ABB Distributed Control System PM825 3BSE010796R1 Embedded Card Communication

Description

PM825 3BSE010796R1 embedded card communication
At the beginning of 2016, ABB released a new concept of upgrading the entire set of PM825 3BSE010796R1 single stand cold rolling mill electrical control system. The basic starting point is to improve the overall performance of the unit, create high added value for users, while maintaining the advantages of low investment costs, so that users can quickly recover the investment in upgrading and transformation. To sum up, ABB’s transformation concept of single stand cold rolling mill is divided into two points:
◆ Modularization: transformation at different scales and levels, fully integrated with the original system;
◆ Self selection: The old electric control system can be used to upgrade the core parts (such as AGC function) that improve the quality of the rolling mill.
The solution of “self-learning mathematical model embedded in AC 800PEC controller” proposed by ABB PM825 3BSE010796R1 relies on the powerful hardware platform of AC 800PEC controller, gives consideration to the cost and return on investment, and the scale of upgrading and transformation can be large or small. Users can choose flexibly according to the status of the original electric control equipment of their rolling mill:
◆ If the original basic automation PLC can still be used: AGC process control+drive control can be upgraded, and self-learning modified mathematical model can be embedded in the AC 800PEC controller to effectively preset the rolling mill
◆ If the PLC of the original basic automation has been abandoned: PM825 3BSE010796R1 can choose the comprehensive upgrade of the electronic control system platform. All control programs including the basic automation are added to the 800PEC main controller of the process control (built-in self-learning modified mathematical model), leaving only the original remote I/O system.

ABB’s solutions fully take into account the common demands of users: small investment scale, short project cycle, short downtime, fast investment and high economic returns. As a result of the mathematical model with self-learning correction, the electric control system of the unit has been upgraded on the whole, without increasing the complexity and cost of the system. This forward-looking single rack electric control transformation concept has received positive response from small and medium-sized private enterprise users in the carbon steel field once it was introduced.
3 Transformation practice
3.1 Basic information of Shandong Kerui users
Shandong Kerui Steel Plate Co., Ltd. is located in Boxing County, Binzhou City, Shandong Province, one of the top 100 counties in China’s economy. Over the past 20 years, the investment, construction and production of cold rolled steel sheets and strips in Boxing County have developed rapidly, forming a cold rolled industrial cluster for the production of plain carbon steel sheets. Thin strip steel products are widely used in construction, household appliances and food packaging. The products are sold throughout the country, with high output, production and marketing in the right direction, and are exported in large quantities to Southeast Asia, Europe and Africa.
Kerui Steel invested in the new cold rolling phase I project in 2010, including four reversible single stand six high cold rolling mills, namely, two 1150mm rolling mills, with a design annual capacity of 160000 tons; Two 1450mm rolling mills, with a single designed annual capacity of 250000 tons.
1150mm six high cold rolling mill:
1) Raw material specification
Raw material: ordinary low carbon steel, high-quality low carbon steel; Representative steel grades: Q195, Q235, SPHC, SPHD; Raw material specification: 1.5-4.5mm thick.
2) Specification of rolled products
Strip steel specification: 0.15-1.5mm thick; Width 700-1000mm.
3) Rolling speed
The maximum rolling speed is 1200m/min.
1450mm six high cold rolling mill:
1) Raw material specification
Raw material: ordinary low carbon steel, high-quality low carbon steel; Representative steel grades: Q195, Q235, SPHC, SPHD; Raw material specification: 1.5-4.5mm thick.
2) Specification of rolled products
Strip steel specification: 0.2-1.5mm thick; Width 800-1280mm.
3) Rolling speed
The maximum rolling speed is 1200m/min.
3.2 Rolling mill system upgrading scheme and implementation
Kerui Cold Rolling Phase I Project was completed and put into operation in 2011. However, the production has not been smooth since the project was put into operation, due to the inherent defects of the electric control system itself. It is mainly reflected in the following aspects:
◆ The degree of automation of the rolling mill is seriously insufficient, and the manual operation is too much;
◆ There is no adaptive mathematical model, the thickness calendering distribution depends heavily on the skill level of operators, and human factors have too much influence on the rolling process to ensure the consistency of finished product quality;
◆ Without adaptive mathematical model, shape setting and adjustment rely on human intervention, resulting in poor shape performance;
◆ The pre setting of the rolling mill depends on the operator. The time from the completion of threading, the establishment of tension to the starting of the rolling mill is too long, which seriously reduces the effective rolling time;
◆ The head and tail thickness of each steel coil are too long;
◆ In case of belt breakage, the electric control system is unable to effectively protect the roll, resulting in serious damage to the roll, high roll consumption and a lot of increase in daily operating costs.
Kerui Company decided to upgrade the electric control system of 4 rolling mills in 2015. After the project entered the stage of technical exchange and scheme design, ABB carried out on-site inspection, collected and recorded the original performance parameters of the rolling mill, checked the supply of spare parts for the components of the original electric control equipment in the market, and discussed their needs for production efficiency and product quality in depth with the production manager of Party A. ABB put forward a targeted technical proposal to determine the most valuable part of the existing electrical equipment of the rolling mill to be retained, Specify the parts that need to be upgraded, and finally determine the configuration of the automation system upgrading scheme

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