The Improvement Of Control System And Communication System Of Flying Shear In High-speed Wire Rolling Mill

Bao Steel High-Speed Wire Rolling Mill?the “Mill”? is a leading manufacturer of high-end wire products in China. Its mechanical equipment is primarily imported from Morgan Co. in the U.S., and electrical equipment is primarily imported from ABB in Sweden. The Mill is the first high-speed wire manufacturer in China to adopt alternating current speed adjustment throughout the whole production line.The Mill owns three flying shears, driven by ABB's ACS600 adjustable speed varying frequency system, which are among the first generation equipment ABB produced for rod and wire mills. With the aging of equipment as well as the increasing demand from customers for better products, several problems have surfaced, and they include: failure to effectively track speed reference while performing high-speed cutting tasks; failure to establish stable communication with PLC; non-standardized firmware on control panels result in poor exchangeability and difficulty in locating faults; poor accuracy in controlling the length of top cutting; lack of effective methods for fault diagnosis and data analysis; poor real-time communication capability with process control system?L2?; etc.This paper intends to address the aforementioned problems from both hardware structure and software design perspectives. Firstly, impact by time lag on control system is mitigated by improving return circuit; Secondly, an optimized control curve is achieved by multiple parameter adjustments;Thirdly, fault diagnosis and data analysis system of flying shear is established based upon actual needs; Finally, issue on high-speed communication between flying shear control system and L2 server is resolved.Major research results of this paper include:1). To address the major problem in existing flying shear control system?response time lag?, a new control return circuit is designed by adopting new control hardware and by coding new control and connector programs, and that effectively reduced the response time lag, and increased response speed for flying shear control system.2). Modeling is conducted for the new flying shear control system by adopting in ZN method, robust control theory?H₂ Control,H_? Control? to optimizing parameters of the systems. Parameters with superior effectiveness are chosen by comparison with simulated curves in Mat Lab. It is validated through monitoring of on-site application that this control method is effective and satisfies relevant needs on-site.3). Practical significance of establishing shear fault diagnosis and data analysis system is explored. PDA high-speed data collection system from iba in Germany is introduced. VIP TCP/IP protocol is chosen based upon the particular situation, and communication is established between AC450 PLC and data station. There is also a detailed introduction of configuration plans of the communication protocol, the hardware and software of PLC port and data collection site, as well as the operational instructions of data collection software iba PDA and data analysis software iba Analyzer.4). There is a discussion on the structure of underlying automation computer system of Bao Steel High-Speed Rolling Mill. The communication issue between the existing flying shear control system and L2 server is identified. Significance of transforming such communication is stated. There is also a detailed introduction of the specific requirements and content of the transformation, as well as a detailed introduction of core communication format and text, with list of text attached herein.Due to the fact that ABB's OSC system is widely adopted by automation sectors such as steel-manufacturing and paper-making industries, results from this research is also applicable to other production lines in those sectors.