双辊铸机参数检测及控制系统研制
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摘要
薄带连铸被称为21世纪前沿连铸技术，是不经过中间冷却过程和再加热工序，由液态金属直接加工成金属成品或半成品的一种新型加工工艺。与传统铸造工艺相比有着显著的优势，代表着钢铁产品扁平材生产技术优化发展的方向，是钢铁企业实现优化生产流程的关键技术。
利用计算机实现对生产过程进行检测与控制是计算机在铸造生产中应用的重要内容，也是生产高质量铸件、降低铸造成本、提高生产效率的必备条件。
双辊铸机参数检测及控制系统的研制是重庆市重点科研项目双辊连铸高速钢薄带产业化技术的子课题。整个系统由液压控制系统和电控系统组成，电控系统的主要任务即是对现有实验用小型双辊铸机进行自动化改造，实现对连铸过程的监控，包括参数的采集显示和实施控制等，以便于深入探索薄带连铸工艺，研究各种工艺参数对连铸过程和最终产品质量的影响；以及提高控制精度、获得更好的控制性能、积累连铸系统自动控制方面的生产经验。是将自动控制理论应用于实践、推动传统工业向现代化迈进的有益尝试。
根据需求分析并结合以往工程经验，系统控制部分由工控机、控制仪表、操作台共同组成，兼具自动、手动、硬手动等多种控制方式，下位机为基于C51的单片机系统，由C语言编程实现，上位工控机中监控软件用VC++编程实现。上、下位机之间用并口联接，编写通信程序交换数据。
系统需要进行监测的参数有五个，即有五路输入信号：铸辊位移、铸辊转速、铸轧压力、浇铸温度、冷却水流速，分别采用光栅、光电编码器、应变式压力传感器、热电偶和涡轮流量计作为检测元件。三个控制信号，即三路输出，分别为：铸辊转速、铸辊位移、熔池液面高度，控制转速的执行元件为变频器，位移和熔池液面高度都用伺服阀进行控制。自动模式下采用工程PID算法进行控制，算法可修改，参数由界面输入。
此外，项目中还对主电机系统进行了改造，将现有电机调速系统改造为变频调速系统。
完成后的系统实现了所要求的全部功能，已投入试运行。
In the 21st century, Continuous casting technology of thin belt is an advanced and new technique in casting field. Through it, liquid metal can be directly processed to finished products or semi finished articles without cooling and reheat procedures. Relative to traditional technique, it is of more advantages and leads the trend of flat steel production tech, so it is the key technique of modern production in steel factories.
The implementations of computer detect and control in the casting process make higher quality, lower cost and higher efficiency.
The research of the checking and controlling system of parameter of the double-roller cast machines is the sub-project of the emphasis project---double-roller cast machine.The whole system is made up with hydraulic pressure system and electronic control system. The main task for electronic control system is to rebuild the current minitype double-roller cast machine into automation and to monitor the process of continuous casting technology including sample-data showing and controlling. It's useful to study the continuous casting technology of thin belt tech and what's the parameter effect on the process of the continuous casting and the final products. It's also helpful to raise the accuracy , to get better control performance, to accumulate the experience of continuous casting automatic control. It's another trying to put the automatic theory into practice and modernization.
According to requirements and experiences, industrial computer, control instruments and operation desk compose the control system. Automatic, manual and hardware controls are available. The lower side controller is based on MCS51, and the upper side computer executes monitoring software programmed with VC++. Through a parallel port, upper and lower computers can exchange data with communication software.
There are five parameters need to be measured. There are five channels for input: the displacement of casting-roller, the rotate speed of casting-roller, the pressure of casting and rolling, the casting temperature and the water-speed of cooling water. They are measured by raster, photoelectric coder, strain pressure sensor, thermocouple and turboflowmeter. There are three controlling signs for output: the displacement of casting roller, the casting temperature, the surface height of melting pool. The executing element for rotate speed is the frequency conversion
adjustable-speed machine and the displacement and the surface height of the melting pool are controlled by the servo valve. The control algorithm is either PID whose parameters can be input and modified through interface or others.
In additional, current motor timing system is advanced to frequency converting system.
The system fulfills all functionalities in an intuitionistic and convenient way. After being worked stably and reliably in field for long time, the system has put into practical work.
利用计算机实现对生产过程进行检测与控制是计算机在铸造生产中应用的重要内容，也是生产高质量铸件、降低铸造成本、提高生产效率的必备条件。
双辊铸机参数检测及控制系统的研制是重庆市重点科研项目双辊连铸高速钢薄带产业化技术的子课题。整个系统由液压控制系统和电控系统组成，电控系统的主要任务即是对现有实验用小型双辊铸机进行自动化改造，实现对连铸过程的监控，包括参数的采集显示和实施控制等，以便于深入探索薄带连铸工艺，研究各种工艺参数对连铸过程和最终产品质量的影响；以及提高控制精度、获得更好的控制性能、积累连铸系统自动控制方面的生产经验。是将自动控制理论应用于实践、推动传统工业向现代化迈进的有益尝试。
根据需求分析并结合以往工程经验，系统控制部分由工控机、控制仪表、操作台共同组成，兼具自动、手动、硬手动等多种控制方式，下位机为基于C51的单片机系统，由C语言编程实现，上位工控机中监控软件用VC++编程实现。上、下位机之间用并口联接，编写通信程序交换数据。
系统需要进行监测的参数有五个，即有五路输入信号：铸辊位移、铸辊转速、铸轧压力、浇铸温度、冷却水流速，分别采用光栅、光电编码器、应变式压力传感器、热电偶和涡轮流量计作为检测元件。三个控制信号，即三路输出，分别为：铸辊转速、铸辊位移、熔池液面高度，控制转速的执行元件为变频器，位移和熔池液面高度都用伺服阀进行控制。自动模式下采用工程PID算法进行控制，算法可修改，参数由界面输入。
此外，项目中还对主电机系统进行了改造，将现有电机调速系统改造为变频调速系统。
完成后的系统实现了所要求的全部功能，已投入试运行。
In the 21st century, Continuous casting technology of thin belt is an advanced and new technique in casting field. Through it, liquid metal can be directly processed to finished products or semi finished articles without cooling and reheat procedures. Relative to traditional technique, it is of more advantages and leads the trend of flat steel production tech, so it is the key technique of modern production in steel factories.
The implementations of computer detect and control in the casting process make higher quality, lower cost and higher efficiency.
The research of the checking and controlling system of parameter of the double-roller cast machines is the sub-project of the emphasis project---double-roller cast machine.The whole system is made up with hydraulic pressure system and electronic control system. The main task for electronic control system is to rebuild the current minitype double-roller cast machine into automation and to monitor the process of continuous casting technology including sample-data showing and controlling. It's useful to study the continuous casting technology of thin belt tech and what's the parameter effect on the process of the continuous casting and the final products. It's also helpful to raise the accuracy , to get better control performance, to accumulate the experience of continuous casting automatic control. It's another trying to put the automatic theory into practice and modernization.
According to requirements and experiences, industrial computer, control instruments and operation desk compose the control system. Automatic, manual and hardware controls are available. The lower side controller is based on MCS51, and the upper side computer executes monitoring software programmed with VC++. Through a parallel port, upper and lower computers can exchange data with communication software.
There are five parameters need to be measured. There are five channels for input: the displacement of casting-roller, the rotate speed of casting-roller, the pressure of casting and rolling, the casting temperature and the water-speed of cooling water. They are measured by raster, photoelectric coder, strain pressure sensor, thermocouple and turboflowmeter. There are three controlling signs for output: the displacement of casting roller, the casting temperature, the surface height of melting pool. The executing element for rotate speed is the frequency conversion
adjustable-speed machine and the displacement and the surface height of the melting pool are controlled by the servo valve. The control algorithm is either PID whose parameters can be input and modified through interface or others.
In additional, current motor timing system is advanced to frequency converting system.
The system fulfills all functionalities in an intuitionistic and convenient way. After being worked stably and reliably in field for long time, the system has put into practical work.
引文
[1]Fink F. Continuous strip casting[J]. Metalurgija. 1998. 37(2). 87~91
[2]Senk D,etc. In-line rolling and cooling of direct cast steel strip[J]. Stahl und Eisen. 2000. 120(6). 65~69
[3]任丽君、甑晋萍. 薄板坯连铸的技术经济分析与展望[J]. 铸造设备与研究. 2000(2). 42~44
[4]Sahai Y、Gupta M. Simulation and analysis of thin strip casting processes[A].IPMM'99: The Second International Conference on Intellingent Processing and Manufacturing of Materials Proceedings[C]. 1999. (1). 34~36
[5]施家红. 双辊薄带连铸装置产业化技术经济系统评估[J]. 上海钢研. 1999. (1). 34~36
[6]Matbeeb B H. 应用辊式结晶器的带钢连铸[J]. 国外钢铁. 1997. 9. 29~30
[7]Opalka W A. Direct strip caster for stainless steel starts up at Nippon[J]. Iron and Steel maker. 1998. 25(12). 13
[8]杨春楣、周守则. 双辊铸轧硅钢薄带研究现状[J]. 材料导报. 1999. 13(1). 24~26
[9]Opalka W A. BHP achieves breakthrough with project M [J]. Iron and Steel maker. 1998. 25(12). 19~21
[10] Opalka W A. Direct strip casting developments quicken [J]. Iron and Steel maker. 1999. 26(2). 39~40
[11]邸洪双、鲍培玮等. 双辊铸轧薄带钢实验研究及工艺稳定性分析 [J]. 东北大学学报（自然科学版）. 2000. 21(3). 274~277
[12]孟繁德、施红家. 带钢近终形连铸的开发和应用 [J]. 上海钢研. 1999. (6). 41~48
[13]施红家. 我国双辊薄带连铸技术的开发与展望 [J]. 上海钢研. 1998. (4). 28~34
[14]徐光、徐楚韶. 带钢近终形生产技术的发展概况 [J]. 武汉冶金科技大学学报（自然科学版）. 1999. 22(2). 125~128
[15]吕立华. 轧制理论基础 [M]. 第一版. 重庆. 重庆大学出版社. 1991. 121~123
[16]刘迎春. 传感器原理、设计及应用 [M]. 第一版. 湖南. 长沙国防科技大学出版社. 1995. 39~40.
[17]吴华等. Windows NT Win32软件开发使用详解 [M]. 第一版. 北京. 电子工业出版社. 1995
[18]Buchner A R. Thin strip casting of steel with a twin-roll caster correlations between process parameters [J]. Steel Research. 1997. 68(6). 247~257
[19]Guthrie R I L. Isac M. Steel strips in the context of near net shape casting production [J]. Steel Research. 1999. 70(8~9). 343~348
[20]马少武、韩华伟等. 异径双辊薄带铸轧熔池中钢液流动特性 [J]. 东北大学学报. 1999.
20(3). 290~293
[21]Lee D S、Joo M G etc. The control of the strip thickness in twin roll strip casting process [J]. RIST Journal of R&D. 1999. 13(3). 290~296
[22]金以慧、方崇智. 过程控制[M]. 第一版. 北京. 清华大学出版社. 1996
[23]顾绳谷. 电机及拖动基础 [M]. 第一版. 北京. 机械工业出版社. 1996
[24]陈伯时. 电力拖动自动控制系统 [M]. 第二版. 北京. 机械工业出版社. 1992. 256~257
[25]Bolognani S, BujaG. Control System Design of a Current Inverter Induction Motor Drive. IEEE Trans. IA-21 No.5, 1985. 9/10
[26]David J.Kruglinski, Scot Wingo George Shepherd. ProgrammingVisual C++6.0技术内幕. 希望图书创作室译. 北京. 北京希望电子出版社. 1999
[27]王华，叶爱亮，祁立学，曹凌云. Visual C++6.0编程实例与技巧. 北京. 机械工业出版社. 1999
[28]刘小石. 精通Visual C++6.0 [M]. 第一版. 北京. 清华大学出版社. 2000
[29]Stewart J R, Wilson D D. High Phase Order Transmission-a Feasibility Analysis, Part ONE----Steady State Considerations. IEEE Trans. On Power Application System. 1978, PAS-97. 2300~2307
[30]Hava A M. Simple Analytical and Graphical Tools for Carrier Based PWM Methods. IEEE-PESC Conf. Records. St. Louis, Missouri. 1997. 1462~1471
[31]Hamid A Toliyat. Analysis and Simulation of Five-phase Variable-speed Inducion Motor Drives Under Asymmetrical Connections. IEEE Trans. Power Elctro. 1998. 13(4)
[2]Senk D,etc. In-line rolling and cooling of direct cast steel strip[J]. Stahl und Eisen. 2000. 120(6). 65~69
[3]任丽君、甑晋萍. 薄板坯连铸的技术经济分析与展望[J]. 铸造设备与研究. 2000(2). 42~44
[4]Sahai Y、Gupta M. Simulation and analysis of thin strip casting processes[A].IPMM'99: The Second International Conference on Intellingent Processing and Manufacturing of Materials Proceedings[C]. 1999. (1). 34~36
[5]施家红. 双辊薄带连铸装置产业化技术经济系统评估[J]. 上海钢研. 1999. (1). 34~36
[6]Matbeeb B H. 应用辊式结晶器的带钢连铸[J]. 国外钢铁. 1997. 9. 29~30
[7]Opalka W A. Direct strip caster for stainless steel starts up at Nippon[J]. Iron and Steel maker. 1998. 25(12). 13
[8]杨春楣、周守则. 双辊铸轧硅钢薄带研究现状[J]. 材料导报. 1999. 13(1). 24~26
[9]Opalka W A. BHP achieves breakthrough with project M [J]. Iron and Steel maker. 1998. 25(12). 19~21
[10] Opalka W A. Direct strip casting developments quicken [J]. Iron and Steel maker. 1999. 26(2). 39~40
[11]邸洪双、鲍培玮等. 双辊铸轧薄带钢实验研究及工艺稳定性分析 [J]. 东北大学学报（自然科学版）. 2000. 21(3). 274~277
[12]孟繁德、施红家. 带钢近终形连铸的开发和应用 [J]. 上海钢研. 1999. (6). 41~48
[13]施红家. 我国双辊薄带连铸技术的开发与展望 [J]. 上海钢研. 1998. (4). 28~34
[14]徐光、徐楚韶. 带钢近终形生产技术的发展概况 [J]. 武汉冶金科技大学学报（自然科学版）. 1999. 22(2). 125~128
[15]吕立华. 轧制理论基础 [M]. 第一版. 重庆. 重庆大学出版社. 1991. 121~123
[16]刘迎春. 传感器原理、设计及应用 [M]. 第一版. 湖南. 长沙国防科技大学出版社. 1995. 39~40.
[17]吴华等. Windows NT Win32软件开发使用详解 [M]. 第一版. 北京. 电子工业出版社. 1995
[18]Buchner A R. Thin strip casting of steel with a twin-roll caster correlations between process parameters [J]. Steel Research. 1997. 68(6). 247~257
[19]Guthrie R I L. Isac M. Steel strips in the context of near net shape casting production [J]. Steel Research. 1999. 70(8~9). 343~348
[20]马少武、韩华伟等. 异径双辊薄带铸轧熔池中钢液流动特性 [J]. 东北大学学报. 1999.
20(3). 290~293
[21]Lee D S、Joo M G etc. The control of the strip thickness in twin roll strip casting process [J]. RIST Journal of R&D. 1999. 13(3). 290~296
[22]金以慧、方崇智. 过程控制[M]. 第一版. 北京. 清华大学出版社. 1996
[23]顾绳谷. 电机及拖动基础 [M]. 第一版. 北京. 机械工业出版社. 1996
[24]陈伯时. 电力拖动自动控制系统 [M]. 第二版. 北京. 机械工业出版社. 1992. 256~257
[25]Bolognani S, BujaG. Control System Design of a Current Inverter Induction Motor Drive. IEEE Trans. IA-21 No.5, 1985. 9/10
[26]David J.Kruglinski, Scot Wingo George Shepherd. ProgrammingVisual C++6.0技术内幕. 希望图书创作室译. 北京. 北京希望电子出版社. 1999
[27]王华，叶爱亮，祁立学，曹凌云. Visual C++6.0编程实例与技巧. 北京. 机械工业出版社. 1999
[28]刘小石. 精通Visual C++6.0 [M]. 第一版. 北京. 清华大学出版社. 2000
[29]Stewart J R, Wilson D D. High Phase Order Transmission-a Feasibility Analysis, Part ONE----Steady State Considerations. IEEE Trans. On Power Application System. 1978, PAS-97. 2300~2307
[30]Hava A M. Simple Analytical and Graphical Tools for Carrier Based PWM Methods. IEEE-PESC Conf. Records. St. Louis, Missouri. 1997. 1462~1471
[31]Hamid A Toliyat. Analysis and Simulation of Five-phase Variable-speed Inducion Motor Drives Under Asymmetrical Connections. IEEE Trans. Power Elctro. 1998. 13(4)