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Smart Manufacturing of Metal Pass
in Steel Industry

Technical consultation and development based on existing project cases and existing software

I. Experience Overview of the Team Leader

1. Smart Manufacturing experts in iron and steel and metallurgy industry, with German doctor of engineering and American doctor of software, have several years of on-site working experience in seven or eight professional fields related to iron and steel industry (such as process, material, equipment, automation and other fields), with a total of more than 20 years on-site in metallurgical enterprises. As the only student sent abroad by the state on behalf of the metallurgical industry in this year, the team leader has deep roots with experts in Demag, Germany. He has been invited  for three times by Italy Danieli to communicate with its headquarters. He once served as a senior engineer of Morgan (now merged with Siemens) in the United States and has contact with about 1 / 3 of the technical vice presidents of major automation companies in the world. It can guide enterprises in metallurgical industry to carry out Smart Manufacturing and specialized model development.

2. He is proficient in material deformation trend. During his doctoral thesis, he completed a large number of hot rolling based on surface grid and cross-section grid, including flat plate rolling and six pass rolling of complex section angle steel, and six pass rolling of H-beam; All rolling processes were simulated by finite element method, and the deformation process was carefully studied by the deformation display tool Mentat. Finite element simulation and rolling with mesh fully verified the correctness of the model. The research results were published in Stahl und Eisen, the largest magazine in the world metallurgical industry, and a book was written (German version).

II. Plate production

1. Level 2 Model Improvement, to upgrade the existing Level 2 system and to develop a New-Generation Level 2 system.  In recent years, microalloyed elements are added to carbon steel to form microalloyed steel, which only increases a small amount of cost, but significantly improves the properties of steel. The corresponding secondary system needs considerable model improvement in order to achieve high-precision prediction. Because the Level 2 is a large system with strong engineering logic, which is traditionally developed by automation engineers, the lack of understanding of material model leads to the logical weakness of relevant material properties in self-study. If it is not improved, it is difficult to achieve high prediction accuracy. Hard and thin products require extremely accurate models, otherwise there will be corresponding defective products. At least it is difficult to produce hard, wide and thin products (such as X80 medium plate more than 3.5m wide and 5mm thick or thinner).In addition, there is also great room for optimization in software engineering. For example, the site needs the enterprise version of windows to understand the engineering logic, so it can run the engineering software faster. The Level 2 containing microstructure model, intelligent self-study and high-end software engineering is called the new generation Level 2, which was first developed by myself and filled the technical gap in the world. If the on-site defective products are serious, this technology can optimize the operation to eliminate the corresponding defective products. Relevant product development has been carried out in Oregon company of the United States and Nangang of China for more than ten years, and more than 30 application papers have been published internationally.

2. Under the guidance of Two-Parameter Learning, the metallographic microstructure model is added to the existing Level 2 in an extremely simple and easy-to-use way, and the corresponding self-study is carried out. Related optimization work includes changing the classification of steel grades based on use to that based on chemical composition, and designing thousands or even tens of thousands of models with software. The corresponding model design software has been developed and used in Nangang project. One set of models is adopted for each specific product, and then machine learning is carried out based on the corresponding model. Japanese colleagues once claimed that based on a set of models including steel grade and temperature, machine learning on deformation amount and deformation speed can obtain very accurate prediction; What we are based on is not one set, but thousands to tens of thousands of sets of microstructure models (one set of data is called for each steel)!

3. The microstructure model results of the iron and steel industry are used to predict the recovery, recrystallization, grain growth and related mechanical properties in the rolling process. Based on the resources of a large technology company in the iron and steel industry and integrating the R & D achievements of all countries in the world, a complete set of microstructure model is successfully developed. There are 28 variables in each rolling pass. The model is optimized and corrected by using the existing measurement results of all countries in the world. A set of microstructure simulation software is developed.

4. Sickle bend and other defects. When I worked as a technical consultant of Oregon company, I also led the research and development of eliminating sickle bending defects of the company. I have sickle bending data of millions of steel and a complete set of solutions.
5.  I have done more than 20 years of technology development in the iron and steel industry and have corresponding experience in many fields. In recent years, Tencent has detected the medium wave and side wave of steel plate by machine vision, but it can not eliminate them. I can use the roll bending device to assist the Level 2 to eliminate the medium wave or side wave.

III. Wire and Bar production

1. In the production of wire and bar, the temperature field at each time point is calculated from various rolling processes such as rough rolling, medium rolling, finish rolling, water cooling and high-speed unit. Based on the model development of decades of research results in this field of an internationally renowned company, the company's existing finite difference method software and model are further upgraded.This company is the world leader in the field of wire and bar production. It has carried out various experiments for more than 100 years. There are more than a dozen experimental research results of wire and bar water cooling alone, and has the finite difference method software to track the rolling and cooling temperature in the production process and calculate the temperature design in the control rolling. I have worked as a senior engineer in charge of models in this company for many years, specializing in relevant models. Through further optimization of existing models and existing software, I have developed a set of high-quality finite difference method software system.Before that, my German team has completed 15 years of research and development based on the four continuous high-speed wire rod mill (built in the 1980s, the maximum speed is 70m / s, and all parameters can be measured). I brought more than 40 doctoral theses on wire and bar rolling to Morgan. Based on a large number of models and the software I further developed, the calculated temperature results are compared with the measured field data, and the two are in full agreement.

2. Size change tracking based on various deformation models in the production process of wire and bar. Relevant models include but are not limited to the influence of process influencing factors such as temperature, speed and material on the spread, and the influence of process influencing factors such as temperature, speed and material on the forward slip, etc. There are nearly ten common calculation methods for each impact. The system provides the calculation methods that should be preferred in various occasions. Spread is the amount that a material expands to the width direction in a specific pass when it is pressed down in the height direction. There are different calculation methods of hole types, such as square hole type, rhombic hole type and round hole type. Forward slip is the relative difference between the outlet speed of the material and the linear speed of the roll when the material is under pressure in the pass. It also has different calculation methods with the above different pass types. There are mainly two sets of relevant software, in addition to the rough four pass system. One is simple and easy to use, which allows non design engineers to carry out simple pass design based on the developed model; The other set is specially developed for pass design engineers. It is a complex pass design system with high accuracy considering various influencing factors. The specific version is:

  • Software series of billet box pass vertical box pass elliptical pass round pass during rough rolling of wire and bar. The relevant design software has been verified and optimized in the wire and bar rolling site of Puxiang and other companies in Korea.

  • The ellipse round hole series designed continuously for 30 passes can reach a speed of 120 meters per second. There are a large number of calculation models about spread and forward slip, which can enable the on-site pass design engineers to carry out accurate and exquisite design. It has been strictly verified by Taiyuan Iron and steel, which is completely consistent with the production measurement results.

  • Pass design can be carried out by non designers on site. One elliptical pass and one circular pass can be designed at a time, and the circular elliptical pass series can be designed by infinite circulation. All parameters consider important influencing factors, such as the influence of material, temperature and speed. A lot of validation has been done.

3. Material deformation and force energy demand involved in upgrading and optimization of high-speed wire rod or other wire and bar. A set of force and energy parameter models and deformation models for high-speed rolling are developed (the deformation speed can be greater than 2000 / s). Based on this, more than ten sets of prediction models of force and energy parameters in various pass environments are developed.

4. Vibration of high-speed wire rod. As the high-speed wire rod rolling unit drives 8 to 12 rolling mills by one motor, the second flow between stands is difficult to adjust, and resonance is easy to occur during high-speed rolling up to more than 100 meters per second, the rolling mill vibration and scream interfere with the operation of production. I have worked as a senior engineer of Morgan company, the main technical provider of high-speed wire mill in the world, and I have a complete set of solutions in this field. As a supplier of high-speed wire rod mill, Morgan dug holes in the designed high-speed wire mill in order to measure the material deformation. It's hard for a second company in the world to dare to do so! The high-speed wire rod mill built by Hafei and other enterprises generally has the problem of vibration at high speed with reference to Morgan's technology.

IV. Steel Smelting

1. The existing achievements include three Level 2s of electric furnace (EAF, 150t), refining furnace (LMF) and continuous casting (CC), including a well-designed interface developed with VB class based technology (including database data update function), functional logic developed with C + + (including model), and a database system based on Oracle to ensure that data is not lost.

2. The main functions include production planning, scrap feeding, process tracking, delay tracking (no operation for a certain period of time is regarded as delay; the cause of delay must be filled in on site; a series of treatment on the cause of delay can be carried out), event tracking, material addition (adding alloy powder) Chemical treatment (to achieve the required chemical composition for steelmaking; alloy can be added in electric furnace, refining furnace and continuous casting cylinder to optimize the chemical composition; when it is difficult to achieve the required target composition, the target steel can be changed), hardware life, refining furnace tracking, temperature sample, data report, and picture customization, etc.

3. Through the data model (data structure, class and database form a Trinity Structure) to describe the whole workshop. The data collected from PLC is processed by software and stored in database, MMF (to speed up operation) and Level 2 interface respectively. The model and machine learning are used to predict the parameters, such as the temperature in the electric furnace after adding scrap steel; Graphics show the calculation results, such as how many square billets can be cast.
See Level 2 Optimization Model and New Development


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