Plant Control Apparatus, Plant Control Method And Plant Control Program
Abstract:
A plant control apparatus for performing feedback control on the basis of a state
amount deviation of a control subject plant (300) has: an interstand tension control unit (10) for
performing the feedback control of at least one of proportional control, integral control, and
derivative control based on the state amount deviation; a steady-state deviation compensating
apparatus (201) for performing the integral control of a control gain lower than a control gain by
the interstand tension control unit (10) on the basis of the state amount deviation; a control
operation restricting apparatus (200) for, when an absolute value of the state amount deviation is
equal to or less than a predetermined value, restricting the feedback control by the interstand
tension control unit (10) and allowing the steady-state deviation compensating apparatus (201) to
execute the integral control; and a control gain correcting apparatus (203) for adjusting the
control gain of the interstand tension control unit (10) on the basis of a control response of the
control subject plant (300) to the integral control by the steady-state deviation compensating
apparatus (201).
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Notices, Deadlines & Correspondence
C/O HITACHI, LTD., INTELLECTUAL PROPERTY GROUP,
12TH FLOOR, MARUNOUCHI CENTER BUILDING, 6-1, MARUNOUCHI 1-CHOME, CHIYODA-KU, TOKYO 100-8220, JAPAN
2. FUKUCHI YUTAKA
C/O HITACHI, LTD., INTELLECTUAL PROPERTY GROUP,
12TH FLOOR, MARUNOUCHI CENTER BUILDING, 6-1, MARUNOUCHI 1-CHOME, CHIYODA-KU, TOKYO 100-8220, JAPAN
Specification
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BACKGROUND OF THE INVENTION
The invention relates to a plant control apparatus, a plant control method, and a
plant control program and, more particularly, to an adjustment of a control gain in a state where a
state amount deviation is large.
5 As shown in Fig. 17, plant control is performed by a method whereby a state
amount result of a control subject plant 300 is detected or predicted by some means and
controlled by a control apparatus 301 so as to coincide with a state amount instruction. As a
control apparatus 301, generally, PID (Proportional Integral Derivative) control is made.
Although the PID control includes proportional control, integral control, and derivative control,
10 actually, necessary functions are combined and used in accordance with characteristics of the
control subject plant 300 or characteristics of control which is needed.
Although various kinds of plants exist as control subject plants serving as subjects
of the plant control, for example, there is a hot tandem mill. In the hot tandem mill, a tension
and a rolling load which are applied to a material to be rolled (hereinbelow, referred to as a roll
15 material) are controlled by using a roll gap serving as an interval between upper and lower work
rolls and rolling speeds of equipment before and after the mill, thereby performing the rolling
operation.
A looper for supporting the roll material between mill stands is disposed between
the mill stands. The looper pushes the roll material upward between the stands, so that a
20 tension of the roll material changes. The tension of the roll material can be detected by
measuring a pressure of the roll material applied to the looper. A height of roll material which
is supported by the looper is controlled so as to become a desired height by a pressure applied by
a hydraulic cylinder. In this control, the proportional integral control is used. In order to
prevent a decrease in plate width caused by a loose of the roll material between the mill stands or
25 by an overtension, tension control is necessary. For this purpose, the tension control is
performed by using the proportional integral control.
As a technique of such a control system, a method whereby precedent control by
an open loop and the proportional integral feedback control are switched and used has been
proposed (for example, refer to JP-A-9-209712). According to the technique disclosed in JP-A-
30 9-209712, by using the precedent control by the open loop, difficulty of gain setting regarding
load trackability in the feedback control is avoided and, if a deviation lies within a predetermined
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range, by switching the control from the open loop to the feedback control, a deterioration in
load trackability is prevented. However, since it is a prerequisite condition that when the
deviation is large, the feedback control is not used, its essence differs from the present invention
using the feedback control as a prerequisite.
5 SUMMARY OF THE INVENTION
In the control subject plant such as production facilities or the like in a factory in
the plant control, there is a case where the operation has to be stopped when the control becomes
abnormal. When such a situation occurs, since a production activity in the control subject plant
stops, an influence which occurs increases, that is, there is a case where a product cannot be
10 provided to the customer, an influence is exerted on the production of subsequent steps, or the
like. Therefore, an abnormality of the control in the plant control has to be avoided.
For example, in the hot tandem mill, since the roll materials of various kinds of
product specifications are rolled, the characteristics of the control subject plant 300 become
variable and the control gain of the control apparatus 301 also become variable. Therefore, it is
15 necessary to set the control gain in accordance with the product specification. However, since a
model of a rolling phenomenon serving as a control subject plant 300 and parameters such as
deformation resistance, coefficient of friction, and plate temperature which are used for the
model are inaccurate, there is such a problem that an error of the control gain setting to the
control apparatus 301 is large.
20 Fig. 18 shows a response difference due to the control gain in the case where the
state amount instruction is changed in a step-like manner. As shown in Fig. 18, when the
control gain setting to the plant control apparatus 301 is improper, it takes a time until the state
amount result coincides with the state amount instruction (in the case where the control gain is
too small) or the state amount is oscillated or diverged (in the case where the control gain is too
25 large). In any of those cases, an influence is also exerted on product quality in the the control
subject plant.
Therefore, like a case of newly starting up the control subject plant 300, a case of
starting the production of new products, or the like, when a state of the control subject changes
and a state amount deviation increases as a result, it takes a long time to adjust the control
30 apparatus 301 and there is also a possibility that a production stop of the control subject plant is
caused or defective products are caused due to the defective control that is caused by the
excessive or insufficient control gain.
A subject to be solved by the invention is to provide a plant control method and a
I
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plant control apparatus in which in the case where a control subject plant is newly started up or
the production of new products is started, the occurrence of an operation abnormality such as
defective products or production stop due to an excessive or insufficient control gain of the
control apparatus 301 is prevented, and at the same time, the control gain of the control
5 apparatus 301 can be automatically adjusted.
In correspondence to the foregoing problems, it is an object of the invention to
preferably perform a gain setting at the time when a state of a control subject changes largely in a
feedback control system.
According to an aspect of the invention, there is provided a plant control
10 apparatus for performing feedback control on the basis of a state amount deviation of a control
subject plant, comprising: a first control unit for performing the feedback control of at least one
of proportional control, integral control, and derivative control based on the state amount
deviation; a second control unit for performing the integral control of a control gain lower than a
control gain by the first control unit on the basis of the state amount deviation; a control
15 switching unit for, when an absolute value of the state amount deviation is equal to or less than a
predetermined value, restricting the feedback control by the first control unit and allowing the
second control unit to execute the integral control; and a gain adjusting unit for adjusting the
control gain of the first control unit on the basis of a control response of the control subject plant
to the integral control by the second control unit.
20 According to another aspect of the invention, there is provided a plant control
method of switching a first control unit for performing feedback control of at least one of
proportional control, integral control, and derivative control based on a state amount deviation of
a control subject plant and a second control unit for performing the integral control of a control
gain lower than a control gain by the first control unit on the basis of the state amount deviation
25 and controlling the control subject plant, comprising the steps of: when an absolute value of the
state amount deviation is equal to or less than a predetermined value, restricting the feedback
control by the first control unit and allowing the second control unit to execute the integral
control; and adjusting the control gain of the first control unit on the basis of a control response
of the control subject plant to the integral control by the second control unit.
30 According to another aspect of the invention, there is provided a plant control
program for switching a first control unit for performing feedback control of at least one of
proportional control, integral control, and derivative control based on a state amount deviation of
a control subject plant and a second control unit for performing the integral control of a control
gain lower than a control gain by the first control unit on the basis of the state amount deviation
s
j x
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and controlling the control subject plant, wherein the plant control program allows an
information processing apparatus to execute: a step of, when an absolute value of the state
amount deviation is equal to or less than a predetermined value, restricting the feedback control
by the first control unit and allowing the second control unit to execute the integral control; and a
5 step of adjusting the control gain of the first control unit on the basis of a control response of the
control subject plant to the integral control by the second control unit.
By using the invention, the gain setting when the state of the control subject
changes largely in the feedback control system can be desirably performed.
Other objects, features and advantages of the invention will become apparent
10 from the following description of the embodiments of the invention taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a diagram showing a whole construction of a rolling apparatus according to an
embodiment of the invention.
15 Figs. 2 A and 2B are diagrams showing the operation of a looper in the rolling apparatus
according to the embodiment of the invention.
Fig. 3 is a diagram showing a construction of feedback control in a general rolling apparatus.
Fig. 4 is a diagram showing a frequency response of a control gain in the general rolling
apparatus.
20 Figs. 5 A, 5B and 5C are diagrams showing a convergence, an oscillation, and a divergence of a
state amount due to a difference of the control gains, respectively.
Fig. 6 is a diagram showing a construction of plant control in the embodiment of the invention.
Fig. 7 is a diagram showing a construction of feedback control in the rolling apparatus according
to the embodiment of the invention.
25 Fig. 8 is a diagram showing a setting form of a control gain according to the embodiment of the
invention.
Figs. 9 A, 9B and 9C are diagrams showing a response of a state amount due to a difference of
the control gains according to the embodiment of the invention.
Fig. 10 is a diagram showing a frequency response of the control gain in the rolling apparatus
30 according to the embodiment of the invention.
Figs. 11A and 11B are diagrams showing a response of a state amount in the case where a
steady-state deviation compensation according to the embodiment of the invention.
Fig. 12 is a diagram showing a form of tension control according to the embodiment of the
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invention.
Fig. 13 is a diagram showing a form of tension control according to the embodiment of the
invention.
Fig. 14 is a diagram showing a form of tension control according to the embodiment of the
5 invention.
Fig. 15 is a diagram showing a construction about a learning of the control gain according to the
embodiment of the invention.
Fig. 16 is a diagram showing a hardware construction of an information processing apparatus
constructing a plant control apparatus according to the embodiment of the invention.
10 Fig. 17 is a diagram showing a construction of plant control according to a related art.
Fig. 18 is a diagram showing a response of a state amount deviation due to a difference of
control gains according to the related art.
DESCRIPTION OF THE EMBODIMENTS
Embodiment 1
15 An embodiment of the invention will be described hereinbelow with respect to
tension control between mill stands in a hot mill as an example. Fig. 1 is a diagram showing a
tension control system according to the embodiment. As shown in Fig. 1, in an interstand
tension control unit 10, a tension which is applied to a roll material 8 existing between an i-1
stand rolling mill 1 and an i stand rolling mill 2 of a hot tandem mill is detected by a tension
20 meter 9 disposed in a looper 7 and a speed instruction to an i-1 stand speed control apparatus 11
is changed, thereby controlling a rolling speed of the i-1 stand rolling mill 1.
The looper 7 is constructed by: a looper arm 15 which can be rotated around a
looper fulcrum 14 existing at a position which is mechanically fixed; a hydraulic cylinder 13 for
changing a position of a looper roll 16 by rotating the looper arm 15 around the looper fulcrum
25 14; and a cylinder position detector 17 for detecting a cylinder position. By pushing the roll
material 8 upward, the looper roll 16 receives the tension which is applied to the roll material 8.
By measuring the force which is applied to the looper roll 16 by the tension meter 9, the
interstand tension control unit 10 obtains the tension which is applied to the roll material 8.
The operation of the looper 7 is shown in Figs. 2 A and 2B. When a front edge
30 portion 30 of the roll material exists between the i-1 stand rolling mill 1 and the i stand rolling
mill 2, if the looper roll 16 collides with the roll material front edge portion 30, a machine is
broken. Therefore, the looper roll 16 is on standby at a position lower than a passing position
of the roll material 8 as shown in Figs. 2A. When the roll material front edge portion 30
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reaches the i stand rolling mill 2, the looper roll 16 is moved to such a position that the roll
material 8 is lifted up as shown in Figs. 2B, so that the tension which is applied to the roll
material 8 can be measured by the tension meter 9.
Since the tension of the roll material 8 is propagated from the looper roll 16 to the
5 hydraulic cylinder 13 through the looper arm 15, when the tension of the roll material 8
fluctuates, a difference occurs between this tension and a pressure of the hydraulic cylinder 13
and the cylinder position changes. Thus, the position of the looper roll 16 changes. Since the
position fluctuation of the looper roll 16 becomes a tension fluctuation and also exerts an
influence on the stability of the rolling operation, looper position control adapted to make the
10 position constant is made. A looper position control apparatus 20 operates and controls the
pressure of the hydraulic cylinder 13 by using the cylinder position measured by the cylinder
position detector 17 so that the position of the looper roll 16 becomes constant.
Fig. 3 is a block diagram showing a construction of interstand tension control in
the hot tandem mill in the related art. The interstand tension control unit 10 outputs a control
15 instruction to the i-1 stand speed control apparatus 11 by using the proportional integral control
so as to eliminate a deviation between a tension instruction and a tension result, and changes an
i-1 stand rolling speed. That is, in the embodiment, the interstand tension control unit 10
functions as a first control unit. As control by the first control unit, the feedback control by the
proportional control, integral control, and derivative control can be used. When the i-1 stand
20 rolling speed changes, the tension result changes by a speed - tension response 31. This
fluctuation is detected by the tension meter 9 and used as a tension result.
The fluctuation of the tension result becomes a pressure fluctuation of the
hydraulic cylinder 13 by a plate tension - cylinder pressure 32 serving as a mechanical system.
However, when the pressure of the hydraulic cylinder 13 fluctuates, the cylinder position
25 changes, the looper position fluctuates by a looper mechanical system 35, and an interstand plate
road length fluctuates eventually by a looper position - interstand plate road length 34.
The interstand plate road length fluctuation becomes a tension fluctuation by a
plate road length change - tension response 33 and the tension result fluctuates. The speed -
tension response 31 is shown by the following equation (1). The plate road length change -
30 tension response 33 is shown by the following equation (2).
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^L = -J^_ (1)
^ _ »WS
(2)
^dL- 1+Tf f-S
The speed - tension response 31 and the plate road length change - tension
response 33 are caused by a rolling phenomenon and change in dependence on a material, a plate
thickness, a rolling speed, and the like (hereinbelow, called a rolling schedule) of the roll
material 8. On the contrary, if their values are known, a response of the i-1 stand speed control
5 apparatus 11 can be measured and since it does not depend on the rolling schedule, a control gain
of the interstand tension control unit 10 can be set as shown in Fig. 4.
Generally, since it is considered that the order of Ta is equal to about a few ms,
1/TCT is larger than a response