Roll system configuration optimization method of 20-roll mill

Abstract

The invention relates to a roll system configuration optimization method of a 20-roll mill, which relates to the field of structural design and performance analysis of integral 20-roll mills, and comprises the following steps of: 1, determining specific parameters of a process and equipment; 2, the number of rolling procedures is set according to the original thickness and the target finished product thickness; 3, calculating and distributing the initial thickness, tension and speed; determining distribution of initial tension; determining the initial setting of the maximum rolling speed; 4, an objective function is set, and the optimal number of rolling procedures and the optimal distribution of the thickness and tension of each pass are sought; 5, according to the performance limit, the maximum rolling speed is determined, and mechanical and energy parameters are calculated; setting a rolling speed; calculating the maximum tension of the uncoiling machine and the coiling machine, and calculating mechanical and energy parameters; and 6, the flow and the rolling speed of the emulsion are adjusted. The capacity of equipment is fully exerted, different rolling requirements are met, and the product quality and the production efficiency are effectively improved.

Description

Technical Field

[0001] The invention relates to the field of structural design and performance analysis of an integral 20-roller rolling mill, and in particular to a roll system configuration optimization method for a 20-roller rolling mill. Background Art

[0002] Since the 1940s, the integrated 20-roller rolling mill has been invented and applied in engineering practice overseas. After decades of continuous improvement and progress, the technology has become more mature.

[0003] At present, many enterprises often manufacture integrated 20-roll mills by mapping imported old equipment and drawings of unknown origin. Many companies and engineers fail to truly understand the original intention of the mill design and its inherent subtleties, making it difficult to manufacture high-performance, precision integrated 20-roll mills. Most products can only imitate its shape, but cannot touch its spirit, and can only obtain short-term benefits.

[0004] Although some research institutions and design institutes have solved some technical problems through long-term research, due to the late start, there is still a lack of sufficient practical experience as a basis for the selection and setting of key parameters. Some companies that imitate such equipment have to rely on cumbersome CAD drawings to actually measure the position relationship of the roll gap during the drawing process, which is not only risky but also labor-intensive. Due to the failure to fully understand the deep principles of the design structure of the integral 20-roll mill, innovative development is naturally out of the question. Summary of the invention

[0005] The purpose of the present invention is to provide a method for optimizing the roll configuration of a 20-roll mill so as to reduce risks, reduce workload, give full play to the capabilities of the equipment, and effectively improve product quality and production efficiency.

[0006] In order to achieve the above object, the technical solution of the present invention provides a method for optimizing the roll configuration of a 20-high rolling mill, comprising the following steps:

[0007] Step 1: Collect and determine the specific parameters of the process and equipment;

[0008] Step 2: Set the initial number of rolling processes based on the original thickness of the raw material and the target finished product thickness;

[0009] Step 3: Calculate and allocate the initial thickness, tension and speed for each pass; determine the allocation of initial tension based on the deformation resistance of the steel strip and the load-bearing capacity of the uncoiling / reeling equipment; determine the initial setting of the maximum rolling speed based on the load-bearing capacity of the rolling mill and the uncoiling / reeling equipment;

[0010] Step 4: Establish an objective function with necessary constraints and use mathematical optimization methods to find the optimal number of rolling processes and the optimal distribution of thickness and tension of each pass;

[0011] Step 5: Determine the maximum rolling speed of each process according to the performance limit of the equipment, and calculate the corresponding mechanical and energy parameters; set the rolling speed of each pass according to the rated power of the main motor of the rolling mill; calculate the maximum tension of the uncoiler and coiler to determine the tension distribution of each pass, and calculate the corresponding mechanical and energy parameters;

[0012] Step 6: Adjust the emulsion flow rate and rolling speed to ensure that the temperature of the steel strip during each rolling process and the temperature during final coiling meet the process standards.

[0013] Preferably, in step 1, the process parameters include two parts: strip steel characteristics and cooling conditions:

[0014] Strip steel characteristic parameters include steel material type, strip steel width, initial thickness of raw material and final product thickness, weight, initial temperature and inner diameter of strip coil;

[0015] The cooling condition parameters include the concentration and temperature of the emulsion and the temperature of the surrounding environment.

[0016] Preferably, the device parameters are divided into three parts:

[0017] Parameters of the uncoiler, including its rated power, basic speed of the motor, efficiency of the transmission system, maximum speed that can be achieved, and transmission ratio;

[0018] The parameters of the rolling mill include the diameter of the working roll, the maximum rolling speed, the maximum rolling force, the rated power of the motor, the basic speed of the motor, the maximum speed of the motor, the transmission ratio, the transmission efficiency, and the acceleration and deceleration capabilities;

[0019] The parameters of the coiler include rated power, basic speed of the motor, transmission efficiency, maximum speed and transmission ratio.

[0020] Preferably, in step 6, in the first three passes of the rolling process, a preset maximum rolling speed and a lower emulsion flow rate are used to ensure that the strip reaches a specified process temperature range.

[0021] Preferably, in step 6, the strip temperature of the third pass should be controlled between 200°C and 230°C; then, in the fourth pass and subsequent rolling processes, the strip temperature is reduced by increasing the emulsion flow rate to ensure that after the last rolling pass, the coiling temperature of the strip is maintained in the range of 50°C to 70°C; if the expected coiling temperature range cannot be achieved even with the maximum emulsion flow rate, then consideration should be given to reducing the rolling speed of the last pass to meet the temperature requirements.

[0022] In summary, the present invention includes the following beneficial technical effects:

[0023] By flexibly constructing different objective functions and using the most optimized mathematical method to automatically obtain the best rolling schedule, it does not rely on manual experience, can give full play to the capabilities of the equipment, meet different rolling needs, and effectively improve product quality and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 The mechanical structure of the roll system configuration optimization method of a 20-roller rolling mill of the present invention is simplified. Figure 1 ;

[0025] Figure 2 The mechanical structure of the roll system configuration optimization method of a 20-roller rolling mill of the present invention is briefly described. Figure 2 ;

[0026] Figure 3 This is a force analysis diagram of the roll system in a roll system configuration optimization method for a 20-roller rolling mill according to the present invention. DETAILED DESCRIPTION

[0027] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] Embodiment 1:

[0029] The embodiment of the present invention discloses a method for optimizing the roll configuration of a 20-roll mill, which comprises the following steps:

[0030] Step 1: Collect and determine the specific parameters of the process and equipment;

[0031] Step 2: Set the initial number of rolling processes based on the original thickness of the raw material and the target finished product thickness;

[0032] Step 3: Calculate and allocate the initial thickness, tension and speed for each pass; determine the allocation of initial tension based on the deformation resistance of the steel strip and the load-bearing capacity of the uncoiling / reeling equipment; determine the initial setting of the maximum rolling speed based on the load-bearing capacity of the rolling mill and the uncoiling / reeling equipment;

[0033] Step 4: Establish an objective function with necessary constraints and use mathematical optimization methods to find the optimal number of rolling processes and the optimal distribution of thickness and tension of each pass;

[0034] Step 5: Determine the maximum rolling speed of each process according to the performance limit of the equipment, and calculate the corresponding mechanical and energy parameters; set the rolling speed of each pass according to the rated power of the main motor of the rolling mill; calculate the maximum tension of the uncoiler and coiler to determine the tension distribution of each pass, and calculate the corresponding mechanical and energy parameters;

[0035] Step 6: Adjust the emulsion flow rate and rolling speed to ensure that the temperature of the steel strip during each rolling process and the temperature during final coiling meet the process standards.

[0036] Embodiment 2:

[0037] This embodiment is a further limitation based on Embodiment 1.

[0038] In step 1, the process parameters involved include two parts: strip characteristics and cooling conditions:

[0039] Strip steel characteristic parameters include steel material type, strip steel width, initial thickness of raw materials and final thickness of finished products, weight, initial temperature and inner diameter of the coil;

[0040] The cooling condition parameters include the concentration and temperature of the emulsion and the temperature of the surrounding environment.

[0041] At the same time, the detailed description of the device parameters is also divided into three parts:

[0042] Parameters of the uncoiler, including its rated power, basic speed of the motor, efficiency of the transmission system, maximum speed that can be achieved, and transmission ratio;

[0043] The parameters of the rolling mill include the diameter of the working roll, the maximum rolling speed, the maximum rolling force, the rated power of the motor, the basic speed of the motor, the maximum speed of the motor, the transmission ratio, the transmission efficiency, and the acceleration and deceleration capabilities;

[0044] The parameters of the coiler include its rated power, basic speed of the motor, transmission efficiency, maximum speed and transmission ratio.

[0045] Step 2 includes sub-steps: determining target thickness, evaluating raw material thickness, calculating thickness difference, and preliminarily estimating the number of passes.

[0046] Specifically, first clarify the thickness requirements of the finished steel strip and understand the initial thickness of the raw steel strip, calculate the difference between the raw steel strip thickness and the target finished product thickness, and study the minimum and maximum thickness change capabilities of the rolling mill, that is, the thickness reduction that can be achieved in each pass. Based on the thickness difference and the thickness reduction capacity of each pass, a preliminary estimate of the number of rolling passes required is made; this can be obtained through simple division operations. For example, if the raw material thickness is 5 mm, the target thickness is 1 mm, and the thickness can be reduced by 0.5 mm per pass, the preliminary estimate of the number of passes is (5-1) / 0.5=8(5-1) / 0.5=8 times.

[0047] Based on the preliminary estimate, adjustments can be made according to the material flow, equipment load and product quality requirements in actual production to achieve the best rolling effect. In some cases, empirical formulas or mathematical models can be used to predict the required number of rolling passes. These models may be based on the mechanical properties of the material and the physical phenomena in the rolling process. Before actual production, the rationality of the number of rolling passes can be verified by computer simulation or small-scale experiments, and necessary adjustments can be made. Finally, data is collected during the production process to continuously optimize and improve the rolling process.

[0048] Step 3 includes sub-steps: collecting data, determining initial thickness distribution, calculating tension distribution, and determining rolling speed.

[0049] Specifically, first of all, you need to have an in-depth understanding of the rolling process, including the rolling principle, material deformation mechanism and the working characteristics of the equipment, and collect necessary data, including the original thickness, width, material properties (such as yield strength, tensile strength) of the raw steel strip, and the technical parameters of the rolling mill, uncoiler and coiler; based on the target finished product thickness and raw material thickness, calculate the thickness reduction of each pass, which usually requires considering the hardening characteristics of the material and the minimum thickness reduction capacity of the rolling mill; use the material mechanics model to estimate the tension required for each pass to overcome the deformation resistance of the material, consider the maximum tension bearing capacity of the uncoiler and coiler, and ensure that the tension distribution does not exceed the limit of the equipment; determine the maximum rolling speed of each pass based on the design parameters of the rolling mill and the motor power, and consider the influence of the plastic deformation and temperature change of the material on the rolling speed.

[0050] In addition, the calculated allocation scheme can be verified to be reasonable through computer simulation, and small-scale tests can be carried out in actual production to ensure the feasibility of the scheme. According to the simulation and test results, the allocation scheme can be adjusted and optimized as necessary to improve production efficiency and product quality. In the actual production process, rolling parameters such as thickness, tension and speed are monitored in real time and dynamically adjusted according to feedback information.

[0051] Step 4 includes sub-steps: defining the objective function, determining the design variables, collecting data, establishing constraints, establishing a mathematical model, selecting a suitable optimization algorithm, and performing numerical calculations.

[0052] Specifically, first determine the optimization goal, which can of course also be minimizing energy consumption, maximizing production efficiency, minimizing costs or ensuring product quality, etc.; design variables may include thickness, tension, speed, etc. of each pass, collect all relevant data, including material properties, equipment parameters, process requirements, etc., establish thickness constraints, tension constraints, speed constraints, and other process constraints; according to the design variables and constraints, establish a mathematical model, which can be a linear programming, nonlinear programming, integer programming or dynamic programming problem; select a suitable optimization algorithm according to the nature of the problem, such as gradient descent, genetic algorithm, simulated annealing algorithm, etc.

[0053] Among them, thickness constraint: the thickness change of each pass must be within the capacity of the rolling mill; tension constraint: the tension must be between the elastic limit of the material and the maximum load-bearing capacity of the equipment; speed constraint: the rolling speed cannot exceed the maximum safe speed of the equipment; other process constraints: such as temperature control, lubrication conditions, etc.

[0054] Step 5 includes sub-steps: collecting equipment specifications, determining maximum rolling speed, calculating mechanical parameters, calculating energy parameters, calculating tension, and distributing tension.

[0055] Specifically, collect equipment specifications: obtain detailed technical specifications of all relevant equipment, including the maximum speed, maximum torque, rated power, etc. of rolling mills, uncoilers, and coilers; determine the maximum rolling speed: determine the maximum rolling speed of each process based on the maximum speed limit of the rolling mill and the rated power of the main motor; calculate mechanical parameters: use the mechanical property data of the material, such as yield strength, tensile strength, and deformation during rolling to calculate the required rolling force; calculate energy parameters: combine rolling force and rolling speed to calculate the energy required for each process to ensure that it does not exceed the rated power of the main motor; calculate tension: calculate the maximum tension of the uncoiler and coiler based on the elastic modulus, yield strength and thickness of the material; distribute tension: distribute appropriate tension to each process based on the deformation characteristics of the material during rolling and the tension bearing capacity of the equipment.

[0056] In step 6, the detailed operation is as follows: In the first three passes of the rolling process, use the preset maximum rolling speed and a lower emulsion flow rate to ensure that the strip reaches the specified process temperature range. Specifically, the strip temperature in the third pass should be controlled between 200°C and 230°C. Subsequently, in the fourth and subsequent rolling processes, the strip temperature is reduced by increasing the emulsion flow rate to ensure that the coiling temperature of the strip is maintained in the range of 50°C to 70°C after the last rolling pass. If the expected coiling temperature range cannot be achieved even with the maximum emulsion flow rate, then consider reducing the rolling speed of the last pass to meet the temperature requirements.

[0057] Embodiment 3:

[0058] This embodiment is a further limitation based on Embodiment 1 or Embodiment 2.

[0059] This embodiment is a set of algorithms based on the structural design and optimization of the integral 20-roller rolling mill and data analysis, in order to provide a calculation tool for the mill engineering design and mill optimization and improvement. The specific contents are as follows:

[0060] Upper Idler Roll (upper idler roller) 4J (X4, Y4)

[0061]

[0062] UpperDriverRoll (upper drive roller) 3K (X3k, Y3k)

[0063]

[0064]

[0065] Upper1stIntermediateRoll (Upper intermediate roller) 5p (X5p, Y5p)

[0066]

[0067] Lower IdlerRoll (X9, Y9)

[0068]

[0069] LowerDriverRoll (lower idler roller) 3L (X3L, Y3L)

[0070]

[0071] Lower 1st Intermediate Roll (Lower first intermediate roller) 8Q (X8q, Y8q)

[0072]

[0073] Force Calculations

[0074] Calculation of force analysis

[0075]

[0076]

[0077] Hold-inForce(UpperIntermediates)(%)

[0078] Cohesion between the previous and the next center (%)

[0079]

[0080] Bearing Load (A&D) (%)

[0081] Bearing load (A&D) (%)

[0082]

[0083] Hold-in Force (Upper Driver) (%) The cohesive force between the upper drive rollers (%)

[0084]

[0085] Bearing Load (B&C) (%)

[0086] Bearing load (B&C) (%)

[0087]

[0088] Hold-inForce(LowerIntermediates)(%)

[0089] The cohesive force between the next middle (%)

[0090]

[0091] Bearing Load (E&H) (%)

[0092] Bearing load (E&H) (%)

[0093]

[0094] Hold-inForce(LowerDriver)(%)

[0095] Cohesion force between lower driving rollers (%)

[0096]

[0097] Bearing Load (F&G) (%)

[0098] Bearing load (F&G) (%)

[0099]

[0100] Since the integrated 20-roll cold rolling mill is the jewel of extremely high-end precision strip processing equipment, the key technical core of the design link is the roll system calculation and the force evaluation of each component. The roll system optimization algorithm of the 20-roll rolling mill in this embodiment provides key and rigorous technical support and theoretical basis for engineering designers, and also provides accurate data basis for solving problems that may arise during the manufacturing and operation of the rolling mill.

[0101] The roll matching optimization algorithm for the 20-roll rolling mill in this embodiment adopts an iterative calculation method, which takes the center point of the physical structure of the rolling mill as the reference, and connects the center points of the 20 rollers into one through layer-by-layer iteration using mathematical methods. When the external input parameters change, a complete set of data such as the roll gap, the mutual force between the rollers, and the bearing force inside the roll system can be quickly and accurately calculated.

[0102] The calculation algorithm of this embodiment is based on trigonometric functions and iterative algorithms, which are clear and easy for engineering and technical personnel to understand. At the same time, some key alarm thresholds are set in combination with the practical experience summarized by engineering and technical personnel over the years to help designers accurately grasp and select correct technical parameters.

[0103] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for optimizing the roll configuration of a 20-roll mill, characterized in that: The following steps are involved: Step 1: Collect and determine the specific parameters of the process and equipment; Step 2: Set the initial number of rolling processes based on the original thickness of the raw material and the target finished product thickness; Step 3: Calculate and distribute the initial thickness, tension and speed of each pass; determine the distribution of initial tension based on the deformation resistance of the steel strip and the load-bearing capacity of the unwinding / rewinding equipment; Determine the initial setting of the maximum rolling speed based on the load capacity of the rolling mill and the unwinding / coiling equipment; Step 4: Establish an objective function with necessary constraints and use mathematical optimization methods to find the optimal number of rolling processes and the optimal distribution of thickness and tension of each pass; Step 5: Determine the maximum rolling speed of each process according to the performance limit of the equipment, and calculate the corresponding mechanical and energy parameters; set the rolling speed of each pass according to the rated power of the main motor of the rolling mill; calculate the maximum tension of the uncoiler and coiler to determine the tension distribution of each pass, and calculate the corresponding mechanical and energy parameters; Step 6: Adjust the emulsion flow rate and rolling speed to ensure that the temperature of the steel strip during each rolling process and the temperature during final coiling meet the process standards.

2. The method for optimizing the roll configuration of a 20-high rolling mill according to claim 1, characterized in that: In step 1, the process parameters include two parts: strip characteristics and cooling conditions: Strip steel characteristic parameters include steel material type, strip steel width, initial thickness of raw material and final product thickness, weight, initial temperature and inner diameter of strip coil; The cooling condition parameters include the concentration and temperature of the emulsion and the temperature of the surrounding environment.

3. The method for optimizing the roll configuration of a 20-high rolling mill according to claim 1, characterized in that: The device parameters are divided into three parts: Parameters of the uncoiler, including its rated power, basic speed of the motor, efficiency of the transmission system, maximum speed that can be achieved, and transmission ratio; The parameters of the rolling mill include the diameter of the working roll, the maximum rolling speed, the maximum rolling force, the rated power of the motor, the basic speed of the motor, the maximum speed of the motor, the transmission ratio, the transmission efficiency, and the acceleration and deceleration capabilities; The parameters of the coiler include rated power, basic speed of the motor, transmission efficiency, maximum speed and transmission ratio.

4. The method for optimizing the roll configuration of a 20-high rolling mill according to claim 1, characterized in that: In step 6, during the first three passes of the rolling process, a preset maximum rolling speed and a lower emulsion flow rate are used to ensure that the strip reaches the specified process temperature range.

5. The method for optimizing the roll configuration of a 20-high rolling mill according to claim 1, characterized in that: In step 6, the strip temperature of the third pass should be controlled between 200°C and 230°C; then, in the fourth pass and subsequent rolling processes, the strip temperature is reduced by increasing the emulsion flow rate to ensure that the coiling temperature of the strip is maintained in the range of 50°C to 70°C after the last rolling pass; if the expected coiling temperature range cannot be achieved even with the maximum emulsion flow rate, then the rolling speed of the last pass should be reduced to meet the temperature requirements.

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