DCC - Digital Coil Conversion and full process quality management

Process Data Acquisition – CHPDA -- Detailed analysis of quality manage&industrial big data sources		高速数采方案 High speed data acquisition scheme	系统 System	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 Project performance and typical project application
10 RCM - Roller Current Monitoring system	21 Research Form for PDA System Configuration in the Steel Industry
11 HDP - High frequency density and speed Data Platform construction

6 DCC - Digital Coil Conversion and full process quality management

6.1 Application of digital steel coil

The Digital steel coil conversion system is an important component of the hot and cold rolling information system and can also operate independently.

The so-called digital steel coil refers to a series of data sets that are attached to the physical steel coil with relevant production digital information. It realizes the "full process visualization" and "digitization" of the steel coil, providing a complete, accurate, and reliable data foundation for subsequent big data analysis and mining. It is the most crucial step in realizing an intelligent factory. It can be delivered with physical steel coils or stored in big data centers for 5G download, with the advantage of product traceability. Because there are millisecond and centimeter level numbers recorded on the steel coil, if applied to household appliances, construction, especially automotive, silicon steel, and stainless steel products, this will further ensure quality. Accelerate the construction of a manufacturing powerhouse, accelerate the development of advanced manufacturing industries, and promote the deep integration of the Internet, big data, artificial intelligence, and the real economy. "Digital steel coil" is a typical case of cross-border integration between manufacturing and big data.

(1) Digital steel coils are divided into length digital steel coils, timing digital steel coils, equipment digital steel coils, and equipment diagnostic digital steel coils, each with corresponding purposes.

(2) According to timeliness, it can be divided into real-time digital steel coils (calculated in seconds) and online digital steel coils (calculated in minutes).

(3) According to production processes, it can be divided into hot-rolled digital steel coils, cold-rolled digital steel coils, digital steel plates, digital steel pipes, etc.

(4) Regardless of rough rolling, finishing rolling, or coiling, each signal is equally divided into 30000 parts according to length, truly accurate to the centimeter level, while achieving natural length alignment.

(5) Search for 20 year old steel coils based on certain indicators such as head, middle, and tail (which can be divided into 20 sections) and total length. The results will be returned within 10 seconds, without the need for hours. Generally, it takes only 3 seconds.

(6) Compared with other digital steel coils at home and abroad, the concept of this system is the most distinctive. It is truly accurate to the centimeter level and millisecond level, and the core of the analysis tool is consistent with the PDA system, making it very suitable for processing large amounts of data.

(7) Digital steel coil is a relatively independent system that can operate independently or as a part of the information system of factories, companies, and groups. It provides various fully open interfaces such as file sharing, database, FTP, HTTP, MQTT, etc. for other systems.

ü The synchronous delivery of digital steel coils and physical steel coils is beneficial for downstream process control of product quality. For example, high-end cold rolled steel plates are mainly used for automotive outer panels, with high quality requirements and high processing difficulty. When delivering the steel coils to customers, the data attached to the physical products is also submitted together. This type of "digital steel coil" not only contains common data of the same batch of steel, but also carries the material, process, and Personalized data such as performance is equivalent to comprehensively collecting the "process fingerprint" of the steel coil, thereby helping automobile manufacturers better control the quality of the entire vehicle.

ü Quickly identify quality statistical indicators through classification to guide decision-making.

ü Improving yield: width control, analyzing the control accuracy that physical steel coils can achieve, reducing the width margin by 1mm, will generate considerable economic benefits: for example, the width margin of a certain specification, statistical analysis of all similar steel coils in history, and finding the optimal value when setting the model and control strategy unchanged.

ü Improving quality: such as controlling flatness, analyzing the reasons for each meter, changing control methods, controlling convexity, thickness, temperature, etc.

ü Improve control level: set values, accurately track steel coil numbers.

ü Improved model: able to easily identify commonalities, optimize models and parameters.

ü Quality objection handling: The digital steel coil records all quality data at the centimeter level, which can be quickly analyzed and processed without having to go to the user's site, shortening the time frame and reducing costs.

ü The existing data related to steel coils is dispersed in various systems, and the names of the data are not unified, which brings great difficulties to the comprehensive application of these data. "Digital steel coils" will establish a unified data platform, on which a series of information such as equipment data, operation records, energy consumption data, defect data, process data, cost data, and user information will be integrated into a unified data. The collected data is uniformly encoded according to the steel coil number, using the steel coil as the carrier, and assigned values in both chronological and length dimensions to produce a "digital steel coil" that is synchronized with the actual steel coil, providing a data foundation for in-depth applications such as equipment intelligent monitoring, production intelligent scheduling, cost management, and intelligent spot checks.

ü With the increasing demand for product quality from users, those with stable product quality and high performance indicators will be the first to promote digital steel coil delivery nationwide. With the widespread implementation of information technology, it can be foreseen that physical steel coils that provide digital steel coils will be more popular. Leaving the forefront of information technology will win market advantages, not only providing convenience for users to improve product quality but also reducing costs, Moreover, it greatly promotes the continuous improvement of product quality momentum upstream, not only being traceable, but also providing full process data for analysis throughout the entire industry chain.

ü Provide data sources for B/S and big data analysis.

6.2 Digital coil conversion calculation

The conversion work and length calculation are calculated by QDRServer based on the temporal data file. Support two tracking methods: zone occupancy and continuous calculation. By collecting and merging the individual quality data record files formed by each process, the entire process quality data files can be obtained, providing data sources for B/S and big data systems.

Figure 6.1 Process quality data calculation

ü Data recording based on coil number and length

ü Millisecond time resolution

ü Centimeter size of length

ü Whole process data integration

ü Efficient quality analysis tool - product Explorer

ü Rich analysis function

Figure 6.2 Digital Steel Coil System Architecture

Figure 6.3 Converting and caclulating of quality data recording files

Figure 6.4 Quality data converting flow chart

Figure 6.5 The quality data recording files generated

6.3 Length timing equipment and equipment diagnosis digital steel coil

The digital steel coil includes high-resolution data files of length, time-series high-frequency data files, equipment diagnosis ultra-high frequency data files and their header, body, tail, full-length feature value statistical data, and frequency reduction data of length and time series, as shown in the file list below.

Figure 6.6 Digital steel coil file for length, timing, and equipment diagnosis

6.4 Alignment

Each signal in the length direction is divided into 30000 equal parts, and different process sections and production lines of the same production line are naturally aligned. It is also compatible with the entire process of hot rolling, cold rolling, and processing lines; The timing direction is aligned according to the sampling time, and the equipment diagnosis ultra-high frequency raw data is aligned according to the sampling time.

6.5 Real time digital steel coil

Within 1 second after throwing steel in each zone of rough rolling, finishing rolling, and coiling, the PDAServer of each zone starts the QDRServer digital steel coil calculation. The QDRServer completes the calculation within 2 seconds, and completes the judgment of quality, equipment, model accuracy, etc. within 1 second, while also completing the curve display.

The startup signal in PDAServer is set in the configuration file Config.csv, and the unwinding signal of each coiler in the coiling area is an OR relationship.

Curve display: Display the real-time curves of 2 historical and current strip steels before steel throwing, and display the curves of 2 historical and current strip steels within 1 second after QDRServer calculation is completed.

Rough rolling: final pass curves such as outlet width, centerline deviation, and outlet temperature.

Precision rolling: thickness, width and deviation, FT0, FT7, flatness, convexity measurement and target values, etc.

Coiling: Coiling temperature, width and deviation, measured centerline, and target values.

Template switching can be used for roll gap, rolling force, current, servo valve signal, etc.

Figure 6.7 Real time digital steel coil system configuration

Figure 6.8 Directory structure of digital steel coil system for a certain project

6.6 Basic, Standard, Professional, and Enterprise Editions

Basic version: L1 data for rough rolling, finishing rolling, and coiling areas (length+timing)

Standard version: Basic version+L2, L3, L4, large instrument data (length+timing)

Professional Edition: Standard Edition+Search System

Enterprise Edition: Professional Edition+Device Diagnosis (Timing)

6.7 High resolution real-time quality judgment and device status discrimination

The determination of length direction can be accurate to the centimeter level.

The timing direction determination can be precise to the millisecond level.

Immediately start the digital steel coil calculation in each area after throwing steel, and complete quality judgment, model accuracy evaluation, servo equipment status discrimination, etc. within 10 seconds.

6.8 Digital steel coil analysis tool BigOffice

Obtaining data from a data warehouse is a difficult task for anyone. Intuitively extracting raw data, efficiently displaying raw curves, conveniently selecting analysis methods, and quickly displaying analysis results are the last mile for industrial big data to enter the desktop of professional engineers. Otherwise, it is difficult to land, and massive data will be shelved.

In the era of big data, engineering and technical personnel urgently need a set of BigOffice.

PDA is a set of industrial millisecond level real-time big data tools and also the basic platform for big data collection.

PDA simplifies complex operations, efficiently performs a large amount of mathematical operations, and visualizes the presentation of data.

PDA provides high-speed data services for various architectures such as C/S and B/S.

PDA can also be naturally compatible with second or minute level data frequency. For example, for Tieqian big data, all data related to ironmaking, sintering, and coking can be extracted from the data warehouse by day, week, or month and saved in PDA format data files. Equipment and process engineers can analyze from their respective angles. PDA has conventional mathematical analysis methods, and big data specific analysis methods can be integrated into PDA in the form of plugins, In this way, users' diverse ideas can be incorporated into the PDA platform, and the ecosystem will gradually be established. PDA data and functions are completely open and transparent.

Figure 6.9 Curve of relationship between flatness and crown and rolling force and roll gap

Figure 6.10 Relationship between rolling force roll gap and outlet thickness and FT7

Figure 6.11 The relationship curve between RM FM DC temperature and FM speed

Figure 6.12 The relationship curve between rolling force gap and main transmission current

Figure 6.13 Shape and curve of 6 strip head

Figure 6.14 Shape and curve of 6 pieces of strip in the middle

Figure 6.15 Shape and curve of 6 strip tail

6.9 Application of digital steel coil in quality inspection

Quality inspectors need to manually check all quality index curves of each steel coil. The calculation of product length, time translation, and length alignment for each index are almost manually completed, which is labor-intensive and tedious.

The digital steel coil iSearch high-speed search locates the steel coil, displays all quality curves according to the upper and lower limits of PDI indicators, displays the measured plate shape in three-dimensional graphics, and quickly switches quality inspection content using analysis templates.

Figure 6.16 PDI Indicator Upper and Lower Limits Showing All Quality Curves

Figure 6.17 Analysis Template Quick Switching Quality Inspection Content

Figure 6.18 3D Graphic Display of Measured Plate Shape

6.10 Digital Steel Coil and DeepSeek

Combining high-resolution digital steel coils with DeepSeek improves setting and product accuracy.

The segmentation and management of raw high-speed time-series data significantly reduces the workload of DeepSeek.

Millisecond level and centimeter level full process data, with no distortion of details.

Process, production line, full process L1, L2, L3, All kinds of instrument data, complete and centralized.

High speed performance is beneficial for improving learning speed.

The natural length alignment method is highly compatible with DeepSeek deep learning.

Apparatus test&Fault diagnosis&Quality analysis

Millisecond data sampling

Real-time data compression

Capture signal instantaneous mutation

友情链接百度腾讯新浪网易搜狐凤凰淘宝京东中国自动化网中国工控网西门子罗克韦尔华军软件园天空软件站非凡软件站多多软件站携程知乎

中国五矿中冶集团中冶赛迪中冶南方中冶京诚中冶华天中冶长天中冶北方中冶焦耐中国宝武宝信宝钢武钢鞍钢河钢首钢沙钢山钢涟钢

Develop communication protocol, Customized analysis function, Open data interface, Localization of XinChuang

PDAServer PDAClient