Design Of The Electrical Control System Of Continuous Casting Roller Automatic Surfacing Welding Machine With Bidirectional Swing Function

Steel is an indispensable product for the development of the national economy.With the rapid development of China’s economy after the reform and opening up,China’s demand for steel has also increased.At present,China’s crude steel production has ranked first in the world for more than 20 consecutive years.In 2021,China’s crude steel output was 103.29 million tons.In that year,the global crude steel output accounted for 52.95%,making it the world’s largest steel producer.With the comprehensive introduction of Japanese Nippon Steel technology by Bao-Steel Company in the 1980 s,Thetechnology of Continuous Ccasting began to enter China and made great progress.Continuous casting and rolling is the main production process of modern iron and steel enterprises,and the continuous casting roller,as the main component of the continuous casting machine,is prone to cracks,wear and other defects and cannot be used normally due to long-term cold and hot fatigue,corrosion and friction.Frequent replacement of continuous casting rollers will greatly increase production costs.In order to improve the service life of continuous casting rollers,various surface strengthening technologies are used in the manufacturing and remanufacturing of continuous casting rollers.As an important means of surface strengthening technology,surfacing technology has been deeply studied and widely used due to its advantages of high bonding strength,good impact resistance and high melting efficiency.With the continuous progress of continuous casting roller surfacing materials and processes,China’s traditional continuous casting roller surfacing welding equipment can no longer meet the requirements of modern technology due to the single mechanical structure function and the control system following the analog control of relays and frequency converters.At present,the surfacing welding equipment of domestic manufacturers is mainly imported,which is widely used due to its stable operation,strong anti-interference ability and low failure rate.However,imported equipment is relatively expensive,and maintenance is very inconvenient,so the cutting-edge technology of continuous casting roller automatic surfacing welding machine is also being studied in China.As a logical control element that can control both analog quantities and digital quantities,PLC has attracted widespread attention for its excellent anti-interference ability and powerful logical computing functions.At first,it was not widely used because of its high price,but with the investment and construction of factories in China after China’s entry into the WTO,the price has been greatly reduced.At present,it has been widely used in the industrial automation industry because of its extremely high cost performance.Compared with the PC-based control system,the advantage of PLC is that the instructions are relatively simple,the operation is more convenient and functional,and the control system is less prone to potential safety hazards.Relying on the mechanical structure designed by Harbin Welding Research Institute,according to the needs of modern continuous casting roller surfacing welding technology,combined with the requirements of the continuous casting roller surfacing welding machine design task statement,this paper completes the research and development of a continuous casting roller automatic surfacing welding machine through two aspects: control system hardware design and software design.Using the mechanical structure combination of base,gantry frame and robotic arm,Siemens S7-200 PLC is selected as the automatic control system of the machine.Through Siemens STEP 7 Micro WIN V4.0 programming software,a complete set of control programs is designed to enable the mechanical structure to realize the translation,up and down movement of the robotic arm,swing,as well as the welding gun for welding,workpiece rotation,the stepping of the rotation and matching of the manipulator and other actions,so that the automatic surfacing machine can realize transverse and longitudinal swing welding and longitudinal direct welding,covering other welding processes such as wire embed arc welding,wire extremely bright arc welding process.The continuous casting roller automatic surfacing welding machine designed in this paper has been successfully applied.Through the actual use of many steel mills,it has proved that the design is reasonable,comprehensive and technologically advanced.As a leader in the welding industry,Harbin Welding Research Institute has made remarkable progress in this field.Various automatic surfacing welding equipment based on PLC+HMI developed have also been continuously applied in different fields and adopted by many domestic enterprises,such as Anshan Iron and Steel Co.,Ltd.and Baoshan Iron and Steel Co.,Ltd.,and have been widely recognized and praised.