Project performance and typical project application

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Process Data Acquisition – PDA -- Detailed analysis of quality manage&industrial big data sources	高速数据采集方案 High speed data acquisition scheme		专题系统 Thematic System	联系我们 Contact us
1 Background and significance		12 HDC - Hot rolled high-frequency high-density Digital steel Coil
2 PDA - data acquisition and analysis system		13 CDC - Cold rolled Digital steel Coil
3 LTA - Long historical Trend Analysis system		14 DSP - Digital Steel Plate
4 HDS - open time series high frequency Historical database		15 DTP - Digital Steel Pipe
5 DBU - Database system and Upgrade tools		16 CDS - Continuous casting Digital Slab
6 DCC - Digital Coil Conversion and full process quality management		17 TDA - Typical high-speed Data Acquisition scheme
7 CFS - Coil Fast Search and statistics system		18 QMS - Quality Manage and analysis System
8 DSO - Device diagnostic Synchronous Oversampling system		19 Common debugging tools and development board
9 RSA - Roll Spalling Alarm and Quick Stop System		20 Research Form for PDA System Configuration in the Steel Industry
10 RCM - Roller Current Monitoring system		21 Project performance and typical project application
11 HDP - High frequency density and speed Data Platform construction

21 Project performance and typical project application

The PDA system is widely used in the large and medium-sized enterprises. Its project performance is not listed one by one.

No.	Process equipment
1	The silicon steel sheet mill
2	Hot strip rolling mill
3	CSP - Compact strip production
4	Cold rolling mill
5	Composite mill (bullet shell)
6	Steelmaking, continuous casting
7	Steel pipe
8	Heating furnace
9	Temper mill
10	Laboratory
11	Flash butt welding machine
12	Measurement of battery consumption curve
13	Pneumatic conveying experiment
14	Cement
15	Energy management
16	Data telemetering service
17	Reforming of Data Acquisition System
18	Brewery information system
19	Point Map Analysis System of a Brewery
20	Data analysis for Brewery CO₂ recovery prediction and measured data
21	Main drive SL150
22	Quality management and digital coil
23	Unmanned locomotive and intelligent iron metal transportation system
24	All-weather umanned wharf
25	Electro hydraulic servo control system
26	Automobile monitoring system
27	HSM digital coil system
28	CSM digital coil system
29	IGBT Flexible DC Chopper Power Supply - Green Intelligent Super Arc Furnace
30	MPT(Mill Pacing Tracing)
31

21.1 PDA system of a hot temper mill

Temper mill occasionally oscillated in 2011.3.8, and could not product, inappropriate pressure ring parameter setting was found after the historical curve (in red circle below) was analyzed, and normal production was restored after adjustment.

Figure 21.1 Application of PDA in Leveling Machine

21.2 Hydraulic vibration PDA system for thick slab continuous casting mould in a steel factory

The mould is the core equipment of continuous casting machine, Hydraulic vibration can effectively reduce the friction resistance of casting billet and mould room compared with the mechanical vibration, so as to improve the surface quality of billet, improve the drawing speed, increased yield; the plate spring guide is used, no mechanical wear, equipment maintenance workload and cost can be reduced; anisotropic small deviation; online adjustable amplitude, frequency and waveform, achieve sinusoidal and non sinusoidal oscillation can be realized when the prestressed spring orientation precision is used, to meet the requirements of the steel casting process.

Figures 21.2 and 21.3 show the vibration process of starting and stopping, commissioning personnel may adjust various parameters according to waveform, make feedback to follow reference as fast as possible and the overshoot is small, sometimes the servo valve blockage can be analyzed Intuitively from the curve because hydraulic oil is not clean, the reasons is found out quickly. Normal production worker can call historical curve after vibration stopping, the quantitative analysis may be done with signal interference, high friction, oil plug or irregular operation.

Figure 21.2 Mold Hydraulic Vibration Starting Process Curve

Figure 21.3 Hydraulic Vibration Stop Process Curve of Crystallizer

Figure 21.4 shows the vibration curve during normal production, with a sampling period of 2ms. Based on the curve, control system parameters can be adjusted, system working status can be determined, and fault causes can be identified. The control system is S7-400+FM458.

Figure 21.4 Hydraulic vibration curve of a certain thick plate continuous casting mould

21.3 PDA system at 1700mm hot strip mill

The below figure is PDA curve of 1700mm Hsm, 9200 points are collected, time base is 1.95ms, Three PDA systems of German brand are replaced after control system is reformed. Performance is significantly improved, the operation is simpler.

Figure 21.5 Application of PDA in the Hot Strip Rolling Control System

21.4 Performance testing system for a large AGC oil cylinder factory

Figure 21.6 shows the hysteresis test curve of an AGC cylinder from a certain oil cylinder factory. The hysteresis reflects performance indicators such as hydraulic cylinder friction, with a sampling period of 0.5ms. A report can be directly generated based on the measurement curve.

Figure 21.6 hysteresis test curve of a large AGC oil cylinder

21.5 A pneumatic conveying experimental data testing system

PDA supports complex mathematical formula, It may open a week of experimental data and find the law.

Figure 21.7 Application of PDA in pneumatic conveying systems

21.6 PDA system of a steel pipe plant

9906 points are collected, collection period is 2ms, PLC is the SIEMENS S7-1500 and TDC, the acquisition control function is: hydraulic pass control system, main drive and auxiliary drive, mill district hardware IO, control logic, stretch reducing mill main drive, stretch reducing mill cooling bed auxiliary transmission, hardware IO and control logic.

Figure 21.8 Application of PDA in Steel Pipe Plants

The function RisingEdgeInterval calculates the rolling time of each steel pipe.

Figure 21.9 Customized function statistics of rolling time for steel pipe factories

21.7 Power management system of a cement plant

Energy saving and emission reduction is an effective means to reduce costs. PDA provides a comprehensive analysis by equipment energy consumption characteristics, and also as a daily management tool. The report column is dynamically set according to the .pda analysis strategy. The following figure shows the electricity statistics of hundreds of meters in a cement plant.

Figure 21.10 Statistical Report on Electricity Consumption of Air Compressors in the Whole Plant

Figure 21.11 Summary Statistical Report of Total Score Reduction Table

Figure 21.12 Statistical Table of Electric Energy of Cement Mill

Figure 21.13 Electric Energy Statistics Report of Kiln Head Coal Mill Equipment 1

The Acuvim II series three-phase network power instruments jointly developed by Beijing Aibo Precision Electric Co., Ltd. have relatively complete functions: full parameter measurement, bidirectional four quadrant 0.2S level electricity metering; The power quality event recording and waveform recording functions provide technical basis for accident recall; RS485, PROFIBUS, Ethernet, support for web browsing, scheduled email sending, ModbusTcp; Provide full parameter timed recording function; Real measurement of communication refresh per cycle, suitable for occasions with high response speed requirements.

Figure 21.14 A Full Parameter Energy Meter

21.8 A railway data teletransmission system

The control system of a certain railway station is S7-200smart, and the railway bureau needs to collect signals from it, but only supports the ModbusTcp protocol. The ModbusTcp protocol of S7-200smart is relatively troublesome. PDAServer communicates with PLC through the S7 protocol, and the collected real-time data is mapped to the Modbus register. The railway bureau can communicate with ModbusTcpServer, and the following figure is a schematic diagram of a railway data remote transmission system.

Figure 21.15 Schematic diagram of PDA data remote transmission network for a certain railway station

21.9 A data collection and statistics system for operation time of a certain machine set

The below figure is a operation time statistics report of a certain machine set, daily, monthly and team reports may be automatically generated.

Figure 21.16 Daily and monthly operation time reports of a certain machine set

Figure 21.17 Daily and monthly team operation time report of a certain machine set

21.10 Dynamic running record report and meter reading system

Reports are automatically generated according to the analysis policy files(.pda) in \BigData, the default record time interval is one second. Counting accumulative values(I=1 in Config.csv) by minute or the average value(I=2) of the accumulative value or instantaneous value(I<>1 or 2), a value is calculated per hour. Only instantaneous value is calculated for bool and string.

Figure 21.18 Dynamic operation record and meter reading system operation interface

21.11 A hot rolling mill main drive SL150

SL150 is Siemens' new generation high-power alternating current frequency main drive system, with core units of Simotion D445 (or D455) template and Sinamics CU320 template. The PDA system collects data through standard Ethernet and Profinet, with a data refresh cycle of 1ms.

Figure 21.19 Main Drive Data Collection Network Diagram

21.12 Reforming of Data Acquisition System

Some special equipment, special communication network and special servers are used in some data acquisition systems. The system is very complex and expensive. Once it breaks down, it is very difficult to recover. The following figure is a transformative replacement of PDA system used in a steel plant.

Figure 21.20 PDA System Transformation Host Network Diagram

21.13 Statistical Process Control

The purpose of SPC is to prevent, control and forestall.

The main functions of SPC are: real-time monitoring and early warning of the production process, timely taking measures for abnormal fluctuations, real-time improvement; judging whether the process fluctuations are random or abnormal fluctuations; realizing process stability and control.

SPC index is calculated for the data between x1 and x2 of the first curve in the current display area.

Figure 21.21 Statistical Process Control SPC Curve

21.14 Data Acquisition and Point Map Analysis System of a Brewery

Collect data from over 30 PLCs and electricity meters. The point maps include CO2 recovery and consumption, low-voltage electricity meters, high-voltage electricity meters, water volume, compressed air, steam, etc. Second-level data is promoted to SQL Server, millisecond level data is promoted to InfluxDB, and all tables are automatically created, with a structure consistent with the PDA system.

Figure 21.22 Energy consumption data collection for breweries

21.15 CO2 Recovery Prediction and Measurement Data Analysis System for a Beer Factory

Based on the mother liquor and fermentation tank data, the CO2 recovery curve can be predicted and compared with the real-time curve for analysis, achieving balanced and stable production of CO2 and beer.

Figure 21.23 CO2 Recovery Prediction Curve

21.16 Unmanned locomotive and intelligent hot metal transportation system

Including driverless, uncoupling, parking anti slip, positioning, derailment detection, environmental awareness, equipment support, traffic scheduling, remote centralized control and other subsystems, any failure may cause catastrophic consequences.

The follow is locomotive operation.

Figure 21.24 Diagram of Molten Iron Transport Locomotive

The follow is locomotive operation status.

Figure 21.25 Data curve recorded by unmanned locomotives

21.17 All-weather unmanned wharf

It includes unmanned port machinery, steel coil automatic lifting, intelligent management and control of the terminal and other subsystems, which liberates the operators from the heavy and dangerous environment.

The follow is automatic lifting of steel coil at wharf.

Figure 21.26 All weather dock operation site

The follow is wireless signal strength and SNR of leaky wave cable.

Figure 21.27 All weather dock PDA monitoring curve

21.18 Electro hydraulic servo control system

The servo motor drives the hydraulic cylinder for high-precision closed-loop control, Its positioning accuracy can reach um level, Servo valve and large-scale hydraulic station are cancelled, so the system has low cost, small maintenance and high reliability.

The follow is MS level data curve.

Figure 21.28 Millisecond level data curve of the electro-hydraulic servo control system

The follow is day data of second level.

Figure 21.29 Second-level Data Curve of Electro-hydraulic Servo Control System

21.19 Automobile monitoring system

The car is controlled by CAN bus. PDA supports standard frame and extended frame. It can collect all frame IDs at high speed. It is an effective tool for car monitoring, development and driverless debugging.

Figure 21.30 Various Cars Based on CAN Bus

Figure 21.31 CAN Bus Data Collection for a Certain Car

21.20 Rolling mill stiffness tracking report

Figure 21.32 Measurement curve of rolling mill stiffness

Figure 21.33 Linear fitting results of rolling mill stiffness

Figure 21.34 Original and fitted curves of rolling mill stiffness

Figure 21.35 Calculated stiffness under various rolling forces

Figure 21.36 Stiffness Evaluation of a Steel Plant

21.21 MPT - Mill Pacing Tracing

MPT (Mill Pacing Tracing) calculates the accurate tracking position of the head and tail once every 50ms.

Reduce waiting for steel placement.

The rolling pacing is increased by 3 seconds, and an additional 20 pieces of steel can be produced per day.

Figure 21.37 Rolling Pacing Tracing

21.22 IGBT Flexible DC Chopper Power Supply - Green Intelligent Super Arc Furnace

The project won the second prize of the National Science and Technology Progress Award. The PDA system can collect 20KHz data of current and voltage in each phase, and perform online and offline analysis of harmonics such as 3, 5, 7... 13, 15, 17.

Figure 21.38 Green Intelligent Super Arc Furnace

The application of advanced technologies such as new IGBT flexible DC power supply technology, electrode stepless dual control intelligent regulation technology, continuous preheating technology for scrap steel, step wise continuous feeding technology for scrap steel, air-cooled contact needle bottom electrode technology, dioxin treatment and waste heat recovery technology, intelligent steelmaking technology, etc. can quickly respond to the smelting energy supply demand in the electric arc furnace and respond to short circuit and over current impact conditions, shorten the smelting cycle to within 30 minutes, and reduce power consumption to 250-300 kWh/t, The electrode consumption is 0.6-0.8kg/t, which is a new generation of green, energy-saving, environmentally friendly, and efficient electric furnace. Compared with conventional electric furnaces, it has great advantages in improving production efficiency, reducing electricity and electrode consumption, and improving metal recovery rate.

Figure 21.39 Performance Comparison Curve between Green Intelligent Super Electric Arc Furnace and Traditional Electric Arc Furnace

21.23 Mobile APP

PDA.apk is an Android installation package that requires storage permissions. The on-site configuration information for each project needs to be downloaded to a storage card for future use.

Figure 21.40 Real time data display and production monitoring system for various styles

21.24 PLC ring network fault detection

The ring network composed of multiple S7-1500 controllers and HMIs seems to be working properly. When the PDA was connected to the network for 2ms data collection, it was found that dozens of data packets were lost every 6 seconds. However, when the PDA was directly connected to the PLC, everything was normal. Further investigation revealed that disconnecting the ring network was also normal. Later, the PLC version was lowered and the ring network was normal. It's not that the higher the PLC version, the better.

21.25 Mathematical Model Log

Modern steel rolling mathematical models are becoming increasingly complex. The traditional method is to write key data into. log files and analyze the. log text files when problems are found, which is not intuitive and inefficient. By sharing memory or networks, a large amount of model data can be recorded in PDA systems, accelerating the debugging progress of the model and the convenience and accuracy of fault analysis.

Apparatus test&Fault diagnosis&Quality analysis

Millisecond data sampling

Real-time data compression

Capture signal instantaneous mutation

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