Integrated Measuring System for a Workpiece, Moving along the Processing Line of a Rolling Mill
The system ensures rational workpiece cutting on the shears and keeps automatic record of the quality metal weight in the roughing mill.
The system's main functions are:
- to generate a rational plan of the workpiece cutting into slabs;
- to determine the position of the front end of the workpiece relative to the shears cutting line in the process of the workpiece positioning before cutting the slabs (blooms) and to determine the slab (bloom) length at the moment of cutting;
- to carry out automatic measurement of cross-sectional dimensions (width and thickness) of slabs (blooms) in the processing line of a rolling mill;
- to calculate the weight of the slabs (blooms) to be cut;
- to visualize the results of the slab length, width and thickness measurement, the rational workpiece cutting plan and process data;
- to record the results of the length measurement and slabs (blooms) weight calculation;
- self-diagnostics of the system operation
The system's main specifications:
- type: an information-measuring system;
- system supply voltage ~ 220V, 50Hz;
- the system has two modes of operation: with automatic and manual selection of the slab length measurement range;
- length measurement ranges 2 - 5 m; 10 - 12,5 m;
- width measurement range 800 - 1600 mm;
- thickness measurement range 80 - 200 mm
- length measurement error ±20 mm;
- width measurement error ±2 mm;
- thickness measurement error ±1,5 mm
- information displaying facility TFT monitor 15";
- presentation of length measurement results crude estimate linear scale with a scale factor of 50 mm; numeric code, which corresponds to the absolute value, lower-order digit makes 1 mm;
- presentation of width and thickness measurement results numeric code, which corresponds to the absolute value, lower-order digit makes 0,1 mm;
- symbolic mode of process data presentation;
- the system has 2 external communication channels: channel 1 - RS 422 interface; channel 2 - Ethernet.
The system's components:
- main computer;
- optoelectronic linear scanning devices - LSD-1, LSD-2;
- LSD data processing unit;
- operator's indicator panel of the control pulpit-1
- a unit for monitoring temperature conditions of the LSD operation
- portable control console
- camera-recorders, one of which provides visual inspection of the crops length, the others - slabs (blooms) length, width and thickness measurement;
- remote data acquisition and data transformation unit, which polls the process equipment sensors
Short description of the system's operation:
Periodic measurement of the section width and thickness is carried out during the workpiece movement to the shears after the ingot rolling. After the workpiece leaves the measurement zone the system calculates average cross-sectional dimensions, which are transferred to the main computer and to the operator panel on the control pulpit-1.
The beginning of the workpiece cutting cycle is defined by the system at the moment of its approach to the shears. At that moment the main computer receives process data about the given stock, on the basis of which a rational - regarding the optimal crops size - cutting schedule is calculated and displayed on the control console.
After the cutter has removed the crops at the front end of the workpiece, the latter moves forward to be cut into slabs (blooms). At a distance of 2 m from the cutting line the system continuously tracks the workpiece front end and displays the results as a scale and as an absolute value. At the moment of cutting the system determines the slab (bloom) length, calculates its weight and defines its identification number. When the cutting cycle is accomplished, the calculated and measured values concerning each slab (bloom) are filed with time and identification number indication. This information is transferred to the factory system "Steel Rolled stock".
To define the crops length at the workpiece front end more accurately, the cutter has a possibility to view the shears travel zone with a coordinate scale, superimposed onto the visible surface of the workpiece.
The system's design and hardware ensure its error-free performance under hard working conditions (dust, high temperature, vibration etc.), which exist at the rolling shops of metallurgical works.
In July 2000 the system was implemented and is in continuous operation as an information system of hot stock cutting at the roughing plant of the JSC "Zaporozhstal". In January 2003 the full-scale integrated system for measurement of the moving workpiece geometry was implemented for experimental-industrial use at the roughing plant of the JSC "Zaporozhstal".
The system can be efficiently used on rolling mills of metallurgical works.
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