Firmware System for Data Acquisition and Control over the Main Drives Operating Parameters on Roughing and Continuous Billet Mills

The system increases the efficiency of the attendants work, speeds up emergency situations and standard rolling process disturbances analysis. The above-mentioned effect is obtained as a result of continuous registration and visualization of an extended number of parameters, measurement devices application and the results presentation in a form, suitable for analysis.

The system's main functions are:

to process 60 analog and 18 discrete signals in real-time mode:
the following signals are controlled on the blooming mill main drive:
- voltage of the rotation rate setting from the operator's control device
- motor armature currents;
- motor rotation rates;
- motor armature voltages;
the following signals are controlled on the rolling stands main drives of a continuous billet mill:
- voltage of the rotation rate setting from the operator's control device
- motor armature current;
- motor rotation rate;
- logic signal of power circuit readiness;
the following signals are controlled on the flying shears drive:
- voltage of the metal free cutting rate setting;
- motor armature current;
- motor rotation rate;
- state of the line contactor of the armature circuit;
additionally there are 7 backup analog channels for on-line registration.
All the channels have an individual galvanic isolation module.

The systems ensures continuous operation in the following modes:

automatic load from the moment of switching-on and continuous automatic record, visualization and data base maintenance;
on-line operation mode on the workstation of the automation group server (AGS), which includes control of all the modes from the AGS keyboard, process recording within a period of at least 3 months to the AGS hard disk, visualization of graphic information on the AGS monitor in real-time mode, printing of graphic and text information, working with the data base;
on-line operation mode with the terminal capabilities on the workstation of the control room operator (CROW): control of the operation modes from the CROW keyboard, visualization of graphic information on the CROW monitor in real-time mode, working with the data base. During the process analysis on the CROW the data about the processes is received on-line from the server data base, all the system operation requirements are fulfilled;
frequency of all input signals polling makes 10 Hz;
the system works in a continuous record mode, current state of the drives and sensors as well as open graphic windows are displayed on the AGS and CROW monitors;
automatic disk cleaning and data base updating within a period of at least 3 preceding months;
the system processes 60 analog and 18 discrete signals in real-time mode (with the possibility of further extension);
AGS and CROW are connected to an uninetrruptible power supply;
the system can be extended and coupled with other shop and plant information systems.

The object-oriented software works in QNX real-time operational system and provides:

measurement reliability;
multitasking;
efficient on-line data exchange;
high reliability.

Hardware:

sensors and galvanic isolation modules produced by JSC "Preobrazovatel".
digital part of the system uses industrial modules produced by "Octagon System" and "Advantech".
the communication within the system is realized through industrial high-performance Ethernet.

The system was implemented and is used on a processing line of Blooming-2 and continuous-billet mill of KRSIMMW "Krivorozhstal". The version with an increased record frequency is being implemented on Blooming-1 of KRSIMMW "Krivorozhstal".

The system can be efficiently used for continuous record and analysis of operation parameters of distributed electrical facilities on metallurgical plants.

The system is implemented at:

KRSIMMW "Krivorozhstal"