The steel and iron profession competition was in recent years intense day after day, but the enterprise only had unceasingly carries on the technological transformations, improved the product quality, reduced the production cost, could obtain the further development. Proclaims the steel for to meet the market requirement, the newly built two types have been consistent six machine six linger casting machine, and in the afterwards promotion transformation, carried on Lian Zhuji to increase flows the transformation, at present single plane year productivity already ultra million tons. This article mainly introduced two Lian Zhuji transforms after the automated system network architecture, the main line layout and the main function.

Outline

Proclaims steel steel mill 4#, 5# Lian Zhuji is proclaims the steel the priority project project, its automation control level had achieved the domestic advanced level, the system uses the present popular three electricity integration design, massively uses the field bus technology, the automated system software and hardware by the Rockwell Automation product primarily, constitutes three levels of network architectures, realizes the Lian Zhuji production automatic control and the production scheduling direction, the product quality control.

System network architecture like chart 1:

Chart 1 control system network structure drawing

May see from on chart, Lian Zhuji automated system had considered the practical application need, fully uses the software and hardware the resources characteristic, constructs three network architectures, namely information level, control level, equipment level.

1 information level

The information level must for Lian Zhuji the main body operation, the maintenance and the factory level computer system provides the network connection, visits the workshop level the production and the management data, for the entire factory scope in the control system data gathering, the surveillance provides the service, connects in parallel fashion the production scheduling instruction, coordinates the entire factory production. This characteristic is the data quantity is bigger, but has not had the high request to timeliness, simultaneously for is advantageous for different merchant PLC and the computer system interconnection, carries on the essential control and the coordination, thus uses conforms to public standard TCP/IP the agreement 100Mbps speed ethernet.

Considered the industry controls to the reliable request and the industry scene adverse circumstance, the ethernet uses the redundant light ring net constitution, two bench work industry levels ethernet switchboard has the redundancy management function. A Lian Zhuji server, four operations stands through the ethernet card turns on the network, PLC system each installment has the CPU module the frame to turn on through the ethernet interface module.

2 controls levels

The control level is responsible in the public PLC system, respectively to cast flows PLC to be systematic and between long-distance Flex I/O carries on the control data the transmission, the exchange, the coordination control, and provides function and so on network programming, procedure maintenance, equipment configuration, trouble shooting.

This network not only requests the stable reliable connection, moreover must guarantee the information transmission timeliness. ControlNet uses the main line topology, communication speed 5Mbps, its characteristic lies in ControlNet is definite, this also meant in the network the I/O equipment and the controller all are the time which prearranges is carrying on the communication. In ControlNet each part all already when configuration firmly has arranged ahead of time the communication time and when long, therefore it extremely stable and is reliable, specially is suitable to requests the higher industrial application to the time. Meanwhile for guarantees the communication not to be able to appear the severance, used the redundancy communication medium in these us further to enhance the reliability.

3 equipment levels

The equipment level mainly uses in the master line transmission equipment, namely the frequency changer, the soft starter direct company receives in the respective PLC system, no longer through the traditional numeral, the simulation quantity connects realizes the control, does this not only facilitates but is fast, but also may gather the scene equipment the data, carries on the disposition, the surveillance and the real-time control to it. This uses Remote the IO net.

Three network architectures cause to be allowed to act according to Lian Zhuji the system the concrete application request choice appropriate communication way, this kind of network overhead construction not only has provided EtherNet/IP, ControlNet, Remote the IO network connection, but also has contained the high-quality software connection which optimizes face the automatic control, guarantees the highly effective data transmission.

System composition and function

1 hardware disposition

Each Lian Zhuji the automated system hardware mainly by 9 set of Rockwell Automation Corporation's ControlLogix series PLC, 4 operations stands, 1 server as well as long-distance Flex the I/O station is composed, in the transmission system the host production line equipment all actuates by the vector frequency changer, the water pump uses the soft starter, the auxiliary transmission equipment controls by MCC. The measuring appliance system is mainly fast by the molten steel and continuously measured the warm system, the large package, center Bao Chengzhong the system, the crystallizer liquid level monitor and the governing system, the crystallizer water, two cold water current capacities examination and the governing system compose.

Lian Zhuji the public system uses set of belts to expand the rack the PLC system, uses in Lian Zhuji on main body and the semifinished product partial altogether uses the equipment the examination control, the PLC system every time to cast a class set, uses in this to cast flows the system the monitor, the control. The operation station arrangement controls the room in the host, cuts the handling room to use in the equipment carries on the surveillance, the operation, processing to Lian Zhuji reports to the police the information as well as the essential artificial intervention. The server uses in to collect the production data, and carries on processing, the preservation, the transmission.

2 system functions

Lian Zhuji the automated system uses three electricity integrations design, all electric control, the meter control the signal to turn on PLC, installs in the scene thermal resistance, changes delivering, the current capacity takes into account other examination measuring appliance gathering instrumented datas, equipment collection craft production process data and the equipment running status and so on switch, spacing, all data collect into the PLC system, the recombination come the instruction which stands from on position operation, according to establishes the procedure realization process return route adjustment in advance, the electrical equipment sequential control and the transmission device control.

1) measuring appliance system

The measuring appliance examination mainly includes big, the middle Baotou Steel Factory water temperature fast and the second-by-second measurement, is big, the middle package molten steel weight survey, the crystallizer hydraulic pressure, the current capacity, the import and export temperature difference survey, two cooling water pressures, each section of flow measurement, adjustment. In order to reduce operates worker's labor intensity, improves the billet quality, Lian Zhuji also gathers the crystallizer molten steel fluid position, Bao Saibang opens through the electrically operated cylinder adjustment in, causes the molten steel fluid position maintenance to be stable.

Two cooling water distribution systems have manual and the automatic control function, the content including the water volume assignment, the water meter hypothesis, the track adjustment, match the water 修正�?adjustment, the water current capacity, the pressure, the temperature and the valve position demonstration. PLC realizes field data gathering, the track adjustment, the operation station completes the water meter the hypothesis, the water current capacity demonstration and the data record, the data printing and the statistical function.

Manual, automatic control: Each class divides four sections to match the water, namely the full roller section, section, two section, three sections, each section supposes the manual/automaticswitching function. When manual way, the staff the direct hypothesis regulating valve valve opens through the operation station picture in to change the water volume size; Under the automatic way, the system according to in advance will choose the good water meter basis to pull the fast speed automatic control water volume, in the casting process, might revise as necessary according to the billet temperature gives the water volume. Two cold water adjustments flow chart like chart 2 shows.

Chart 22 cold water adjustment flow chart

Water meter choice and revision: Stands the pre- 定数 ten sets in the operation to match the water parameter to be possible to supply the use, the parameter content includes: The serial number, the aluminum, the cross section and each section match the hydraulic modulus, the operator may revise the parameter to change as necessary matches the water.

2) electric system

The electric appliance equipment examination and the control mainly includes: Large package 回转�?revolves, a package of arm rises and falls, the large package drainage opening make and break, the middle chartered car walks, to the center, the fluctuation, the crystallizer vibration, inspires the frequency adjustment, pulls rectifies 机传�?under, pulls rectifies rolls, directs on the spindle pole the line, the recycling track, to make adobe bricks, depositing, casts the semifinished product to decide the ruler to cut around, as well as cuts 辊道, transfer table, the reversing machine, casts the semifinished product splitter, step enters 冷床 control. The hydraulic system, the oil gas lubrication system, 干油 the lubrication system examination, the control also completes by PLC.

All hosts production line transmission equipment completely used the frequency changer actuation, Lian Zhuji from 钢包 回转�? until crosswise moved mechanical device the and so on steel vehicle transmission Chinese Communist Party has used more than 100 frequency changers, the power scope from 0.75KW to 45KW. All frequency changers the communication connection which set through among them join Remote the I/O communication adapter, directly hangs in nine Remote which sets up by nine RIO interface module in the I/O network, constituted based on Remote the I/O network transmission system. The synthesis considered Remote the I/O network the connection is away from and the system to the timely request, uses 115.2Kbps the communication speed.

Remote I/O net work under scanner way, PLC processor through RIO interface module and long-distance I/O adapter establishment serial communication chain. The frequency changer communication connection is Remote in the I/O net network equipment provides directly, the digital communication link, the system through the configuration PLC I/O label, uses the communication connection establishment input, the output data chain. Speaking of PLC, each frequency changer is regarded as is an installment has the I/O module the long-distance frame, only needs to these modules to carry on read-write, may to if the connected frequency changer transmission order, the control device movement; Also may read from the frequency changer takes each data, the supervisory equipment running status, and data real-time transmission to PLC in. May control the room through the picture in the host on the operation station monitor, has real-time provided real-time, the detailed information for the operator, and may the direct operation equipment, even sends out when the frequency changer reports to the police, appears the breakdown, may promptly reposition the frequency changer to avoid because processing from time to time causes the accident to occur. Lian Zhuji electrical system has realized the transmission equipment long-distance network real-time control, caused PLC to realize the network digital control to the frequency changer actuation, has substituted for the massive hard wiring by a communication electric cable, with the traditional simulation quantity, the switch quantity control method compared, not only greatly enhanced the system timeliness, the accuracy and the reliability, moreover installed, the debugging, the maintenance cost also correspondingly obtains reduces.

3) operates the station

The HMI picture software basis technological requirement, is equipped with the host picture, casts flows the general picture, the semifinished product area general picture, pulls rectifying machine and directs the spindle pole, the crystallizer liquid level, the crystallizer vibration, large package/center Bao Chengzhong, the hydraulic system, the drive running status, the PLC condition and so on the nearly 20 pictures. The operator through to the HMI monitoring, may real-time observe the equipment the movement condition, according to the jurisdiction revision craft parameter, and prompt processing reports to the police the event, when the necessity may the manual intervention equipment movement.

4) directs the dispatch system

The steel-making is a complex production process, Lian Zhupi quality receives the casting condition, the process condition direct influence, even if has used the advanced craft, the equipment and the technology, but because the company casts the production craft characteristic influence, the stove time connects with, the equipment failure and the operation not steadily grades can inevitably cause the production process to appear the undulation, to produce exceptionally, thus causes to cast the semifinished product quality to receive the varying degree the harm, is not allow to neglect to the after steel rolling working procedure and the final product quality influence, creates the economical and the product prestige loss to the enterprise. Lian Zhuji needs promptly to understand on the working procedure situation, the converter, the fining system also must grasp Lian Zhuji the casting situation, in order to be advantageous for direct-viewing, the rapid understanding produces the entire process condition, Lian Zhuji automated system provides the network excuse, with the converter, the fining, blows the argon to stand and so on the system turns on the factory level management network together, provides the data for the production scheduling unification coordination direction.

Application effect

Proclaimed steel steel mill Lian Zhuji the automation control system synthesis to integrate the PLC control technology, the picture monitoring technology, the network communication technology as well as the frequency conversion velocity modulation technology, three electricity integrations design adapted the automated development tendency, has realized Lian Zhuji the foundation production technological process automated control, completed the company to cast produces the scene equipment the self-blocking control, the parameter of medium examination adjustment, data communication processing, the breakdown reports to the police diagnosis as well as production condition function and so on on-line monitoring. After more than three years of movements confirmations, the systems control function advanced, stable is reliable, effectively enhanced the labor productivity, reduced staff's labor intensity, to smoothly goes into production, reaches produces, the increase production benefit as well as the maintenance safety in production all played the positive role.