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.

HYDRAULIC ACTIVE GUIDE ROLLER SYSTEM FOR HIGH-SPEED ELEVATOR BASED ON FUZZY CONTROLLER

Increase of elevator speed brings about amplified vibrations of high-speed elevator. In order to reduce the horizontal vibrations of high-speed elevator, a new type of hydraulic active guide roller system based on fuzzy logic controller is developed. First the working principle of the hydraulic guide system is introduced, then the dynamic model of the horizontal vibrations for elevator cage with active guide roller system and the mathematical model of the hydraulic system are given. A fuzzy logic controller for the hydraulic system is designed to control the hydraulic actuator. To improve the control performance, preview compensation for the controller is provided. Finally, simulation and experiments are executed to verify the hydraulic active guide roller system and the control strategy. Both the simulation and experimental results indicate that the hydraulic active guide roller system can reduce the horizontal vibrations of the elevator effectively and has better effects than the passive one, and the fuzzy logic controller with preview compensation can give superior control performance.

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.

Pantograph-catenary electrical contact system of high-speed railways:recent progress,challenges,and outlooks

As the unique power entrance,the pantograph-catenary electrical contact system maintains the efficiency and reliability of power transmission for the high-speed train.Along with the fast development of high-speed railways all over the world,some commercialized lines are built for covering the remote places under harsh environment,especially in China;these environmental elements including wind,sand,rain,thunder,ice and snow need to be considered during the design of the pantograph-catenary system.The pantograph-catenary system includes the pantograph,the contact wire and the interface—pantograph slide.As the key component,this pantograph slide plays a critical role in reliable power transmission under dynamic condition.The fundamental material characteristics of the pantograph slide and contact wire such as electrical conductivity,impact resistance,wear resistance,etc.,directly determine the sliding electrical contact performance of the pantograph-catenary system;meanwhile,different detection methods of the pantograph-catenary system are crucial for the reliability of service and maintenance.In addition,the challenges brought from extreme operational conditions are discussed,taking the Sichuan-Tibet Railway currently under construction as a special example with the high-altitude climate.The outlook for developing the ultra-high-speed train equipped with the novel pantograph-catenary system which can address the harsher operational environment is also involved.This paper has provided a comprehensive review of the high-speed railway pantograph-catenary systems,including its progress,challenges,outlooks in the history and future.

存在旋转圆跳动的轧辊表面的送丝激光熔覆工艺研究

为解决轧辊旋转时产生的圆跳动影响送丝激光熔覆轧辊修复的问题,对轧辊旋转圆跳动对于丝材尖端与轧辊面位置及激光熔覆过程的影响规律进行理论分析,并针对激光功率和光斑直径对存在圆跳动的轧辊激光熔覆修复工艺的影响进行试验研究。研究结果表明:在熔覆过程中,由于圆跳动的影响,前沿送丝成形的熔覆道高度过低,后沿送丝成形的熔覆道易出现大量毛刺,但中间送丝成形的熔覆道表面形貌相对较好;在小光斑、低功率工艺状况下,中间送丝成形的熔覆道也会出现孔隙以及毛刺,增加激光功率和光斑直径可以减少此现象。在圆跳动误差不大于0.6 mm情况下,当激光功率P为2 400 W、指示红光直径为6.5 mm时,几乎不会出现缺陷。采用小搭接率进行多道搭接试验时,圆跳动会影响第1道熔覆道的实际成形位置,搭接率为40%时成形的熔覆道受影响不明显。

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。

一种新型烟丝结构靶向调控设备研发及应用

针对细支卷烟烟丝长丝率偏高,在卷制时易造成烟支质量波动较大、稳定性较差、不合格率高等问题,研制了一种针辊式烟丝结构靶向调控设备。该设备由烟丝选丝机构和断丝机构组成,混配后的烟丝进入烟丝选丝机构,在动态滚动状态下,中、短烟丝经针辊间隙落下,长烟丝则在选丝针辊钢钉挑动作用下逐级传递到断丝机构,在选丝针辊和断丝针辊差速旋转拉扯作用下柔性断丝,实现对长烟丝的靶向调控。以黄金叶(爱尚)细支卷烟烟丝为样品,在实际制丝生产的应用结果表明:该设备稳定性较高,在选丝针辊间距40 mm、选丝针辊电机频率30 Hz、断丝针辊电机频率47 Hz的运行参数下,经调控处理后的烟丝长丝率下降了12.58%,中丝率和短丝率分别上升了8.12%和3.96%,碎丝率仅增加了0.12%,烟丝结构分布更加合理,满足加工质量要求。

HIGH-SPEED FLOW EROSION ON A NEW ROLLER COMPACTED CONCRETE DAM DURING CONSTRUCTION

A new roller compacted concrete dam of Fengman Hydropower Station is to be built in the toe of the old dam,which was identified as a dangerous dam.The new dam during construction would be influenced by the high-speed flow discharged from the old dam,which is an important problem to be considered for the first time in China,and which would affect the construction of the whole project.Therefore,a series of erosion experiments were conducted in this article.A high-speed flow erosion test apparatus was developed for the erosion experiments of the new dam materials.The maximum jet velocity goes up to 40 m/s and the section area of the nozzle is 0.0025 m2.In the process of experiments,the equipment shows a good performance.Erosive wear tests for two types of materials used in the new dam,a roller compacted concrete and a distorted concrete with four kinds of ages were carried out with the flow velocity in the range of 30 m/s-35 m/s.Erosion parameters and erosion laws for the two types of concretes with different ages were determined,and a general relationship between the erosion rate and the flow velocity is obtained as：,with the velocity exponent between 3.33 and 3.93.It is concluded that the erosion resistance of the distorted concrete is better than that of the roller compacted concrete and the mechanical properties of the concretes of over 14 d age are influenced slightly by the water impact.The test results might serve as a practical technique guide for the safety of this project during its construction in the flood season.

ER70S-6M高锰气保焊丝钢盘条生产工艺优化

通过分析影响焊丝钢盘条组织和性能的因素,按照增大原始奥氏体晶粒尺寸、提高盘条吐丝后缓冷效果的控制思路优化生产工艺,高锰焊丝钢盘条抗拉强度平均降低15 MPa,铁素体晶粒度由8.5级降至7级,且未出现贝氏体等异常组织,较好满足了用户使用需求。

彩涂线张力辊的设计

文章主要对某钢铁生产企业,板厚为0.2~1.6 mm,线速度为120 m/min的彩涂板生产线普通张力辊的设计进行描述,包括辊径、电机、减速机、抱闸选型等,以满足生产的需求。

卷扬式启闭机卷筒绳槽旋向反向的补救措施

文章结合武都引水第二期金峰水库工程1×400 kN-35 m双向门机起升机构因卷筒绳槽旋向反向,导致缠绕钢丝绳引起的动滑轮下降时钢丝绳与水工吊物孔边缘干涉的问题,通过在卷筒下方增设钢丝绳托辊装置缩小上下游钢丝绳间距进行补救。经现场按补救方案实施处理后,启闭机动滑轮上的钢丝绳间距被强行缩小,动滑轮进入吊物孔后其钢丝绳不再与吊物孔口边干涉,起升机构起吊荷载能力不受影响,升降运行正常。经运行证明:带导向轮的钢丝绳托辊装置可限制钢丝绳的空间开度,利用该设计原理可为工程建设中需调整或控制钢丝绳位置的场所提供借鉴。

精密异型钛材辊模拉轧加工工艺研究

钛及钛合金与其他六方结构的金属相比,其弹性模量相对较低,故加工时变形力大,回弹也较严重,精密异型钛材在加工成型时较困难。而辊模拉拔法是靠施加在金属上的拉拔力带动轧辊转动来实现金属变形的。辊模拉拔法结合了传统的轧制与拉拔法的特点,其主要特征是将拉拔中的滑动摩擦转变为滚动摩擦,这对难加工金属的变形具有独特的优势。针对精密异型钛材难以加工的特点,设计、制作了四辊辊拉模,其主要特点是:四辊的位置可以调整,根据不同的产品形状,可设计出不同的轧辊孔型。四辊辊拉模用于生产实践,加工出了精密异型钛材。本文介绍了试生产工艺、试生产结果并对辊模拉拔法进行了讨论。试生产结果表明:采用辊模拉拔工艺加工精密异型钛材,克服了钛材变形抗力大,难加工的缺点,能够显著减少拉拔力,增加道次加工率,提高拉拔速度,降低了生产成本。

辊模拉拔药芯焊丝的变形特性

利用MTS材料试验机等研究了固定模与辊模拉拔药芯焊丝的变形特点和工艺特点，给出了变形参数、力能参数、粉末流动等实验结果．结果认为，辊模拉拔具有良好的成型性和较低拉拔力的变形分配条件．

滚模拉拔异型丝新工艺

本文提出了二连式滚模拉拔异型丝新工艺的可行性．在实验研究的基础上，给出了二连式滚模拉拔异型丝的力学特点和变形特点，并得出了实用滚摸孔型系统和孔型设计的基本规律．

精密异型材四辊组合孔型轧机设计

设计了一种精密异型材四辊组合孔型轧机。该轧机成功的将型材轧制与拉拔工艺相结合,可以加工制造多种类型的型材。设计的新型轧辊系统可实现轧辊的快速更换,节省了生产成本;设计了轧辊位置调整机构,包括轴向与径向的轧辊调整,通过两种调整机构的配合,可调整出多种孔型,满足不同需求;并实现轧辊利用率的最大化。通过产品试制,得到了满足要求的型材产品。

高线粗中轧机轧辊轴承烧损原因及对策

通过对高线粗中轧机轧辊轴承烧损情况的原因分析,介绍了正确装配轧辊轴承和现场合理调整使用轧辊的几种方法及解决对策,减少或杜绝了轴承烧损现象的发生,取得了良好的经济效益。

双联式辊模拉制圆形钛丝的成形性研究

利用实验机等研究了整体模与辊模拉制圆形钛丝的变形特点 ,给出了变形参数、力参数等实验参术。结果表明 。

药芯埋弧焊丝W220回火脆性研究

研究了轧辊堆焊用药芯埋弧焊丝W220的回火脆性。将药芯埋弧焊丝W220堆焊成含0.13%～0.17%C,13.1%～14.0%Cr,2.2%～2.8%Mn,4.3%～4.9%Ni(质量分数)的熔敷金属,将焊态熔敷金属在不同温度下回火,通过硬度测试、冲击韧性测定及断口微观分析,对在不同温度下回火后的试样的硬度、冲击功及断口形貌进行研究。研究表明,W220焊丝熔敷金属的回火脆性温度区间为400～550℃。与通常情况不同,W220焊态熔敷金属的高温回火脆性不是在高温回火保温后缓冷情况下出现,而是在快冷条件下产生。

药芯埋弧焊丝W110熔敷金属的焊接热模拟研究

对用于轧辊堆焊的药芯埋弧焊丝W110熔敷金属进行了焊接热模拟研究。通过焊接热模拟试验、硬度测试、微观分析等手段对W110焊丝熔敷金属在七种焊接热循环条件下得到的组织和性能进行了研究。研究表明,该焊丝熔敷金属的Ms点在260～280℃;用W110焊接时的预热温度可选用280～300℃,层间温度应不低于260℃,回火温度应避开450～550℃。

轧辊堆焊用药芯埋弧焊丝W110回火脆性研究

研究了轧辊堆焊用药芯埋弧焊丝W110的回火脆性,将药芯埋弧焊丝W110堆焊成含0.3%～0.45%C,12.5%～14.5%Cr,1.0%～1.6%Mn,0.5%～0.8%Mo,0.8%～1.5%Ni,0.5%～1.2%Si的熔敷金属,将焊态熔敷金属在不同温度下回火,通过硬度测试、冲击韧度测定及断口微观分析,对回火后的试样的性能进行研究。结果表明,在不同回火温度下,试样的硬度分布与冲击韧度分布不是一一对应的,而断口形态与冲击韧度值高度吻合。以回火试样的冲击韧度值确定该焊丝熔敷金属的回火脆性温度区间,其值为100～150℃和450～550℃。