the defect matching module adopts two methods of defect name consistent system matching and defect distance matching to carry out combined judgment:
the S11 unit has 4 defects in the range of 2279.8 +/-10 meters at the head and 50 +/-10 mm at the DS side:
711# black spot defect, 2288.23 m from the head, 59.7mm from DS side, size 23 × 41 mm;
712# peeling B defect, 2281.39 m from the head, 51.2mm from DS side, 56 × 5.6 mm;
713# unsorted defect, 2277.12 meters from head, 54.5mm DS side, 78 × 34 mm;
714# unclassified defect, 2275.98 meters from head, 42.3mm from DS side, 128 x 32 mm;
the closest distance and the closest name are analyzed to be 712# defect warping B.
The H11 unit has 3 defects in the range of 852.5 +/-10 meters at the head and 50 +/-10 mm at the WS edge:
a # 210 pockmark defect, 845.8 meters from the head, 53.7mm from the WS side, 21 × 29mm in size;
the defect of No. 211 protective slag is 855.1 meters away from the head, 51.7mm from the WS side, and 89 × 23mm in size;
212# scale defect, 859.3 meters from head, 41.3mm from WS side, size 90 x 71 mm;
the defect covering slag with the nearest distance and the nearest name is the defect covering slag No. 211.
As shown in fig. 8, the result display layer displays the above determination result, which is convenient for a technician to further analyze. Wherein, the block is the corresponding position area where the potential corresponding defect obtained by the analysis of the preamble set is located, and the system carries out red marking and highlight display on the defect with the highest analysis proximity. In actual use, if a technician wants to analyze 192187540 rolls of other defects, the technician can click and select another defect of a certain defect flat map again, the defect image is switched to the newly selected defect, and then the corresponding defect is analyzed and identified again; if the keyboard is pressed down, the defect pictures can jump alternately among the defects of the unit, and meanwhile, the corresponding defects are analyzed and identified again.
Through one or more embodiments of the present invention, the present invention has the following advantageous effects or advantages:
the invention provides a sheet and strip surface defect analysis system, which finds out corresponding defects of a selected sheet roll corresponding to the selected defects in a front-end unit and/or a subsequent unit by a defect analysis layer, and then simultaneously identifies the selected defects and the corresponding defects of the front-end unit and/or the subsequent unit in a result display layer, so that the selected unit generated when the selected sheet roll is produced in a certain selected unit and the corresponding defects generated when other units are produced are simultaneously displayed, the cross-process quick association and the tracing of the selected defects in the current unit, the front-end unit and/or the subsequent unit are realized, the efficiency of sheet roll surface quality control is improved, the difference in subjective judgment of different people is avoided, and the precision of product surface quality control is improved.
While the preferred embodiments of the present application have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all alterations and modifications as fall within the scope of the application.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present application without departing from the spirit and scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is intended to include such modifications and variations as well.
Claims (10)
1. A system for analyzing surface defects of sheet and strip material, the system comprising: the system comprises an original data layer, a defect analysis layer and a result display layer;
the original data layer is used for storing surface defect original data acquired from a control system, and the surface defect original data comprises defect data of all machine sets passed by each plate roll and plate roll manufacturing data;
the defect analysis layer determines a selected defect and a selected coil corresponding to the selected defect and a selected unit to which the selected coil belongs according to defect selection operation, and determines the corresponding defect of the selected defect when the selected coil is produced in a preamble unit and/or a subsequent unit of the selected unit according to the surface defect original data;
and the result display layer displays a defect floor plan of the selected plate roll in the selected unit and the production of the preamble unit and/or the subsequent unit in a first display area, and marks corresponding defects of the selected defects on the defect floor plan of the preamble unit and/or the subsequent unit.
2. The system of claim 1, wherein the results presentation layer presents image data of the selected defect in a second display area.
3. The system of claim 1, wherein the results display layer displays, in a third display area, coil manufacturing data for the selected coil as produced by the selected crew, the preamble crew, and/or the subsequent crew.
4. The system of claim 1, wherein the results display layer displays location data of the selected defect and corresponding location area data of the corresponding defect for the selected roll of sheet in a fourth display area.
5. The system of claim 1, wherein the results display layer alters selected defects according to a switch defect operation and identifies corresponding defects of the altered selected defects on a defect floor map of the preamble unit and/or the subsequent unit.
6. The system of claim 1, wherein the coil manufacturing data comprises: all machine sets that the coil of strip passed through, the production moment of coil of strip at each machine set, the head and the tail excision volume of coil of strip at each machine set, whether the coil of strip is the head and the tail transferred, whether the coil of strip turns over from top to bottom, whether the coil of strip both sides are transferred, coil of strip length and coil of strip thickness.
7. The system of claim 6, wherein the defect analysis layer comprises a roll-to-roll process module, a roll position matching module, and a defect matching module;
the plate roll continuous production process module determines the defect data and plate roll manufacturing data of the selected plate roll corresponding to the selected defect in the selected unit, the pre-order unit and/or the subsequent unit during production from the surface defect original data;
the coil position matching module determines a corresponding position area of the selected defect in the production of the preorder unit and/or the subsequent unit according to the coil manufacturing data;
and the defect matching module determines the corresponding defect from the corresponding position area according to the defect data.
8. The system of claim 7, wherein the defect matching module determines the corresponding defect from the corresponding location region based on at least one of defect name consistency matching, defect aspect ratio matching, defect gray scale matching, and defect distance matching;
wherein, defect name is consistent to make and matches, specifically includes: determining the defect with the highest corresponding priority as the corresponding defect from all the defects in the corresponding position area according to the corresponding priority mapping relation between the defect name of the selected unit and the defect name of the preorder unit and/or the follow-up unit;
the defect aspect ratio matching specifically comprises: determining a second length/width ratio of the selected defect on the preamble unit and/or the subsequent unit according to a first length/width ratio of the selected defect on the selected unit and a width change rate and a length change rate of the selected coil on the preamble unit and/or the subsequent unit, and determining a defect closest to the second length/width ratio as the corresponding defect from all defects in the corresponding position area;
the defect gray matching specifically comprises the following steps: acquiring the average gray value and the gray level of the selected defect; determining the defect with the same or the closest gray scale as the corresponding defect from all the defects in the corresponding position area;
the defect distance matching specifically comprises the following steps: and determining a theoretical position point of the selected defect in the corresponding position area, and determining the defect with the straight line distance closest to the theoretical position point from all the defects in the corresponding position area as the corresponding defect.
9. The system of claim 8, wherein the results presentation layer presents at least one of defect matching process data, and global defect statistics for each unit in a fourth display area.
10. The system of any one of claims 1 to 9, wherein the coil of sheet material is a coil of steel or titanium.
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