Expert Experience and Data-Driven Based Hybrid Fault Diagnosis for High-SpeedWire Rod Finishing Mills

The reliable operation of high-speed wire rod finishing mills is crucial in the steel production enterprise.As complex system-level equipment,it is difficult for high-speed wire rod finishing mills to realize fault location and real-time monitoring.To solve the above problems,an expert experience and data-driven-based hybrid fault diagnosis method for high-speed wire rod finishing mills is proposed in this paper.First,based on its mechanical structure,time and frequency domain analysis are improved in fault feature extraction.The approach of combining virtual value,peak value with kurtosis value index,is adopted in time domain analysis.Speed adjustment and side frequency analysis are proposed in frequency domain analysis to obtain accurate component characteristic frequency and its corresponding sideband.Then,according to time and frequency domain characteristics,fault location based on expert experience is proposed to get an accurate fault result.Finally,the proposed method is implemented in the equipment intelligent diagnosis system.By taking an equipment fault on site,for example,the effectiveness of the proposed method is illustrated in the system.

Modeling and finite element analysis of rod and wire steel rolling process

Two thermomechanical coupled elastic-plastic finite element （FE） models were developed for predicting the 12-pass continuous rolling process of GCrl 5 rod and wire steel. The distances between stands in the proposed models were set according to the actual values, and the billets were shortened in the models to reduce the calculation time. To keep the continuity of simulation, a technique was developed to transfer temperature data between the meshes of different models in terms of nodal parameters by interpolation functions. The different process variables related to the rolling process, such as temperature, total equivalent plastic strain, equivalent plastic strain rate, and contact friction force, were analyzed. Also, the proposed models were applied to analyze the reason for the occurrence of an excessive spread in width. Meanwhile, it was also utilized to assess the influence of the roll diameter change on the simulated results such as temperature and rolling force. The simulated results of temperature are found to agree well with the measured results.

Influence of Wires Properties on Warp-Knitted Loop Geometry in Plane Based on Theory of Elastic Rod

Based on classic theory of elastic rod,the warp-knitted loop geometry in plane is independent of yarn properties,while there is a certain gap between the geometrical model and the actual fabrics.According to this problem,further analysis of loop geometry is done based on the theory of elastic rod with theoretical calculation and experiments.The theoretical analysis found that the distance between the contacted points at the loop root affected the loop geometry,and the distance was affected by the ratio of bending rigidity and the friction between yarns.The experiments,forming simple loop by taking the yarn as an elastic rod,found that the bending rigidity affected the loop geometry.Then the relationships between warp-knitted loop geometry in plane of metallic fabrics and wires properties were studied.The results show that metallic fabrics are more suitable for the theory of elastic rod;the friction and bending rigidity of wire yarns affect the loop geometry in plane.Also,the elongation of yarn affects the loop geometry in the actual warp-knitted fabric.

The Quality Specifications of Mischmetal Wire and Rod and the Method of Adding Rare Earth in Steel

The quality of mischmetal wire and rod and the method of adding rare earth into steel are quite important for making high quality steel. This paper proposes a quality specification of wire and rod as well as related adding method. The paper also provides principles for selecting raw material and adding method.

Force Analysis and Curve Design for Laying Pipe in Loop Laying Head of Wire Rod Mills

Laying head is a high-precision engineering device in hot-rolled high speed wire rod production line. Previously research works are focused on the laying pipe wear-resisting. Laying pipe curve design method based on wire rod kinematics and dynamics analyses are not reported before. In order to design and manufacture the laying pipe, the motion and force process of the wire rod in the laying pipe should be studied. In this paper, a novel approach is proposed to investigate the force modeling for hot-rolled wire rod in laying pipe. An idea of limited element method is used to analysis and calculates the forces between laying pipe inner surface and wire rod. The design requirements of laying pipe curve for manufacturing are discussed. The kinematics and dynamics modeling for numerical calculation are built. A laying pipe curve equation is proposed by discussing design boundary conditions. Numerical results with di erent laying pipe curves design parameters are plotted and compared. The proposed approach performs good result which can be applied for laying pipe curve design and analysis for engineering application.

Present situation and countermeasure of low-alloy spring steel wire rod for domestic automobile

The variety,inner quality and surface quality of low-alloy spring steel wire rod for domestic automobile is summarized in detail.And according to commercial low-alloy spring steel wire rod variety, product quality level and its actual application situation on automobile supplied by present industrially developed country metallurgy enterprises,it is pointed that the variety of low-alloy spring steel wire rod for domestic automobile can't satisfy the requirements of automobile industry development,compare with overseas advanced technology,product quality has the following gaps:the first is that steel purity is low,the control level of non-metallic inclusions is not steady,there is often large grain difficult deforming non-deformation inclusions existing,the control level of steel purity has big difference,the level of large steel factory is high,but its steady has a large gap compare with foreign advanced level,not to mention small steel factory which research and development powder is low.The second is surface complete decarburization can' t be avoided completely.The third is that surface defects are more.The fourth is that composition segregation and structure segregation are not steady,steel wire can't be drawn normally when the segregation is serious. In all,the segregation of 55SiCrA is superior to 60Si2MnA obviously.The industrialization of domestic high level low-alloy spring steel wire rod can't seek quick success and instant benefits,independent innovation perseveringly must be adopted,the success may be reached after master core technologies and adopt the science way of step by step.

High-Speed Wire Rod Finishing Mill

The high-speed wire rod finishing mill production line consisting of more than 10 key items of equipment such as a heating furnace,major rolling mill, secondary rolling mill,preliminary refining mill, finishing mill, carrier roller, wire-drive machine, coiler, and packing machine, is a technology-intensive product combining modern rolling technology with the high-technology of machinery, electronics,hydromatic drive and instrumentation, which only a few countries in the world can produce.

BWR4耐候钢热轧盘条的研制开发

主要介绍了首钢长钢公司采用转炉、LF精炼炉、小方坯连铸机和55万t棒线复合产线工艺路线生产BWR4耐候钢热轧盘条的关键工艺技术。轧制盘条力学性能稳定,1/3冷顶锻合格率为100%,耐大气腐蚀指数在6.54以上,轧制盘条质量指标符合《耐候钢结构紧固件用热轧盘条及圆钢》标准要求,可满足用户加工5.8级螺栓使用要求。

小切口复位临时固定辅助股骨近端防旋髓内钉治疗股骨转子间骨折

目的探讨小切口复位临时固定辅助股骨近端防旋髓内钉(PFNA)治疗股骨转子间骨折的疗效。方法采用小切口复位临时固定辅助PFNA治疗28例股骨转子间骨折患者。记录术中出血量、手术时间、骨折复位质量、骨折愈合情况。采用Harris评分评价髋关节功能。结果患者均获得6个月随访。术后无切口感染情况发生。术中出血量95~110(100.5±8.0)ml,手术时间45~57(50.5±4.5)min。骨折复位质量:解剖复位20例,功能复位5例,复位不良3例。术后3个月Harris评分67~95(88.32±8.07)分,其中优20例、良5例、差3例,优良率25/28。26例骨折愈合,时间3~4个月,其中1例术后髋内翻畸形,无螺钉松动,应患者要求未做特殊处理;1例术后螺旋刀片向外侧切出、1例术后骨折不愈合,考虑二次行翻修手术治疗。结论小切口复位临时固定辅助PFNA治疗股骨转子间骨折,手术操作简单,创伤小,不影响PFNA操作,可辅助增强牵引床的牵引作用,疗效满意。

绕丝燃料棒自动外观缺陷检测系统设计

绕丝燃料棒是核反应堆中燃料组件的核心部件,燃料棒外径绕丝是燃料棒制造的关键工序,其外观质量是燃料组件十分关键的质量特性。本文以视频图像为切入点,机器视觉为技术支撑,借助深度学习建立绕丝燃料棒外观缺陷智能判别及自动定位方法。针对燃料棒表面缺陷特征,搭建高精度的图像采集系统,获取便于识别的燃料棒外观图像信息,研究检测算法能准确识别焊缝氧化色、划伤、异物、焊缝成形不良等缺陷,实现绕丝燃料棒外观缺陷的自动化检测。

埋弧焊丝用H08Mn钢盘条氧化铁皮研究及其轧制工艺

H08Mn钢盘条多用于制作埋弧焊丝,其表面的氧化铁皮对拉拔前机械除鳞效果有明显影响。介绍了盘条氧化铁皮的形成机制、氧化铁皮的种类和构成;采用不同的工艺参数,包括始轧温度、精轧温度、吐丝温度和首道辊速度,轧制了H08Mn钢盘条,随后检测了盘条氧化铁皮的厚度、盘条的晶粒度和抗拉强度。结果表明:采用这样的工艺参数即880℃的精轧温度、900℃的吐丝温度和18 m/min(按5%递增)的首段辊道速度轧制的H08Mn钢盘条,其氧化铁皮厚度小于20μm且易剥落,晶粒度和抗拉强度均有利于后续拉拔加工。

60Si2Mn弹簧钢盘条拉拔裂纹原因分析

针对60Si2Mn弹簧钢盘条在拉拔、淬火后出现的表面裂纹,通过对缺陷钢丝进行取样分析,确认为连铸坯缺陷导致,进而检查铸坯发现铸坯存在角部裂纹与之相对应。对铸坯角裂产生的原因进行分析,并提出了有效的控制措施,最终消除了铸坯角部裂纹缺陷。

6V轧机减速机输入轴端轴承损坏原因及解决措施

介绍了棒线材生产线的工艺特点,分析了螺纹钢6V轧机减速机输入轴端双列圆锥滚子轴承易损坏的原因,提出了解决措施并予以实施,成功地解决了6V轧机减速机轴承研磨的问题。

轧钢硬线盘条卷形质量控制优化改造实践

为了提升硬线盘条卷形质量和尺寸精度,先后实施了预精轧水冷段失水段参数调整、优化加热工艺,降低均热段加热温度,优化轧机动态速降补偿系数,优化17架轧机料形尺寸,设计吐丝管专用存放货架,在双芯棒升降缸处设置防挂线装置等技术改造,项目实施后取得了良好的效果。

胎圈钢丝用钢盘条C82DA的CCT曲线测定及应用

为了研究分析高性能胎圈钢丝用钢盘条C82DA在不同冷却速度下组织转变,达到产品工艺精细化控制的目的,利用Gleeble-3500热模拟试验机和光学显微镜对不同冷却速率的试样进行显微组织分析,绘制连续冷却转变曲线。分析结果显示:开始产生马氏体组织的临界冷速为20℃/s,冷却速度在0.5~10℃/s时组织为珠光体和索氏体,但组织中有明显网状渗碳体;冷却速度在12~20℃/s时组织为珠光体和索氏体;通过对比发现,冷却速率为10~15℃/s时,胎圈钢丝用钢盘条C82DA的综合性能达到最佳。

基于机器视觉的棒线材废料尺寸综合测量

从控制棒线材剪切废料长度进而提高棒线材轧制过程自动化水平的角度出发,提出了一种基于机器视觉的棒线材剪切废料外形尺寸测量方法,并设计了对应图像采集装置。基于图像合并和UNet神经网络,该方法提出了剪切废料中变形段和正常段的判定标准并给出了变形段长度测量结果。所提出的测量方法对检测环境和目标外形的变化具有鲁棒性,对于样本量要求远低于其他传统神经网络因而更适用于实际工业数据集,而长度方向的量程也可随图像数量的增减而灵活调整。采用真实剪切废料样本进行测量实验,结果表明该测量方法简单有效、精确度高,且由于模型具有轻量化、可预训练的特点,该方法具备在线监测部署潜力。

800 MPa高强焊丝用盘条退火工艺研究

针对热轧800 MPa高强焊丝用盘条组织中存在较多淬火组织,在拉拔过程中不变形,深度拉拔时发生断裂问题,研究盘条退火工艺。利用马弗炉对盘条试样进行不同的退火工艺处理,研究退火工艺对盘条金相组织和力学性能的影响。结果表明:采用650℃退火并保温2 h,然后在炉内冷却至300℃后再空冷至室温,能得到铁素体和颗粒状的渗碳体,这种组织的抗拉强度低,对盘条的后续拉拔生产更有利。

YL82B盘条抗拉强度异常原因分析

YL82B盘条抗拉强度和断面收缩率出现异常。将异常试样与正常试样进行对比,出现抗拉强度和断面收缩率异常的盘条金相组织、索氏体化率均无异常,符合国家相关标准要求,晶粒度小于正常试样;采用扫描电镜测量试样心部、直径1/4处、边部索氏体片层间距,发现异常试样都比正常试样的索氏体片层间距大;显微硬度测试发现,异常试样的显微硬度值均低于正常试样,正常试样索氏体片层间距小的位置显微硬度大。试验结果表明,YL82B盘条发生异常是因为晶粒较粗大、索氏体片层间距较大,力学性能受到影响,导致其抗拉强度和断面收缩率异常。

骨水泥棒外固定支架治疗第五掌骨颈骨折的有限元分析

目的采用三维有限元数值模拟方法分析比较骨水泥棒外固定支架与交叉克氏针在力学稳定性方面的差异,为手术治疗第五掌骨颈骨折(特别是第五掌骨颈开放性骨折)提供理论依据。方法选取1名健康志愿者,采集其手腕关节的三维CT图像数据,首先利用Mimics Research 21.0、Geomagic Studio 2021软件进行三维图形数据处理,在此基础上应用Solidworks 2020软件构建第五掌骨颈骨折骨水泥棒外固定支架模型(A模型)和第五掌骨颈骨折交叉克氏针固定模型(B模型)。在ANSYS Workbench 17.0中对各模型的材料属性进行赋值、划分网格,建立三维有限元模型。最后通过在第五掌骨头远端关节面进行轴向施加和第五掌骨三点弯曲实验,计算得出两种施压方式的远端骨折块的最大位移,以此评价骨水泥棒外固定支架治疗第五掌骨颈骨折的稳定性。结果(1)轴向施压时,A模型远端骨折块的最大位移、最小位移和平均位移的值大于B模型,A模型近端骨折块的最大位移、最小位移和平均位移的值小于B模型,A模型最大相对位移、最小相对位移和平均相对位移大于B模型。(2)在三点折弯给力时,A模型远端骨折块最大位移小于B模型,远端骨折块最小位移等于B模型,近端骨折块的最大位移和最小位移的均值大于B模型,A模型最大相对位移、最小相对位移和平均相对位移大于B模型。(3)与B模型相比较,A模型的总体应力、固定物应力均明显较小。结论骨水泥棒外固定支架及克氏针交叉固定在治疗第五掌骨颈骨折方面,在轴向和纵向上的位移及总位移均未超过1 mm,差异较小;但骨水泥棒外固定支架在两种施力方式中与交叉克氏针相比应力更小,提示骨水泥棒外固定支架能提供可靠的力学稳定性。

基于电力驱动的10 kV可伸缩式接地线设计及应用

受电压等级和设备的限制,在进行高空设备接地、多层铝排接地的操作时,操作人员往往无法顺利完成倒闸操作任务。基于此,对现有接地线进行改造,设计了一款基于电力驱动的10 kV可伸缩式接地线。该接地线由多段环氧树脂棒组合而成,采用伸缩式设计,适用于各种尺寸导流设备及高位设备的接地线装设。使用该接地线,操作人员可就地开展作业,无需登高,从而避免了人员高摔,其电动分合导体端触头可杜绝电气伤害,实现了安全作业,缩短了停电时间。