Quality Instrumentation Data Integrated Standard System In Cold Rolling Mill

Y. B. Park*, J. H. Hong*, W. H. Hong* and K. W. Kim*

ABSTRACT
This paper proposed a standardization of instrumentation system aimed at standardizing the system architecture and the design methods on quality instrumentation of coil rolling mill at steel works. In first, as developing instrumentation controller, we proposed the H/W specification and standard I/O library to be used on various device drivers and common components such as communication and device handler. In second, we proposed Quality Instrumentation Data Integrated Server that the system can integrate the data about product and instrumentation and users can access and analyse information through web browser in all plan area. Keywords : cold rolling mill, quality instrumentation, standardization, component, system integration

1. INTRODUCTION
In the major application of instrumentation and quality management on steel product, the architecture of the instrumentation system is an essential factor because it directly affects product quality work such as the range and time of quality analysis. For this reason, a number of instrumentation systems have been developed, especially in the field of steel plants. The legacy system had been developed by each developer and raised as to the degradation of system stability, the complexity of application maintenance and the usability of data. A great deal of effort has been made on standardization of process computer and component development. What seems to be lacking, however, is on quality instrumentation system. This paper proposes the integrated system aimed at standardizing the system architecture

and the design methods on quality instrumentation of coil rolling mill at steel works. In first, as developing instrumentation controller, we explain the H/W specification and standard I/O library to be used on various device driver and common components such as communication and device handler. In second, we propose Quality Instrumentation Data Integrated Server that can integrate the data about product and instrumentation and access and analyse information through web browser in all plan area.

2. SYSTEM STARDARDIZATION FOR QUALITY INSTRUMENTATION

2.1 Legacy Instrumentation System
The legacy controller was the standalone system that includes the controller that could acquire and manipulate data and execute internal algorithm and the HMI that could monitor and

* Instumentation Research Group, Technial Lab. POSCO

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control sensors/actuators. Developer had built in one system that could acquire and monitor instrumentation data. The system had risen as to the degradation of system stability, the complexity of application maintenance and the usability of data. For high quality production, it is necessary to retain and integrate data on product and instrumentation. It is also important to have the stability and reliability on the related system. The motives have combined to make a proposal on standardization and integration on quality instrumentation system.

Fig. 1 Legacy Instrumentation System Configuration

2.2 Standard Instrumentation System

The improvement of standard instrumentation system has shown the importance of three features. First, we could divide the system into instrumentation controller and Quality Instrumentation Data Integrated System. The controller can acquire the data from sensors, control actuators and monitor the data. QIDIS can be used to store, access and analyse the data to be acquired by the controller. This approach

could improve performance and stability of the systems and make an upgrade of the system easy. In second, we standardized specifications of the internal device and the systems. We let the developer access use device driver of board through our standard library. We made common components such as communication module, data access module that can use commonly in the instrumentation controllers. It made an upgrade and modification of application easy. It could also reduce time and money that needs to develop the system end improved the stability of the system using the verified components. The developer could focus on the development of the algorithm on instrumentation. In last, QIDIS can be broken down into three layers : data store layer, application layer, presentation layer. The modern approach to server-side Internet computing partitions the task of constructing a deployment into separate roles. Rather than build an entire deployment from scratch, a corporation can purchase a server-side platform from a middleware vendor, re-usable components from an application vendor, and development and management tools from a tools vendor. Greater efficiency is achieved through specialization, and instrumentation developer is free to focus on solving the business problem at hand.

3. SYSTEM STARDARDIZATION FOR QUALITY INSTRUMENTATION

3.1 Instrumentation Controller Architecture
Instrumentation controller receives data from sensor, controls actuators and communicates with the other systems in the plant. The controller should be mainly differentiated into embedded system, pc based system, VME system. We decided to use pc based system in developing the controller. We proved the fact that pc based system met the requirements for the stability and the performance through the

Fig. 2 Standard Instrumentation System Configuration

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adaptation of the system. PC based system has many advantages that we can have an abundant spare part and lean how to use and repair the system. We can connect the system easily with various kinds of sensors and devices.

to program the interfaces were so vary and difficult that it had invoked many problems such system down and communication breakdown. It was very serious in the plant automation. The new comer could not under stand and update rapidly the program.

3.2 Standard Instrumentation System

We had implemented application program directly in legacy system using by the device driver to be supported by the device maker. When these codes including device handling functions were modified or changed, they spread so wide that we could not change easily with new device handling modules. In new standard system, we proposed standard IO API in interface layer. We recommended the application program should be coded using the standard API. It makes it possible not to be seriously affected by changing devices. Whenever we introduce new device, it is enough to develop new standard IO interface module for the device.

Fig. 4 Common Components

Fig. 3 Stand IO interface Layer

The common modules such as Database handling, Communication handling, device handling was used commonly in many instrumentation applications. Whenever the application is built, it is unnecessary to develop these newly common modules. Developers that have much experience in system program extracted common module from instrumentation application and built common components to be reused in many application. It was robust component that had tested in many applications and was stable. As using common components, we could focus on developing in new instrumentation algorithm and could reduce time and cost to be needed.

3.3 Common Components 3.4 Human Man Interface

Instrumentation controller executes the data transportation with each devices and systems and processes the received data, stores the results of the algorithm or sends them to the related systems. In development of the legacy system, our developers had coded not only the program related to instrumentation algorithm, but also the communication programs and various kinds of interface programs. These techniques that used The most important feature of HMI in the controller is the real-time data display and realtime control such as emergency stop function. We restricted the function of the HMI system that it could monitor the real-time data and display real-time trend graphs and control the importance device setting. The access and analysis of the previous instrumentation data was

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supported through QIDIS. It made possible the real-time monitoring to be stabilized and the structure of the application to be simplified. We detached the algorithmic codes as separated files from the HMI application so that the application can be easily understood and modified. There are three kinds of methods that develop a HMI application in PC based system. Using commercial package such as intouch or citect SCADA tools. Using GUI programming tool and commercial component Using GUI programming tool We proposed the second approach that uses GUI programming tool and graphic handling component. Instrumentation controller application. The elements of HMI in instrumentation application consist of mainly the data display items and the trend graphs to display micro data in real-time. We could develop the application using the development tool such as visual studio .NET except for trend graph display. The graphic display component provided developers advanced charting features with minimal integration efforts. This feature allowed developers to focus their attention on the functional aspect of the application rather than visuals or other platform specific issues.

systems. The server is connected to intranet so that many users can access data and monitor graph through web browser in all plant area.

Fig. 5 System Architecture of QIDIS.

4. QUALITY INSTRUMENTATION DATA INTEGRATED SYSTEM (QIDIS)

4.1 System Architecture
Operators in our plants want to inquire directly of the data for quality information and know from the information whether there are problems in products. They also want to access the information at all areas in the plant (operator room, office) and improve product quality using various analytic tools such as statistics, OLAP and data mining. The server stores all data that received from controllers and the related control

The basic architecture of QIDIS is depicted in Fig. 5. QIDIS consists of DB server, application server and web server but we have constructed in a single server because we are in the test stage of prototype system. It has module structure to be expanded efficiently for a later time. It may be divided into three layers: presentation layer, application logic layer, data store. Presentation layer: This layer is responsible for the presentation of data, receiving user events and controlling the user interface. Users can access the server through we browser in their desktop. We developed web HMI using ASP.net and web form in .NET and established on IIS. As controller HMI to be explained in previous section, we also included the web form graphic display components. Application Logic Layer: This layer processes the data to be received and send results to other layers. This tier protects the data from direct access by the clients. It mainly includes inquiring the summary result, displaying trend graphs; display the result of statistics analysis. It was

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implemented using C# on .NET framework and other tools. Data Store: This layer is responsible for data storage. Besides the widespread relational database systems, existing legacy systems databases are often reused here.

display.

4.3 Web Server

In legacy instrumentation controller, we had stored micro data to each controllers storage and let them be maintained by each system. As quality management gets more important and user need to do complex data analysis such as statistical analysis, user have wanted micro data to be integrated to one system and analysed in there. We have built up a web server that support quality analysis using simple product and data inquiry and trend data graph The functions of web server are as follow: QIDIS introduction * System Information, configuration and function Basic Information Inquiry * Inquiring into product setup and result information Trend Data Inquiry * Making graph of micro instrumentation data such as temperature, XRD. Trend Data Basic Statistics Inquiry * Making graph of micro instrumentation data and displaying basic statistic information. Summary Data Statistic Information Inquiry * Displaying daily/weekly/monthly summary data using control chart

4.2 Data Store

Data store consists of product setup data, product result data, micro summary data, and micro data files extra data. Product Setup Data Table: Record data such as coil id, target thickness and width, speed is stored on per a coil. Product Results Table: Record data such as coil id, final average thickness and width, average temperature is stored on per a coil. Micro Data Summary Table : Micro Data Files: It stores micro data to be acquired by instrumentation controller in time period rates. The files are created in text type such CSV format. Etc: this is used in server .for internal information handling.

4.3 Data Storing Flow

Whenever the processing of a coil is completed, web server receives micro data from instrumentation controller. The data file is stored in buffer through socket of TCP/IP. The server calculates the representative values from the data and stores it to micro data summary table. The micro data files are classified by date and named with coil id. They are mainly used in trend graph

4.4 Web based HMI

Trend graph on temperature micro data received from controller is depicted in Fig 7. First, the coil id was selected and the item to be shown among more 50 items was selected. User could detect abnormal temperature condition and compare the relation between graph data and product quality. User could also display graph with basic statistics information. Control chart on temperature summary data is depicted in Fig 8. Making a control chart of summary data let us monitor abnormal data to be

Fig.6 Data Storing Flow in QIDIS

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5. Conclusion
This paper proposed the integrated system aimed at standardizing the system architecture and the design methods on quality instrumentation of coil rolling mill at steel works. We proposed the H/W specification, standard I/O library and common components. An evaluation study showed the time of quality analysis in QIDIS system could be reduced and the information to be supported in the new system was more enough than legacy system. Based on the test result, we will extend the analytic functions and adapt the system to cold rolling mill in near future.

Fig. 7 Trend graph Display on Micro Data.

REFERENCES
(1) Szyperski, Clemens/ Gruntz, Dominik/ Murer, Stephan( ) Component Software:Beyond Object-Oriented Programming, Addison-Wesley (2) Esposito, Dino (2002) : Building Web Solutions With Asp.Net and Ado.Net, Microsoft Press

Fig. 8 Control Chart Example

generated in some product easily. As investigating the cause of abnormal data in detail, we could understand the relation of production and the cause of abnormality. As comparing graphs in top and bottom simultaneously, user could investigate the relation of the variables in top and bottom and add statistical relational analysis.

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