计与应用研究
重庆大学硕士学位论文
学生姓名：***
指导教师：蒙建波副教授
专业：控制理论与控制工程
学科门类：工学
重庆大学自动化学院
二OO八年四月
Electrical design and study on the walking beam heating furnace in bar-steel
factory of Baosteel
A Thesis Submitted to Chongqing University
in Partial Fulfillment of the Requirement for the Degree of Master of Engineering
by
Xie Jingxin
Supervisor: Ass. Prof. Meng Jianbo
Major: Engineering
College of Automation of
Chongqing University , Chongqing, China
April 2008
摘要
步进梁式加热炉是现阶段比较先进的加热炉，其主要特点是规模大，炉内热值利用率高，板坯加热均匀等[1]。加热炉的正常运行，是整个轧线生产系统经济、高效运行的基础。宝钢条钢厂此次改造新建的步进梁式加热炉，是依照原有热轧线的生产进行设计，作为其钢坯轧制前的加热设备。 步进梁式加热炉的电气控制系统关系到整个加热炉的正常运行。本文按照宝钢条钢厂所提出的设计要求，在充分考虑系统的可行性和经济性后，提出了本电气控制系统。针对此项目设备多，控制复杂，精度要求高的特点，本文设计了以现场设备功能和地域划分的分布式控制系统。
在设备方面，本系统的电气控制系统采用了西门子公司先进的S7-400系列CPU，保证系统的高效稳定运行；在监控管理方面，本系统采用了二级管理模式，即“现场总线+PLC”为一级控制，“工业以太网+上位机交互界面”为二级控制，形成包含整个系统的监控网络，保证整个系统的监控和操作灵活方便。
在动力驱动方面，本系统结合了液压驱动和电气驱动的方式，根据设备的运行特点进行回路设计，保证了各设备的平稳，精确运行。本系统配备了多种检测设备，能够从位置，速度，距离等物理量多方面监控设备的运行状况，保障设备的正常运行和控制的及时进行。
在逻辑控制方面，本系统采用了先进的逻辑算法，使设备的控制精确稳定。在程序设计中，我们充分考虑了现场设备的实际情况，制定了相应的控制程序方案，效果良好。在系统非正常运转时，本系统也能最大限度保证生产的继续运行，为客户创造最大限度的利益。而在安全方面，本系统也设计了严密的保护措施，保障系统设备和人员的安全。
在本方案应用于实际项目后，现场设备运行良好。经过测试，所有设备各项运行指均标达到或优于设
计标准，通过了客户验收，并受到设计院和客户的一致好评。
文章的最后分析了系统的不足，并提出了改进和探讨的思路和方向。
关键词：步进梁式加热炉，分布式控制系统，PLC
ABSTRACT
The walking beam heating furnace is one kind of the advanced heating furnaces. The features of it are: large scale of productivity, high utilization of heating capacity and the uniformity of heating effect. The efficient and economy operation of the rolling mill is depending on the well function of the heating furnace. The reconstruction of a walking beam heating furnace in bar-steel factory of Baosteel is based on the old rolling mill system, and the furnace is as a heating slab provider of the rolling mill.
The electrical control system is the key to the normal function of the walking beam heating furnace. After the consideration of economy and efficiency, we are putting forward this design schema. According to the multiple control objects and complicated control signals, we decide to use a distributed control system.
We use high performance S7-400 series CPU in electrical control system; it brings the system stability and efficiency. We designed a 2-level supervisory control system which covered all the field devices; include “field-bus + PLC”and “industry Ethernet + upper monitor HMI”. This system will bring the working operator the most convenience and efficient experience.
The system is both driven hydraulically and electrically, the driving control is designed based on the feature of the field device, which guarantees the field devices most stability and accuracy. The monitory system includes point, speed and distance detection, which provides the controlling system full information of the devices.
The system is under advanced logic control methods, and the operation of the device is accurate and stable. We designed well performed program, by means of the actual condition of the field devices. When an abnormal condition happens, the system will function mostly to guarantee the production process, thus brings the customer best profit. The safety of this system is well too, we provide best protection to the operators and the devices.
This design schema is applied to the project, and well performed. All designed parameters are fulfilled the criterions. The project is passed the check, and praised by the design institute and the customer.
At the last part of this passage, we discussed the further development issue and probably methods.
Keywords: Walking Beam Heating Furnace, Distributed Control System, PLC
目录
中文摘要.......................................................................................................................................... I 英文摘要........................................................................................................................................ II 1 绪论.. (1)
1.1 课题的研究意义 (1)
1.2 国内外研究现状 (2)
1.3 本文的主要内容 (3)
2 步进梁式加热炉工艺及设备简介 (4)
2.1 步进梁式加热炉工艺概述 (4)
2.2 主要设备及功能简介 (5)
3 电气控制方案设计 (8)
3.1 装钢区电气控制 (8)
3.1.1 上料台架 (8)
3.1.2 取料装置 (10)
3.1.3 称重装置 (12)
3.1.4 入炉辊道 (13)
3.1.5 装钢机 (17)
3.2 步进梁式加热炉电气控制 (21)
3.2.1 装料炉门 (21)
3.2.2 炉内步进梁 (21)
3.2.3 出料炉门 (25)
3.3 出钢区电气控制 (25)
4 动力及检测系统设计 (28)
4.1 系统主要动力回路 (28)
4.1.1 液压回路 (28)
4.1.2 电气回路 (29)
4.2 检测系统 (29)
4.2.1 液压检测系统 (29)
4.2.2 电气检测系统 (30)
步进式加热炉
5 PLC控制设计与功能调试 (32)
5.1 PLC系统选型 (32)
5.2 PLC系统设计 (32)
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