Conceptual Directions of Creating Digital Twins for Electrotechnical Systems of Rolling Mill Facilities

Radionov, Andrey A.; Karandaev, A. S.; Loginov, B. M.; Gasiyarova, O.A.; Iron, Magnitogorsk; Works, S

doi:10.17213/0136-3360-2021-1-54-68

Cited by 7 publications

(6 citation statements)

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“…Cycle time to calculate the stand motor signals is 5 ms and can be reduced to 1 ms. The system was developed and configured using a method covered in paper [50] by the authors. Using the method, we sampled data on an industrial unit using signals from the stand motor control system (i.e., the PDA system).…”

Section: Resultsmentioning

confidence: 99%

“…The proposed observer configuration algorithm is a specific case of using digital twins to virtualize the commissioning of electric drive control systems. This area of focus is detailed in [50], where the authors call it a promising application for the creation and improvement of electrical and mechatronic systems in rolling mills.…”

Section: Discussion Of the Resultsmentioning

confidence: 99%

“…In essence, these curves over time demonstrate an approach to configuring digital twins, which is used when control systems are commissioned virtually [50]. Under this approach, the control algorithms (in this case the observed signal reconstruction algorithm) are debugged in Matlab Simulink.…”

Section: Methodsmentioning

confidence: 99%

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Development of an Automatic Elastic Torque Control System Based on a Two-Mass Electric Drive Coordinate Observer

et al. 2021

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Development of control system based on digital twins of physical processes is a promising area of research in the rolling industry. Closed-loop control systems are developed to control the coordinates of two-mass electromechanical systems in order to limit the dynamic loads on the equipment of main rolling lines. These control systems are based on observers (digital shadows) that indirectly detect (reconstruct) the roll speed and the elastic torque of the shaft (spindle) in real time. Notably, observers are required to work fast in order to reconstruct transients attributable to shock (impact) loads. Literature review shows that the known observers, which use complex algorithms to compute coordinates, do not respond fast enough. The paper analyzes the kinematic diagram of Mill 5000, a plate rolling mill. It presents oscillograms that prove that the elastic torque does oscillate as the rolls grip the strip dynamically. The authors hereof have developed an observer that reconstructs the coordinates of the uncontrolled mass (the shaft) and the spindle torque from the parameters of the controlled mass, namely the torque and speed of the motor. The paper further rationalizes an approach that consists of simulating the processes on a model to further directly configure them on the object. The authors analyze the transients of the reconstructed two-mass system coordinates, which are associated with the rolls gripping the strip. The paper compares data against oscillograms recorded on the mill itself. The accuracy is satisfactory. The proposed observer has been used to developed a three-loop automatic speed control system for the uncontrolled mass. Controller configurations are substantiated. The paper shows coordinates obtained by simulation modeling as functions of time. It further presents experiments run on Mill 5000; the conclusions are that the amplitude and oscillations of the elastic torque drop significantly. The paper concludes with recommendations on industrial adoption of the observer and the novel electric drive coordinate control system. Study presented herein substantiates and implements a concept of developing algorithms that solve specific problems and are readily implementable on the existing equipment without need for additional computing devices. The contribution of the paper consists of stating and solving the problem of developing and testing an automatic elastic torque control system for the shaft of a heavy-duty rolling mill. This system has been implemented in the form of algorithms that run in the software of the existing industrial controllers (PLCs). It is simple and performs well. It does not need additional sensors or computers to be implemented, nor does it rely on complex computational algorithms. Such algorithms are based on computational tables that require a priori data on numerous process parameters. In our literature review, we have not come across any industrial implementation of such algorithms on hot-rolling mills.

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Section: Resultsmentioning

confidence: 99%

Section: Discussion Of the Resultsmentioning

confidence: 99%

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Development of an Automatic Elastic Torque Control System Based on a Two-Mass Electric Drive Coordinate Observer

et al. 2021

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“…Разработанный математический аппарат позволяет проводить исследования переходных процессов отдельных электростанций с различным числом генераторов, отличающихся мощностью, напряжением и структурой АРВ. Это сделает реальным переход в недалёком будущем от цифровой модели к цифровым двойникам [49].…”

Section: Introductionunclassified

Analysis of Excitation Systems of Synchronous Generators of Factory Power Plants

Корнилов¹,

Gazizova²,

Sokolov³

et al. 2022

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One of the priorities in the development of metallurgical enterprises is to increase own generation of electricity. At the largest enterprises in the sector – PJSC MMK (Magnitogorsk), Severstal PJSC (Cherepovets), PJSC “NLMK” (Lipetsk) Electricity generation is 60–70% of total consumption. This contributes to two factors: firstly, the presence of secondary fuel gases – coke and domain; and secondly, unreasonably high electricity tariffs. Thus there is an urgent need to ensure sustainable trouble-free operation of factory generators and basic systems. Automatic excitation control systems (ARV) are the most important factor when determining the state of the generator in various modes. The main requirements for ARV systems determine the specific working conditions. We will highlight the most significant and significant of these. 1. Low power 10–50 MW generators are connected to an external power system on 110 kV buses, where the short circuit capacity is within 3000–5000 mba. Thus the possibilities of regulating and maintaining voltage are very limited. 2. Since the electricity produced by its own power plants is 2–2.5 times cheaper than purchased power, almost all generators work with a power factor close to one. This significantly reduces their stability in the power supply system. 3. The voltage at the point of connection and loading of the Eigen needs for the generator voltage stations are unsta-ble. Therefore, in order to preserve the stability of generators in transient modes, the most preferred is the ARV system with a switching structure in which the settings and regulation laws are selected depending on Work modes. The work gives a general review of the existing laws and the proposed arousal regulation law, adapted to the condi-tions of factory generators of small and medium-sized power, working concomitantly with a high power grid.

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“…Альтернативой прямому измерению упругого момента является его вычисление (восстановление) с помощью наблюдателей, по сути, цифровых теней физической системы [3]. Согласно определению, данному в [4], «наблюдатель состоянияэто модель, подключенная параллельно объекту управления и получающая непрерывную информа-цию об изменениях регулирующего воздействия и регулируемой координаты».…”

Section: Introductionunclassified

Elastic Torque Observer of a Two-Mass Electromechanical System

Karandaev¹,

Loginov²,

Khramshin³

et al. 2022

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To reduce the accident rate and increase the service life of electromechanical systems with shock load changes, the monitoring of elastic moments in mechanical gears is necessary. This task is relevant for the main lines of stands of hot rolling mills. The implementation of monitoring systems based on physical measuring devices is inefficient due to their complexity and low operational reliability. As an alternative, a relatively simple elastic moment observer is proposed, which is a fragment of an industrial controller software. The structure of the observer is presented and its advantages in comparison with known analogues are shown. The adequacy of the measured and reconstructed elastic moment signals is proved using the example of electromechanical systems of the stand of the thick-sheet mill 5000. A quasi-experimental analysis of emergency modes is substantiated, which allows the processing of signals stored in the form of data arrays. Based on this approach, an assessment of the dynamic moments in the emergency shutdown mode of the crate with metal in the rolls is given. The expediency of creating an online monitoring system for overloads of spindles and methods for calculating their resource is emphasized.

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Conceptual Directions of Creating Digital Twins for Electrotechnical Systems of Rolling Mill Facilities

Cited by 7 publications

References 0 publications

Development of an Automatic Elastic Torque Control System Based on a Two-Mass Electric Drive Coordinate Observer

Development of an Automatic Elastic Torque Control System Based on a Two-Mass Electric Drive Coordinate Observer

Analysis of Excitation Systems of Synchronous Generators of Factory Power Plants

Elastic Torque Observer of a Two-Mass Electromechanical System

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