冷轧带钢连续退火模拟实验机的研究与开发
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摘要
高等级冷轧产品的组织和性能主要是通过连续退火过程来控制的。连续退火是冷轧带钢生产的重要工艺,与最终产品力学性能有关的微观组织和织构主要是由退火过程决定的。为了能迅速、经济而准确地考察不同工艺过程对最终产品性能的影响,工艺开发人员需要有方便、灵活、精确的开发工具。产品开发人员为了选择最佳的生产工艺,也有同样的需求。
冷轧带钢连续退火模拟实验机的研究与开发课题应运而生。本论文以国家自然科学基金科学仪器基础研究专项基金项目“冷轧带钢连续退火模拟实验机的研究与开发”、宝钢股份不锈钢分公司技术中心与东北大学签订的“光亮退火模拟实验机的研究与开发”、太钢技术中心与东北大学签订的“太钢技术中心中间试验场实验设备研制与丌发项目”等项目为背景,确立了“冷轧带钢连续退火模拟实验机的研究与开发”这一研究课题。
冷轧带钢连续退火模拟实验机采用单片试样,模拟再现冷轧带钢在连续退火过程中的张力、加热、冷却和炉内气氛等工艺过程和现象,从而获得退火工艺与材料组织性能之间的定量关系,为实际生产服务。
本课题的研究丌发工作分为冷轧带钢连续退火模拟实验机的整体结构与功能设计、实验机控制系统的研究与丌发、模糊专家温度控制系统的研究与开发、用氢安全控制策略的研究与开发、实验机应用研究等。成功研制出的第一台冷轧带钢连续退火模拟实验机已在宝钢股份不锈钢分公司运行近三年,并发挥了较大的科研作用。该实验机的开发成功,对冷轧产品开发及退火工艺的研究具有重要意义,同时填补了国内空白,提高了国内模拟实验机设备研究与国外相关领域研究的竞争能力。
论文主要工作及创新性研究成果如下:
(1)本文在充分研究己知的国内外连续退火模拟实验机的结构特点的基础上,提出了用单工位的结构来模拟连续退火生产的设计思想。该设计思想抛弃了依靠试样在不同工艺炉段之间的穿行来实现加热、冷却、过时效等工艺过程的方法,直接在一个炉体中实现试样的加热、均热、缓冷、快冷、过时效和终冷等工艺过程。多工位的设计思想虽然从设备整体结构上和试样的运行方式上切合了实际的生产过程,但是不仅没有很好的模拟连续退火生产过程,反而使设备结构复杂化,设备功能不够全面,降低了模拟实验和实际生产过程的相似性。
(2)根据冷轧带钢连续退火模拟实验机的设计原则、设计指标和多功能的设计要求,确定实验机的功能结构主要包括:实验机本体、加热系统、冷却系统、张力系统、气水分配系统、气体分析系统、真空和气体排放系统、控制系统几个部分。在实验机各功能部分的设计中结合实验机的功能要求和模块化、集成化的设计理念,使得各功能部分相辅相成,设备装卸和维修十分简便。在各功能部分的设计中还充分考虑和实现了使用氢气的安全保护功能。
(3)冷却技术是连续退火机组的核心技术。本文中把冷却系统的设计开发作为了一个关键的技术课题。设计开发出一套拥有自主知识产权的能够模拟气冷、水冷以及气雾冷却的组合式冷却装置。通过该装置灵活的位置布置实现试样的均匀冷却。气体冷却介质为氮氢混合气体,可实现全氢冷却。
(4)根据实验机控制系统的功能要求,设计开发了控制系统硬件及网络结构原理和配置,包括主控制系统、氢气安全报警系统和控制系统现场电气件分布三部分。实验机基础自动化主控制系统采用SIEMENS公司S7-400系列PLC+FM458的基本结构。S7-400 CPU通过PROFIBUS-DP网与现场远程I/O,以及传动装置进行数据交换,通过工业以太网与HMI进行快速数据交换。氢气安全报警系统配置选用SIEMENSLOGO系列PLC。
(5)控制系统软件开发包括PLC控制软件开发和HMl人机界面系统开发。PLC软件系统主要包括功能逻辑控制系统、炉内压力控制系统、用氢安全控制策略、张力控制系统、模糊专家温度控制系统、气水分配和调节系统等部分。实验机人机界面系统用于操作人员设定退火工艺参数、监视实验状态和获取实验数据。
(6)由于冷轧带钢连续退火模拟实验机温度控制系统的非线性、时变性、变结构、多层次和大滞后等缺点而导致常规PID控制效果不理想,不能够达到实验机的设计性能指标。而在实际调试过程中发现采用分段PID控制方法和动态变规格控制方法相结合的控制策略具有很好的控制效果。因此引入模糊专家系统的结构和理论基础,并结合实际调试过程中总结出的专家策略,建立了模糊专家温度控制系统。
(7)针对氢气使用的安全性,通过分析模拟实验机的气体工作原理和氢气的物理特性,设计开发出一整套氢气使用的安全控制策略。主要包括炉体密封性能的安全控制、炉体内气体含量的安全控制、厂房内氢气检测报警的安全控制、安全互锁和紧急处理、安全操作规程等策略。
The microstructures and properties of high grade cold rolled products are determined by continuous annealing process. Continuous annealing which determines the mechanical properties of the final products is an important technology of cold rolled strip steel. A convenient, flexible, and accurate development device is in urgent need for the development of annealing technologies and products.
A project of "research and development of continuous annealing simulator for cold rolled strip steel" is proposed based on the project of "research and development of continuous annealing simulator for cold rolled strip steel" which is supported by National Natural Science Foundation of China, the contract of "research and development of bright annealing simulator" between Northeast University and Stainless Steel Branch of Baosteel Group Corporation Limited, the contract of "research and development of experimental equipments of pilot test laboratory of TISCO technology center" between Northeast University and TISCO technology center.
The continuous annealing simulator for cold rolled strip steel uses small specimens to simulate a series of technological processes of continues annealing of cold rolled strip steel, for example: tension, heating, cooling and protective atmosphere. The quantitative relationships between the annealing technology and the microstructure and properties of tested steels can be obtained after the experiment.
The research and development works include the design of function structure, research and development of control system, development of temperature fuzzy expert control system, research and development of the safety control strategy for hydrogen utilization, preliminary application of the simulator, etc. After plenty of hard works the first continuous annealing simulator for cold rolled strip steel which had therefore been developed successfully has been used for about three years in Stainless Steel Branch of Baosteel Group Corporation Limited, and plays an important role there. This simulator which fills a domestic gap has important significance to the research and development of cold rolled products and annealing technologies. It also improves the international competition in the related fields.
Main contents and innovative achievements of this dissertation are as follows:
(1) The idea of single work position is proposed after a sufficient study about the continuous annealing simulators of home and abroad. It abandons the method of moving the sample through different work positions but uses just one work position to simulate the heating, soaking, slow cooling, fast cooling and over aging processes of annealing. The idea of different work positions just is the same as the actual annealing line about the mechanical structure and working mode, but it doesn't simulates the continuous annealing process well and makes the simulator's structure complicated. As a result, simulator's functions are not comprehensive and the similarities between experiments and the real production are decreased.
(2) The function structure of continuous annealing simulator for cold rolled strip steel was designed according to the design principles, design indexes and multifunctional requirements. The function parts include mechanical body of simulator, heating system, cooling system, tension system, gas and water distribution system, gas analysis system, vacuum and exhaust system, control system. The design of function structure embodies the concept of modularization and integration and the function parts supplement each other well. So handling and maintenance are very convenient. The safety function of hydrogen utilization is also considered and implemented.
(3) Cooling technology is the key technology of continuous annealing line. Research and development of cooling system is the key topic of this dissertation. A combined cooling device which owned a patent of invention can simulates the cooling means of gas jet cooling (GJC), water quenching (WQ) and spray cooling was designed and developed successfully. By flexible arrangement of the cooling devices uniform cooling can be achieved. The cooling gases are composed of hydrogen and nitrogen. Full-hydrogen cooling can be implemented.
(4) According to the functional demands of simulator's control system, the configuration of hardware and network structure was designed and implemented, including main control system, hydrogen safety alarming control system, arrangement plan of field sensors and actuators. The hardware of basic automation control system adopts the S7-400 PLC+FM458 configuration structure. S7-400 CPU communicates with ET200M and transmission system by PROFIBUS-DP net, and communicates with HMI by Industrial Ethernet. The hardware of hydrogen safety alarming control system adopts the SIEMENS LOGO PLC.
(5) The software of control system is composed of PLC system software and HMI system software. PLC system software includes logical control system, furnace pressure control system, safety control strategy of hydrogen utilization, tension control system, temperature fuzzy expert control system, gas and water distribution system. HMI system provides the interface for operators to set experiment parameters, monitor experiment status and obtain experiment dates.
(6) Because of some disadvantages of the simulator's temperature control system, for example: nonlinearity, time-varying, variable structure, multi-level, large time delays etc, the control effects were not ideal and can't meet the control performance indexes. We found that the control strategy which was composed of sectional PID control and flying gauge change (FGC) control can get a good performance. A temperature fuzzy expert control system was built after introducing the structure and theoretical basis of fuzzy expert system and combined with some expert control strategies. The control performance was good and the overshoot was small.
(7) Analyzing the working principle of continuous annealing simulator and physical characteristics of hydrogen, a safety control strategy of hydrogen utilization was proposed including the controls of hermetical performance of furnace, gas content in furnace, alarm of hydrogen detection in plant, safety interlocking and emergency measures, safety operation specification, etc.
冷轧带钢连续退火模拟实验机的研究与开发课题应运而生。本论文以国家自然科学基金科学仪器基础研究专项基金项目“冷轧带钢连续退火模拟实验机的研究与开发”、宝钢股份不锈钢分公司技术中心与东北大学签订的“光亮退火模拟实验机的研究与开发”、太钢技术中心与东北大学签订的“太钢技术中心中间试验场实验设备研制与丌发项目”等项目为背景,确立了“冷轧带钢连续退火模拟实验机的研究与开发”这一研究课题。
冷轧带钢连续退火模拟实验机采用单片试样,模拟再现冷轧带钢在连续退火过程中的张力、加热、冷却和炉内气氛等工艺过程和现象,从而获得退火工艺与材料组织性能之间的定量关系,为实际生产服务。
本课题的研究丌发工作分为冷轧带钢连续退火模拟实验机的整体结构与功能设计、实验机控制系统的研究与丌发、模糊专家温度控制系统的研究与开发、用氢安全控制策略的研究与开发、实验机应用研究等。成功研制出的第一台冷轧带钢连续退火模拟实验机已在宝钢股份不锈钢分公司运行近三年,并发挥了较大的科研作用。该实验机的开发成功,对冷轧产品开发及退火工艺的研究具有重要意义,同时填补了国内空白,提高了国内模拟实验机设备研究与国外相关领域研究的竞争能力。
论文主要工作及创新性研究成果如下:
(1)本文在充分研究己知的国内外连续退火模拟实验机的结构特点的基础上,提出了用单工位的结构来模拟连续退火生产的设计思想。该设计思想抛弃了依靠试样在不同工艺炉段之间的穿行来实现加热、冷却、过时效等工艺过程的方法,直接在一个炉体中实现试样的加热、均热、缓冷、快冷、过时效和终冷等工艺过程。多工位的设计思想虽然从设备整体结构上和试样的运行方式上切合了实际的生产过程,但是不仅没有很好的模拟连续退火生产过程,反而使设备结构复杂化,设备功能不够全面,降低了模拟实验和实际生产过程的相似性。
(2)根据冷轧带钢连续退火模拟实验机的设计原则、设计指标和多功能的设计要求,确定实验机的功能结构主要包括:实验机本体、加热系统、冷却系统、张力系统、气水分配系统、气体分析系统、真空和气体排放系统、控制系统几个部分。在实验机各功能部分的设计中结合实验机的功能要求和模块化、集成化的设计理念,使得各功能部分相辅相成,设备装卸和维修十分简便。在各功能部分的设计中还充分考虑和实现了使用氢气的安全保护功能。
(3)冷却技术是连续退火机组的核心技术。本文中把冷却系统的设计开发作为了一个关键的技术课题。设计开发出一套拥有自主知识产权的能够模拟气冷、水冷以及气雾冷却的组合式冷却装置。通过该装置灵活的位置布置实现试样的均匀冷却。气体冷却介质为氮氢混合气体,可实现全氢冷却。
(4)根据实验机控制系统的功能要求,设计开发了控制系统硬件及网络结构原理和配置,包括主控制系统、氢气安全报警系统和控制系统现场电气件分布三部分。实验机基础自动化主控制系统采用SIEMENS公司S7-400系列PLC+FM458的基本结构。S7-400 CPU通过PROFIBUS-DP网与现场远程I/O,以及传动装置进行数据交换,通过工业以太网与HMI进行快速数据交换。氢气安全报警系统配置选用SIEMENSLOGO系列PLC。
(5)控制系统软件开发包括PLC控制软件开发和HMl人机界面系统开发。PLC软件系统主要包括功能逻辑控制系统、炉内压力控制系统、用氢安全控制策略、张力控制系统、模糊专家温度控制系统、气水分配和调节系统等部分。实验机人机界面系统用于操作人员设定退火工艺参数、监视实验状态和获取实验数据。
(6)由于冷轧带钢连续退火模拟实验机温度控制系统的非线性、时变性、变结构、多层次和大滞后等缺点而导致常规PID控制效果不理想,不能够达到实验机的设计性能指标。而在实际调试过程中发现采用分段PID控制方法和动态变规格控制方法相结合的控制策略具有很好的控制效果。因此引入模糊专家系统的结构和理论基础,并结合实际调试过程中总结出的专家策略,建立了模糊专家温度控制系统。
(7)针对氢气使用的安全性,通过分析模拟实验机的气体工作原理和氢气的物理特性,设计开发出一整套氢气使用的安全控制策略。主要包括炉体密封性能的安全控制、炉体内气体含量的安全控制、厂房内氢气检测报警的安全控制、安全互锁和紧急处理、安全操作规程等策略。
The microstructures and properties of high grade cold rolled products are determined by continuous annealing process. Continuous annealing which determines the mechanical properties of the final products is an important technology of cold rolled strip steel. A convenient, flexible, and accurate development device is in urgent need for the development of annealing technologies and products.
A project of "research and development of continuous annealing simulator for cold rolled strip steel" is proposed based on the project of "research and development of continuous annealing simulator for cold rolled strip steel" which is supported by National Natural Science Foundation of China, the contract of "research and development of bright annealing simulator" between Northeast University and Stainless Steel Branch of Baosteel Group Corporation Limited, the contract of "research and development of experimental equipments of pilot test laboratory of TISCO technology center" between Northeast University and TISCO technology center.
The continuous annealing simulator for cold rolled strip steel uses small specimens to simulate a series of technological processes of continues annealing of cold rolled strip steel, for example: tension, heating, cooling and protective atmosphere. The quantitative relationships between the annealing technology and the microstructure and properties of tested steels can be obtained after the experiment.
The research and development works include the design of function structure, research and development of control system, development of temperature fuzzy expert control system, research and development of the safety control strategy for hydrogen utilization, preliminary application of the simulator, etc. After plenty of hard works the first continuous annealing simulator for cold rolled strip steel which had therefore been developed successfully has been used for about three years in Stainless Steel Branch of Baosteel Group Corporation Limited, and plays an important role there. This simulator which fills a domestic gap has important significance to the research and development of cold rolled products and annealing technologies. It also improves the international competition in the related fields.
Main contents and innovative achievements of this dissertation are as follows:
(1) The idea of single work position is proposed after a sufficient study about the continuous annealing simulators of home and abroad. It abandons the method of moving the sample through different work positions but uses just one work position to simulate the heating, soaking, slow cooling, fast cooling and over aging processes of annealing. The idea of different work positions just is the same as the actual annealing line about the mechanical structure and working mode, but it doesn't simulates the continuous annealing process well and makes the simulator's structure complicated. As a result, simulator's functions are not comprehensive and the similarities between experiments and the real production are decreased.
(2) The function structure of continuous annealing simulator for cold rolled strip steel was designed according to the design principles, design indexes and multifunctional requirements. The function parts include mechanical body of simulator, heating system, cooling system, tension system, gas and water distribution system, gas analysis system, vacuum and exhaust system, control system. The design of function structure embodies the concept of modularization and integration and the function parts supplement each other well. So handling and maintenance are very convenient. The safety function of hydrogen utilization is also considered and implemented.
(3) Cooling technology is the key technology of continuous annealing line. Research and development of cooling system is the key topic of this dissertation. A combined cooling device which owned a patent of invention can simulates the cooling means of gas jet cooling (GJC), water quenching (WQ) and spray cooling was designed and developed successfully. By flexible arrangement of the cooling devices uniform cooling can be achieved. The cooling gases are composed of hydrogen and nitrogen. Full-hydrogen cooling can be implemented.
(4) According to the functional demands of simulator's control system, the configuration of hardware and network structure was designed and implemented, including main control system, hydrogen safety alarming control system, arrangement plan of field sensors and actuators. The hardware of basic automation control system adopts the S7-400 PLC+FM458 configuration structure. S7-400 CPU communicates with ET200M and transmission system by PROFIBUS-DP net, and communicates with HMI by Industrial Ethernet. The hardware of hydrogen safety alarming control system adopts the SIEMENS LOGO PLC.
(5) The software of control system is composed of PLC system software and HMI system software. PLC system software includes logical control system, furnace pressure control system, safety control strategy of hydrogen utilization, tension control system, temperature fuzzy expert control system, gas and water distribution system. HMI system provides the interface for operators to set experiment parameters, monitor experiment status and obtain experiment dates.
(6) Because of some disadvantages of the simulator's temperature control system, for example: nonlinearity, time-varying, variable structure, multi-level, large time delays etc, the control effects were not ideal and can't meet the control performance indexes. We found that the control strategy which was composed of sectional PID control and flying gauge change (FGC) control can get a good performance. A temperature fuzzy expert control system was built after introducing the structure and theoretical basis of fuzzy expert system and combined with some expert control strategies. The control performance was good and the overshoot was small.
(7) Analyzing the working principle of continuous annealing simulator and physical characteristics of hydrogen, a safety control strategy of hydrogen utilization was proposed including the controls of hermetical performance of furnace, gas content in furnace, alarm of hydrogen detection in plant, safety interlocking and emergency measures, safety operation specification, etc.
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