中厚板轧机振动特性与轧辊磨损评价研究
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摘要
中厚板钢材广泛应用于船舶、桥梁、容器等众多领域，随着中厚板轧机向大型化、高速化、连续化和自动化方向的不断发展，轧机的振动问题成为困扰各大钢铁企业的技术难题，不仅会降低轧机的机械性能，减少其使用寿命，增加零部件的更换频率，使生产成本上升，而且降低了轧机的轧制精度，严重地影响了产品的质量，甚至威胁生产安全并造成巨大的经济损失。
在中厚板板坯加热热应力分析、轧机轧制力分析的基础上，建立中厚板轧机分析模型，研究了中厚板轧机动态振动特性，在有限故障现象样本基础上，建立基于支持向量回归的故障诊断模型，用于轧机的故障诊断，提高设备安全运行水平，减少停机维修时间，对于提高我国中厚板整体技术水平和增强行业竞争力具有重要意义。本文主要研究内容如下：
板坯加热热应力分析研究。建立了全尺寸板坯加热三维有限元仿真模型，利用现代CAE软件对板坯加热过程数值仿真，根据实际加热工艺参数，仿真研究了加热过程，研究板坯在加热过程中加热工艺参数，包括加热温度、加热速度、加热时间对板坯内部温度均匀性的影响，得到热应力分布规律。
基于加热应力分布的轧制力分析研究。建立了基于板坯加热温度场和应力场分布的轧制三维有限元仿真模型，根据实际轧制工艺参数，仿真分析了多道次轧制过程，得到了轧辊直径变化对轧制力的影响规律、压下率对板材轧制力的影响规律、摩擦系数对板材轧制力的影响规律。
基于动态轧制力的轧机振动分析研究。运用动力学理论及其方法，在热应力分析、轧制力分析的基础上，建立了系统的垂直振动力学模型和数学模型。通过对轧机系统动力学模型进行计算与仿真分析，得到轧机系统在不同工况下振动位移随时间的变化关系。研究在不同阻尼条件下，对各部件频率响应曲线进行综合分析，得到了轧机系统的上、下工作辊和机架振动特性，以及典型轧辊磨损的振动特性。
基于支持向量机的轧辊磨损评价研究。在支持向量机相关理论知识的基础上，对支持向量机常用几种多分类方法特点进行对比分析，针对轧辊磨损的有限样本，建立了基于支持向量回归的轧辊磨损评价模型。通过仿真分析，验证了基于支持向量回归的轧辊磨损评价模型，具有较高的准确率。
轧辊磨损评价实验研究。设计了轧机振动测试方案，采用高精度轧机振动测试系统，对轧机辊系和机架进行了不同速度下的压靠实验振动测试、轧制速度对机架和辊系的振动测试、两种压下量对辊系和机架影响的振动测试、轧辊磨损对机架和辊系的振动影响测试。使用DASPV10分析软件，对数据做了在线采集和离线分析，运用时域分析、自谱分析、互谱分析、概率密度分析等方法，从不同角度对轧机辊系和机架振动信号进行了计算与分析，得到了四辊实验轧机在实际运行工况下的真实振动规律，以及轧辊磨损的特征信号，验证了基于支持向量回归的轧辊磨损评价模型，实现轧机振动的定量分析和轧辊磨损的准确评价。
The plate products are widely used in many fields of ship， bridge， container，especially raw material used as a production aircraft carriers， large ships and large diameterlongitudinal welded pipe， which relates to national security and energy security. It has animportant strategic significance to improve the plate production efficiency and product quality.In thick plate rolling，the large-scale，high-speed，continuous and higher automated are themain stream. The vibration is a common and urgent problem，which is a worldwide technicalproblems plagued the major iron and steel enterprises. Because the vibration phenomenon notonly reduces the mechanical properties of the mill， decreases its service life， increases thefrequency of replacement parts， so that production costs rise， but also reduces the precisionof rolling mill， seriously affecting the quality of the products. Severe vibration even causes alot of waste， broken belt， rolling mill shutdowns or does some damage to equipment，which is a serious threat to safe production and cause huge economic losses.
Based on the slab heating thermal stress analysis and rolling force analysis， the modelof plate rolling is established in this paper， which is using study on the dynamic vibrationcharacteristics of plate mill. The support vector regression identification model is establishedin accordance with fault phenomenon， which is used in fault diagnosis for rolling mill. Thismodel improves the operation safety level， reduces downtime， repair time， and improvesthe overall technical level of the plate， which is great significance to enhance thecompetitiveness of the industry. The main content of the paper are as follows：
Stress analysis of slab heating. A full size slab heating three-dimensional finite elementsimulation model is established in this chapter，which simulates the slab heating process withthe modern CAE software. According to the actual heating process parameters， the thermalstress distribution law is obtained. The heating parameters include heating temperature， heating rate， heating time.
Rolling force analysis based on heating stress distribution. The three-dimensional finiteelement rolling model is established based on the slab heating temperature field and heatingstress field. According to the actual rolling parameters， the multi passes of rolling processare analyzed. The rolling force distributions are obtained. The main influencing factorsinclude roll diameter， compression ratio， friction coefficient， and so on.
Rolling vibration analysis based on dynamic rolling force. Using dynamics theory andmethod， the vertical vibration model and mathematical model are established in this chapterbased on the thermal stress analysis and the rolling force analysis， Through analysis andsimulation of system dynamics model， the vibration characteristics is obtained. Research ondifferent damping conditions， each component of the frequency response curves areanalyzed. The vibration characteristics of the mill frame and working roller， and the typicalfault vibration characteristics are gained.
Roller wearing evaluation analysis based on Support Vector Machine. On the basis ofrelevant theoretical knowledge of Support Vector Regression， Comparative analysis is usingin several classification methods of analysis. For wear phenomenon for finite sample， theidentification model is established based on support vector regression. Through the simulationanalysis， the identification model of support vector regression is verified to have the betterfitting precision， the good identification accuracy and efficiency， which can provide theequipment management personnel with comprehensive and accurate information to ensuresafe production.
Wear evaluation experiment analysis. The rolling mill vibration test scheme is designedin this chapter， which uses high precision rolling vibration test system. The experiment ofvibration measurement of roller and framework is finished in the condition of different speedswithout load， which can gain the mill system unload vibration characteristics; the influenceexperiment of compression ratio on the framework and roller system is finished， which cangain the vibration characteristics of different compression ratio; the effect experiment ofroller wear fault on the framework and roll roller is finished， which can gain the vibrationcharacteristics of roller wear fault;
Using DASP V10. analysis software， the data is analyzed by online acquisition andoff-line， using time domain analysis， frequency domain analysis， the spectral analysis，the cross spectral analysis， probability density analysis theory and method. Through thecalculation and analysis of vibration signal， the real law of vibration of four rollers mill inthe actual operating conditions are gained， which is used in roller wear evaluation analysis， this experiment verifies the identification model based on support vector regression has betterprecision， which realizes the accurate wear evaluation analysis resulted by rolling vibration.
在中厚板板坯加热热应力分析、轧机轧制力分析的基础上，建立中厚板轧机分析模型，研究了中厚板轧机动态振动特性，在有限故障现象样本基础上，建立基于支持向量回归的故障诊断模型，用于轧机的故障诊断，提高设备安全运行水平，减少停机维修时间，对于提高我国中厚板整体技术水平和增强行业竞争力具有重要意义。本文主要研究内容如下：
板坯加热热应力分析研究。建立了全尺寸板坯加热三维有限元仿真模型，利用现代CAE软件对板坯加热过程数值仿真，根据实际加热工艺参数，仿真研究了加热过程，研究板坯在加热过程中加热工艺参数，包括加热温度、加热速度、加热时间对板坯内部温度均匀性的影响，得到热应力分布规律。
基于加热应力分布的轧制力分析研究。建立了基于板坯加热温度场和应力场分布的轧制三维有限元仿真模型，根据实际轧制工艺参数，仿真分析了多道次轧制过程，得到了轧辊直径变化对轧制力的影响规律、压下率对板材轧制力的影响规律、摩擦系数对板材轧制力的影响规律。
基于动态轧制力的轧机振动分析研究。运用动力学理论及其方法，在热应力分析、轧制力分析的基础上，建立了系统的垂直振动力学模型和数学模型。通过对轧机系统动力学模型进行计算与仿真分析，得到轧机系统在不同工况下振动位移随时间的变化关系。研究在不同阻尼条件下，对各部件频率响应曲线进行综合分析，得到了轧机系统的上、下工作辊和机架振动特性，以及典型轧辊磨损的振动特性。
基于支持向量机的轧辊磨损评价研究。在支持向量机相关理论知识的基础上，对支持向量机常用几种多分类方法特点进行对比分析，针对轧辊磨损的有限样本，建立了基于支持向量回归的轧辊磨损评价模型。通过仿真分析，验证了基于支持向量回归的轧辊磨损评价模型，具有较高的准确率。
轧辊磨损评价实验研究。设计了轧机振动测试方案，采用高精度轧机振动测试系统，对轧机辊系和机架进行了不同速度下的压靠实验振动测试、轧制速度对机架和辊系的振动测试、两种压下量对辊系和机架影响的振动测试、轧辊磨损对机架和辊系的振动影响测试。使用DASPV10分析软件，对数据做了在线采集和离线分析，运用时域分析、自谱分析、互谱分析、概率密度分析等方法，从不同角度对轧机辊系和机架振动信号进行了计算与分析，得到了四辊实验轧机在实际运行工况下的真实振动规律，以及轧辊磨损的特征信号，验证了基于支持向量回归的轧辊磨损评价模型，实现轧机振动的定量分析和轧辊磨损的准确评价。
The plate products are widely used in many fields of ship， bridge， container，especially raw material used as a production aircraft carriers， large ships and large diameterlongitudinal welded pipe， which relates to national security and energy security. It has animportant strategic significance to improve the plate production efficiency and product quality.In thick plate rolling，the large-scale，high-speed，continuous and higher automated are themain stream. The vibration is a common and urgent problem，which is a worldwide technicalproblems plagued the major iron and steel enterprises. Because the vibration phenomenon notonly reduces the mechanical properties of the mill， decreases its service life， increases thefrequency of replacement parts， so that production costs rise， but also reduces the precisionof rolling mill， seriously affecting the quality of the products. Severe vibration even causes alot of waste， broken belt， rolling mill shutdowns or does some damage to equipment，which is a serious threat to safe production and cause huge economic losses.
Based on the slab heating thermal stress analysis and rolling force analysis， the modelof plate rolling is established in this paper， which is using study on the dynamic vibrationcharacteristics of plate mill. The support vector regression identification model is establishedin accordance with fault phenomenon， which is used in fault diagnosis for rolling mill. Thismodel improves the operation safety level， reduces downtime， repair time， and improvesthe overall technical level of the plate， which is great significance to enhance thecompetitiveness of the industry. The main content of the paper are as follows：
Stress analysis of slab heating. A full size slab heating three-dimensional finite elementsimulation model is established in this chapter，which simulates the slab heating process withthe modern CAE software. According to the actual heating process parameters， the thermalstress distribution law is obtained. The heating parameters include heating temperature， heating rate， heating time.
Rolling force analysis based on heating stress distribution. The three-dimensional finiteelement rolling model is established based on the slab heating temperature field and heatingstress field. According to the actual rolling parameters， the multi passes of rolling processare analyzed. The rolling force distributions are obtained. The main influencing factorsinclude roll diameter， compression ratio， friction coefficient， and so on.
Rolling vibration analysis based on dynamic rolling force. Using dynamics theory andmethod， the vertical vibration model and mathematical model are established in this chapterbased on the thermal stress analysis and the rolling force analysis， Through analysis andsimulation of system dynamics model， the vibration characteristics is obtained. Research ondifferent damping conditions， each component of the frequency response curves areanalyzed. The vibration characteristics of the mill frame and working roller， and the typicalfault vibration characteristics are gained.
Roller wearing evaluation analysis based on Support Vector Machine. On the basis ofrelevant theoretical knowledge of Support Vector Regression， Comparative analysis is usingin several classification methods of analysis. For wear phenomenon for finite sample， theidentification model is established based on support vector regression. Through the simulationanalysis， the identification model of support vector regression is verified to have the betterfitting precision， the good identification accuracy and efficiency， which can provide theequipment management personnel with comprehensive and accurate information to ensuresafe production.
Wear evaluation experiment analysis. The rolling mill vibration test scheme is designedin this chapter， which uses high precision rolling vibration test system. The experiment ofvibration measurement of roller and framework is finished in the condition of different speedswithout load， which can gain the mill system unload vibration characteristics; the influenceexperiment of compression ratio on the framework and roller system is finished， which cangain the vibration characteristics of different compression ratio; the effect experiment ofroller wear fault on the framework and roll roller is finished， which can gain the vibrationcharacteristics of roller wear fault;
Using DASP V10. analysis software， the data is analyzed by online acquisition andoff-line， using time domain analysis， frequency domain analysis， the spectral analysis，the cross spectral analysis， probability density analysis theory and method. Through thecalculation and analysis of vibration signal， the real law of vibration of four rollers mill inthe actual operating conditions are gained， which is used in roller wear evaluation analysis， this experiment verifies the identification model based on support vector regression has betterprecision， which realizes the accurate wear evaluation analysis resulted by rolling vibration.
引文
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