信息技术和自动化的研究成果

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信息技术和自动化的研究成果。

International Publications of Metal Pass

Introduction: Over 30 papers on steel automation especially on the Level 2 improvement and further development were written in the period from mid-February to mid-March and were published.

Report on the development of steel mill Level 2 supervisory system (75 pages)

Contents

(1) Rolling Mill Level 2 Systems
     1.1 Reheating Furnace Level 2
     1.2 Level 2 System for Rod Mills
     1.3 A Cold Mill Control And Automation System
     1.4 Coil Tracking and Maintenance Management
(2) Level 3 Systems
     2.1 Level 3 Scheduling (Mill Scheduling)
     2.2 Level 3 Reporting
(3) General Structure and Layout of a Meltshop Level 2
     - Network
     - PLC Data Collection & Level 1
     - Database
     - General Functions of each Sub-Systems
     - Furnace/CAS/RM or EAF/LMF/CAS/RM
     - L2 Monitor
(4) Implementation of Level 2 System for the Meltshop
     4.1 Scheduling
     4.2 Interface to PLC
     4.3 Data Manager
     4.4 Heat Tracking System
     4.5 Interface to Database Server
     4.6 Interface to Labs (Chemical and Mechanical)
     4.7 Inter-Application Server (EAF-LMF-CAS)
     4.8 Process Modeling
Total pages: 75

Development for an Upgradeable Level 2 System with Metallurgical Principles (30 pages)

Project Summary: The proposed project will develop a supplement software package for the existing steel mill automation system to accurately predict rolling process parameters, by fully applying the metallurgical principles, rolling process models and most current information technologies. Since long the steel mills has increasingly applied technologies such as microslloying, physical metallurgy and controlled rolling. The metallurgical parameters such as the strain retained from the previous passes and the grain size pass by pass, play a critical role in the model accuracy in the automation system. The current systems, however, usually only treat the steel rolling as a mechanical process and ignore its metallurgical phenomena. The inaccurate automation systems create poor draft schedules that lead to poor product quality (shape and properties), low production efficiency and high energy consumption.

The proposed system will simulate microstructure evolution, integrate about 100 rolling process models and apply intelligent learning technologies, so that the accuracy for the rolling parameter prediction is sufficiently high. The software package will use most current information technologies, in comparison with many current packages which are still running on old OpenVMS rather than Windows. The technology will be commercialized as a new module within the company's existing automation system, and it will performs three possible functions: (1) it predicts metallurgical parameters, such as the retained strain and initial grain size for each pass; (2) it provides a full range of rolling process parameters and it may also modify the draft schedules created by the existing model; and, (3) it replace existing Level 2 model in the current automation system.

Strip Mill Process Modeling and Computer Integration (63 pages)

Introduction: This research document deals with various issues of the strip mill modeling and computer control, especially the Level 2 system.

Contents:

Part I: Strip Mill Process Model and Control System	2

Strip Mill Setup Model	2
General	2
Parameters to be Predicted	2
Function to be performed	3
Prediction	3
Data I/O	3
Mill Setup	3
Models available through partners	4
Steel Mill Equipment	5
Mill Operation	6
Control System	6
Mill Control & Information Systems development	6

Part II: Multi-Level Control System	7

2.1 Introduction to Multi-Level Control	7
Purdue Model for Control Hierarchy	7
Evaluation of Purdue Model	8
Control & Information System	8
Evaluation of Level 2 Control System	9
Advantages of Using Level 2 Model	9
Disadvantages of Using Level 2 Model	9
Types of Level 2 Models	9
Model Complexity and Accuracy	10
Model Simplification	11

2.2 Level 2/Level 3 Function Specification	11
Functions of Level-2 Model	11
Tuning and Learning	12
Level 2 Force Set Up Calculation	13
Data Flow of Level 2 Set Up Model	14
Practical Considerations on Set Up	14
Level-2 Learning Model	15
Relationship between Level 1, Level 2, and Level 3	16
Web-based Automation System	17

Part III: Rolling Mill Basics	21

Calculation of Rolling Force	21
Factors Affecting Rolling Force	21

Part IV: Crown	22

Crown	22
Thermal/Wear Models	23
Factors Affecting Thermal Profiles	24
Thermal Models - Roll Cooling	25
Two Approaches on Thermal Models	25
Lumped System ?Results	26
1-D Exact Solution	27

V. Automatic Gauge Control (AGC)	27

Gauge Control ?Single Stand	27
Control Theories	28
Mill Modulus Concept	28
Gaugemeter Principle	28
Sim抯 Gaugemeter Principle	29
Application of Gaugemeter Principle	30
Mass Flow Rule in Roll Bite	30
Force/Torque/Slip Sensitivity	30
Automatic Gauge Control	31
Controlling Systems	32
AGC Step Response in Time Domain	32
Gauge Control ?Tandem Stands	33
Solving Mill Dynamics	34
Rolling Schedules for Case Study	35
Exit Gauge Changes Due to Disturbance of Screw Position and Friction Coef.	35
Exit Gauge Changes, Due to Disturbance of Speed, Entry/Anneal Gauge, and Hardness	36
Control System of a Tandem Mill	36
Exit Gage Frequency Response	37
Rolling Mill Gauge Control Components	37
Definition of Gauge	37
Definitions of Profile	37
Gauging Systems	38
Discussion on Gauge Deviation Bandwidth	39
AGC Requirements	40
Mill Threading Considerations	40
Material Stiffness Gain Calculations	41
AGC System Design Considerations	42
Constant Mass Flow Considerations	43

Part VI: Model Based Thickness Control of the Cold Strip Rolling Process	48

Thickness Control	48
Thickness Control of a Reversing Cold Rolling Mill	48
The Drive System of a Reversing Mill	50
Sensors of a Cold Rolling Mill	50
Roll Adjusting System	52
AGC - Automatic Gauge Control	53
In-Gap Control and Similar Methods	54
Gaugemeter Control	55
Monitor Control	57
Feed Forward Control	58
Mass-Flow Control	59
Strip flatness and profile	60

Summary	61

Plate Mill Level 2 Model A: Mathematical Models (5 pages)

Abstract: This file describes the basic mathematical formulas as the algorithm of a plate mill Level 2 model, to predict parameters such as Q-factor, Flow stress, Force, Torque, and temperature (deformation work, radiation, conduction and mill water, etc.).

Plate Mill Level 2 Model B: Mill Operation Prediction (13 pages)

Abstract: This document describes the logics for the mill operation processes and parameters prediction. The contents can be broken into following sections. (1) Operation practice handling including Edge Setup and Learning, Controlled Rolling Model (hold, two-piece rolling, etc.), Shape Model, Mill Deflection Model, Work Roll Thermal and Wear Model, Work Roll Bending Model, and Leveller Setup and Learning, etc. (2) Learning Model, which includes Adaptive Learning, Short-Term Correction, Long-term learning, Flow stress Model Adaption, Torque Model Adaption, and Temperature Model Adaption, etc.

Plate Mill Level 2 Model C: Programming (52 pages)

Introduction: This document describes the implementation logics for the major components and sub-ystems of the Level 2 model.

Contents:

1	Mill Model and Model Components	1
2	Programming Issues	2
2.1	Data Structure and Files	2
2.2	Data Files	2
2.2.1	Data Files	2
2.2.2	Global Commons	2
2.2.3	Local Commons	3
2.3	Data File Descriptions	3
2.3.1	Mill Constants File	3
2.3.2	Grade Files	4
2.3.3	Family Files	4
2.3.4	Product Files	5
2.3.5	Practice Files	5
2.3.6	Width Spread and Recovery File	5
2.3.7	Alternate Gauge File	5
3	Mill Setup (Draft Distribution) Model	7
3.1	General	7
3.2	Model Modes of Operation	8
3.3	Inputs to Setup Model	8
3.4	Outputs from the Setup Model	9
3.5	Alternate gauges	9
3.6	Other Setup Functions	9
3.7	Mill Setup Software Structure	10
3.8	Software Routines	10
4	Roll Bite and Temperature Evolution Models	17
4.1	Software Routines	17
5	Edge Setup and Learning	19
5.1	General	19
5.1.1	Edger Model Parameters and Flags	19
5.2	Software and programming Issues	20
5.2.1	Edger Setup Software Structure (DD_CALC)	20
5.2.2	Edger Setup Software Routines	20
5.2.3	Edger Learning Software Structure (LEARNING)	22
5.2.4	Edger Learning Software Routines	22
6	Controlled Rolling Model	23
6.1	Software Routines	23
7	Shape Model	23
8	Mill Deflection Model	26
8.1	Software Structure	26
8.2	Software Routines	27
9	Work Roll Thermal and Wear Models	29
9.1	Software and Programming	29
9.1.1	Software Structure	29
9.1.2	Software Routines	29
10	Work Roll Bending Model	30
10.1	Software	30
10.1.1	Bending Setup Subroutines	30
10.1.2	Crown Learning	31
10.1.3	Crown Learning Subroutines	31
11	Adaptive Learning Model	33
11.1	Software	33
11.1.1	Software Structure	33
11.1.2	Software Routines	33
12	Leveller Setup and Learning	39
12.1	General	39
12.2	Software	40
12.2.1	Leveller Data Tables	40
12.2.2	Leveller Gap Setup	40
12.2.3	Leveller Gap Setup Routines	40
12.2.4	Leveller Torque and Gap Learning	41
12.2.5	Leveller Gap and Torque Learning Routines	41
13	Models Interface	42
13.1	General	42
13.1.1	Models Interface	42
13.2	Software Structure	43
14	Model File Directory Structure	45
14.1	General	45
14.2	Directory Contents	46
15	Monitoring Model Performance	47
15.1	Man Machine Interface	47
15.2	Model Evaluation Logs	47
15.3	Program Event Files	48
15.4	Error Files from Program Crashes	48
16	Model Tuning	49
16.1	General	49
16.2	Mill Constants	49
17	Setting Up New Grade and Family Files	49
17.1	General	49
17.2	Grade File Copying Procedure	50
17.3	Family File Copying Procedure	50
18	Models Utility Programs and Procedures	50
18.1	General	50
18.2	Command Procedures	50
18.3	Utility Programs	52

Plate Mill Level 2 Model D: Monitoring Model Performance (25 pages)

Abstract: This file illustrates the design and the application of the log files, so that the Level 2 administrator can monitor the model performance by reviewing or evaluating the log files. Examples are illustrated to discuss Mill constants, Mill process and operation parameters, Grade constants, and Family constants, etc.

Plate Mill Level 3/Level 2 Interaction (18 pages)

Introduction: This document specifies the design of the Level3 to Level2 Primary Data Input (PDI) file for the combination mill. The PDI is the production scheduling instruction that the Level 2 uses as guideline to execute the production operation.

Contents

1	Level 2 / Level 3 Interaction	1
1.1	Introduction	1
1.1.1	Communication Protocol	1
1.1.2	PDI File	2
1.2	Data Contained in the PDI Files	3
1.2.1	PDI File Directory Structure	3
1.2.2	PDI File Detail Slab Information and Record Structure	3
1.2.3	Slab Information	4
1.2.4	Practices	5
1.2.5	Coil Information	6
1.2.6	Max Plate Information	7
1.2.7	Mini Max Plate Information	9
1.3	Mill Level 2 Control System Requirements	11
1.3.1	Required Tests	11
1.3.2	Practices	11
1.3.3	Marking Instructions	11
1.3.4	Processing Instructions	11
1.3.5	Max Plate Information	12
1.3.6	Mini Max Plate Information	12
1.3.7	Stacker Location	12
1.4	Software Module Process and Data-flow	13
1.4.1	Main Program Module	13
1.4.2	Description of Selected Functions	15

Level 2 to Level 3 Database Tables (5 pages)

Abstract: This is the cross-refererence for the definition of both the data structures and the database table columns. Over 20 data definition tables are listed in this document. The definition is used to implement the functions to move data from Level 2 system to the Level 3 database. Related data include those for reheating furnace, rolling mills and the controlled cooling operation.

Level 2 Management - Design Document (20 pages)

This design document describes the tools or software modules for the Level 2 system management in various platforms.

Contents:

1	Overview	1
1.1	Level 2 Modules	1
1.2	Application Software	2
1.2.1	System Data Flow	3
1.3	Utility Programs	11
1.3.1	Parameter Editor	11
2	General Design	12
2.1	Directory structure	12
2.2	Operator Interface	14
3	Data Manager	14
3.1	Data management	14
3.2	MMF creation	14
3.3	MMI data supply	15
3.4	DBMS data preparation	15
3.5	Event Data	15
3.5.1	Windows	15
3.5.2	OpenVMS	15
3.6	Standard Subroutines	15
3.6.1	Windows and OpenVMS	15
3.6.2	OpenVMS only	16
4	Process Manager (L2Mgr)	18
5	Inter-Process communication	18
6	Mill Interface	19
6.1	Mill	19
6.2	Downcoiler/Leveller	19
6.3	Shear Trimmer	19
6.4	Coiling bed	19
7	Reheating furnace interface	19
8	ACC interface	19
9	Other interfaces	19

Tippins Level 2 Source Code Functions Cross-Reference (12 pages)

Abstract: This is an Excel file based on the research of the Tippins Level 2 source code, especially those implementing Level 2 model. The file lists Function Name, Description, Called_By (called by which functions), Chapter (in the document), and Folder (in the Level 2 production server), etc. This files describes over 300 functions. (The file was created inside a consulting project to improve the Tippins Level 2 model).

Meltshop EAF/LMF Level 2 General Function Specification (28 pages)

Abstract: This document outlines the general function specifications from the user's perspective. Besides the general screens and functions (Scheduling, Charging, Delays, Events, Parts life, Heat Line-up, Process tracking, Cutting, etc.), it also covers some calculation algorithms such as those for Scrap and alloy addition, and chemistry prediction and temperature modeling, etc.

Level 2 Data and Database Design (49 pages)

Introduction: This document (also served as the Chapter 4 of the book ***) coves detailed data and database design for the meltshop Level 2 systems (EAF/LMF Level 2 and Caster Level 2). It includes designs for data variables, data structures (in the programming level) and database tables (e.g. in Oracle). and cross-reference for the data, data structure and database. It also provides the cross-references among the data structure, Memory-Mapped-Files, flat files and database tables.

Level 2 System Configuration (24 pages)

Introduction: This document (also served as the Chapter 5 of the book*** ) provides guidelines for the system integration among the Level 1, Level 2, Level 3 and the general IT system in a steel plant environment. The configuration for the Level 2 systems covers HMI computer configuration (including Windows Registry configuration), Level 2 server configuration (including those for Windows Registry), and Level 2 manager setup, etc.

Level 2 Interfaces (15 pages)

Introduction: Communication interface (Chapter 7 of the book*** ) of the Level 2 system with Scrap Handling System computer, EAL PLCs, LMF PLCs, Caster PLCs and Chemical Lab data acquisition system, etc. Level 2 collects the data based on the designated PLC addresses and other system interfaces.

Human-Machine Interface (HMI) screen Implementation (5 pages)

Introduction: This file (Chapter 8 of the book***)) discusses dozens of Visual Basic classes that implement the HMI screens. About 50 well-designed screens were used in the Level 2 systems that the reporter designed. Code reuse and object-oriented principle were integrated in the design and implementation.

EAF/LMF Level 2 implementation (13 pages)

Abstract: This document (Chapter 9 of the book*** )) discussess with software programming issues for the EAF/LMF Level 2 system. Contents include Memory-Mapped Files (MMFs) structures and coding, diagrams on class composition and derivation (parent/derived classes), diagrams on structure association and composition and global structures, and the detailed code discussion on some key classes such as those to send data into the Oracle database.

Caster Level 2 implementation (10 pages)

Abstract: This file (Chapter 10 of the book***)) discusses the software programming issues with both diagram illustration and text explanation. Topics covered are such as the association and composition of over a dozen structures, association and derivation of about 20 classes, difinition of the major structures, and the properties and functions for each of the primary classes. In addition, code examples of the major classes and implementations are discussed.

Level 2 Data and Data Storage Implementation (36 pages)

Abstract: This document (Chapter 11 of the book***)) deals with the software programming of the following issues: (1) Table category and table functions; (2) Definition of major parameters during coding, and the links to the corresponding columns in Oracle table; (3) Data linking among various Level 2 systems (EAF/LMF Level2 and Caster Level 2); (4) Diagrams on data association among PLCs, Level 2 systems, HMIs and Oracle Database; (5) Detailed table definitions for Oracle tables; and (6) definition of related flat file structures and some code examples.

Level 2 Data Security Design and Implementation (5 page)

Abstract: This document describes the design and implementation of the steel mill Level 2 supervisory system to guarentee there is no data loss during the Level 2 operation. The Windows Level 2 server sometimes lost connection with the Oracle data and thus caused data loss. The fix to the problem was to store the SQL INSERT scripts (containing data) in the Level 2 server whenever the Level 2 found no connections with the Oracle database server; and whenever the Level 2 server regained the connection with the database server, it would immediately execute the INSERT script to send the kept data into the database server. This file contains the class diagrams and function descriptions for the implementation of such a data security component.

Software and Technologies Related to the Level 2 Projects (11 pages)

Abstract: This document (Chapter 13 of the book*** )) introduces major software packages and technologies based on which the said Level 2 software systems were designed and implemented. Selected topics include: (1) Introduction of RSView and RSLinks; (2) RSView basic setup issues; (3) Introduction to DDE, DDE Link and Network DDE; (4) PLC card (e.g. Allen-Bradley 1784-KT card) configuration; (5) DDE conversation setup via RSView; (6) OPC basics; and (7) Oracle database topics collection and Oracle setup through Windows ControlPanel.

Appendix: EAF Bits (6 pages)

Introduction: This is one of the most fundamental design documents in bridging the EAF PLC bits and the Level 2 parameters. This PDF file is based on the original Excel work sheets.

Steel Mill Slab Management System Design and Function Specification (50 pages)

Summary: This is the design by Dr. Benjamin Li on the steel plate mill slab providing and optimization. Besides a slab inventory system for slab history tracking and management, there are slab size optimization and slab grade optimization. The optimizations are based on the steel rolling process models established by Dr. Benjamin Li.

Short evaluation of ABB Level 2 supervisory system (25 pages)

Abstract: The report covers the tracking and reporting system, and hardware, software and services, etc. The software includes functions such as order management, material tracking, tracking correction, data security, calculation, delay handling, roll management, equipment monitor, and various data reports, etc.

Evaluation of Morgan's Mill Supervisory System Proposal (20 pages).

Abstract: Though many or Morgan's mill use ABB control, Morgan has its own additions to the control vendor's system or its own proposals in this aspect. The evaluated proposals include mill scheduling editor, mill tracking, Stelmor conveyor tracking, Roll management, etc. in addition to general functions of a supervisory system.

OpenVMS User Guide Created for Steel Mill Systems (500 Pages)

Introduction: This is a 500-page document created particularly for the steel mill engineers who use OpenVMS to run their engineering applications such as the Level 2. Some steel mill applications based on OpenVMS are used as example

Metal Pass 108 Mill-related Projects

Introduction: The projects are primarily focused on steel mill Level 2 and mill process modeling. 96 of them were done by Dr. Benjamin Li while the rest 12 were from other consultants.

Metallurgical, Modeling and Software Engineering Issues in the Further Development of the Steel Mill Level 2 Models (Extracted from the paper published in AIST 2008 Conference)

Level 2 Model Basics

Metallurgical Issues in Level 2

Modeling Issues in Level 2

Software Engineering Issues in Level 2

Next-Generation Level 2 System

*** Some documents were used as a chapter of a book in writing on Steel Mill Process Modeling and Computer Application. Due to the large amount of the first-hand results, the book is now intended to be used as the consulting project resources rather than for publishing with a publisher.

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