軋制模型設(shè)計(jì)描述(軋制理論)

1、Shandong Nanshan Industry Co., Ltd.Cold Rolling Mill 1/2Design DescriptionRolling Model山東南山工業(yè)有限公司冷軋機(jī)1/2軋制模型設(shè)計(jì)描述Table of Contents目錄1. Overview .3概述2. References .5參考資料3. Abbreviations .5縮略語(yǔ)4. Definitions.5定義5. Pass Schedule Calculation.6軋制道次表的計(jì)算6. Submodels.9子模型6.1 Calculation of reduction distributi

2、on.9壓下率分布計(jì)算6.2 Calculation of tensions .11張力計(jì)算6.3 Determination of maximum speed.11最大速度的確定6.4 Roll Gap Model.12軋輥輥縫模型屈服應(yīng)力模型摩擦力模型6.5 Mill Stretch Model.14軋機(jī)拉伸模型6.6 Strip Temperature Model.14帶材溫度模型6.7 Thermal Crown Model .15熱凸度模型6.8 Flatness Model .16平整度模型7. Adaption.18調(diào)整7.1 Overview.18概述7.2 Recording

3、 and filtering of measured data.19測(cè)量數(shù)據(jù)的記錄和過(guò)濾7.3 Recalculation and learning .19重新計(jì)算和自學(xué)習(xí)8. Test Calculations.20試計(jì)算9. Interface to MES .21與MES的接口9.1 Triggering Events .21觸發(fā)事件軋制道次表計(jì)算的要求軋輥更換軋機(jī)零位調(diào)整（調(diào)零）生產(chǎn)開(kāi)始生產(chǎn)結(jié)束循環(huán)測(cè)量9.2 Transferred data .21轉(zhuǎn)移的數(shù)據(jù)卷材數(shù)據(jù)軋輥數(shù)據(jù)設(shè)定值10. Data Management.26數(shù)據(jù)管理11. Human System Interface

4、.26人機(jī)系統(tǒng)界面（HIS）11.1 Dialogs.26對(duì)話11.2 Reports.27報(bào)告12. Model Tuning Manual.29模型調(diào)諧手冊(cè)13. Technical Data .29技術(shù)數(shù)據(jù)13.1 Main Mill Technical Parameter .29軋機(jī)主要技術(shù)參數(shù)13.2 Main Rolling Material Parameter .30主要軋制材料參數(shù)1. Overview概述The task of the Rolling Model is to determine the setup of a cold mill, which is used t

5、oproduce cold rolled strips from hot rolled strips. The number of passes is calculated aswell as all setpoints needed for each pass in the basic automation system.軋制模型的任務(wù)是進(jìn)行冷軋機(jī)設(shè)定，生產(chǎn)來(lái)自熱軋帶材的冷軋帶材。在基本的自動(dòng)化系統(tǒng)中計(jì)算道次數(shù)和每個(gè)道次需要的所有設(shè)定值。The main control variables are gauge and shape. Other important variables like

6、 surfacequality can be controlled indirectly by referring to product dependent practice tables duringschedule generation.主要的控制變量是厚度和板形。其它重要的變量像表面質(zhì)量，在道次計(jì)算過(guò)程中根據(jù)與產(chǎn)品相關(guān)的工藝制度表間接進(jìn)行控制。The aims of the Rolling Model is to reduce軋制模型的目標(biāo)是減少：. strip breaks斷帶. threading time穿帶時(shí)間. off-gauge length厚度超差部分長(zhǎng)度and to im

7、prove the quality as well as to provide stable rolling conditions with minimal needof operator interventions.改進(jìn)質(zhì)量，以最小的人工干預(yù)操作，提供穩(wěn)定的軋制狀態(tài)。For prediction of control variables the scheduling and setup system uses various processmodels which are mainly based on physical principles. The Cold Rolling Model

8、consists ofa calculation package and a number of parameter tables.為了對(duì)控制變量進(jìn)行預(yù)測(cè)，道次表計(jì)算和設(shè)定系統(tǒng)使用以物理原理為基礎(chǔ)的各種工藝模型。冷軋模型中包括一個(gè)計(jì)算包和很多參數(shù)表。Sensors on the mill continuously monitor operating conditions. Measured data are used toupdate the models to the variations in product and plant conditions. Thus, the system i

9、sable to respond to such changes and maintain product quality.軋機(jī)上的傳感器連續(xù)地監(jiān)控操作狀態(tài)。根據(jù)產(chǎn)品和工廠條件的變化，用測(cè)定數(shù)據(jù)來(lái)更新模型。因此，系統(tǒng)能夠響應(yīng)這些變化和保持產(chǎn)品質(zhì)量。The main functions of the model application software are:模型應(yīng)用軟件的主要功能：. Pass Schedule Calculation for all passes所有道次的軋制道次表計(jì)算. Set-up Calculation for next pass下一個(gè)道次設(shè)定計(jì)算. Test Cal

10、culation試計(jì)算. Data Acquisition, Filtering and Logging數(shù)據(jù)獲得，過(guò)濾和記錄. Estimation of the work rolls thermal crown工作輥熱凸度估算. Model Adaptation模型調(diào)整. Reporting報(bào)告. Human System Interface人機(jī)系統(tǒng)界面The figure below shows the main interactions between the functions of the Rolling Modelapplication software.下圖顯示了軋制模型應(yīng)用軟件

11、功能之間主要的相互作用。2. References參考資料Document “Function Description pcs Rev A 02 .pdf” dated 9-Dec-20032003年12月9日發(fā)來(lái)的資料“功能說(shuō)明pcs Rev A 02 .pdf”3. Abbreviations縮略語(yǔ)AMI ABB Message Interface AMI ABB信息接口AMS Alarm and Message SystemAMS 報(bào)警信息系統(tǒng)BOC Begin of Coil (current passBOC 卷材開(kāi)始軋制（當(dāng)前軋制道次）CRM Cold Rolling MillCRM

12、 冷軋機(jī)EOC End of Coil = Production finished (current passEOC 卷材軋制結(jié)束生產(chǎn)結(jié)束（當(dāng)前軋制道次）ERP Enterprise Resource Planning = Level 3ERP 企業(yè)資源規(guī)劃，即3級(jí)系統(tǒng)HIS Human System InterfaceHIS 人機(jī)系統(tǒng)接口L1 Level 1 = OCSL1 1級(jí)系統(tǒng)= OCSL2 Level 2 = MESL2 2級(jí)系統(tǒng)= MESL3 Level 3 = ERP L3 3級(jí)系統(tǒng)= ERPMES Manufacturing Executions System = Level

13、2MES 制造執(zhí)行系統(tǒng)，即2級(jí)系統(tǒng)OCS Open Control System = Level 1OCS 開(kāi)放控制系統(tǒng)，即1級(jí)系統(tǒng)PDI Primary Data Input (Coil data and order dataPDI 原始數(shù)據(jù)輸入（卷材數(shù)據(jù)和訂單數(shù)據(jù)）RDBMS Relational Data Base Management SystemRDBMS 關(guān)系數(shù)據(jù)庫(kù)管理系統(tǒng)SOAP Simple Object Access ProtocolSOAP 簡(jiǎn)單目標(biāo)訪問(wèn)協(xié)議VIP Vendor Internet ProtocolVIP 廠商網(wǎng)間協(xié)議4. Definitions定義Mater

14、ial class： Group of material grades with similar behaviour (yield stress curve材料分類：有相似性能（屈服應(yīng)力曲線）的材料等級(jí)的集合Product ：Combination of material class and pretreatment of a coil (prior typeof process; e.g. type of annealing and/or treatment of coil (e.g. typeof work rolls used for final pass產(chǎn)品：材料分類和卷材預(yù)處理（以前

15、工藝類型例如退火的類型）和/或卷材處理（例如用于最后道次的工作輥類型）的結(jié)合5. Pass Schedule Calculation軋制道次表計(jì)算The rolling model calculates the pass schedule which comprises all the setpoints of a coilfor all remaining passes of this coil to be rolled in this mill. 軋制模型計(jì)算的道次表包括所有的要在這臺(tái)軋機(jī)上軋制的卷材所有剩下的道次的所有設(shè)定值。The calculated preset values of

16、 the next pass to be rolled can be viewed by the operator. After possible modifications and final check the operator transfers the preset values to OCS (Level 1 and threading can be started. 操作員能夠看到要軋制的下一個(gè)道次計(jì)算的預(yù)設(shè)值?？赡艿男薷暮妥罱K的檢查后，操作員把預(yù)設(shè)值傳輸?shù)絆CS（1級(jí)），開(kāi)始穿帶。The state of the coil changes from “next coil” to

17、“current coil”. Preset values for that coil can only be changed when the mill is stopped. The operator can view the setpoints of the current coil and can prepare the setpoints for the next coil. 卷材狀態(tài)從下一個(gè)卷材更換到當(dāng)前卷材。卷材的預(yù)設(shè)值僅能在軋機(jī)停止時(shí)變換。操作員能夠看到當(dāng)前卷材的設(shè)定值，能夠?yàn)橄乱粋€(gè)卷材準(zhǔn)備設(shè)定值。The pass schedule calculation is activat

18、ed automatically在以下情況，軋制道次表計(jì)算自動(dòng)激活：. at the exit of the coil storage在卷材倉(cāng)庫(kù)的出口. at the last roller table before mill在軋機(jī)前的最后輥道. by manual request of the operator操作員手動(dòng)要求(See chapter “Triggering Events” for more details（為獲得更多內(nèi)容見(jiàn)“觸發(fā)事件”這一章）The set-up calculation is mainly based on the following data entitie

19、s, which will bedelivered by the MES production order management and the rolls management:設(shè)定值計(jì)算主要是基于下列數(shù)據(jù)，將由MES生產(chǎn)訂單管理和軋輥管理提供。Strip properties帶材性能. Entry thickness, width, entry temperature入口厚度，寬度，入口溫度. Exit thickness出口厚度. Hot rolling thickness or last annealing thickness熱軋厚度或最終退火厚度. Material grade, a

20、nnealing type材料等級(jí)，退火類型. Strip profile, outer coil diameter帶材形狀，卷材外徑Roll properties軋輥性能. Diameter, crown, taper, length, texture直徑，凸度，錐度，長(zhǎng)度，表面（紋理）Data entities stored locally within the rolling model:在軋制模型里局部存儲(chǔ)的數(shù)據(jù)實(shí)體：. Mill and drive limits, standard practices軋機(jī)和傳動(dòng)限制，標(biāo)準(zhǔn)操作規(guī)程. Adaption coefficients, yie

21、ld stress and friction values調(diào)整系數(shù)，屈服應(yīng)力和摩擦力值The following preset values are calculated for the different rolling phases and for allpasses required:為不同軋制階段和所有要求的道次計(jì)算下列預(yù)設(shè)值：. Intermediate thicknesses中間厚度. Rolling speed軋制速度. Entry and exit tensions入口和出口張力. Rolling force軋制力. Forward slip value前滑值. Rolling

22、 torque軋制扭矩. Roll gap position輥縫位置. Flatness actuators (bending and axial roll shifting平整度執(zhí)行機(jī)構(gòu)（彎輥和中間輥軸向竄動(dòng)）. Cooling quantity冷卻液數(shù)量. Exit strip temperature出口帶材溫度. Bridle position張緊輥位置. Flatness curve number平直度曲線值. Horizontal Shifting (HS of work roll工作輥的水平位移The preset values support the level1 to setu

23、p the roll gap in force or position controlThe following rolling phases can be distinguished:預(yù)設(shè)值支持1級(jí)系統(tǒng)設(shè)定輥縫，可用作用力控制方式或位置控制方式。能夠區(qū)分下列軋制階段：a Feeding:給料Closed roll gap waiting for strip head to roll target reduction, neither back nor forwardTension閉合輥縫，等料頭達(dá)到目標(biāo)壓下量，沒(méi)有后張力和前張力。b Threading:穿帶Strip head betwee

24、n roll gap and coiler; no forward tension, only back tension料頭在輥縫和卷取機(jī)之間，沒(méi)有前張力，僅有后張力。c Crawling:爬行Strip head winded on coiler, forward and back tension, slow speed料頭卷在卷取機(jī)上，有前張力和后張力，速度慢。d Rolling:軋制like c but with max. rolling speed像c）但是有最大的軋制速度e Tail out:拋出like b, coil end between uncoiler and roll g

25、ap, no back tension, only forward tension像b料尾在開(kāi)卷機(jī)和輥縫之間，沒(méi)有后張力，僅有前張力。i.e. the calculations consider the rolling phases by having certain side conditions regardingtension and speed.即計(jì)算時(shí)要考慮軋制階段中某些關(guān)于張力和速度的現(xiàn)場(chǎng)條件。The different sub-models are closely connected to each other. Outputs of one modeldeliver input

26、s for other models.不同的子模型相互間是緊密相連的。一個(gè)模型的輸出是其它模型的輸入。The following picture gives a survey of the submodels and their main interactions:下圖給出了子模型概觀和它們主要相互作用。6. Submodels子模型6.1 Calculation of reduction distribution壓下率分布計(jì)算The rolling model calculates the reduction distribution (thickness distribution betw

27、een anentry thickness and a given exit thickness considering various restrictions regarding millability, material quality and productivity goals.軋制模型在入口厚度和一個(gè)給定的出口厚度間計(jì)算壓下率分布（厚度分布），考慮到各種關(guān)于軋機(jī)能力，材料質(zhì)量和生產(chǎn)效率目標(biāo)的約束。For a specific type of product the following limits can be configured using practice tables:對(duì)于

28、一種具體類型的產(chǎn)品，用工藝制度表能夠設(shè)定下列限制因素：. Maximum and minimum reduction最大和最小壓下量. Maximum specific roll force最大單位軋制力. Maximum draft最大壓下量Satisfying these restrictions ensures a strip quality concerning the metallurgical properties, flatness and strip surface. 滿足這些限制因素確保冶金性能，平整度和帶材表面這些帶材質(zhì)量。They need to be defined i

29、n close cooperation with the customer.需要在與客戶密切合作中定義他們。(The surface quality will be adjusted in the last pass using the appropriate work rolltextures. The model will preplan the reduction in this pass and provide the roll typespecific friction values.（在最后道次用適當(dāng)?shù)墓ぷ鬏伡y理（表面）調(diào)整帶材表面質(zhì)量。模型將預(yù)先計(jì)劃在這個(gè)道次的壓下量，提供軋輥型

30、的具體特定摩擦值）Additionally the production goals are satisfied by considering the following restrictions:因此，通過(guò)考慮下列因素來(lái)實(shí)現(xiàn)生產(chǎn)目標(biāo)：. ensure an effective utilization of the plant by calculating the minimum number ofPasses通過(guò)計(jì)算道次最小數(shù)來(lái)確保設(shè)備的有效利用。. remain within the mill limits (max. force, max. torque保持在軋機(jī)限制范圍內(nèi)（最大軋制力，

31、最大軋制扭矩）A fixed reduction in the final pass can be configured due to material grade or a moregeneral operation practice code. Level3 or operator will input information into Level2 formax. one possible annealing thickness and max. one possible trim thickness. Thesethicknesses will be treated as fixed

32、intermediate thicknesses by the pass schedulecalculation.根據(jù)材料等級(jí)或更多的操作實(shí)踐代碼設(shè)定最后道次的固定壓下量。3級(jí)系統(tǒng)或操作員將輸入信息到2級(jí)系統(tǒng)，以最大可能的退火厚度和最大可能的剪切厚度。這些厚度通過(guò)軋制道次表計(jì)算將作為固定的中間厚度。The reduction distribution can be calculated to achieve a minimum rolling time, b equalreductions or c linear force distribution from pass to pass:能夠計(jì)

33、算壓下率分布來(lái)實(shí)現(xiàn)從一個(gè)道次到另一個(gè)道次的a）最小軋制時(shí)間，b）等同的壓下量或c）軋制力線性分布。Explanations:說(shuō)明a Minimum rolling time is achieved when high reductions are rolled at the end of thesequence of passes and small reductions in the beginning.當(dāng)較高的壓下率在道次表的末尾和較小的壓下率在道次表的前面時(shí)，能夠?qū)崿F(xiàn)最短的軋制時(shí)間。b The total logarithmic deformation is devided by a m

34、inimum number of passes in sucha way that each pass has the same deformation rate within the allowed limitations.用這樣一種方式使每個(gè)道次在允許的范圍內(nèi)有相同的變形率，把整個(gè)對(duì)數(shù)變形應(yīng)變量分到最小的道次數(shù)。c The preconfigured force difference between succeeding passes (linear declining orrising or equal distribution determines the amount of redu

35、ction in each pass預(yù)設(shè)定后續(xù)道次間的軋制力差異（軋制力線性減小或增加或均等分布）決定每個(gè)道次的壓下率。During rolling of several passes a recalculation correcting the subsequent passes can beperformed when e.g. an intermediate thickness was not reached or the material appearedto be harder than estimated.在幾個(gè)道次的軋制期間，當(dāng)沒(méi)有達(dá)到中間厚度或材料比估計(jì)的更硬時(shí)，能夠進(jìn)行為隨后

36、道次校準(zhǔn)的重新計(jì)算。Fig.: Different gauge hoses for different products圖：不同產(chǎn)品的不同厚度分布曲線The reduction distribution is calculated in the following way:以下列方式計(jì)算壓下率分布1st step:第一步：Determine the minimum number of passes by concatenating, beginning from the startthickness, the maximum reductions per pass until the exit

37、 thickness falls below thedesired final thickness.從起始厚度開(kāi)始，按每個(gè)道次的最大壓下率，一直往下排，直到出口厚度達(dá)到希望的最終厚度以下，從而確定最小道次數(shù)。2nd step:第二步：Shorten the reductions per pass according to one of the strategies in such a way that theexit thickness exactly meets the desired final thickness.按照某一種控制策略減小每個(gè)道次的壓下率，直到在出口厚度的確為所希望的最終厚

38、度。3rd step:第三步：Calculate the entry and exit thickness for each pass.計(jì)算每個(gè)道次的入口和出口厚度。6.2 Calculation of tensions張力計(jì)算The spec. tension (unit:N/mm² can be configured in the database due to thickness andyield stress. The difference (additive or multiplicative value between entry and exittension can

39、be configured in the database as well.單位張力能夠在數(shù)據(jù)庫(kù)根據(jù)厚度和屈服應(yīng)力進(jìn)行配置。出口和入口厚度的差異（加法值或乘積）也能在數(shù)據(jù)庫(kù)里進(jìn)行配置。The absolute tension (unit: kN is calculated by tension = spec. tension x width x strip thickness.根據(jù)張力單位張力x寬度x帶材厚度計(jì)算絕對(duì)張力（單位：kNThe tensions are limited by the maximum entry and exit tension.最大入口張力和出口張力限制張力。6.3

40、 Determination of maximum speed最大速度的確定The max. rolling speed can be determined due to material or product dependent practicesdefined in the database. This preconfigured speed will be checked against the availablemotor powers of the mill drive, uncoiler and coiler drives using the following equations

41、:最大的軋制速度能夠根據(jù)材料或數(shù)據(jù)庫(kù)里定義的與產(chǎn)品相關(guān)的工藝制度進(jìn)行確定。預(yù)配置的速度通過(guò)軋機(jī)傳動(dòng)、開(kāi)卷機(jī)和卷取機(jī)傳動(dòng)的電機(jī)功率來(lái)核算，用下列等式進(jìn)行驗(yàn)算。. Mill drive power = Rolling torque x Rolling Speed / Work roll radius軋機(jī)傳動(dòng)功率軋制扭矩/工作輥半徑x軋制速度. Uncoiler power = Entry tension x Strip entry speed開(kāi)卷機(jī)功率入口張力x帶材進(jìn)入速度. Coiler power = Exit tension x Strip exit speed卷取機(jī)功率出口張力x帶材出口速

42、度The maximum rolling speed given to the operator will be the minimum of the rollingspeeds given by the preconfiguation / equations mentioned above:Vr_max = min(Vr_max1, Vr_max2, Vr_max3, Vr_max4用于操作員操作的最大軋制速度將是預(yù)配置/上述提到的等式規(guī)定的最小軋制速度，即：Vr_max = min(Vr_max1, Vr_max2, Vr_max3, Vr_max4。6.4 Roll Gap Model軋

43、輥輥縫模型The roll gap model calculates軋輥輥縫模型計(jì)算：. roll force軋制力. roll torque軋制力矩. deformation and friction energy變形和摩擦能量. forward slip前滑It uses the yield stress and friction model and adaptation coefficients. This model takesinto account the roll flattening and plastic and elastic deformation of the stri

44、p in the rollgap. 它使用屈服應(yīng)力和摩擦力模型和適應(yīng)系數(shù)。這個(gè)模型考慮軋輥的壓扁和輥縫里帶材的塑性和彈性變形。The roll force and torque is calculated according to the theory by Bland, Ford, Ellis solvinga differential equation and integrating the pressure along the contact length between stripand work roll.依據(jù)布萊德，福特，埃利斯的理論對(duì)一個(gè)微分方程求解，對(duì)帶材和工作輥間的接觸弧長(zhǎng)度

45、上的壓力進(jìn)行積分計(jì)算軋制力和軋制扭矩。The forward slip is determined by the difference between strip exit speed and neutral pointspeed (rolling speed related to the rolling speed.前滑值由帶材出口速度和與軋制速度相關(guān)的中性點(diǎn)速度（軋制速度）間的差異確定。屈服應(yīng)力模型The yield stress curve is a function of degree of deformation, deformation rate and striptemperat

46、ure. The dependencies of the yield stress of a given alloy is determined bylabority tests and is approximated by an empirical equation.屈服應(yīng)力曲線是變形程度，變形率和帶材溫度的函數(shù)。給定合金的屈服應(yīng)力的相關(guān)性由實(shí)驗(yàn)室試驗(yàn)確定和經(jīng)驗(yàn)公式近似得到。Calculation:計(jì)算（注：Phi）：k = 1.15 * k(phi * k(dphi * k(Tk = 1.15 * k( * k(d * k(Tk(phi Deformaton influencek(phi

47、變形影響。Phik(dphi Deformaton speed influencek(dphi 變形速率影響k(T Temperature influencek(T 溫度影響k(phi =a1 + a2 * phi a3 ; phi = ln(h/h0;k( =a1 + a2 * a3 ; = ln(h/h0;h = strip thickness, h0 = hot rolling/annealing thicknessh帶材厚度，h0熱軋/退火厚度k(dphi = (dphi / dphi_Ref a4k(dphi = (dphi / dphi_Ref a4dphi = deformati

48、on speed, dphi_Ref = reference value of dphidphi變形速率，dphi_Ref =變形速率的參考值k(T = 1 - a5 * (Tb -Tb_RefTb= strip temperature, Tb_Ref = reference value of TbTb=帶材溫度，Tb_Ref =帶材溫度的參考值Parameters ai will be stored in the database due to material grade.將根據(jù)材料等級(jí)把參數(shù)ai存放在數(shù)據(jù)庫(kù)里。摩擦力模型The friction coefficient in the roll gap was determined by adaptation with the measured rollforce and forward slip and is approximated by an empirical equation. This friction curve isa function of speed and roll properties. (The dependency on material grade regarding rollforce calculation is realized by t