西门子奥钢联AFC板型控制系统培训教程

VATECH,VANTAGEControlSystem(VantageisaVAItrademark),WhatistheVantageSystem,TheVantagesystemisageneralpurposeindustrialcontrolsystemdevelopedbyVAI.Thismodelwasconfiguredforshapeandgaugecontrolonrollingmills.ItisanaturalprogressivedevelopmentfromitspredecessorsDavymap,System_Two,System21andVioneersystemstakingadvantageofthelatestPChardwareandoperatingsystemimprovements.Sincemanyofthedevelopmentengineersarethesamepeoplethatworkedontheearliersystems,manyoftheshortcomingsexperiencedwiththosesystemshavebeenremoved.Asthesystemisauniversalcontrolsystem(forhotmills,reversingmillsetc.)somefeatureswillnotbeapplicabletoallinstallations.Thus,someofthedescriptionswithinthegeneraldocumentationwillnotapplytothisinstallations.ItisnotVAIspolicytotailorthedocumentationtospecificinstallations.Inotherwordsifthefeaturedoesnotapplythenignoreit.,ControlFeaturesVantage,AGC(GEFB)modesShapeControl,Load(Force)TensionSpeed+combinationsBendSteerSprays,AdditionalVantagefeatures,PictorialOperatorandmaintenancediagnostictools.HistorydisplayofshapeandgaugetracesRollLoadCylinderposition(gap)control.Widows2000operatingsystem.“Offtheshelf”hardware.Fulldiscbaseddocumentation.Individualcoildataloggingforpostrollingdiagnostics.,TheOperatorsinterfacecomponents,FlatScreenMonitor,keyboard/andtrackerball/mouseattachedtoanetworkedPC.TheMonitor,keyboardandswitcheshavebeenselectedtoberesilienttoindustrialgrimefromtheexpectednormalusage(oilyfingersanddustshouldnotcauseproblems).AndviaaProfibusnodePushbuttonswitchesforvarioussimplecontrolfunctionselectionSpinwheelmodules(digitalpotentiometers)foradjustmentsto“analoguethread/runreferences.Theprimaryrootpageofthedisplayistermedthe“processpage”displayingtheoperatingconditionsandstatusinformation.Additionaldiagnosticanddataentrypagesareaccessedbycursorselectedpulldownmenus(ordirectkeyboardfunctionswitchesF1F12).,GaugehistoryTrace,OperatorsProcesspage,Instantaneousshape/spraydisplay,ShapehistoryTrace,MillMimic,Pulldownmenu,ShapeTracedisplays,CurrentshapeAbove=tightBelow=loose,ActivespraylevelsGreen=autoBluemanual,Clickheretoincrease/decreasescale,ShapehistoryBluetightRedLoose,Start,Timedtraverse,“Now”,Gaugetrace,Clickheretoincrease/decreasetracescale,GEFBstatusGreynotselectedYellowselectedbutwaitingGreen-active,Digitalgaugeerrorvalue,Gaugeerrorbargraph,Historictrace,TypicalPullDownmenuoptionsEnteredbyF12or“clickonmenu”,EnteredbyF11or“clickonmenu”,EnteredbyF2or“clickonmenu”,TypicalSubdiagnosticpanels,Clicktogetthis,pause,Ifyouwantmoredetailedexplanationsofthe“diagnostics”andadditionalpagesthentheyarefullyexplainedintheOperatorsUserGuideManual.Storedonthesystemasatextdocument.Naturallynotallpossiblefaultscanbeaccessedfromtheoperatorsdiagnosticscreens.MoredetailedVAI-SPYsareavailableontheSystemManagerandtheEngineersterminal.Ingeneralthefirstpointofinvestigationsshouldbebytheoperator.E.G.ifthesystemrefusestoallowexitfromventtheremaybeasimplereasonsayhydraulicfailureorsomemoremajorfaultsuchasaservovalvefailure.,CriticalDataEntry,Inprinciplealldataentryiscriticalforvariousreasonsandwillhavesomeeffectonthesystemperformance.Enterwrongdata-thenthesystemwillrespondbymakingthewrongcalculationsandcorrections.EntryIfthegaugeisovertarget(thick)thentheprimaryisincreased.Therearenohardandfastrulesthatdefineanexactthicknessthatanyparticularprimaryactuatormustbeuseditwillvaryfrommilltomillandproduct.Thegeneralrule:-Forthickexitgauge(strip)usecylinders.FormediumthicknessusetensionForthinfoilusespeed.,Effectiveness,10micron,10mm,100micron,1mm,Cylinder,Tension,Speed,Typicalcontrollerresponsewiththickness,GEFBcylindercontrol,Fromthepreviousdiagramcylindercouldbeuseddownto200micron,howevertherearetwocontrolmodesoftherollloadcylinders.GAP-thegapbetweentheworkrollsisadjustedrelativetothecalibrated“zero”position.Therollforceisallowedtogowhereitneedsto.Forcethepressureintherollloadcylindersisadjustedandthe“rollgap”willgowhereitneedstogo.Theadvantagesofusinggapcontrolisthatthemillisrelativelystiffandchangesofinputgaugetendtobeattenuatedbeforethegaugemeasurementsystemseesthem.Thedisadvantageisthatrolleccentricitiescanbeimprintedintotheproduct.Atsmallgapsettingstheworkrollswilltouchtogetheroutsideofthestripthusreducingtheeffectivenessofgapchanges.Theadvantageofusingforceisthattherolleccentricityimprintsaremuchless.Thedisadvantageisthatthemillbecomessoftsothatmostoftheinputgaugechangesarepassedthroughthebyte.Thepointatwhichgaporforceshouldbeusedisdependantonthemillandproduct.,GEFBTensionControl,Thismodeusesthepayoff(entryunwind)tensioncontrollertoalterthestriptension.Normallyusedforthethinnerpasseswhentherollsareincontactandchangesinrollforcetendtobeabsorbedbythemillratherthantheproduct.Sincethetensionisproducedbyamotor/gearboxthatmayhavetoturn10tonnecoils,theresponseisslowerthancylindercontrol.Thusfastchangesingaugecannotbecorrected,plusmostoftheinputchangesdopassthroughthebyte(cylindersinforcecontrol).SPEEDCONTROLThiscontrolmodeisusedforthethinnestgauges.Oftenthenonpreferredmodeasthemillspeedcanchangealot.,SecondaryGEFBmode.,Secondarycontrolisameanswherebytheprimaryisdrivenbackintoapreferredoperatingrangebyadjustingoneoftheothercontrollers.E.g.TENSION/speedTENSION/forceSPEED/tension.Theprimaryisstillallowedtobeadjustedoveritsfullpermittedrange.Theprincipleis:-iftheprimaryisabovetheupperspilloverlimitthenthesecondarycontrollerisincreased(untilitreachesitsmaximumlimit)thusallowingAGCtopulltheprimarybackbelowtheupperspilloverlimit.Iftheprimaryisbelowthelowerspilloverlimitthenthesecondaryisreduced(whileaboveitslowerlimit)thusallowingAGCtobringtheprimarybackabovethelowerspilloverlimit.Iftheprimaryisbetweenthespilloverlimitsthenthesecondaryisleftalone.,cccExamplefortension/speed,_Absolutemachinemaximum-MaximumTension(stress)-INCREASESPEEDINTHISAREA-upperspilloverlimit-=nominalstress=-=-lowerspilloverlimit-DECREASESPEEDINTHISAREA-MinimumTension(stress)-_AbsolutemachineminimumIftheupperspilloverlimitisclosetothenominallevelthenthespeedwilltendtoincreaseuntilitreachesthelimitsetwithreferencetotheenteredrunspeed.Bysettingthelowerspilloverlimitclosetotheminimumlevelthenthespeedwillnotnormallyreducebyspilloveraction.,Whatcanintroducepoorgaugespread?Besidesmillmechanical/hydraulicproblems.,spool,Badinitialwrap,Actualtensiondependsontheradius!,Duetothebadstartonthepreviouspasstheentrytensionwillvaryastheentrycoilrotatesbecausetheradiuschanges,Themorethatacoiliseccentricthegreaterthetensioneffect.,Mostcommonproblemistheinputcoil,ShapeControl,Whatdoes“shapecontrol”reallymean?Whatisan“I”unit?Wheredothe“shapeerrors”comefrom?Howdowecorrecttheseshapeerrors?,ShapeControl,Shapeorflatnessofsheetmaterialisadescriptionofthetensiondistributionsacrossit.Ifthetensiondistributionisuneventhenthesheetwilltendtobucklewhenlaidflat.Shapecontrolevensoutthetensions(stresses)totherequiredflatness.Profileisthevariationsinthicknessacrossthesheet.Shapecontrolisnot“profile”control.Themeasurementunitofshapeisthe“I”unit.,Whatisan“I”unit?,TheIunitistheunitmeasurementofeffectiveshapeandisbasedonthedifferencesin“lengths”ofportionsofthesheetthatproducethestressesinthesheetcausingthewrinkles.,AverageNominalLength“L”,Shapeerror=x*100,000Iunits,L,Ifthesheetissplitintostripsalongitslengththensomeofthestripswillbeofdifferentlengthsastheyarereleasedfromthenearbystrip.The“loose”sectionswillbelongerthanthe“tight”sections.,Differenceinlength“x”,AnIunitisaverysmallnumber!,Wheredotheshapeerrorscomefrom?,Shapeerrorsarealwaysclassifiedintwogroups“online”and“offline”.OnlinethedynamicerrorsduringtherollingprocessOfflinetheerrorsseenafterthecoilhasbeenremovedandallowedtocool.,Howdowecorrectshapeerrors?,Beforewecancontrolshapeweneedsomemeansofmeasuringtheshapeashapemeter.VAInormallyuseanairbearingrolltomeasureshape.Thisrollhasaseriesofrotorsonastaticarbour.Theclearancebetweentherotorsandarbourchangesdependantontheforcepressingdownoneachrotor,thisdisturbstheaircushion.Apressuresensorforeachrotordetectsthedifference,producingasignalproportionaltotheappliedforceontherotors.Theamountofforcetransferredfromthestriptensionisdependantonhowmuchareaofthestripisindirectcontactwiththerotor(thewrapangle).,TypicalShapeDisplay,Steererror,Benderror,Theshapeerrorcanbesplitintothreebasicformats,Andwhatisleftovergoestosprays,Theseerrors,Reallydoadduptothis,Steererror,Thissymmetricallinearerroriscompensatedforbyadjustingtherollloadcylinderforce(orposition),Tomaintainthecentreatnominalgauge,halfofthecorrectionisaddedtothedriveside,halfsubtractedfromthenon-driveside.,Thissymmetricalparabolicerroriscompensatedforbyadjustingtherollbendcylinderforces,Benderror,Ifthecentreisloose(beingoverrolled)thenthebendistoopositiveandneedstobereduced.Iftheedgesareloose(thereverseofthefigure)thenthebendneedstobemovedmorepositive.,SprayControl,SprayError,Abovetheline=tig