轧制模型设描述(轧制理论)

Shandong Nanshan Industry Co., Ltd.Cold Rolling Mill 1/2Design DescriptionRolling Model山东南山工业有限公司冷轧机1/2轧制模型设计描述Table of Contents目录1. Overview .3 概述2. References .5 参考资料3. Abbreviations .5 缩略语4. Definitions.5 定义5. Pass Schedule Calculation.6轧制道次表的计算6. Submodels.9 子模型6.1 Calculation of reduction distribution.9 压下率分布计算6.2 Calculation of tensions .11 张力计算6.3 Determination of maximum speed.11 最大速度的确定6.4 Roll Gap Model.12 轧辊辊缝模型6.4.1 Yield-Stress Model .12屈服应力模型6.4.2 Friction Model .13摩擦力模型6.5 Mill Stretch Model.14轧机拉伸模型6.6 Strip Temperature Model.14带材温度模型6.7 Thermal Crown Model .15热凸度模型6.8 Flatness Model .16平整度模型7. Adaption.18调整7.1 Overview.18概述7.2 Recording and filtering of measured data.19测量数据的记录和过滤7.3 Recalculation and learning .19重新计算和自学习8. Test Calculations.20试计算9. Interface to MES .21与MES的接口9.1 Triggering Events .21触发事件9.1.1 Request of pass schedule calculation .21轧制道次表计算的要求9.1.2 Roll change.21轧辊更换9.1.3 Mill zeroing .21轧机零位调整（调零）9.1.4 Begin of production.21生产开始9.1.5 End of production .21生产结束9.1.6 Cyclic measurements .21循环测量9.2 Transferred data .21转移的数据9.2.1 Coil data .21卷材数据9.2.2 Roll data .23轧辊数据9.2.3 Setup values.23设定值10. Data Management.26数据管理11. Human System Interface .26人机系统界面（HIS）11.1 Dialogs.26对话11.2 Reports.27报告12. Model Tuning Manual.29 模型调谐手册13. Technical Data .29技术数据13.1 Main Mill Technical Parameter .29轧机主要技术参数13.2 Main Rolling Material Parameter .30主要轧制材料参数1. Overview概述The task of the Rolling Model is to determine the setup of a cold mill, which is used toproduce cold rolled strips from hot rolled strips. The number of passes is calculated aswell as all setpoints needed for each pass in the basic automation system.轧制模型的任务是进行冷轧机设定，生产来自热轧带材的冷轧带材。在基本的自动化系统中计算道次数和每个道次需要的所有设定值。The main control variables are gauge and shape. Other important variables like surfacequality can be controlled indirectly by referring to product dependent practice tables duringschedule generation.主要的控制变量是厚度和板形。其它重要的变量像表面质量，在道次计算过程中根据与产品相关的工艺制度表间接进行控制。The aims of the Rolling Model is to reduce轧制模型的目标是减少：. strip breaks断带. threading time穿带时间. off-gauge length厚度超差部分长度and to improve the quality as well as to provide stable rolling conditions with minimal needof operator interventions.改进质量，以最小的人工干预操作，提供稳定的轧制状态。For prediction of control variables the scheduling and setup system uses various processmodels which are mainly based on physical principles. The Cold Rolling Model consists ofa calculation package and a number of parameter tables.为了对控制变量进行预测，道次表计算和设定系统使用以物理原理为基础的各种工艺模型。冷轧模型中包括一个计算包和很多参数表。Sensors on the mill continuously monitor operating conditions. Measured data are used toupdate the models to the variations in product and plant conditions. Thus, the system isable to respond to such changes and maintain product quality.轧机上的传感器连续地监控操作状态。根据产品和工厂条件的变化，用测定数据来更新模型。因此，系统能够响应这些变化和保持产品质量。The main functions of the model application software are:模型应用软件的主要功能：. Pass Schedule Calculation for all passes所有道次的轧制道次表计算. Set-up Calculation for next pass下一个道次设定计算. Test Calculation试计算. Data Acquisition, Filtering and Logging数据获得，过滤和记录. Estimation of the work rolls thermal crown工作辊热凸度估算. Model Adaptation模型调整. Reporting报告. Human System Interface人机系统界面The figure below shows the main interactions between the functions of the Rolling Modelapplication software.下图显示了轧制模型应用软件功能之间主要的相互作用。2. References参考资料Document “Function Description pcs Rev A 02 .pdf” dated 9-Dec-20032003年12月9日发来的资料“功能说明pcs Rev A 02 .pdf”3. Abbreviations缩略语AMI ABB Message Interface AMI ABB信息接口AMS Alarm and Message SystemAMS 报警信息系统BOC Begin of Coil (current pass)BOC 卷材开始轧制（当前轧制道次）CRM Cold Rolling MillCRM 冷轧机EOC End of Coil = Production finished (current pass)EOC 卷材轧制结束生产结束（当前轧制道次）ERP Enterprise Resource Planning = Level 3ERP 企业资源规划，即3级系统HIS Human System InterfaceHIS 人机系统接口L1 Level 1 = OCSL1 1级系统= OCSL2 Level 2 = MESL2 2级系统= MESL3 Level 3 = ERP L3 3级系统= ERPMES Manufacturing Executions System = Level 2MES 制造执行系统，即2级系统OCS Open Control System = Level 1OCS 开放控制系统，即1级系统PDI Primary Data Input (Coil data and order data)PDI 原始数据输入（卷材数据和订单数据）RDBMS Relational Data Base Management SystemRDBMS 关系数据库管理系统SOAP Simple Object Access ProtocolSOAP 简单目标访问协议VIP Vendor Internet ProtocolVIP 厂商网间协议4. Definitions定义Material class： Group of material grades with similar behaviour (yield stress curve)材料分类：有相似性能（屈服应力曲线）的材料等级的集合Product ：Combination of material class and pretreatment of a coil (prior typeof process; e.g. type of annealing) and/or treatment of coil (e.g. typeof work rolls used for final pass)产品：材料分类和卷材预处理（以前工艺类型例如退火的类型）和/或卷材处理（例如用于最后道次的工作辊类型）的结合5. Pass Schedule Calculation轧制道次表计算The rolling model calculates the pass schedule which comprises all the setpoints of a coilfor all remaining passes of this coil to be rolled in this mill. 轧制模型计算的道次表包括所有的要在这台轧机上轧制的卷材所有剩下的道次的所有设定值。The calculated preset values of the next pass to be rolled can be viewed by the operator. After possible modifications and final check the operator transfers the preset values to OCS (Level 1) and threading can be started. 操作员能够看到要轧制的下一个道次计算的预设值。可能的修改和最终的检查后，操作员把预设值传输到OCS（1级），开始穿带。The state of the coil changes from “next coil” to “current coil”. Preset values for that coil can only be changed when the mill is stopped. The operator can view the setpoints of the current coil and can prepare the setpoints for the next coil. 卷材状态从下一个卷材更换到当前卷材。卷材的预设值仅能在轧机停止时变换。操作员能够看到当前卷材的设定值，能够为下一个卷材准备设定值。The pass schedule calculation is activated automatically在以下情况，轧制道次表计算自动激活：. at the exit of the coil storage在卷材仓库的出口. at the last roller table before mill在轧机前的最后辊道. by manual request of the operator操作员手动要求(See chapter “Triggering Events” for more details)（为获得更多内容见“触发事件”这一章）The set-up calculation is mainly based on the following data entities, which will bedelivered by the MES production order management and the rolls management:设定值计算主要是基于下列数据，将由MES生产订单管理和轧辊管理提供。Strip properties带材性能. Entry thickness, width, entry temperature入口厚度，宽度，入口温度. Exit thickness出口厚度. Hot rolling thickness or last annealing thickness热轧厚度或最终退火厚度. Material grade, annealing type材料等级，退火类型. Strip profile, outer coil diameter带材形状，卷材外径Roll properties轧辊性能. Diameter, crown, taper, length, texture直径，凸度，锥度，长度，表面（纹理）Data entities stored locally within the rolling model:在轧制模型里局部存储的数据实体：. Mill and drive limits, standard practices轧机和传动限制，标准操作规程. Adaption coefficients, yield stress and friction values调整系数，屈服应力和摩擦力值The following preset values are calculated for the different rolling phases and for allpasses required:为不同轧制阶段和所有要求的道次计算下列预设值：. Intermediate thicknesses中间厚度. Rolling speed轧制速度. Entry and exit tensions入口和出口张力. Rolling force轧制力. Forward slip value前滑值. Rolling torque轧制扭矩. Roll gap position辊缝位置. Flatness actuators (bending and axial roll shifting)平整度执行机构（弯辊和中间辊轴向窜动）. Cooling quantity冷却液数量. Exit strip temperature出口带材温度. Bridle position张紧辊位置. Flatness curve number平直度曲线值. Horizontal Shifting (HS) of work roll工作辊的水平位移The preset values support the level1 to setup the roll gap in force or position controlThe following rolling phases can be distinguished:预设值支持1级系统设定辊缝，可用作用力控制方式或位置控制方式。能够区分下列轧制阶段：a) Feeding:给料Closed roll gap waiting for strip head to roll target reduction, neither back nor forwardTension闭合辊缝，等料头达到目标压下量，没有后张力和前张力。b) Threading:穿带Strip head between roll gap and coiler; no forward tension, only back tension料头在辊缝和卷取机之间，没有前张力，仅有后张力。c) Crawling:爬行Strip head winded on coiler, forward and back tension, slow speed料头卷在卷取机上，有前张力和后张力，速度慢。d) Rolling:轧制like c) but with max. rolling speed像c）但是有最大的轧制速度e) Tail out:抛出like b), coil end between uncoiler and roll gap, no back tension, only forward tension像b)料尾在开卷机和辊缝之间，没有后张力，仅有前张力。i.e. the calculations consider the rolling phases by having certain side conditions regardingtension and speed.即计算时要考虑轧制阶段中某些关于张力和速度的现场条件。The different sub-models are closely connected to each other. Outputs of one modeldeliver inputs for other models.不同的子模型相互间是紧密相连的。一个模型的输出是其它模型的输入。The following picture gives a survey of the submodels and their main interactions:下图给出了子模型概观和它们主要相互作用。6. Submodels子模型6.1 Calculation of reduction distribution压下率分布计算The rolling model calculates the reduction distribution (thickness distribution) between anentry thickness and a given exit thickness considering various restrictions regarding millability, material quality and productivity goals.轧制模型在入口厚度和一个给定的出口厚度间计算压下率分布（厚度分布），考虑到各种关于轧机能力，材料质量和生产效率目标的约束。For a specific type of product the following limits can be configured using practice tables:对于一种具体类型的产品，用工艺制度表能够设定下列限制因素：. Maximum and minimum reduction最大和最小压下量. Maximum specific roll force最大单位轧制力. Maximum draft最大压下量Satisfying these restrictions ensures a strip quality concerning the metallurgical properties, flatness and strip surface. 满足这些限制因素确保冶金性能，平整度和带材表面这些带材质量。They need to be defined in close cooperation with the customer.需要在与客户密切合作中定义他们。(The surface quality will be adjusted in the last pass using the appropriate work rolltextures. The model will preplan the reduction in this pass and provide the roll typespecific friction values.)（在最后道次用适当的工作辊纹理（表面）调整带材表面质量。模型将预先计划在这个道次的压下量，提供轧辊型的具体特定摩擦值）Additionally the production goals are satisfied by considering the following restrictions:因此，通过考虑下列因素来实现生产目标：. ensure an effective utilization of the plant by calculating the minimum number ofPasses通过计算道次最小数来确保设备的有效利用。. remain within the mill limits (max. force, max. torque)保持在轧机限制范围内（最大轧制力，最大轧制扭矩）A fixed reduction in the final pass can be configured due to material grade or a moregeneral operation practice code. Level3 or operator will input information into Level2 formax. one possible annealing thickness and max. one possible trim thickness. Thesethicknesses will be treated as fixed intermediate thicknesses by the pass schedulecalculation.根据材料等级或更多的操作实践代码设定最后道次的固定压下量。3级系统或操作员将输入信息到2级系统，以最大可能的退火厚度和最大可能的剪切厚度。这些厚度通过轧制道次表计算将作为固定的中间厚度。The reduction distribution can be calculated to achieve a) minimum rolling time, b) equalreductions or c) linear force distribution from pass to pass:能够计算压下率分布来实现从一个道次到另一个道次的a）最小轧制时间，b）等同的压下量或c）轧制力线性分布。Explanations:说明a) Minimum rolling time is achieved when high reductions are rolled at the end of thesequence of passes and small reductions in the beginning.当较高的压下率在道次表的末尾和较小的压下率在道次表的前面时，能够实现最短的轧制时间。b) The total logarithmic deformation is devided by a minimum number of passes in sucha way that each pass has the same deformation rate within the allowed limitations.用这样一种方式使每个道次在允许的范围内有相同的变形率，把整个对数变形应变量分到最小的道次数。c) The preconfigured force difference between succeeding passes (linear declining orrising or equal distribution) determines the amount of reduction in each pass预设定后续道次间的轧制力差异（轧制力线性减小或增加或均等分布）决定每个道次的压下率。During rolling of several passes a recalculation correcting the subsequent passes can beperformed when e.g. an intermediate thickness was not reached or the material appearedto be harder than estimated.在几个道次的轧制期间，当没有达到中间厚度或材料比估计的更硬时，能够进行为随后道次校准的重新计算。Fig.: Different gauge hoses for different products图：不同产品的不同厚度分布曲线The reduction distribution is calculated in the following way:以下列方式计算压下率分布1st step:第一步：Determine the minimum number of passes by concatenating, beginning from the startthickness, the maximum reductions per pass until the exit thickness falls below thedesired final thickness.从起始厚度开始，按每个道次的最大压下率，一直往下排，直到出口厚度达到希望的最终厚度以下，从而确定最小道次数。2nd step:第二步：Shorten the reductions per pass according to one of the strategies in such a way that theexit thickness exactly meets the desired final thickness.按照某一种控制策略减小每个道次的压下率，直到在出口厚度的确为所希望的最终厚度。3rd step:第三步：Calculate the entry and exit thickness for each pass.计算每个道次的入口和出口厚度。6.2 Calculation of tensions张力计算The spec. tension (unit:N/mm) can be configured in the database due to thickness andyield stress. The difference (additive or multiplicative value) between entry and exittension can be configured in the database as well.单位张力能够在数据库根据厚度和屈服应力进行配置。出口和入口厚度的差异（加法值或乘积）也能在数据库里进行配置。The absolute tension (unit: kN) is calculated by tension = spec. tension x width x strip thickness.根据张力单位张力x宽度x带材厚度计算绝对张力（单位：kN)The tensions are limited by the maximum entry and exit tension.最大入口张力和出口张力限制张力。6.3 Determination of maximum speed最大速度的确定The max. rolling speed can be determined due to material or product dependent practicesdefined in the database. This preconfigured speed will be checked against the availablemotor powers of the mill drive, uncoiler and coiler drives using the following equations:最大的轧制速度能够根据材料或数据库里定义的与产品相关的工艺制度进行确定。预配置的速度通过轧机传动、开卷机和卷取机传动的电机功率来核算，用下列等式进行验算。. Mill drive power = Rolling torque x Rolling Speed / Work roll radius轧机传动功率轧制扭矩/工作辊半径x轧制速度. Uncoiler power = Entry tension x Strip entry speed开卷机功率入口张力x带材进入速度. Coiler power = Exit tension x Strip exit speed卷取机功率出口张力x带材出口速度The maximum rolling speed given to the operator will be the minimum of the rollingspeeds given by the preconfiguation / equations mentioned above:Vr_max = min(Vr_max1, Vr_max2, Vr_max3, Vr_max4)用于操作员操作的最大轧制速度将是预配置/上述提到的等式规定的最小轧制速度，即：Vr_max = min(Vr_max1, Vr_max2, Vr_max3, Vr_max4)。6.4 Roll Gap Model轧辊辊缝模型The roll gap model calculates轧辊辊缝模型计算：. roll force 轧制力. roll torque 轧制力矩. deformation and friction energy变形和摩擦能量. forward slip 前滑It uses the yield stress and friction model and adaptation coefficients. This model takesinto account the roll flattening and plastic and elastic deformation of the strip in the rollgap. 它使用屈服应力和摩擦力模型和适应系数。这个模型考虑轧辊的压扁和辊缝里带材的塑性和弹性变形。The roll force and torque is calculated according to the theory by Bland, Ford, Ellis solvinga differential equation and integrating the pressure along the contact length between stripand work roll.依据布莱德，福特，埃利斯的理论对一个微分方程求解，对带材和工作辊间的接触弧长度上的压力进行积分计算轧制力和轧制扭矩。The forward slip is determined by the difference between strip exit speed and neutral pointspeed (rolling speed) related to the rolling speed.前滑值由带材出口速度和与轧制速度相关的中性点速度（轧制速度）间的差异确定。6.4.1 Yield-Stress Model屈服应力模型The yield stress curve is a function of degree of deformation, deformation rate and striptemperatu