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CN112036626B - Online forecasting method for edge linear defects of hot rolled strip steel - Google Patents

Online forecasting method for edge linear defects of hot rolled strip steel Download PDF

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CN112036626B
CN112036626B CN202010852476.3A CN202010852476A CN112036626B CN 112036626 B CN112036626 B CN 112036626B CN 202010852476 A CN202010852476 A CN 202010852476A CN 112036626 B CN112036626 B CN 112036626B
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王东城
段伯伟
徐扬欢
汪永梅
张亚林
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Abstract

本发明公开了一种热轧带钢边部线状缺陷在线预报方法,其主要步骤包括:1、收集热轧带钢生产数据作为样本数据并对样本数据预处理;2、根据GA‑DNN神经网络建立热轧带钢边部线状缺陷预报模型;3、对热轧带钢边部线状缺陷预报模型进行训练与验证;4、GA‑DNN神经网络热轧带钢边部线状缺陷预报模型在线预报与分析。该方法具有预测精度高、响应速度快、能够实时在线参与控制等特点,对热轧带钢表面质量控制具有重要意义。

The invention discloses an online prediction method for linear defects at the edge of hot-rolled strip steel. The main steps include: 1. Collecting production data of hot-rolled strip steel as sample data and preprocessing the sample data; 2. According to GA‑DNN Network establishment of linear defect prediction model of hot-rolled strip edge; 3. Training and verification of the hot-rolled strip edge linear defect prediction model; 4. GA-DNN neural network hot-rolled strip edge linear defect prediction Model online forecasting and analysis. This method has the characteristics of high prediction accuracy, fast response speed, real-time online participation in control, etc., and is of great significance to the surface quality control of hot-rolled strip steel.

Description

一种热轧带钢边部线状缺陷在线预报方法An Online Prediction Method for Edge Defects of Hot-rolled Strip Steel

技术领域technical field

本发明属于冶金轧制技术中热轧带钢表面质量控制领域,特别涉及一种热轧带钢边部线状缺陷智能在线预报方法。The invention belongs to the field of surface quality control of hot-rolled steel strips in metallurgical rolling technology, and in particular relates to an intelligent online prediction method for linear defects at the edges of hot-rolled steel strips.

背景技术Background technique

随着我国工业的高速发展,高质量热轧带钢的使用需求越来越大,表面质量是影响热轧带钢产品质量的重要指标之一。边部线状缺陷是热轧带钢表面质量缺陷的一种,根据严重程度不同,表现为翘皮或黑线。这种缺陷不仅严重影响成材率,还可能对热轧下游工序(如酸轧机组)生产过程造成影响。With the rapid development of my country's industry, the demand for high-quality hot-rolled strip steel is increasing, and the surface quality is one of the important indicators that affect the quality of hot-rolled strip steel products. Edge linear defect is a kind of surface quality defect of hot-rolled strip steel, which is manifested as warped skin or black line according to the severity. This defect not only seriously affects the yield, but may also affect the production process of the downstream processes of hot rolling (such as the acid rolling unit).

目前关于热轧带钢线状缺陷的控制与分析已有一些相关的文献。例如:“利用SSP模块改善热轧带钢边部线状缺陷”(《冶金设备》2011,第2期:28-30+49)、“热轧板带边部缺陷形成机理及研究现状”(《河南冶金》2008,第16卷第3期:1-4+27)均认为中间坯侧面褶皱是形成边部线状缺陷的主要原因,而窄面褶皱的严重程度与加热温度和加热时间直接相关,并提出了相应的补偿性解决措施;“轧制过程边部线状缺陷形成机理研究”(《重庆理工大学学报》2018,第32卷第4期:107-110)认为粗轧过程板坯宽度方向温度分布不均,板坯边角部温度过低,易提前进入两相区,变形抗力变小,导致该区域发生了超过其它位置的变形量,后续轧制过程中,中间坯侧面金属不断翻平到上、下表面,最终导致褶皱与线状缺陷的形成;“热轧钢板表面翘皮缺陷分析”(《物理测试》2009,第27卷第1期:46-51)认为边部线状缺陷的产生与钢区原始缺陷直接相关。At present, there are some relevant literatures on the control and analysis of linear defects in hot-rolled strip. For example: "Using SSP module to improve the linear defects of hot-rolled strip edges" ("Metallurgical Equipment" 2011, No. 2: 28-30+49), "Formation mechanism and research status of hot-rolled strip edge defects" ( "Henan Metallurgy" 2008, Volume 16, No. 3: 1-4+27) all believe that the side wrinkles of the intermediate billet are the main reason for the formation of edge linear defects, and the severity of the narrow surface wrinkles is directly related to the heating temperature and heating time. Corresponding compensatory solutions are put forward; "Study on the Formation Mechanism of Edge Linear Defects in the Rolling Process" ("Journal of Chongqing University of Technology" 2018, Vol. 32, No. 4: 107-110) thinks The temperature distribution in the width direction of the slab is uneven, and the temperature at the edge and corner of the slab is too low, it is easy to enter the two-phase region in advance, and the deformation resistance becomes smaller, resulting in the deformation of this region exceeding that of other positions. During the subsequent rolling process, the side of the middle slab The metal is continuously flattened to the upper and lower surfaces, eventually leading to the formation of wrinkles and linear defects; The generation of linear defects is directly related to the original defects in the steel area.

从目前的研究结果看,边部线状缺陷的影响因素复杂多变,但总体可以分为钢区与轧区两个部分。对于轧区,尽管对于边部线状缺陷的具体产生机理的认知也不完全相同,但普遍认为加热温度、加热时间与粗轧温度是关键影响因素。此外,尽管国内、外已经提出过各种解决措施,但基本是根据经验进行设备或工艺参数优化,至今仍未进行边部线状缺陷的在线预报。According to the current research results, the influencing factors of edge linear defects are complex and changeable, but they can be generally divided into two parts: the steel area and the rolling area. For the rolling area, although the specific mechanism of edge linear defects is not completely the same, it is generally believed that the heating temperature, heating time and rough rolling temperature are the key influencing factors. In addition, although various solutions have been proposed at home and abroad, the optimization of equipment or process parameters is basically based on experience, and the online prediction of edge linear defects has not been carried out so far.

综上所述,本发明以轧区的加热温度、加热时间与粗轧出口温度作为主要影响因素,依据实际生产数据,采用智能方法建立一种热轧带钢边部线状缺陷智能在线预报方法,可以根据当前工艺参数对缺陷发生与否进行实时预报,以此为基础进行参数优化调整,对于生产过程中热轧带钢表面质量控制具有重要意义。In summary, the present invention takes the heating temperature of the rolling area, the heating time and the exit temperature of the rough rolling as the main influencing factors, and adopts an intelligent method to establish an intelligent online prediction method for the linear defects of the hot-rolled strip edge according to the actual production data. According to the current process parameters, real-time prediction of the occurrence of defects can be carried out, and parameter optimization and adjustment can be carried out on this basis, which is of great significance for the surface quality control of hot-rolled strip steel in the production process.

发明内容Contents of the invention

本发明的目的在于提供一种热轧带钢边部线状缺陷在线预报方法。本发明根据深度神经网络模型,基于实际生产数据,建立了热轧带钢边部线状缺陷神经网络智能在线预报模型。该模型主要考虑加热温度、加热时间与粗轧出口温度三个方面,具体包括:入炉温度、预热段温度、一加温度、二加温度、三加温度、出炉温度、R2反馈温度、预热时间、一加时间、二加时间、三加时间、均热时间以及产品钢种13个变量参数,以此预测热轧带钢边部线状缺陷产生情况。该方法具有预测精度高、响应速度快、能够实时在线参与控制等特点,对实际生产具有重要意义。The object of the present invention is to provide an online prediction method for linear defects at the edge of hot-rolled strip steel. According to the deep neural network model and based on the actual production data, the present invention establishes an intelligent online prediction model of the neural network neural network for edge linear defects of the hot-rolled strip steel. The model mainly considers three aspects of heating temperature, heating time and rough rolling exit temperature, including: furnace entry temperature, preheating section temperature, first-addition temperature, second-addition temperature, third-addition temperature, furnace exit temperature, R2 feedback temperature, and preheating temperature. The 13 variable parameters of heating time, first adding time, second adding time, third adding time, soaking time and product steel grade are used to predict the occurrence of linear defects at the edge of hot-rolled strip steel. This method has the characteristics of high prediction accuracy, fast response speed, and real-time online participation in control, etc., which is of great significance to actual production.

一种热轧带钢边部线状缺陷在线预报方法,其包括以下步骤:A method for online prediction of linear defects at the edge of a hot-rolled strip, comprising the following steps:

S1、收集热轧带钢生产数据作为样本数据并对样本数据预处理:S1, collecting hot-rolled strip steel production data as sample data and sample data preprocessing:

S11、收集现场实际生产数据并建立原始数据集,所述生产数据包括入炉温度Tf、预热段温度Tp、一加温度T1、二加温度T2、三加温度T3、出炉温度To、R2反馈温度TR、预热时间SR、一加时间S1、二加时间S2、三加时间S3、均热时间Sa、钢种m及其对应的线状缺陷发生情况O,选取数量为n组,得到原始数据集dataset为:S11. Collect the actual production data on site and establish the original data set. The production data include furnace entry temperature T f , temperature T p in the preheating section, temperature T 1 for the first addition, temperature T 2 for the second addition, T 3 for the third addition, and Temperature T o , R2 feedback temperature T R , preheating time S R , first-adding time S 1 , second-adding time S 2 , third-adding time S 3 , soaking time S a , steel type m and its corresponding linear defects Occurrence of situation O, select the number of n groups, and get the original dataset dataset as follows:

{(Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m)|O}i(i=1,2,3···n);{(T f ,T p ,T 1 ,T 2 ,T 3 ,T o ,T R ,S R ,S 1 ,S 2 ,S 3 ,S a ,m)|O} i (i=1,2 ,3···n);

S12、对原始数据集dataset预处理,经线状缺陷数据分布不均处理和异常数据剔除处理后得到数量为n′组的数据集dataset1为:S12. Preprocessing the original data set dataset, after processing the uneven distribution of linear defect data and eliminating abnormal data, the data set dataset1 with the number of n' groups obtained is:

{(Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m)|O}j(j=1,2,3···n′);{(T f ,T p ,T 1 ,T 2 ,T 3 ,T o ,T R ,S R ,S 1 ,S 2 ,S 3 ,S a ,m)|O} j (j=1,2 ,3···n′);

S13、对数据集dataset1中非数字类型的钢种m进行One-Hot独热编码处理,使其转换成数字类型;S13. Perform One-Hot one-hot encoding processing on the non-digital steel type m in the dataset dataset1 to convert it into a digital type;

S14、将数据集dataset1划分为训练样本和测试集,随机抽取86%的数据作为训练样本的数据集dataset2,剩余的作为测试集testset;S14. Divide the dataset dataset1 into training samples and test sets, randomly extract 86% of the data as the dataset dataset2 of the training samples, and use the rest as the test set testset;

S2、根据GA-DNN神经网络建立热轧带钢边部线状缺陷在线预报模型:S2. Based on the GA-DNN neural network, an online prediction model for linear defects at the edge of the hot-rolled strip is established:

S21、确定DNN神经网络结构,具体包括以下步骤:S21. Determine the structure of the DNN neural network, specifically including the following steps:

S211、首先确定神经网络的输入层变量有入炉温度Tf、预热段温度Tp、一加温度T1、二加温度T2、三加温度T3、出炉温度To、R2反馈温度TR、预热时间SR、一加时间S1、二加时间S2、三加时间S3、均热时间Sa以及钢种m,所以输入层的神经元节点数为A1=13;S211. First, determine the input layer variables of the neural network, including furnace entry temperature T f , preheating section temperature T p , primary heating temperature T 1 , secondary heating temperature T 2 , third heating temperature T 3 , furnace output temperature T o , and R2 feedback temperature T R , preheating time S R , first adding time S 1 , second adding time S 2 , third adding time S 3 , soaking time S a and steel type m, so the number of neuron nodes in the input layer is A 1 =13 ;

S212、神经网络的输出为带钢线状缺陷发生情况O,所以神经网络的输出层节点数为Ak=1;S212, the output of the neural network is the occurrence situation O of strip steel linear defects, so the number of nodes in the output layer of the neural network is A k =1;

S213、确定隐藏层的层数以及各层节点个数A2,A3…Ak-1S213. Determine the number of hidden layers and the number of nodes in each layer A 2 , A 3 ... A k-1 ;

S214、选取各层的激活函数activation、误差损失函数loss、优化器optimizer和矩阵函数;S214. Select activation function activation, error loss function loss, optimizer optimizer and matrix function of each layer;

S215、设置学习率lr;S215, setting the learning rate lr;

S216、确定小批量训练样本batch和训练步数Epoch;S216. Determine the small batch training sample batch and the number of training steps Epoch;

S22、设定GA算法参数,所述GA算法参数包括初始化种群规模Q、最大迭代次数N、交叉概率p1和变异概率p2S22, setting GA algorithm parameters, the GA algorithm parameters include initial population size Q, maximum number of iterations N, crossover probability p1 and mutation probability p2 ;

S3、训练热轧带钢边部线状缺陷在线预报模型:S3. Train the online prediction model of linear defects on the edge of hot-rolled strip steel:

S31、将训练样本的数据集dataset2划分为训练集与验证集,随机选取数据集dataset2中的80%作为GA-DNN神经网络的训练集trainset,剩余的20%作为验证集validationset;S31. Divide the dataset dataset2 of the training samples into a training set and a verification set, randomly select 80% of the dataset dataset2 as the training set trainset of the GA-DNN neural network, and use the remaining 20% as the verification set validationset;

S32、训练GA-DNN神经网络,当网络模型达到训练步数时,停止训练;S32, train the GA-DNN neural network, and stop training when the network model reaches the number of training steps;

S33、模型训练结束后,做出训练集trainset与验证集validationset的误差损失图和精度图,判断网络模型的平均损失误差是否小于0.5,以及精度是否能达到85%的生产要求;S33. After the model training is finished, make an error loss map and an accuracy map of the training set trainset and the verification set validation set, and judge whether the average loss error of the network model is less than 0.5, and whether the accuracy can meet the production requirement of 85%;

S34、利用完成训练的GA-DNN神经网络,根据训练集trainset和测试集testset中的参数Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m预测的线状缺陷发生情况数据值,与训练集和测试集中真实线状缺陷发生情况的数据值进行比较并做差值,差值为0表示预测是正确的,差值为±1表示预测是错误的,以此得到训练集与测试集实际误差分布图,判断是否满足85%的精度生产要求;S34. Using the trained GA-DNN neural network, according to the parameters T f , T p , T 1 , T 2 , T 3 , T o , T R , S R , S 1 in the training set trainset and the test set testset, S 2 , S 3 , S a , m predict the data value of the occurrence of linear defects, compare with the data values of the actual occurrence of linear defects in the training set and the test set, and make a difference. A difference of 0 means that the prediction is correct If the difference is ±1, it means that the prediction is wrong, so as to obtain the actual error distribution map of the training set and the test set, and judge whether it meets the 85% accuracy production requirement;

S35、判断模型是否符合精度要求,若同时满足S33和S34的条件要求,则保存GA-DNN网络模型作为热轧带钢边部线状缺陷在线预报模型M,打印模型各层的权值阈值系数值;若S33和S34中有一者不满足时,则返回S2中调整网络结构及优化参数,重新训练网络;S35. Determine whether the model meets the accuracy requirements. If the conditions of S33 and S34 are met at the same time, save the GA-DNN network model as the online prediction model M of linear defects at the edge of the hot-rolled strip steel, and print the weight threshold coefficients of each layer of the model. value; if one of S33 and S34 is not satisfied, then return to S2 to adjust the network structure and optimize parameters, and retrain the network;

S4、热轧带钢边部线状缺陷智能在线预报与分析:S4. Intelligent online prediction and analysis of linear defects at the edge of hot-rolled strip:

S41、首先加载步骤S35中所保存的热轧带钢边部线状缺陷在线预报模型M,将其嵌入热轧带钢生产现场的控制系统中;S41, first load the hot-rolled strip edge linear defect online prediction model M saved in step S35, and embed it in the control system of the hot-rolled strip production site;

S42、在生产过程中,针对当前轧制钢种,根据系统自动反馈的入炉温度、预热段温度、一加温度、二加温度、三加温度、出炉温度、R2反馈温度、预热时间、一加时间、二加时间、三加时间、均热时间的数值,实时预报当前带钢的线状缺陷发生情况;S42. During the production process, according to the current rolling steel type, according to the automatic feedback of the system, the furnace entry temperature, the temperature of the preheating section, the first addition temperature, the second addition temperature, the third addition temperature, the exit temperature, the R2 feedback temperature, and the preheating time , the value of one plus time, two plus time, three plus time, and soaking time, real-time forecasting of the occurrence of linear defects in the current strip;

S43、根据热轧带钢边部线状缺陷在线预报模型M,分析不同钢种各因素诱发其产生线状缺陷的数值区间,以此为依据优化工艺,指导实际生产。S43. According to the online prediction model M of linear defects at the edge of the hot-rolled strip, analyze the numerical range of linear defects induced by various factors of different steel types, and optimize the process based on this to guide actual production.

优选的,步骤S12中对数据集dataset预处理具体包括以下步骤:Preferably, the preprocessing of the dataset dataset in step S12 specifically includes the following steps:

S121、采用自动筛选方法,将采集到的原始数据集dataset按线状缺陷发生与线状缺陷发生未发生分开处理;S121. Using an automatic screening method, the collected original dataset dataset is processed separately according to occurrence of linear defects and non-occurrence of linear defects;

S122、按1:1的比例随机抽取发生线状缺陷数据与未发生线状缺陷数据;将二者进行乱序合并处理;S122. Randomly extract the data with linear defects and the data without linear defects at a ratio of 1:1; combine them in random order;

S123、剔除含有缺失项的数据,整理后得到新的可用数据集dataset1。S123. Eliminate data containing missing items, and obtain a new usable dataset dataset1 after sorting.

优选的,步骤S35中对GA-DNN神经网络结构以及参数进行优化调整具体包括以下步骤:Preferably, optimizing and adjusting the GA-DNN neural network structure and parameters in step S35 specifically includes the following steps:

S351、调整神经网络隐藏层个数,以及各个隐藏层的神经网络节点个数;S351. Adjust the number of hidden layers of the neural network and the number of neural network nodes in each hidden layer;

S352、调整各层神经网络层输出层的激活函数activation;S352. Adjust the activation function activation of the output layer of each neural network layer;

S353、调整网络训练优化器optimizer;S353. Adjust the network training optimizer optimizer;

S354、调整小批量训练样本batch以及训练步数Epoch;S354, adjusting the small batch training sample batch and the number of training steps Epoch;

S355、向GA-DNN神经网络各隐含层引入regularization正则化处理;S355. Introduce regularization to each hidden layer of the GA-DNN neural network;

S356、对GA-DNN神经网络的输入层进行dropout处理。S356. Perform dropout processing on the input layer of the GA-DNN neural network.

与现有技术相比,本发明具有如下有益效果:Compared with the prior art, the present invention has the following beneficial effects:

本发明所提出的热轧带钢边部线状缺陷在线预报方法,能够根据实际生产数据实时对带钢边部线状缺陷的发生情况进行在线预报。该方法准确率高,泛化性强,执行速度快,可移植性高,符合工业生产要求,能够很好的嵌入于生产现场控制系统参与指导生产,对热轧带钢边部线状缺陷的治理改善具有较好效果,对降低剪裁率、提高成材率、提升产品核心竞争力具有重要意义。The online prediction method for edge linear defects of hot-rolled steel strip proposed by the present invention can perform online prediction on the occurrence of linear defects at the edge of strip steel in real time according to actual production data. This method has high accuracy, strong generalization, fast execution speed, high portability, and meets the requirements of industrial production. It can be well embedded in the production site control system to participate in guiding production. Governance improvement has a good effect, which is of great significance to reduce the tailoring rate, increase the yield rate, and enhance the core competitiveness of products.

附图说明Description of drawings

图1是本发明热轧带钢边部线状缺陷GA-DNN神经网络流程图;Fig. 1 is the GA-DNN neural network flow diagram of the edge linear defect of hot-rolled steel strip of the present invention;

图2是GA-DNN神经网络结构图;Figure 2 is a structural diagram of the GA-DNN neural network;

图3是本发明实施例神经网络训练集和验证集的误差损失图;Fig. 3 is the error loss figure of neural network training set and verification set of the embodiment of the present invention;

图4是本发明实施例神经网络训练集和验证集的精度图;Fig. 4 is the accuracy figure of neural network training set and verification set of the embodiment of the present invention;

图5是本发明实施例训练集实际误差分布图;Fig. 5 is the actual error distribution figure of the training set of the embodiment of the present invention;

图6是本发明实施例测试集实际误差分布图;以及Fig. 6 is the actual error distribution diagram of the test set of the embodiment of the present invention; and

图7是本发明热轧带钢边部线状缺陷在线预报方法的流程图。Fig. 7 is a flow chart of the online prediction method for edge linear defects of hot-rolled strip steel according to the present invention.

具体实施方式Detailed ways

以下,参照附图对本发明的实施方式进行说明。Hereinafter, embodiments of the present invention will be described with reference to the drawings.

如图1所示,为本发明的一种热轧带钢边部线状缺陷智能在线预报方法的流程图,具体包括以下步骤:As shown in Figure 1, it is a flow chart of a method for intelligent online prediction of linear defects at the edge of a hot-rolled strip according to the present invention, which specifically includes the following steps:

S1、收集热轧带钢生产数据作为样本数据并对样本数据预处理:S1. Collect production data of hot-rolled strip steel as sample data and preprocess the sample data:

S11、收集现场实际数据并建立原始数据集,具体包括:入炉温度Tf、预热段温度Tp、一加温度T1、二加温度T2、三加温度T3、出炉温度To、R2反馈温度TR、预热时间SR、一加时间S1、二加时间S2、三加时间S3、均热时间Sa以及钢种m和与之对应的线状缺陷发生情况O,其中0代表发生线状缺陷,1代表未发生线状缺陷,其数量共有n=12538组,得到原始数据集dataset为:S11. Collect the actual data on site and establish the original data set, specifically including: furnace entry temperature T f , preheating section temperature T p , first heating temperature T 1 , second heating temperature T 2 , third heating temperature T 3 , and furnace output temperature T o , R2 feedback temperature T R , preheating time S R , first-adding time S 1 , second-adding time S 2 , third-adding time S 3 , soaking time S a and steel type m and the corresponding occurrence of linear defects O, where 0 represents the occurrence of linear defects, and 1 represents the absence of linear defects. There are a total of n=12538 groups, and the original data set dataset is obtained as follows:

{(Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m)|O}i i=1,2,3…12538。{(T f , T p , T 1 , T 2 , T 3 , T o , T R , S R , S 1 , S 2 , S 3 , S a , m)|O} i i=1, 2, 3...12538.

S12、对原始数据集dataset预处理,具体包括:线状缺陷数据分布不均处理、异常数据剔除处理,具体过程为:S12. Preprocessing the original dataset dataset, specifically including: processing of uneven distribution of linear defect data, and processing of abnormal data elimination. The specific process is:

S121、采用自动筛选方法,将采集到的原始数据集dataset按线状缺陷发生与线状缺陷发生未发生分开处理;S121. Using an automatic screening method, the collected original dataset dataset is processed separately according to occurrence of linear defects and non-occurrence of linear defects;

S122、按1:1的比例随机抽取发生线状缺陷数据与未发生线状缺陷数据;将两者进行乱序合并处理;S122. Randomly extract the data with linear defects and the data without linear defects at a ratio of 1:1; combine them in random order;

S123、剔除含有缺失项的数据,整理后得到数据集dataset1,其数量为n′=4200组,即{(Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m)|O}j j=1,2,3…4200,其数据结构形式如表1所示。S123. Eliminate data containing missing items, and obtain a dataset dataset1 after sorting, the number of which is n′=4200 groups, namely {(T f , T p , T 1 , T 2 , T 3 , T o , T R , S R , S 1 , S 2 , S 3 , S a , m)|O} j j=1, 2, 3...4200, and its data structure is shown in Table 1.

S13、对数据集dataset1中钢种m这一非数字类型进行One-Hot独热编码处理,使其转换成数字类型。S13. Perform One-Hot one-hot encoding processing on the non-numeric type of steel type m in the data set dataset1 to convert it into a digital type.

S14、将数据集dataset1划分为训练样本和测试集,随机抽取86%作为模型训练样本的数据集dataset2,对百位取整后共计3600组,剩余的600组作为模型测试集样本数据testset。S14. Divide the dataset dataset1 into training samples and test sets, randomly select 86% of the dataset dataset2 as the model training samples, and round up the hundreds to a total of 3600 groups, and the remaining 600 groups are used as the model test set sample data testset.

表1 dataset1中部分数据Part of the data in Table 1 dataset1

S2、根据GA-DNN神经网络建立热轧带钢边部线状缺陷智能在线预报模型:S2. Based on the GA-DNN neural network, an intelligent online prediction model for linear defects at the edge of hot-rolled strip steel is established:

S21、确定DNN神经网络结构,具体包括以下步骤:S21. Determine the structure of the DNN neural network, specifically including the following steps:

S211、首先确定神经网络的输入层变量有入炉温度Tf、预热段温度Tp、一加温度T1、二加温度T2、三加温度T3、出炉温度To、R2反馈温度TR、预热时间SR、一加时间S1、二加时间S2、三加时间S3、均热时间Sa以及钢种m,所以输入层的神经元节点数为A1=13;S211. First, determine the input layer variables of the neural network, including furnace entry temperature T f , preheating section temperature T p , primary heating temperature T 1 , secondary heating temperature T 2 , third heating temperature T 3 , furnace output temperature T o , and R2 feedback temperature T R , preheating time S R , first adding time S 1 , second adding time S 2 , third adding time S 3 , soaking time S a and steel type m, so the number of neuron nodes in the input layer is A 1 =13 ;

S212、因为输入变量只有13个,所以输入层神经元节点个数较少,隐藏层神经元节点数也不能过多,否则会出现过拟合现象,在经过多次模型训练的结果对比与模型结构调整后,最终决定采用k=5层神经网络,设置隐含层的神经元节点个数A2=200,A3=80,A4=50,三个隐藏层的激活函数都为Relu函数;S212. Because there are only 13 input variables, the number of neuron nodes in the input layer is small, and the number of neuron nodes in the hidden layer should not be too many, otherwise overfitting will occur. After multiple model trainings, the results are compared with the model After structural adjustment, it was finally decided to use a k=5-layer neural network, set the number of neuron nodes in the hidden layer A 2 =200, A 3 =80, A 4 =50, and the activation functions of the three hidden layers are all Relu functions ;

S213、神经网络的输出为带钢线状缺陷发生情况O,所以神经网络的输出层节点数为Ak=1,输出层的激活函数选择Softmax函数;S213, the output of the neural network is the steel strip linear defect occurrence situation O, so the output layer node number of the neural network is Ak =1, and the activation function of the output layer selects the Softmax function;

S214、因为输出层为带钢线状缺陷发生情况,只有两种可能,所以loss函数选择Binary-crossentropy、优化器optimizer采用Adam,矩阵函数采用metrics,优化器学习率设置为0.001,确定小批量训练样本batch为32、训练次数Epoch为200次,向神经网络隐藏层引入L2正则化,设置值为0.005,向神经网络隐藏层入dropout函数,设置值为0.02。S214. Because the output layer is the occurrence of strip steel linear defects, there are only two possibilities, so the loss function selects Binary-crossentropy, the optimizer optimizer adopts Adam, the matrix function adopts metrics, and the optimizer learning rate is set to 0.001 to determine the small batch training The sample batch is 32, the number of training Epoch is 200 times, L2 regularization is introduced to the hidden layer of the neural network, the setting value is 0.005, and the dropout function is added to the hidden layer of the neural network, the setting value is 0.02.

S22、设定GA算法参数,具体包括以下步骤:S22. Setting GA algorithm parameters, specifically including the following steps:

S221、根据神经网络的权值阈值规模来设定种群规模Q为80,对随机产生的初始值进行编码;S221. Set the population size Q to 80 according to the weight threshold scale of the neural network, and encode the randomly generated initial value;

S222、将随机产生的初始值作为神经网络的初始权值和阈值,用于训练神经网络后预测输出,将预测输出和预测输出和期望输出之间的误差作为个体适应度值F,其中y为神经网络第i个节点的期望输出;Oi为第i个节点的预测输出;k为系数;S222. Use the randomly generated initial value as the initial weight and threshold of the neural network to predict the output after training the neural network, and use the error between the predicted output and the predicted output and the expected output as the individual fitness value F, Among them, y is the expected output of the i-th node of the neural network; O i is the predicted output of the i-th node; k is the coefficient;

S223、选择出的适应度值较高的个体进行交叉、变异操作,设定交叉概率p1为0.4和变异概率p2为0.2;S223. Perform crossover and mutation operations on the selected individuals with higher fitness values, and set the crossover probability p 1 to 0.4 and the mutation probability p 2 to 0.2;

S224、计算繁衍后的个体的适应度值,设定最大迭代次数N为100次,若达到迭代次数后将最终寻优得到的权值阈值传给神经网络,否则执行S223。S224. Calculate the fitness value of the reproduced individual, set the maximum number of iterations N to 100, if the number of iterations is reached, transmit the weight threshold obtained from the final optimization to the neural network, otherwise execute S223.

S3、热轧带钢边部线状缺陷智能在线预报模型训练:S3. Training of intelligent online prediction model for linear defects at the edge of hot-rolled strip:

S31、将训练样本dataset2划分为训练集与验证集,随机选取训练样本中的80%作为GA-DNN神经网络训练集样本trainset共有2880组数据,剩余的720组数据作为验证集样本validationset。S31. Divide the training sample dataset2 into a training set and a validation set, randomly select 80% of the training samples as the GA-DNN neural network training set sample trainset, a total of 2880 sets of data, and the remaining 720 sets of data as the validation set sample validationset.

S32、训练GA-DNN神经网络,设置模型训练次数;S32, train the GA-DNN neural network, and set the number of model training times;

S321、将数据的变量入炉温度Tf、预热段温度Tp、一加温度T1、二加温度T2、三加温度T3、出炉温度To、R2反馈温度TR、预热时间SR、一加时间S1、二加时间S2、三加时间S3、均热时间Sa以及钢种m输入到模型的输入层中,开始训练时,每层神经元均随机分配给各个输入与神经元之间一个初始权重系数,然后算出所有输入与权重系数乘积的和后经过激活函数计算传出,而上一次的输出又作为下一层的输入将变量传给下一隐藏层以及激活函数,以此类推,一直向前传播到输出层和输出层激活函数,完成首轮训练过程;S321. Put the data variables into the furnace temperature T f , the temperature of the preheating section T p , the temperature of the first addition T 1 , the temperature of the second addition T 2 , the temperature of the third addition T 3 , the output temperature T o , the R2 feedback temperature T R , preheating The time S R , one plus time S 1 , two plus time S 2 , three plus time S 3 , soaking time S a and steel type m are input into the input layer of the model. When training starts, neurons in each layer are randomly assigned Give an initial weight coefficient between each input and the neuron, then calculate the sum of the products of all inputs and the weight coefficient, and then pass the activation function calculation, and the output of the previous time is used as the input of the next layer to pass the variable to the next hidden Layer and activation function, and so on, propagate forward to the output layer and output layer activation function to complete the first round of training process;

S322、当第一轮的前向传播结束后,模型会以线状缺陷发生情况O为网络的输出,然后与训练数据中的真实缺陷发生情况进行对比,通过设置的损失函数计算此轮训练的带钢线状缺陷预测与真实发生情况的损失误差;S322. After the first round of forward propagation is over, the model will take the occurrence of linear defects O as the output of the network, and then compare it with the actual occurrence of defects in the training data, and calculate the training value of this round through the set loss function The loss error between the prediction of strip linear defects and the actual occurrence;

S323、设置优化器,通过损失函数求出的误差来进行反向传播,通过链式求导更新每层神经元的权重系数来使得损失值最小,参数更新结束后,继续将训练数据传入模型进行下一轮训练,直到达到设置的训练次数,停止训练。S323. Set the optimizer, perform backpropagation through the error obtained by the loss function, and update the weight coefficient of each layer of neurons through chain derivation to minimize the loss value. After the parameter update is completed, continue to import the training data into the model Carry out the next round of training until the set number of training times is reached, and stop training.

S33、模型训练结束后,做出训练集trainset与验证集validationset误差损失图如图3所示,精度图如图4所示,结果表明,该网络模型的平均损失误差小于0.5,模型平均精度能达到90%,满足生产要求。S33. After the model training is finished, the error loss diagram of the training set trainset and the validation set is made as shown in Figure 3, and the accuracy diagram is shown in Figure 4. The results show that the average loss error of the network model is less than 0.5, and the average accuracy of the model can Reach 90%, meet the production requirements.

S34、利用完成训练的GA-DNN神经网络,根据训练集trainset与测试集testset上的参数Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m预测的线状缺陷发生情况数据值,与训练集与测试集上真实线状缺陷发生情况数据值比较并做差值,值为0表示预测是正确的,值为±1表示预测是错误的,以此得到训练集3600组数据的实际误差分布图如图5所示,测试集600组数据实际误差分布如图6所示,结果表明,该模型精度达到90%,满足生产要求。S34. Using the trained GA-DNN neural network, according to the parameters T f , T p , T 1 , T 2 , T 3 , T o , T R , S R , S 1 on the training set trainset and the test set testset, S 2 , S 3 , S a , m predict the occurrence data value of linear defects, compare with the data values of real linear defect occurrence data values on the training set and test set, and make a difference. A value of 0 means that the prediction is correct. The value of ±1 means that the prediction is wrong, and the actual error distribution diagram of the 3600 sets of data in the training set is shown in Figure 5, and the actual error distribution of the 600 sets of data in the test set is shown in Figure 6. The results show that the accuracy of the model reaches 90%, meet the production requirements.

S35、模型同时满足S33、S34两者的条件要求,因此保存GA-DNN神经网络模型作为热轧带钢边部线状缺陷智能在线预报模型M,打印模型各层的权值阈值系数值。S35. The model satisfies both the conditions of S33 and S34. Therefore, the GA-DNN neural network model is saved as an intelligent online prediction model M of linear defects at the edge of the hot-rolled strip, and the weight threshold coefficient values of each layer of the model are printed.

S4、热轧带钢边部线状缺陷在线预报与分析:S4. On-line prediction and analysis of linear defects on the edge of hot-rolled strip steel:

S41、加载S35所保存的热轧带钢边部线状缺陷智能在线预报模型M,将其嵌入热轧带钢生产现场的控制系统中。S41. Load the intelligent online prediction model M of linear defects at the edge of the hot-rolled strip saved in S35, and embed it into the control system at the production site of the hot-rolled strip.

S42、在生产过程中,针对当前轧制钢种,根据系统自动反馈的入炉温度、预热段温度、一加温度、二加温度、三加温度、出炉温度、R2反馈温度、预热时间、一加时间、二加时间、三加时间、均热时间这些参数数值,实时预报当前带钢的线状缺陷发生情况。S42. During the production process, according to the current rolling steel type, according to the automatic feedback of the system, the furnace entry temperature, the temperature of the preheating section, the first addition temperature, the second addition temperature, the third addition temperature, the exit temperature, the R2 feedback temperature, and the preheating time , 1st addition time, 2nd addition time, 3rd addition time, soaking time and other parameter values, real-time forecasting of the occurrence of linear defects in the current strip.

S43、根据热轧带钢边部线状缺陷智能在线预报模型M,分析不同钢种各因素诱发其产生线状缺陷的数值区间。以硅钢270为例,通过热轧带钢边部线状缺陷智能在线预报模型M得出结果,诱发其产生线状缺陷的因素为一加温度、二加温度、三加温度、一加时间、三加时间和均热时间,其预报的数值区间见表2,为此,硅钢270实际生产时应按照此加热工艺进行优化。S43. According to the intelligent online prediction model M of linear defects at the edge of the hot-rolled strip, analyze the numerical intervals of the linear defects induced by various factors of different steel types. Taking silicon steel 270 as an example, the results are obtained through the intelligent online prediction model M of linear defects at the edge of hot-rolled strip steel. The predicted value ranges of the three heating times and soaking time are shown in Table 2. For this reason, the actual production of silicon steel 270 should be optimized according to this heating process.

表2硅钢270边部线状缺陷产生的参数区间预报Table 2 Prediction of parameter intervals for the generation of linear defects on the edge of silicon steel 270

以上所述的实施例仅是对本发明的优选实施方式进行描述,并非对本发明的范围进行限定,在不脱离本发明设计精神的前提下,本领域普通技术人员对本发明的技术方案做出的各种变形和改进,均应落入本发明权利要求书确定的保护范围内。The above-mentioned embodiments are only descriptions of preferred implementations of the present invention, and are not intended to limit the scope of the present invention. All such modifications and improvements should fall within the scope of protection defined by the claims of the present invention.

Claims (3)

1.一种热轧带钢边部线状缺陷在线预报方法,其特征在于,其包括以下步骤:1. A method for online prediction of hot-rolled strip edge linear defects, characterized in that it comprises the following steps: S1、收集热轧带钢生产数据作为样本数据并对样本数据预处理:S1, collecting hot-rolled strip steel production data as sample data and sample data preprocessing: S11、收集现场实际生产数据并建立原始数据集,所述生产数据包括入炉温度Tf、预热段温度Tp、一加温度T1、二加温度T2、三加温度T3、出炉温度To、R2反馈温度TR、预热时间SR、一加时间S1、二加时间S2、三加时间S3、均热时间Sa、钢种m及其对应的线状缺陷发生情况O,选取数量为n组,得到原始数据集dataset为:S11. Collect the actual production data on site and establish the original data set. The production data include furnace entry temperature T f , temperature T p in the preheating section, temperature T 1 for the first addition, temperature T 2 for the second addition, T 3 for the third addition, and Temperature T o , R2 feedback temperature T R , preheating time S R , first-adding time S 1 , second-adding time S 2 , third-adding time S 3 , soaking time S a , steel type m and its corresponding linear defects Occurrence of situation O, select the number of n groups, and get the original dataset dataset as follows: {(Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m)|O}i(i=1,2,3···n);{(T f ,T p ,T 1 ,T 2 ,T 3 ,T o ,T R ,S R ,S 1 ,S 2 ,S 3 ,S a ,m)|O} i (i=1,2 ,3···n); S12、对原始数据集dataset预处理,经线状缺陷数据分布不均处理和异常数据剔除处理后得到数量为n′组的数据集dataset1为:S12. Preprocessing the original data set dataset, after processing the uneven distribution of linear defect data and eliminating abnormal data, the data set dataset1 with the number of n' groups obtained is: {(Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m)|O}j(j=1,2,3···n′);{(T f ,T p ,T 1 ,T 2 ,T 3 ,T o ,T R ,S R ,S 1 ,S 2 ,S 3 ,S a ,m)|O} j (j=1,2 ,3···n′); S13、对数据集dataset1中非数字类型的钢种m进行One-Hot独热编码处理,使其转换成数字类型;S13. Perform One-Hot one-hot encoding processing on the non-digital steel type m in the dataset dataset1 to convert it into a digital type; S14、将数据集dataset1划分为训练样本和测试集,随机抽取86%的数据作为训练样本的数据集dataset2,剩余的作为测试集testset;S14. Divide the dataset dataset1 into training samples and test sets, randomly extract 86% of the data as the dataset dataset2 of the training samples, and use the rest as the test set testset; S2、根据GA-DNN神经网络建立热轧带钢边部线状缺陷在线预报模型:S2. Based on the GA-DNN neural network, an online prediction model for linear defects at the edge of the hot-rolled strip is established: S21、确定DNN神经网络结构,具体包括以下步骤:S21. Determine the structure of the DNN neural network, specifically including the following steps: S211、首先确定神经网络的输入层变量有入炉温度Tf、预热段温度Tp、一加温度T1、二加温度T2、三加温度T3、出炉温度To、R2反馈温度TR、预热时间SR、一加时间S1、二加时间S2、三加时间S3、均热时间Sa以及钢种m,所以输入层的神经元节点数为A1=13;S211. First, determine the input layer variables of the neural network, including furnace entry temperature T f , preheating section temperature T p , primary heating temperature T 1 , secondary heating temperature T 2 , third heating temperature T 3 , furnace output temperature T o , and R2 feedback temperature T R , preheating time S R , first adding time S 1 , second adding time S 2 , third adding time S 3 , soaking time S a and steel type m, so the number of neuron nodes in the input layer is A 1 =13 ; S212、神经网络的输出为带钢线状缺陷发生情况O,所以神经网络的输出层节点数为Ak=1;S212, the output of the neural network is the occurrence situation O of strip steel linear defects, so the number of nodes in the output layer of the neural network is A k =1; S213、确定隐藏层的层数以及各层节点个数A2,A3…Ak-1S213. Determine the number of hidden layers and the number of nodes in each layer A 2 , A 3 ... A k-1 ; S214、选取各层的激活函数activation、误差损失函数loss、优化器optimizer和矩阵函数;S214. Select activation function activation, error loss function loss, optimizer optimizer and matrix function of each layer; S215、设置学习率lr;S215, setting the learning rate lr; S216、确定小批量训练样本batch和训练步数Epoch;S216. Determine the small batch training sample batch and the number of training steps Epoch; S22、设定GA算法参数,所述GA算法参数包括初始化种群规模Q、最大迭代次数N、交叉概率p1和变异概率p2S22, setting GA algorithm parameters, the GA algorithm parameters include initial population size Q, maximum number of iterations N, crossover probability p1 and mutation probability p2 ; S3、训练热轧带钢边部线状缺陷在线预报模型:S3. Train the online prediction model of linear defects on the edge of hot-rolled strip steel: S31、将训练样本的数据集dataset2划分为训练集与验证集,随机选取数据集dataset2中的80%作为GA-DNN神经网络的训练集trainset,剩余的20%作为验证集validationset;S31. Divide the dataset dataset2 of the training samples into a training set and a verification set, randomly select 80% of the dataset dataset2 as the training set trainset of the GA-DNN neural network, and use the remaining 20% as the verification set validationset; S32、训练GA-DNN神经网络,当网络模型达到训练步数时,停止训练;S32, train the GA-DNN neural network, and stop training when the network model reaches the number of training steps; S33、模型训练结束后,做出训练集trainset与验证集validationset的误差损失图和精度图,判断网络模型的平均损失误差是否小于0.5,以及精度是否能达到85%的生产要求;S33. After the model training is finished, make an error loss map and an accuracy map of the training set trainset and the verification set validation set, and judge whether the average loss error of the network model is less than 0.5, and whether the accuracy can meet the production requirement of 85%; S34、利用完成训练的GA-DNN神经网络,根据训练集trainset和测试集testset中的参数Tf,Tp,T1,T2,T3,To,TR,SR,S1,S2,S3,Sa,m预测的线状缺陷发生情况数据值,与训练集和测试集中真实线状缺陷发生情况的数据值进行比较并做差值,差值为0表示预测是正确的,差值为±1表示预测是错误的,以此得到训练集与测试集实际误差分布图,判断是否满足85%的精度生产要求;S34. Using the trained GA-DNN neural network, according to the parameters T f , T p , T 1 , T 2 , T 3 , T o , T R , S R , S 1 in the training set trainset and the test set testset, S 2 , S 3 , S a , m predict the data value of the occurrence of linear defects, compare with the data values of the actual occurrence of linear defects in the training set and the test set, and make a difference. A difference of 0 means that the prediction is correct If the difference is ±1, it means that the prediction is wrong, so as to obtain the actual error distribution map of the training set and the test set, and judge whether it meets the 85% accuracy production requirement; S35、判断模型是否符合精度要求,若同时满足S33和S34的条件要求,则保存GA-DNN网络模型作为热轧带钢边部线状缺陷在线预报模型M,打印模型各层的权值阈值系数值;若S33和S34中有一者不满足时,则返回S2中调整网络结构及优化参数,重新训练网络;S35. Determine whether the model meets the accuracy requirements. If the conditions of S33 and S34 are met at the same time, save the GA-DNN network model as the online prediction model M of linear defects at the edge of the hot-rolled strip steel, and print the weight threshold coefficients of each layer of the model. value; if one of S33 and S34 is not satisfied, then return to S2 to adjust the network structure and optimize parameters, and retrain the network; S4、热轧带钢边部线状缺陷智能在线预报与分析:S4. Intelligent online prediction and analysis of linear defects at the edge of hot-rolled strip: S41、首先加载步骤S35中所保存的热轧带钢边部线状缺陷在线预报模型M,将其嵌入热轧带钢生产现场的控制系统中;S41, first load the hot-rolled strip edge linear defect online prediction model M saved in step S35, and embed it in the control system of the hot-rolled strip production site; S42、在生产过程中,针对当前轧制钢种,根据系统自动反馈的入炉温度、预热段温度、一加温度、二加温度、三加温度、出炉温度、R2反馈温度、预热时间、一加时间、二加时间、三加时间、均热时间的数值,实时预报当前带钢的线状缺陷发生情况;S42. During the production process, according to the current rolling steel type, according to the furnace input temperature, preheating section temperature, first heating temperature, second heating temperature, third heating temperature, output temperature, R2 feedback temperature, and preheating time automatically fed back by the system , the values of first adding time, second adding time, third adding time and soaking time, real-time forecasting of the occurrence of linear defects in the current strip; S43、根据热轧带钢边部线状缺陷在线预报模型M,分析不同钢种各因素诱发其产生线状缺陷的数值区间,以此为依据优化工艺,指导实际生产。S43. According to the online prediction model M of linear defects at the edge of the hot-rolled strip, analyze the numerical range of linear defects induced by various factors of different steel types, and optimize the process based on this to guide actual production. 2.根据权利要求1所述的热轧带钢边部线状缺陷在线预报方法,其特征在于,步骤S12中对数据集dataset预处理具体包括以下步骤:2. The hot-rolled strip edge linear defect online prediction method according to claim 1, characterized in that, in step S12, dataset preprocessing specifically includes the following steps: S121、采用自动筛选方法,将采集到的原始数据集dataset按线状缺陷发生与线状缺陷发生未发生分开处理;S121. Using an automatic screening method, the collected original dataset dataset is processed separately according to occurrence of linear defects and non-occurrence of linear defects; S122、按1:1的比例随机抽取发生线状缺陷数据与未发生线状缺陷数据;将二者进行乱序合并处理;S122. Randomly extract the data with linear defects and the data without linear defects at a ratio of 1:1; combine the two out of order; S123、剔除含有缺失项的数据,整理后得到新的可用数据集dataset1。S123. Eliminate data containing missing items, and obtain a new usable dataset dataset1 after sorting. 3.根据权利要求1所述的热轧带钢边部线状缺陷在线预报方法,其特征在于,步骤S35中对GA-DNN神经网络结构以及参数进行优化调整具体包括以下步骤:3. The method for online prediction of hot-rolled strip edge linear defects according to claim 1, wherein in step S35, optimizing and adjusting GA-DNN neural network structure and parameters specifically includes the following steps: S351、调整神经网络隐藏层个数,以及各个隐藏层的神经网络节点个数;S351. Adjust the number of hidden layers of the neural network and the number of neural network nodes in each hidden layer; S352、调整各层神经网络层输出层的激活函数activation;S352. Adjust the activation function activation of the output layer of each neural network layer; S353、调整网络训练优化器optimizer;S353. Adjust the network training optimizer optimizer; S354、调整小批量训练样本batch以及训练步数Epoch;S354, adjusting the small batch training sample batch and the number of training steps Epoch; S355、向GA-DNN神经网络各隐含层引入regularization正则化处理;S355. Introduce regularization to each hidden layer of the GA-DNN neural network; S356、对GA-DNN神经网络的输入层进行dropout处理。S356. Perform dropout processing on the input layer of the GA-DNN neural network.
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