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.

Application of Feedforward and Feedback Control Strategy for Wire Rod Hot Rolling Line

The feedforward and feedback control strategy of water flowrate based on the analysis of thermal process in water cooling box was proposed, and the control strategy was applied to wire rod hot rolling at Baosteel Co. The operation has proved that the strategy can control water flowrate in the cooling water box reasonably to ensure the temperature requirement of the wire discharged from the cooling water box.

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.

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.

A Study on a Wire Tension Adaptive Control System of a Multi-wire Saw in Computer Simulation

Based on the analysis of the mechanism of wire tension control by using torque motors in the multi-wire saw machining process, some mathematical models of a tension control system are studied, and an adaptive algo- rithm is designed for controlling the wire tension. In this algorithm of tension control, the rotation speeds and waving angle of motors are measured and fed back to the controller, and the NLMS（ normalized least mean squares） algorithm is used to calculate the adaptive correction value and control the wire tension accurately. The computer simulation results in Matlab software validate the high accuracy for controlling the system of the wire tension with the NLMS algorithm in the multi-wire saw machining process.

Thermal behavior of the HTR-10 under combined PLOFC and ATWS condition initiated by unscrammed control rod withdrawal

Two tests initiated by unscrammed control rod withdrawal were performed on the High Temperature GasCooled Reactor-Test Module(HTR-10) in November 2003 after the reactor achieved its full power, and the test conditions represented a typical transient scenario of modular high-temperature reactors(HTRs), called pressurized loss of forced cooling, and anticipated transient without scram.Based on the test parameters, the HTR-10 thermal behaviors under the test conditions were studied with the help of the system analysis code THERMIX. The combination of the test results and the investigation results makes the HTR-10 safety potential better understood. Key phenomena, such as the helium natural circulation and the temperature redistribution in the reactor, were revealed. As the safety feature of most significance, there is a large margin between the maximum fuel temperature and its safety limit in each test. Temperatures of thermocouples in different components were calculated by THERMIX and compared with the test values. The applicability of the code was verified by good agreement obtained from the comparison.

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.

Mathematical model for the thermal process of controlled cooling of wires and its numerical simulation

The mathematical model for the thermal process of billets rolling has beenestablished, including transporting in air and temperature-holding cover, descaling withhigh-pressure water, and the process of rolling and cooling in water box. The calculated data by themodel have been compared with the measured data and the results show that the model is right andcreditable. Based on the model, the main thermal characters of rolling line have been simulated andthe influence of all the parameters on the temperature of rolling has been analyzed.

Study of Control rod worth in the TMSR

Control rod is a primary control part of emergency control and power regulation in nuclear reactor. The main application of it is to control fast change of the reactivity. The theoretical analysis for the worth of control rod is necessary in the stage of design. Based on design requirements, some results are calculated. Firstly, control rod worth with different density of neutron absorber is calculated by MCNP here. Secondly, the study of integral and differential control rod worth is presented in this paper while the control rod is inserted into reactor core and total worth of three rods with different positions are also calculated. Finally, the effect of the axial and radial neutron flux in reactor core which is caused by the control rods is simulated. The simulation results of the control rods meet design requirements for TMSR.

Nonlinear adaptive optimal control for vehicle handling improvement through steer-by-wire system

A control algorithm for improving vehicle handling was proposed by applying right angle to the steering wheel,based on the nonlinear adaptive optimal control(NAOC).A nonlinear 4-DOF model was initially developed,then it was simplified to a 2-DOF model with reasonable assumptions to design observer and optimal controllers.Then a simplified model was developed for steering system.The numerical simulations were carried out using vehicle parameters for standard maneuvers in dry and wet road conditions.Moreover,the hardware in the loop method was implemented to prove the controller ability in realistic conditions.Simulation results obviously show the effectiveness of NAOC on vehicle handling and reveal that the proposed controller can significantly improve vehicle handling during severe maneuvers.

Program structures and synchronization schemes in numerical coordinate controllers of three-wire welding

In the three-wire welding system, a welding process consists of the operations of four devices, namely three welding machines and one bogie. The operations need to be synchronized by a numerical coordinate controller （ NCC ）. In this paper, we will discuss a tnsk-job-procedure cubic program structure. Under this structure, the devices are synchronized and isolated at the same time. This cubic program structure can also be used as a reference for other multi-device or multi-unit manufacturing processes.

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.

Self-learning fuzzy neural network control for backside width of weld pool in pulsed GTAW with wire filler

The weld pool shape control by intelligent strategy was studied. In order to improve the ability of self-learning and self-adaptation of the ordinary fuzzy control, a self-learning fuzzy neural network controller (FNNC) for backside width of weld pool in pulsed gas tungsten arc welding (GTAW) with wire filler was designed. In FNNC, the fuzzy system was expressed by an equivalence neural network, the membership functions and inference rulers were decided through the learning of the neural network. Then, the FNNC control arithmetic was analyzed, simulating experiment was done, and the validating experiments on varied heat sink workpiece and varied gap workpiece were implemented. The maximum error between the real value and the given one was 0.39mm, the mean error was 0.014mm, and the root-mean-square was 0.14mm. The real backside width was maintained around the given value. The results show that the self-learning fuzzy neural network control strategy can achieve a perfect control effect under different set values and conditions, and is suitable for the welding process with the varied structure and coefficients of control model.

Rectifying control of wire diameter during dieless drawing by a deformation measuring method of interframe displacement

A deformation measurement method of interframe displacement was proposed in this paper. By online monitoring the shape di- mensions of both the deformation zone and its adjacent zone by machine vision, the initial and terminative positions of deformation were dynamically identified during dieless drawing, and the global monitoring and online closed-loop control of the deformation zone were achieved. The dieless drawing process was systematically carried out on NiTi shape memory alloy wires. It is shown that the deformation measurement method of interframe displacement can track the axial displacement of the wires, but this cannot be achieved by traditional machine vision. The initial and terminative positions of deformation can be accurately identified by this method. The proposed rectifying control technology can effectively decrease the wire diameter fluctuation during dieless drawing, that is, the standard deviation of the wire diameter fluctuation could be decreased fi＇om 0.30 to 0.08 mm after three passes of dieless drawing, indicating that the control system has a good rectifying ability.

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.

Neuron self-learning PSD control for backside width of weld pool in pulsed GTAW with wire filler

In this paper, the weld pool shape control by intelligent strategy was studied. A neuron self-learning PSD controller for backside width of weld pool in pulsed GTAW with wire filler was designed. The PSD control arithmetic was analyzed, simulating experiment by MATLAB software was done, and the validating experiments on varied heat sink workpiece and varied gap workpiece were successfully implemented. The study results show that the neuron self-learning PSD control method can attain a perfect control effect under different set values and conditions, and is suitable for the welding process with the varied structure and coefficients of control model.

Control Rod Calibration and Worth Calculation for Optimized Power Reactor 1000 (OPR-1000) Using Core Simulator OPR1000

Control rod is used to change the power in nuclear reactor.?Certainly, the core at any moment can be made subcritical condition and shut downs when occurring?to emergency instance in the core. The rod is grouped based?on their function and located at different places in the core where their feature is maximized.?Two methods of control rod calibration are the asymptotic period method and the rod-drop method, which were applied in this experiment. In the first method, the reactor is made supcritical by inserting the control rod to be calibrated a certain level. The rod drop method is to determine the subcritical;at the critical state, the rod to be calibrated is dropped into the core, and the resulting decay of neutron flux is observed and related to the reactivity. In this paper, the regulating rod will be calibrated according to the reactivity in OPR-1000 that corresponds to a certain control rod insert or withdraw, and the reactivity in power reactor depends?on the integral and differential control rod group too. The core simulator OPR1000 is used to test those methods.

On Line Measurement of Reactivity Worth of TRIGA Mark-II Research Reactor Control Rods

The reactivity worth measurement system for control rods of the TRIGA MARK-II research reactor of Bangladesh has been design and developed. The theory of the kinetic technique of measuring reactivity has been used by this measurement system. The system comprises of indigenous hardware and software for online acquisition of neutron flux signals from reactor console and then computes the reactivity worth accordingly. Here for the TRIGA MARK-II research reactor, the reactivity measurement system was implemented with a dedicated circuit assembly and a conventional personal computer. A high-level Visual Basic real-time programming has been developed for data acquisition, reactivity calculation, online display (numerically as well as graphically), saving data, etc. To measure reactivity worth of TRIGA reactor control rods the rod drop experimental technique has been adopted. The results of tests experiments, carried out with the rod drop method for measuring various reactivity worth of control rods have been presented in the paper. A comparison between this results with the results using period method and that of computation method, demonstrated that the response of this reactivity measurement system is fast enough to monitor and measure the safety-related reactivity and power excursions in the reactor.

Minimizing torque ripple in a brushless DC motor with fuzzy logic: applied to control rod driving mechanism of MNSR

A permanent magnet BLDC(brushless direct current) motor is used to move the control rod of a miniature neutron source reactor(MNSR). The BLDC motor drive is modeled using MATLAB/SIMULINK. Two main parts of the modeling are the inverter switching and the current control. Current control with chopping used to minimize the torque ripple of the MNSR control rod drive. Fuzzy logic current control together with soft chopping control shows the best response of all the three strategies. The prototype drive mechanism has an ATmega32 controller and power MOSFET switches. The simulation results are compared with experimental drive mechanism.