CN107130199B - Automatic control method for knife distance of continuous hot-dip galvanizing air knife - Google Patents
Automatic control method for knife distance of continuous hot-dip galvanizing air knife Download PDFInfo
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- CN107130199B CN107130199B CN201610115522.5A CN201610115522A CN107130199B CN 107130199 B CN107130199 B CN 107130199B CN 201610115522 A CN201610115522 A CN 201610115522A CN 107130199 B CN107130199 B CN 107130199B
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- 238000000034 method Methods 0.000 title claims abstract description 33
- 238000005246 galvanizing Methods 0.000 title claims abstract description 17
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 77
- 239000010959 steel Substances 0.000 claims abstract description 77
- 238000000576 coating method Methods 0.000 claims abstract description 33
- 239000011248 coating agent Substances 0.000 claims abstract description 31
- 238000007747 plating Methods 0.000 claims description 34
- 230000008569 process Effects 0.000 claims description 15
- 230000008859 change Effects 0.000 claims description 8
- 238000003466 welding Methods 0.000 claims description 8
- 238000004364 calculation method Methods 0.000 claims description 5
- 238000004886 process control Methods 0.000 claims description 5
- 230000007774 longterm Effects 0.000 claims description 4
- 239000011541 reaction mixture Substances 0.000 claims description 4
- 238000001514 detection method Methods 0.000 claims description 3
- 239000004576 sand Substances 0.000 claims description 3
- 230000006978 adaptation Effects 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 11
- 238000013459 approach Methods 0.000 abstract description 2
- 238000005452 bending Methods 0.000 abstract description 2
- 239000010410 layer Substances 0.000 description 13
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 12
- 239000011701 zinc Substances 0.000 description 12
- 229910052725 zinc Inorganic materials 0.000 description 12
- 230000003044 adaptive effect Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 2
- 238000000137 annealing Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000012417 linear regression Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 230000033116 oxidation-reduction process Effects 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/14—Removing excess of molten coatings; Controlling or regulating the coating thickness
- C23C2/16—Removing excess of molten coatings; Controlling or regulating the coating thickness using fluids under pressure, e.g. air knives
- C23C2/18—Removing excess of molten coatings from elongated material
- C23C2/20—Strips; Plates
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
- C23C2/06—Zinc or cadmium or alloys based thereon
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating With Molten Metal (AREA)
Abstract
The invention relates to an automatic control method for the distance between knives of a continuous hot galvanizing air knife, which adopts a comprehensive control method of presetting control for the distance between knives of the air knife, feedforward control for the distance between knives of the air knife and feedback control for the distance between knives of the air knife to finally realize the automatic control for the distance between knives of the air knife. The invention has the advantages that: after the method is applied to actual galvanizing production, the air knife distance is accurately positioned, the coating thickness precision is obviously improved by combining air knife pressure control, the on-site manual operation of the knife distance is replaced, and the risk that the air knife approaches strip steel in a bow-bending state of the strip steel is reduced.
Description
Technical Field
The invention relates to an automatic control method for the distance between knives of a continuous hot galvanizing air knife.
Background
With the rapid development of national economy, automobiles, household electrical appliances, energy sources and city infrastructure are vigorously developed in China, the demand of hot-dip galvanized strip steel is continuously increased, and higher requirements are put forward on the quality of hot-dip galvanized strip steel products. The air knife is one of important process equipment of a hot galvanizing unit, is used for controlling the uniformity and the stability of the thickness of a zinc layer, and directly influences the quality of a galvanized finished product by the quality of a control system. Referring to fig. 1, after the strip steel substrate is subjected to oxidation reduction action by a continuous annealing furnace, liquid zinc is attached to the surface of the strip steel substrate through a zinc pot, then gas is sprayed by air knives arranged on two sides along the width direction of the strip steel, and redundant zinc liquid is scraped back to the zinc pot, so that the thickness control of a zinc coating is realized. The distance adjustment of the air knife from the strip steel is one of the main means for controlling the thickness of the coating, and has great influence on the distribution of the gas pressure. The smaller the distance between the air knife and the strip steel (the distance between the air knife and the strip steel) is, the more advantageous the stable control of the coating is in the case of good plate shape, and the most important is the precise control of the distance between the air knife and the strip steel for controlling the coating thickness. When the speed of the strip steel and the pressure of the air knife are unchanged, if a thin zinc layer is needed, the air knife is close to the strip steel, but in the existing actual production operation, manual operation is performed by an operator, and due to different personal operation experiences, the distance between the operating air knife and the strip steel is sometimes too small, and at the moment, the strip steel is very easy to scratch the knife lip under the condition of poor plate shape or when a welding line passes through, so that the scratch of the strip steel or the blockage of the air knife is caused, and the quality is influenced.
The galvanization process is a complex process with many independent variables combined to affect the final coating thickness including air knife pressure, air knife height, etc., but from the practical point of view of galvanization production only those variables that are controllable are generally considered, including air knife pressure and the distance of the air knife from the strip surface. Because the pressure balance of the purge gas at two sides of the strip steel is not easy to adjust and maintain, when the position adjusting control equipment of the air knife works normally and the control precision is within a certain range, an air knife distance control method is generally adopted firstly. And then the coating thickness precision is ensured by combining the air knife pressure adjusting method only when the position adjusting control device is not stable enough. Therefore, the good and bad control of the knife distance of the air knife greatly affects the thickness precision of a coating, and if the setting control precision of the knife distance of the air knife is high, the instability of a system caused by frequent adjustment of the pressure of the air knife can be avoided.
In 24 years of "Chinese metallurgy", in Liu nations, published "saddle steel hot galvanizing line air knife control system composition and function analysis" in 2014, in the article, only simple introduction is carried out on the composition of an air knife distance adjusting mechanism, and the simple mention that the execution mode of air knife distance control adopts a stepping control mode and does not introduce relevant contents of automatic knife distance control.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide an automatic control method for the distance between the air knife and the surface of the strip steel in the continuous hot galvanizing process, so that the automatic control of the distance between the air knife and the surface of the strip steel in the galvanizing process is realized, manual operation is replaced, the quality of galvanized products is improved, and the consumption of zinc raw materials is reduced.
In order to achieve the purpose, the invention is realized by the following technical scheme:
an automatic control method for the distance between the knives of a continuous hot galvanizing air knife adopts a comprehensive control method of presetting control for the distance between the knives of the air knife, feedforward control for the distance between the knives of the air knife and feedback control for the distance between the knives of the air knife, and specifically comprises the following steps:
1) presetting and controlling the distance of an air knife: under the condition of no detection feedback, roughly controlling the thickness of the plating layer; when the welding line of the strip steel reaches 0-60 seconds (not containing 0) before the air knife, the process computer sends the process parameter data of the next strip steel to the air knife controller unit through the main line PLC, and the preset control unit of the hot galvanizing air knife distance is started to output the preset value of the air knife distance before or after the welding line of the strip steel reaches 0-15 seconds (not containing 0) before or after the air knife;
the preset values of the knife distance of the air knife are as follows:
in the formula (1), the reaction mixture is,a is a margin of thicknesslAnd blFor long-term adaptation of the model coefficient, W, of the coating thicknesstarFor target plating thickness, Vk-1The ratio of the air knife pressure to the air knife distance influencing the thickness of a coating is R: (1-R), DSETThe preset value of the distance between the air knives is obtained;
2) air knife distance feed-forward control: when the speed of the strip steel changes, the feed-forward control unit of the air knife distance is started to predict the air knife distance on line; assuming that the speed, the distance between the air knife and the knife, the pressure of the air knife and the thickness of the coating at the current moment are respectively V1、D1、P1、W1And the next moment variable is V2、D2、P2、W2(ii) a When the strip speed is from V1Becomes V2Then, the feed-forward control model of the air knife distance has the following formula:
in the formula (2), the air knife pressure and the air knife distance are adjusted into two parts, and the ratio of the air knife pressure and the air knife distance is R (1-R) in the control of the thickness of a plating layer; a issAnd bs△ V is a strip steel speed change value, and △ W is a plating thickness change value;
3) air knife distance feedback control: when the difference of the thicknesses of the upper surface coating and the lower surface coating of the strip steel is detected to be deviated, starting an air knife distance feedback control unit, supposing that the speed of the strip steel and the pressure of an air knife at a process section are constant, only considering the horizontal distance feedback compensation of the air knife, wherein the calculation formula of the feedback control compensation quantity of the air knife distance is as follows:
in the formula (3), the reaction mixture is,for the plating thickness model formula: W-KVaDbPcCalculating the partial derivative of the coating thickness to the air knife distance to obtainWherein K is a model constant, the common value is K-1, a, b and c are self-adaptive coefficients of a strip steel plating thickness model, W is the plating thickness, V is the strip steel speed, P is the air knife pressure, G is the strip steel plating thickness, B is the strip steel plating thickness, C is theDFor feedback control of gain, WT、WBThe thickness of the plating layers on the upper surface and the lower surface of the strip steel is measured;
4) setting the boundary value of the air knife distance: the minimum value of the knife distance is preset and stored in a process control computer database, and when the detected value of the knife distance is lower than the minimum value, a process control system sends an instruction to send the minimum value to an air knife distance actuator, so that the air knife nozzle is prevented from being damaged.
The strip steel process parameter data comprises target thickness, plating layer type, strip steel width and strip steel thickness.
Compared with the prior art, the invention has the beneficial effects that:
after the method is applied to actual galvanizing production, the air knife distance is accurately positioned, the coating thickness precision is obviously improved by combining air knife pressure control, the on-site manual operation of the knife distance is replaced, and the risk that the air knife approaches strip steel in a bow-bending state of the strip steel is reduced.
Drawings
Figure 1 is a schematic view of air knife control.
Figure 2 is a schematic diagram of the air knife pitch preset (weld before air knife).
Figure 3 is a schematic diagram of the air knife pitch preset (weld after air knife).
Fig. 4 is a graph of the first application effect.
Fig. 5 is a graph of the application effect of graph two.
In the figure: 1-the upper surface of a strip steel coating 2-the lower surface of the strip steel coating 3-an upper air knife 4-a lower air knife 5-an upper air knife spacing 6-a lower air knife spacing 7-strip steel 8-a zinc pot 9-an annealing furnace 10-a starting preset position 11-the current strip steel 12-the next strip steel.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings, but it should be noted that the present invention is not limited to the following embodiments.
The example is carried out in a continuous hot galvanizing line production plant, the products of the production line are positioned to be building household electric plates and automobile plates, the production process adopts a modified sendzimir method, and the annual output is about 80 ten thousand tons. The air knife was FOEN, Germany, and the production line equipment and the electrical and automatic control system were SIEMENS, Germany. The thickness range of the galvanized layer is 80-276g/m2The plate width is 1004-1256 mm, and the speed variation range of the strip steel is 40-150 m/min.
The specific implementation steps are as shown in FIG. 2:
step 1, collecting the target thickness of the plating layer of 80-276g/m2And (3) carrying out multiple linear regression calculation on the sample data in the range, and obtaining the preset value of the tool distance according to the following formula:
in the formula (1), WtarPlating the target to be thick;the thickness margin value is generally 4% of the target plating thickness value; vK-1Strip speed, a, sampled at a previous momentl，blFor the long-term adaptive model coefficient of the plating thickness, the long-term adaptive model coefficient values of the plating thicknesses with different specifications are as follows:
here, the thickness variation of the plating layer is a result of the change of the air knife pressure and the air knife pitch, so that the ratio of the pressure and the pitch is set to R (1-R), and the value of R is set in the range of: 0< R < 1. The different specifications of the thick strip steel are generally set as follows according to production experience:
as shown in fig. 2, in order to prevent the coating thickness from changing too much and causing an out-of-tolerance during the preset control of the knife distance of the air knife, a slope preset mode is adopted, and the preset control of the knife distance of the air knife follows the following principle:
when the change of the coating changes from thin to thick, the distance between the knives of the air knives is adjusted within 15 seconds before the welding seam of the strip steel reaches the air knives, and when the change of the coating changes from thick to thin, the distance between the knives of the air knives is adjusted within 15 seconds after the welding seam of the strip steel reaches the air knives. When the presetting is operated, other control functions of the plating thickness control system are locked. And if the target thickness of the next strip steel is equal to the thickness of the zinc layer of the current strip steel, presetting function locking.
Step 2, during the galvanizing processWhen the speed of the produced strip steel is changed, the thickness of a zinc layer on the surface of the strip steel is also changed, and the distance between the air knives and the pressure of the air knives must be adjusted in time to keep the thickness of a coating layer constant. Suppose that the current time variable is V1、D1、P1、W1And the next moment variable is V2、D2、P2、W2. When the strip speed is from V1Becomes V2The thickness of the zinc layer will be from W1Is changed into W2And recalculating the tool distance, wherein the feed-forward calculation model of the tool distance at the moment is as follows:
wherein △ W is the plating thickness variation value, △ V is the strip steel speed variation value, asAnd bsThe short-term adaptive model coefficient of the plating thickness is as follows:
step 3, when the difference value of the thicknesses of the coatings on the upper surface and the lower surface of the strip steel is greatly deviated (more than 1 g/m) in the actual coating process2) The deviation is to be eliminated by feedback control. From the perspective of industrial control, considering the rapidity and feasibility of control, assuming that the strip steel speed and the air knife pressure in the process section are constant, only the air knife horizontal distance feedback compensation is considered, and the calculation formula of the compensation quantity of the air knife distance feedback control is as follows:
wherein,
in the formula, the formula of a plating thickness model is as follows: W-KVaDbPcCalculating the partial derivative of the coating thickness to the air knife distance to obtainK is a model constant and takes a value of 1, and a, b and c are strip steel plating thickness model adaptive coefficients and are obtained through multivariate linear regression analysis. WT、WBThe thickness of the plating layers on the upper and lower surfaces of the strip steel is measured. The model self-adaptive coefficients of the strip steel with different specifications are as follows:
GDfor feedback control gain, values are taken according to different interval ranges of plating thickness deviation as follows:
step 4, when the knife distance is adjusted, in order to avoid damaging the air knife due to the fact that the distance is too close to the strip steel, a minimum value is set for the knife distance, when a knife distance detection value is lower than the minimum value, a process control system sends an instruction to send the minimum value to an air knife distance actuator, and the limit value of the air knife distance is set as: 7 mm.
And 5, the output tool distance value is sent to a tool distance control device unit, and the tool distance control device unit mainly comprises a stepping motor controller, a stepping motor, a speed reducer, a connecting rod, a nut, a lead screw, a code disc and the like. The output value is sent to a controller of the stepping motor, the controller drives the stepping motor, and the motor drives the lead screw to move so that the air knife is far away from or close to the steel plate.
The application effect curve is shown in fig. 3. The production parameters were tested as follows: the thickness of the strip steel substrate is 0.80mm, the width of the strip steel is 1350mm, and the target thickness of the coating is 276g/m2Change to120g/m2The distance between the coating thickness gauge and the air knife is 140m, the strip steel speed is 2m/s, and the sampling period T is 0.1 s. 77.5g/m of single-sided target thickness occurs due to the production process2The blade pitch of the air knife is adjusted from 19mm to 11mm under the condition of large change, and the control result ensures that the coating thickness of the upper surface and the lower surface is both 60g/m2Within. The method can ensure that the transition time of the air knife pressure and the knife distance can be quickly responded for only 8.2s, eliminate the thickness deviation caused by process factor interference and ensure that the deviation of the actual thickness and the target thickness is within 4 percent.
Claims (2)
1. An automatic control method for the distance between the knives of a continuous hot galvanizing air knife is characterized in that a comprehensive control method of presetting control of the distance between the knives of the air knife, feedforward control of the distance between the knives of the air knife and feedback control of the distance between the knives of the air knife is adopted, and the method specifically comprises the following steps:
1) presetting and controlling the distance of an air knife: under the condition of no detection feedback, roughly controlling the thickness of the plating layer; when the welding line of the strip steel reaches 0-60 seconds before the air knife and does not contain 0, the process computer sends the process parameter data of the next strip steel to the air knife controller unit through the main line PLC, and the welding line of the strip steel does not contain 0-15 seconds before or after the welding line of the strip steel reaches the air knife, and the hot galvanizing air knife distance preset control unit is started to output the preset value of the air knife distance;
the preset values of the knife distance of the air knife are as follows:
in the formula (1), the reaction mixture is,a is a margin of thicknesslAnd blFor long-term adaptation of the model coefficient, W, of the coating thicknesstarFor target plating thickness, Vk-1The ratio of the air knife pressure to the air knife distance influencing the thickness of a coating is R: (1-R), DSETThe preset value of the distance between the air knives is obtained;
2) air knife distance feed-forward control: when the speed of the strip steel changes, the feed-forward control unit of the air knife distance is started to predict the air knife distance on line; assuming that the speed, the distance between the air knife and the knife, the pressure of the air knife and the thickness of the coating at the current moment are respectively V1、D1、P1、W1And the next moment variable is V2、D2、P2、W2(ii) a When the strip speed is from V1Becomes V2Then, the feed-forward control model of the air knife distance has the following formula:
in the formula (2), the air knife pressure and the air knife distance are adjusted into two parts, and the ratio of the air knife pressure and the air knife distance is R (1-R) in the control of the thickness of a plating layer; a issAnd bs△ V is a strip steel speed change value, and △ W is a plating thickness change value;
3) air knife distance feedback control: when the difference of the thicknesses of the upper surface coating and the lower surface coating of the strip steel is detected to be deviated, starting an air knife distance feedback control unit, supposing that the speed of the strip steel and the pressure of an air knife at a process section are constant, only considering the horizontal distance feedback compensation of the air knife, wherein the calculation formula of the feedback control compensation quantity of the air knife distance is as follows:
in the formula (3), the reaction mixture is,for the plating thickness model formula: W-KVaDbPcCalculating the partial derivative of the coating thickness to the air knife distance to obtainWherein K is a model constant, the common value is K-1, a, b and c are self-adaptive coefficients of a strip steel plating thickness model, W is the plating thickness, V is the strip steel speed, P is the air knife pressure, G is the strip steel plating thickness, B is the strip steel plating thickness, C is theDFor feedback control of gain, WT、WBThe thickness of the plating layers on the upper surface and the lower surface of the strip steel is measured;
4) setting the boundary value of the air knife distance: the minimum value of the knife distance is preset and stored in a process control computer database, and when the detected value of the knife distance is lower than the minimum value, a process control system sends an instruction to send the minimum value to an air knife distance actuator, so that the air knife nozzle is prevented from being damaged.
2. The automatic control method of the knife pitch of a continuous hot dip galvanizing air knife according to claim 1, wherein the strip steel process parameter data comprises target thickness, coating type, strip steel width and strip steel thickness.
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| KR102177525B1 (en) * | 2018-09-21 | 2020-11-11 | 주식회사 포스코 | Coating control device and method |
| CN111118432A (en) * | 2020-01-14 | 2020-05-08 | 邯郸钢铁集团有限责任公司 | Method for automatically controlling weight of zinc layer of galvanized product |
| CN113774307B (en) * | 2021-09-10 | 2023-03-21 | 唐山市佳冠实业有限公司 | Self-control air knife elevator structure of equipment for producing hot-dip galvanized sheet and use method |
| CN115287571A (en) * | 2022-09-29 | 2022-11-04 | 如皋昌哲科技有限公司 | Hot galvanizing post-treatment equipment |
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| CN103695830A (en) * | 2013-12-20 | 2014-04-02 | 鞍钢股份有限公司 | Method for controlling thickness of coating in hot galvanizing production process |
| CN104846306A (en) * | 2015-05-07 | 2015-08-19 | 浙江中控研究院有限公司 | Zincing thickness control system and method |
| TW201546327A (en) * | 2014-06-04 | 2015-12-16 | China Steel Corp | Coating layer weight control method |
| US9217194B2 (en) * | 2012-02-21 | 2015-12-22 | Cockerill Maintenance & Ingénierie S.A. | System for reducing the wiping gas consumption in an air knife |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9217194B2 (en) * | 2012-02-21 | 2015-12-22 | Cockerill Maintenance & Ingénierie S.A. | System for reducing the wiping gas consumption in an air knife |
| CN103695830A (en) * | 2013-12-20 | 2014-04-02 | 鞍钢股份有限公司 | Method for controlling thickness of coating in hot galvanizing production process |
| TW201546327A (en) * | 2014-06-04 | 2015-12-16 | China Steel Corp | Coating layer weight control method |
| CN104846306A (en) * | 2015-05-07 | 2015-08-19 | 浙江中控研究院有限公司 | Zincing thickness control system and method |
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