0 Overview Baosteel 2 continuous casting has 2 continuous casting machines with a total of 4 flows. Its core control device is the CP3500 HPLC of Japan's Yaskawa Corporation. There are a total of seven units connected through VNet. During the construction of Baosteel No.2 Continuous Casting, there was no well-equipped equipment monitoring system. Equipment maintenance personnel could only check the status of a small amount of equipment through the PLC programmer. The vast majority of equipment status was not recorded. This status could not fully meet equipment maintenance requirements. need. In the off-duty, especially the state of the equipment on the holidays, the alarm situation can not be fully grasped, which brings more trouble to the maintenance of the equipment. In order to solve the difficulties in the field, it was decided in 2000 that a monitoring system for electrical equipment was installed in Erlian Casting to realize equipment data recording and remote monitoring.

The prerequisite for the establishment of an electrical equipment monitoring system is that the PLC provides comprehensive, accurate and timely data. Yaskawa's CP3500H PLC, although very reliable, but the model has been discontinued, insufficient data, coupled with the limited openness of the VNet network, a large number of PLC internal data can not be released, so the project team members first developed a VNet-based The network conversion and data interception acquisition technology can obtain all the PLC data and provide a solid data foundation for the implementation of the monitoring system.

The entire electrical equipment monitoring system uses Intellution's iFIX2.6 software, SQL Server software and Ethernet as the platform. In addition to providing traditional remote monitoring functions, it also provides real-time/history curves, monitoring of equipment operating conditions, alarm recording and confirmation, and alarms. Database query analysis and reporting capabilities. The monitoring system can enable maintenance personnel to accurately locate the equipment in a few seconds Fang Zhihong (1968-), male, Qingdao, Shandong, senior engineer, Dr., mainly engaged in monitoring systems. sensor. Smart Meter. Digital signal processing. Research and development of fault diagnosis.

The alarm can facilitate the maintenance personnel to eliminate the fault and greatly reduce the failure time. At the same time, it reduces the labor intensity of the on-site personnel, and ultimately reduces the production cost and equipment operation and maintenance costs, and improves economic efficiency.

1 monitoring system structure design is designed to monitor the structure of the system layout, installation location and mutual relations. The overall structure of the monitoring system is divided into three layers: on the (PLC5~PLC11 in the figure), a specially developed data transmission program sends out special equipment data. The data acquisition IPC is connected to the PLC/VNet through the VNet data conversion program to obtain the original field basic data.

Its real-time requirements are relatively high, so use a single computer.

The server consists of a monitoring server and an alarm database server composed of SQL Server2000.

The monitoring system terminal consists of a database query terminal formed by SQL Server 2000 Query Analyzer. With Ethernet, several inquiring endpoints can be connected to the server for user monitoring.

All in one. It is an open network, connecting important equipment such as ICS, FCS, PLC. The VNet communication rate of 10 Mb/s is a token-based real-time control network that can be double redundant and can connect up to 64 stations in a single area. In this network, only the site that obtained the token can send information.

After fully understanding the principle of VNet communication, combined with the system design manual, and using the intercepted DCS and PLC communication information to obtain the required data, it is possible to realize Yokogawa's CENTUMCS field control station (FCS) and CP3500H. PLC system data acquisition.

Data acquisition device hardware structure see. The original ICS, FCS, PLC and other measurement and control system equipments are connected to the VNet through the coupler. Each device has a VNet station number. The data acquisition IPC is connected to VNet through a newly installed coupler to obtain the various information required.

The role of the data identification module is to obtain the communication data on the VNet and store it in the VNet station data list and real-time database. The VNet station data list reflects various data sent by a station on the VNet and important data and commands received. The function of the real-time database is to record and store various data obtained from the VNet for use in analysis statistics, control optimization, and the like. In the whole structure, the data identification module is the most important, it receives all the messages on the VNet communication, and monitors the entire communication process, and stores the data that needs to be collected in the data list of the corresponding site. The data in the data list is defined and can be further stored in a real-time database.

3 monitoring system user interface design The most essential function of the monitoring system is to communicate the monitored system information to the user through various forms of interface. The commonly used functions include dynamic screen display, real-time/history curve display, alarm overview, etc. In order to facilitate equipment maintenance, the monitoring system also provides special functions such as device status statistics and device operating condition display.

3.1 Screen Monitoring The monitoring system provides monitoring screens for various major equipment. In the screen, the user can easily and intuitively understand the operating status of the field equipment, observe the main process parameters in real time, and conduct analysis. Table 1 describes the contents of each screen.

The overall operation of the continuous casting and casting equipment.

Table 1 Contents of monitor screen Contents Screen name Display Content flow Operation status Tundish, ladle steel liquid level and temperature; tundish sliding outlet (TDSN) opening; mold liquid level, mold oscillator motor (MDOSC) vibration frequency, Motor current, motor torque, casting length, tracking length of the dummy bar (DB), length of pulling and pulling, casting speed, height of DB hoisting, state of tension and pulling roller (pressure, pressure, opening, operation, stop, failure) DB winch Device status; DB position, status; flow operation preparation status; operation flow running status cutting front, lower, rear roller path, deburring roller path, printing roller path, waiting roller path, lifting shutter operation status; Pipe state; cutting machine action and position status; deburring machine, jet printer working status; roller conveyor operation preparation status; the status of the slab on the roller table; slab direction and so on.

Finishing Area Operation Status A/B Transverse Position and Running Status of the Pallet; A1A4 Roller Table, B1B4 Roller Table, Cross Roller Car Roller, Operation of Elevator Baffle; MR2, MR3 Measuring Roller Status; Photocell Status (LA1, LA2, and LA3) A/B pusher, stacker, and weighing machine operating conditions; condition of finished slabs on each roller table; condition of automatic operation; number of slabs on the stacker; weighing machine called slab Weight; slab length, slab width; current value of each roller table and important equipment u shows the status of the global equipment operation of the 2ST continuous casting 1ST4ST, finishing area, and slab conditions in each area.

Hydraulic station (big bag, tundish, weighing, body) Feeding device (main body, weighing) Operation status of the equipment in the hydraulic station; Hydraulic pump current; H, L, LL alarms for oil level, oil temperature, and oil pressure Condition cutting machine, deburring machine, jet printer, tundish car, DB trolley steam exhaust fan and other detailed display of the operating status of each equipment.

Casting Operation Status 3.2 Historical Curve Trends Displaying historical curves can reflect many equipment problems. After on-site user research, it was found that the current and torque can best reflect the condition of the electrical system equipment. In order to facilitate the user to query, analyze, compare, and understand the current or torque value of a certain period of time, the monitoring system displays historical trends of the current values ​​and torque values ​​of the important devices listed in Table 2.

3.3 Equipment status statistics function Table 2 Historical trend display equipment finishing large packages rotary table motor DB winch motor horizontal transfer trolley A/B large package sliding gate motor DB transmission chain motor transverse trolley A/B roller table SWT ( 13) hydraulic pump motor crystallizer vibration motor, widened motor 2) hydraulic pump motor 22106 pull leveling roller motor B Bu B4 roller path CC body (3) hydraulic pump motor before and after cutting roller motor deburring roller path, printing Roller conveyor, waiting roller motor A, B pusher A, B stacker Weighing 12 Hydraulic pump (A/B column) To accurately understand the equipment operating life and facilitate the maintenance of the equipment, this monitoring system provides the equipment running time In statistics, when the running time reaches a certain value, an alarm is generated. The administrator can perform management operations such as query and reset through the device management screen in the monitoring system. The equipment for this function statistics is listed in Table 3.

3.4 List of alarm summary Table 3 List of statistical equipment Finishing large package Rotary table Crystallizer vibration, width adjustment (north and north) traverse trolley A/B tundish trolley TD12 hydraulic pump DB trolley, DB hoisting device B Bu B4 roll Cutting front, lower and rear roller tables A, B Pusher body 13 Hydraulic pump deburr, jet printing, waiting roller A, B stacker weighing 12 Hydraulic pump (A/B column) in each main screen The alarm alarm display system's equipment failure alarm status, can understand the 1~4 flow body equipment, 5CC, 6CC common equipment, finishing equipment and all production equipment failure status, if there is a failure, the corresponding device in the screen will flash yellow . If the user intends to understand the details of the relevant alarm, it can be queried through the 'system database' function.

4 Equipment alarm database and statistical reports 4.1 Database query The alarm function provided by the alarm component of the monitoring system is mainly used to prompt field maintenance personnel. Complex analysis and query can only use the database technology. The electrical equipment alarm data is stored in the SQL Server 2000 database in real time. The electrical equipment users can use the query analyzer provided by SQL Server to perform fault query according to the fault occurrence/end date, time, tag name, and signal description. During this process, the equipment maintenance expert You can use your own experience and the logical relationship between signals to conduct statistics, analysis, and draw conclusions.

The query analysis for completing a group of alarms is now generally performed by only one person in approximately 10 seconds. In the past, the analysis of a group of faults or alarms was completed and several technicians were required to spend one day.

4.2 Database Reports Although in most cases, the query on the computer is sufficient to meet the needs of the user, in special circumstances, such as the exchange of experience of several departments, the reporting of important events, and archiving, you need to use the form of statements. The equipment alarm information obtained from the database query can be converted into an easy-to-understand form for general users (non-equipment maintenance personnel), transmitted to Excel, and printed by the user as needed. It only contains the name of the fault, the fault occurrence, the termination time, the value, and the alarm status and other necessary information to avoid misunderstandings.

5 Concluding remarks After more than one year of on-site assessment at Baosteel No.2 Casting Co., Ltd., the system proved to be very reliable and various functions were abundant. In particular, the alarm database function was very effective, meeting the requirements of on-site users and contributing to the maintenance of the equipment.

Although the system has played a significant role, the author believes that in-depth research work can be carried out on this basis, resulting in greater benefits. It is possible to combine statistical analysis, equipment operation mechanism, and equipment failure mode studies to achieve life prediction and fault management of major equipment and key components. This may reduce over-maintenance and under-maintenance of equipment, reduce maintenance costs, and reduce failure time. . Different equipment, different models, and corresponding settings for different environments (turning to page 57). 46. ​​Exercise.

4.2 The speed control of the speed of the track beam overhead crane is achieved through frequency conversion. Because of the speed, the maximum thrust is obtained stably. During the frequency conversion control, the voltage U and / are proportionally adjusted. See the control principle.

Three-phase phase sequence frequency conversion linear induction power supply control motivation Primary primary linear induction motor control principle. 3 Braking problem of the track beam crown crane The braking problem of the track beam crown crane can not be ignored, mainly using dynamic braking. When there is a large drop in frequency, it will automatically generate a feedback brake, and if necessary, it will use the power supply reverse brake.

5 Benefits of using a linear induction motor to drive the track beam crane As a result of organic integration with production equipment, the use of a track beam as a secondary, and the elimination of the intermediate transmission mechanism, this new research result brings many advantages.

Small size, low height, and low cost. The track beam doubles as the secondary and greatly reduces the production cost of the overhead crane. Compared with the mechanical crane driven by the rotary motor with the same tonnage, it only accounts for 3/4 of it, which reduces the volume, reduces the weight, and reduces the overhead crane. The height saves a lot of space.

High reliability and long life. The significance of eliminating the intermediate transmission is not only to simplify the mechanism, to ensure the reliability of the operation, but also to ensure that there is no mechanical contact during the movement, so that the transmission parts are free from wear, and because the structure is simple, there is almost no maintenance, so the service life is long.

It can directly produce linear motion with low noise. The characteristic of the linear motor is that it can directly produce a linear motion. It does not need to be dragged by a rotary motor like a mechanical track beam crane, and then converted to a linear motion by a mechanical transmission. Good flexibility, easy control, high accuracy and accurate positioning. It can avoid the noise generated by gears, etc.

Electromagnetic force is strong and does not slip. When the track beam crane moves, it is propelled by electromagnetic force. There is no mechanical friction, there is no slippage problem, and the safety and maneuverability are strengthened.

Big thrust and high efficiency. Because it is exposed to the working environment, the track beam is very long and the heat dissipation conditions are good. No cooling device is needed. Therefore, the current rating through which the winding passes can be selected to be higher, the directly generated thrust is large, the transmission process is reduced, and the efficiency is greatly improved.

At present, there are successful cases in China that use linear motors to drive track beam cranes, but the solution using intermediate drives is still in theoretical research and experimental stage.

Proceedings of Taiyuan Academic Conference IC. Beijing: Ordnance Industry Press, 1997 Beijing: Mechanical Industry Press, 1979. Proceedings of the Science and Technology Exchange Committee of the Society of Applied Science. Beijing: Weapons Industry Press, 2001. Research. Optimization Design of Linear Induction Motors for the 1999 Fire Method of China Electrical Engineering Journal . The Journal of the Chinese Electrotechnical Society, 2000,15(2)3(-40.(Continued from page 46)) has different service life, failure modes, and alarm modes. Using this system, these basic research work can be done completely.

2000 Data Processing Technology Press, 1999.

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