Project Unit: Project Department of BaoWu steel Precision Steel Wire Co., Ltd.
Compilation Unit: Shanghai CeZhen Automation Instrument Co.,Ltd.
1 Project Profile
Baosteel Metal Co., Ltd. is one of the wholly-owned subsidiaries of Baosteel Group Co., Ltd. The first phase of the project was completed in 2013, which achieved the expected automotive steel cord products and cutting steel wire products for photovoltaic industry.
According to the overall plan of the design plan for that year, the first phase of the plan has an annual capacity of 50,000 tons, including 10,000 tons of cutting steel wire and 40,000 tons of steel cord. In the planning and design, we consider the development space of the second-stage capacity of 100,000 tons and the forward scale of more than 150,000 tons.
In the first phase of the project, in order to meet the needs of production, the process equipment is equipped with 7 sets of pretreatment + large drawing units, 1 set of intermediate heat treatment, 24 sets of medium drawing units, 4 sets of surface reheat treatment units, 808 sets of wet drawing units, 490 sets of stranding units and 10 sets of rewinding units. They are installed in the large pretreatment span, the middle heat treatment span, the middle heat treatment span, the surface re-heat treatment span, the water tank wire drawing machine span and the steel cord twist span. Equipment occupies more than 50,000㎡ of the workshop.
2. The Present Situation of Production Equipment Management and the Necessity of Reform
2.1 Development Trends of Relevant Technologies at Home and Abroad
At the Hanover Industrial Exposition in April 2013, the German government put forward the strategy of "Industry 4.0", which aims to improve the competitiveness of German industry and take the lead in the new round of industrial revolution. The strategy has been widely recognized by German research institutions and industry. The concept of "Industry 4.0" is the fourth industrial revolution dominated by intelligent manufacturing. It aims to make full use of information and communication technology and the combination of network space virtual system and information physical system to transform manufacturing industry into intelligent one.
China's manufacturing industry has made rapid progress in the past 20 years. With the adjustment of economic institutions, China's labor costs are increasing year by year. It is predicted that the cost advantage of China's manufacturing industry will cease to exist by 2020. Industrial 4.0 technology can help China cope with productivity challenges. In the future, the manufacturing industry is not only to intellectualize the manufacturing process, but also to intellectualize the equipment system management.
With the introduction of modern high and new technology to various industries, especially the wide application of mechatronics and information technology in traditional production fields, the scale of enterprise operation is gradually expanding. Therefore, the need to further strengthen management has become increasingly prominent and urgent, and enterprise management informationization has become a trend of development. An important component of enterprise management informationization is equipment management informationization, and the basis of equipment management informationization is intelligent monitoring of equipment. Through on-line monitoring of on-site equipment to obtain basic data, to provide the underlying technical support platform for enterprise information management, through refining and mining, to help managers timely amend, improve and optimize the management system, methods and means, so as to make management more timely and effective, thereby improving productivity and enhancing the competitiveness of enterprises.
Intelligent monitoring of equipment operation status is the concrete embodiment of equipment diagnosis technology. With the development of military and aerospace technology in the 20th century, reliability theory has promoted the rapid development of equipment diagnosis technology. In the 1970s, with the continuous progress of microelectronics technology, sensor technology and computer technology, equipment diagnosis technology has been continuously promoted to various fields. At the same time, it began to change to intellectualization.
As far as the iron and steel industry is concerned, in modern iron and steel enterprises, the online monitoring technology of hot rolling process and equipment for strip, bar and wire has been gradually popularized, which provides powerful technology for early failure diagnosis of important transmission gears, bearings and other parts, avoiding major accidents, improving yield and product quality. Technical support. It has created powerful conditions for liberating spot checking labor force and reducing the cost of human resources.
In the field of wire products in China, the construction of intelligent manufacturing system has not started yet.
2.2 Present Situation of Equipment Management and Necessity of Reform
In the field of wire products in China, the construction of intelligent manufacturing system has not started yet. It is imperative to build an intelligent manufacturing system for Baosteel metals to dominate the field of wire products.
The construction of intelligent manufacturing system includes many aspects, among which the intelligent on-line monitoring of equipment is an important information base. From the current situation of equipment management:
(1) The process equipment of the first phase project is equipped with 1344 sets. The equipment occupies more than 50,000 ㎡ of the workshop. The number of equipment is large, the area of distribution is large, the intensity of spot inspection is large, and the quality of spot inspection must be affected.
(2) There are many equipments and noises in the workshop, so the experience of spot-checking ears can not judge the location of mechanical failure of equipment at all, let alone predict the failure of key parts of equipment. This result not only affects the planning of production, but also directly affects the consistency of production quality.
(3) There are many equipments with the same specifications. If we master the failure rules of the main parts, we can control the number of parts with failure. It is very important to improve the quality of equipment management and reduce the cost of spare parts.
Where is the solution to the above difficulties and the way to achieve the above expectations? This is the "Intelligent Monitoring System of Equipment Operation" proposed by our project. Popularly speaking, it is the "ECG" system of centralized monitoring equipment. The necessity of establishing the project is obvious.
Main Contents of Project 3
3.1 Reform Contents
3.1.1 Construction Principles of Reconstruction Project
According to the current situation of production and operation of enterprises, we have determined the following principles for the construction of "intelligent monitoring system for equipment operation status" by stages:
(1) Save investment, from small-scale pilot projects to large-scale promotion;
(2) not affecting or less affecting the production plan;
(3) Reduce the change of the original facilities of the workshop;
(4) Equipment procurement should be localized to reduce the cost of subsequent system operation;
(5) Adopt the phased implementation mode to realize the intellectualization of the equipment operation condition monitoring system in the whole plant.
3.1.2 Scope of Implementation
The feasibility and necessity of the equipment are analyzed. The implementation scope of "Intelligent Monitoring System for Equipment Operation Status" is as follows:
3.1.3 Technical Scheme
In view of the above equipment monitoring scope and the layout characteristics of workshop equipment, the proposed "intelligent monitoring system of equipment operation status" mainly consists of three parts: equipment vibration monitoring device, monitoring data collection and transmission system and data processing equipment.
The main feature of this scheme is that there is no need to lay a large number of cables in the workshop. It is easy to install and the intelligent network is safe and reliable.
(1) Vibration monitoring device
Monitoring device is the most important part of the system. With the development of technology, sensors used to capture the state of mechanical equipment can be divided into several categories: temperature sensor, pressure sensor, noise sensor, stress-strain sensor and vibration sensor. The actual selection of sensors should be based on the obvious failure form of equipment parts.
For our wire drawing and twisting equipment, the environment is noisy, and the common failure form of equipment parts is bearing loss of accuracy until damage. Therefore, temperature sensors, stress-strain sensors and vibration sensors should be feasible options.
After exclusive analysis, naturally the best solution in this proposal is to use vibration sensors.
There are several types of vibration sensors. We use CZ9300 piezoelectric vibration transmitter. This kind of sensor, picking up "inertia" is also small, very sensitive. Integral package, equipped with armoured wire, suitable for working environment with oil and water. As shown in the picture:
The main technical parameters are as follows:
Output Current: DC.4-20mA
Measurement range: 0-20mm/s
Corresponding frequency: 5-1000HZ
Suitable ambient temperature: -10-+70 C
Supply Voltage: DC.24V
Shell material: stainless steel
The number of equipment monitoring sensors is shown in Table 2:
(2) Monitoring data collection and transmission system
The monitoring data collection and transmission system adopts ZigBee wireless serial communication system, through which the vibration amplitude of the front-end vibration sensor sensitive equipment is transmitted to the wireless transmitting equipment, and the vibration amplitude is transmitted to the back-end external output equipment in digital form by wireless communication. Data are collected and sent to the back data processing system.
The system has the following characteristics and main technical parameters:
It has the functions of relay routing and terminal equipment, and has strong wireless transmission capability.
The maximum line-of-sight transmission distance is 2000m and the transmission power is 25bdm.
4G DSSS Direct Sequence Spread Spectrum Technology has strong scrambling ability
Maximum baud rate: > 38400 BPS
Target address can be sent
Strong network capabilities, you can set: 65535 network IDs
Suitable for industrial environment, suitable for environmental temperature: -10-+85 ~C
Working humidity: 10-90% non-condensation
Input voltage: DC5-24V
Serial Port Form: TCP/IP
(2) Data Processing Equipment
A. Selection of major equipment
The rear data processing equipment adopts 19"high brightness LED display screen, fan-free low-power industrial tablet computer, Intel #low-power processor, motherboard uses a large number of high-quality solid-state capacitors, sealed inductors, cryogenic MOS transistors and other high-specification devices to adapt to the harsh environment of industrial sites. Front panel up to IP65 protection level.
Environmental Requirements: Working Temperature: - 10 ~70 ~
Hot and humid work: 20-80% RH
The interface of industrial computer directly shows the basic parameters (mm/s) of each equipment.
B. Software Functions
The software of industrial computer is edited by Labview software, which has human-computer interaction interface. The interface has the following functions:
Data and images of each vibration sensor can be displayed simultaneously.
The data image of a single sensor can be selected and enlarged.
Vibration status "normal" can be displayed on the screen. When a running value exceeds the set alarm or danger value, the corresponding display will change to yellow or red prompt.
Data history can be stored automatically and the storage path can be changed. Data can be read and saved manually.
Select software "start", "stop" and other states.
Whether the connection of each sensor is normal or not
It has the condition of late expansion.
4 Project Implementation Plan
5.1 Master Plan
Considering the problems of investment, benefit and technological risk, it is suggested that the construction should be carried out step by step without affecting production. It is divided into four stages:
(1) Test phase: the construction of pilot equipment monitoring will be completed by May 2015;
(2) Implementation of the first stage: by August 2015, the pilot experience was summarized and the first batch of equipment monitoring system was completed.
(3) Implementing the second stage: completing the construction of the second batch of equipment monitoring system by October 2015;
(4) Implementation of the third stage: complete the construction of the remaining equipment monitoring system by December 2015, and form one of the basic systems of intelligent equipment management.
