Rod and wire rolling force measuring method and device based on energy flow

Abstract

The invention relates to a rod and wire rolling force measuring method and device based on energy flow, and the method comprises the following steps: building a test platform which is used for obtaining the motor torque and rolling force of a rolling mill; based on the energy flow of the rolling mill, a rolling force calculation model containing the undetermined parameter force arm coefficient and the friction coefficient is established; recording motor torque and rolling force under different rolling pressing amounts when the rolling mill rolls the preset material to obtain a plurality of groups of motor torque and rolling force data; and a plurality of groups of motor torque and rolling force data are respectively imported into the rolling force calculation model, a group of force arm coefficients and friction coefficients are exported, and average values of the force arm coefficients and the friction coefficients are respectively solved. Compared with a direct measurement method, the method can be implemented on any rod and wire rolling equipment, after the moment arm coefficient and the friction coefficient of rolling related materials are determined, the structure of old equipment does not need to be transformed, only the torque of the motor needs to be detected, the rolling force can be obtained in real time, and the application scene has universality.

Description

Technical Field

[0001] The invention relates to the technical field of bar and wire rolling, and in particular to a bar and wire rolling force measurement method and device based on energy flow. Background Art

[0002] Rod and wire rolling is of great significance in industry and society. It is one of the indispensable core processes in modern manufacturing and is widely used in construction, machinery manufacturing, automobile industry, power transmission and daily life. With the development of society and the improvement of scientific and technological levels, the demand for output and quality of rod and wire rolling products are growing.

[0003] During the rolling process, the choice of rolling force will significantly affect the quality of the rolled product. If the rolling force is too small, the surface quality of the rolled product will be poor and the deformation will be uneven. If the rolling force is too large, the production of rolling waste will increase, and additional energy and material consumption will increase, and even the rolled product will be damaged. Determining the rolling force during the rolling process has a positive effect on improving product quality, production efficiency and energy saving. However, most companies' rolling equipment currently lacks a device to measure the rolling force, and the rolling force cannot be directly obtained. The parameter setting of the rolling process needs to be determined by trial and error or empirical methods, resulting in low efficiency and uneven quality of the rolled products.

[0004] The current methods for determining the rolling force of rolling equipment are:

[0005] (1) Direct measurement method: Pressure sensors are placed at three locations: the hydraulic positioner, the lower support bearing seat, and between the frame base and the press-down nut. Existing dedicated measurement systems include rolling force measurement systems provided by ABB and KELK. This measurement method is generally used in the design and manufacture of new rolling equipment. The structure of the bar and wire rolling equipment that has been put into production is difficult to modify and install, and it is impossible to arrange a measurement system.

[0006] (2) Rolling force prediction model: The traditional rolling force prediction model adopts a certain simplified method, assuming the stress and deformation state of the rolling part, and calculates the rolling force required for rolling through material theory and key parameters obtained by relevant sensors. When using this method, some parameters are difficult to obtain, and the calculated rolling force deviates from the actual one. Nowadays, a data-driven method is used to predict the rolling force using a neural network model, but the training process of the neural network requires obtaining the measured rolling force. Therefore, the rolling force prediction model is difficult to solve the problem of the difficulty in obtaining the actual rolling force.

[0007] The general methods of steel rolling equipment are difficult to apply in bar and wire rolling equipment. For example, the Chinese invention patent with application number 202410707047.5 discloses a method and device for determining rolling force. This method can determine the rolling force during the dynamic rolling process of the rolled piece from thin to thick. However, like the traditional rolling force prediction model, the relevant parameters of this method are difficult to obtain, and the device description in the patent is difficult to install and implement. Patents with application numbers 201910058743.7 and 201610487049.3 disclose methods for modeling the power of continuous rolling production lines based on energy flow models to achieve energy consumption evaluation and energy-saving optimization. The Chinese invention patent with application number CN111250544B discloses a method for predicting the power consumption of a pickling rolling combined unit based on a cold rolling mathematical model, and establishes a rolling torque calculation model, but the rolling force acquisition method is not described. The Chinese invention patent with application number CN111250544B discloses a method for predicting the power consumption of a pickling rolling combined unit based on a cold rolling mathematical model. The rolling force calculation model established is for plate rolling and is a material theory calculation method. According to existing literature and patents, there is currently no method or device that uses the idea of ​​energy flow to determine the rolling force of bars and wires. Summary of the invention

[0008] The technical problem to be solved by the present invention is to provide a method and device for measuring the rolling force of a bar or wire based on energy flow in view of the above shortcomings.

[0009] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0010] A method for measuring rolling force of a bar or wire rod based on energy flow comprises the following steps:

[0011] Build an experimental platform to obtain the motor torque and rolling force of the rolling mill;

[0012] Based on the energy flow of the rolling mill, a rolling force calculation model with unknown parameters, namely, the arm coefficient and the friction coefficient, is established.

[0013] Record the motor torque and rolling force of the rolling mill at different rolling pressures when the rolling mill is rolling a preset material, and obtain several sets of motor torque and rolling force data;

[0014] Importing several groups of motor torque and rolling force data into the rolling force calculation model, deriving a group of arm coefficients and friction coefficients, and calculating the average values ​​of the arm coefficients and friction coefficients, respectively, to obtain the arm coefficients and friction coefficients when rolling the preset materials;

[0015] Applying the force arm coefficient and the friction coefficient when rolling the preset material to the rolling force calculation model to obtain the rolling force calculation model for calculating the rolling of the preset material;

[0016] When rolling a preset material, the motor torque is introduced into a rolling force calculation model used to calculate the rolling force when rolling the preset material, and the real-time rolling force can be output.

[0017] Furthermore, establishing a rolling force calculation model including the undetermined parameters of the force arm coefficient and the friction coefficient includes the following steps:

[0018] It is determined that the energy source of the rolling mill is provided by the motor. The energy input by the motor is consumed by the work done by the rolling force and the thermal work at each support of the roller shaft. The power calculation formula is obtained:

[0019] P M =P Z +P fb

[0020] Where P M is the output power of the motor, P Z is the power consumption of the vertical downward rolling of the working roll, P fb The heat consumption power of all bearings on the roller shaft of the working roll;

[0021] According to the calculation formula of the motor output power, the calculation formula of the vertical downward rolling power consumption and the calculation formula of the bearing heat consumption power, the undetermined parameters of the power calculation formula including the arm coefficient and the friction coefficient are determined to obtain the rolling force calculation model.

[0022] Furthermore, the output power P of the motor M The calculation formula is:

[0023]

[0024] Where M m is the motor torque, n is the speed;

[0025] Power consumption P of vertical downward rolling of working rolls Z The calculation formula is:

[0026]

[0027] Where M P is the vertical downward rolling torque; M P The calculation formula is:

[0028]

[0029] Where P is the rolling force, R is the radius of the working roll, β is the angle between the rolling pressure point and the center line of the roll axis, ψ is the force arm coefficient, and Δh is the thickness difference before and after rolling.

[0030] Heat consumption power P of all bearings on the roll shaft of the working roll fb The calculation formula is:

[0031]

[0032] In the formula, F fi is the support force of the ith bearing, μ i is the friction coefficient of the ith bearing, r i is the roller radius at the i-th bearing; the function of converting the supporting force into the rolling force P is F fi =f i (P);

[0033] According to the above formula, the rolling force calculation model can be obtained:

[0034]

[0035] Among them, the friction coefficient μ i and the lever arm coefficient ψ are unknown parameters.

[0036] Furthermore, the bearings used to support the working rolls include oil film bearings and rolling bearings, and the friction coefficient includes the oil film bearing friction coefficient μ 油膜 and rolling bearing friction coefficient μ 滚动 ;

[0037] Friction coefficient of oil film bearing μ 油膜 The calculation formula is:

[0038]

[0039] Where η is the dynamic viscosity of the lubricating oil, is the relative clearance of the oil film bearing, ξ is the correlation coefficient of the aspect ratio of the oil film bearing, when B / d<1, When B / d≥1, ξ=1, B and d are the width and inner diameter of the oil film bearing respectively; P m is the average pressure of the oil film bearing, P m The calculation formula is

[0040] According to the above formula, the calculation model of rolling force is further obtained:

[0041]

[0042] Among them, the rolling bearing friction coefficient μ 滚动 and the lever arm coefficient ψ are unknown parameters.

[0043] Furthermore, the force arm coefficient ψ is approximately calculated using the following formula:

[0044]

[0045] Furthermore, the modified adjustment coefficient λ is introduced to obtain the actual value calculation formula of the lever arm coefficient ψ:

[0046]

[0047] According to the above formula, the calculation model of rolling force is further obtained:

[0048]

[0049] Among them, the rolling bearing friction coefficient μ 滚动 and adjustment coefficient λ are unknown parameters.

[0050] A bar and wire rolling force measuring device based on energy flow, including a torque sensor, a pressure sensor, an acquisition card and a host computer.

[0051] The torque sensor is used to detect the motor torque of the rolling mill.

[0052] The pressure sensor is used to detect the rolling force of the rolling mill.

[0053] The acquisition card is used to collect the detection data of the torque sensor and the pressure sensor, and transmit the data to the host computer.

[0054] Furthermore, it also includes a rotation speed sensor, which is used to detect the motor rotation speed of the rolling mill.

[0055] After adopting the above technical solution, the present invention has the following advantages compared with the prior art:

[0056] (1) Compared with the direct measurement method, the present invention can be implemented on any bar and wire rolling equipment. After determining the arm coefficient and friction coefficient of the rolling-related materials, there is no need to modify the structure of the old equipment. The rolling force can be obtained in real time by simply detecting the torque of the motor. The application scenario is universal.

[0057] (2) Compared with the existing prediction models, the present invention requires fewer key parameters. It only needs to determine the force arm coefficient and friction coefficient of the rolling equipment when rolling the relevant materials. The above parameters can be obtained through the test device of the present application, which has strong feasibility;

[0058] (3) The measuring method of the present invention can be used to obtain the rolling force during the rolling process, which can provide a basis for adjusting the process parameters to improve the rolling efficiency, reduce the generation of waste, and ensure the rolling quality.

[0059] The present invention is described in detail below with reference to the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 It is a schematic diagram of the measuring method of the present invention;

[0061] Figure 2 It is the force analysis diagram of the rolling process;

[0062] Figure 3 This is a diagram of the measuring device of the present invention.

[0063] In the accompanying drawings, the components represented by the reference numerals are listed as follows:

[0064] 1. Torque sensor; 2. Pressure sensor; 3. Acquisition card; 4. Host computer; 5. Motor; 6. Working roller; 61. Oil film bearing; 62. Rolling bearing; 7. Press-down balancing device. DETAILED DESCRIPTION

[0065] The principles and features of the present invention are described below in conjunction with the accompanying drawings. The examples given are only used to explain the present invention and are not used to limit the scope of the present invention.

[0066] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", "clockwise" and "counterclockwise" etc. indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.

[0067] like Figure 1 As shown, a method for measuring rolling force of a bar or wire rod based on energy flow comprises the following steps:

[0068] (1) Design of experimental platform:

[0069] Based on the working roll part of the existing rolling mill equipment, a torque sensor is arranged between the output shaft of the motor and the rotating shaft of the working roll, and the torque sensor is used to detect the motor torque. A pressure balancing device and a pressure sensor are arranged on the working roll, and the pressure sensor is used to detect the rolling force.

[0070] (2) Establishing rolling force calculation model:

[0071] Based on the energy flow concept, the friction coefficient μ of rolling bearing with unknown parameters is established. 滚动 The rolling force calculation model of the friction coefficient with adjustment coefficient λ is obtained in the following steps:

[0072] It is determined that the energy source of the rolling mill is provided by the motor, and the energy input by the motor is consumed by the work done by the rolling force and the thermal work of each support of the roller shaft, and the energy supply and consumption are equal at any time, and the power calculation formula is obtained:

[0073] P M =P Z+P fb

[0074] Where P M is the output power of the motor, P Z is the power consumption of the vertical downward rolling of the working roll, P fb The heat consumption power of all bearings on the roller shaft of the working roll;

[0075] Motor output power P M The calculation formula is:

[0076]

[0077] Where M m is the motor torque, n is the speed, the motor torque is obtained by the torque sensor installed on the motor output end (i.e. the output shaft of the motor), and the speed is obtained by the speed sensor installed on the motor output end;

[0078] P Z The power consumption of vertical downward rolling of the working rolls is P, which includes the pressure from the contact point to the axis of the bar and wire and the friction between the working rolls and the bar and wire at the contact point. Z The calculation formula is:

[0079]

[0080] Where M P is the vertical downward rolling torque; M P The calculation formula is:

[0081]

[0082] Where P is the rolling force, R is the radius of the working roll, β is the angle between the rolling pressure point and the line connecting the roll axis center, ψ is the force arm coefficient, and Δh is the thickness difference before and after rolling (h1-h2);

[0083] P fb The heat power consumed by the supporting bearings. The working rolls are generally supported by oil film bearings and rolling bearings. The heat power consumed by all bearings on the roll shaft of the working roll is P fb The calculation formula is:

[0084]

[0085] In the formula, F fi is the support force of the ith bearing, μ i is the friction coefficient of the ith bearing, r i is the roller radius at the i-th bearing; the function of converting the supporting force into the rolling force P is F fi =fi (P);

[0086] Friction coefficient of oil film bearing μ 油膜 The calculation formula is:

[0087]

[0088] Where η is the dynamic viscosity of the lubricating oil, is the relative clearance of the oil film bearing, ξ is the correlation coefficient of the aspect ratio of the oil film bearing, when B / d<1, When B / d≥1, ξ=1, B and d are the width and inner diameter of the oil film bearing respectively; P m is the average pressure of the oil film bearing, P m The calculation formula is

[0089] According to the above formula, the calculation model of rolling force is further obtained:

[0090]

[0091] In the above rolling force calculation model, most parameters can be obtained through measurement and selection, while the arm coefficient ψ and the friction factor μ of the rolling bearing are 滚动 It cannot be measured directly, so the arm coefficient ψ is approximately calculated using the following formula:

[0092]

[0093] Introducing the modified adjustment coefficient λ, the actual value calculation formula of the lever arm coefficient ψ is obtained:

[0094]

[0095] Finally, the calculation model of rolling force is obtained:

[0096]

[0097] The final rolling force calculation model only needs to obtain the arm coefficient ψ of the rolling mill (that is, to determine the above adjustment coefficient λ) and the friction factor μ of the rolling bearing. 滚动 , the calculation model of rolling force can be determined.

[0098] (3) Conduct tests on the test platform to determine the parameters:

[0099] Determine the rolling material, and carry out multiple rolling by cooperating with the rolling mill and the test platform. The reduction amount (i.e., the thickness difference Δh before and after rolling) of each rolling is different. Read the pressure value of the pressure sensor (i.e., the rolling force P) and the torque value of the torque sensor (i.e., the motor torque M m), to obtain multiple sets of pressure values ​​and torque values, import the multiple sets of pressure value and torque value data into the rolling force calculation model, and solve multiple sets of adjustment coefficients λ and rolling bearing friction factors μ 滚动 And take the average value to obtain the average value of the adjustment coefficient and the average value of the friction factor of the rolling bearing.

[0100] (4) Determine the calculation model when rolling the same material:

[0101] The average value of the adjustment coefficient and the average value of the friction factor of the rolling bearing are substituted into the rolling force calculation model to determine the rolling force calculation model when rolling the material.

[0102] (5) Apply the calculation model to the production line equipment to calculate the rolling force:

[0103] A torque sensor is installed at the motor output end of the rolling mill equipment on the production line. During rolling, the motor torque is input into the rolling force calculation model to obtain the real-time rolling force.

[0104] In summary, the above calculation model is designed based on the energy flow of the rolling equipment. After the pending parameters are determined, it can be put into use in the rolling production line. During use, it is only necessary to detect the motor torque to derive the rolling force data. After obtaining the rolling force data, it is convenient to adjust the rolling force according to the rolling process, thereby optimizing the process and reducing the production of defective rolling products.

[0105] like Figure 2 Shown is the force analysis during the rolling process (specifically, a cross-sectional view at two working rolls).

[0106] The design of the test platform needs to consider the acquisition of rolling force and motor drive torque. The pressure sensor is installed in the pressure balance device to obtain the rolling force in real time. The sensor data is read by the host computer through the acquisition card. By simulating the rolling process on the test platform, the rolling force and drive motor torque corresponding to different rolling pressures Δh are recorded, and a set of force arm adjustment coefficients λ and rolling bearing friction coefficients μ are obtained by substituting them into the rolling force calculation model. 滚动 , and take the average of the same group of data as the final coefficient value to determine the rolling force calculation model. In the actual rolling production process of bars and wires of the same specifications, it is only necessary to collect the real-time driving torque of the motor and input the corresponding rolling force calculation model to obtain the real-time rolling force.

[0107] like Figure 3 As shown, a bar and wire rolling force measuring device based on energy flow includes a torque sensor 1, a pressure sensor 2, an acquisition card 3 and a host computer 4.

[0108] The rolling mill includes a motor 5, a working roll 6 and a pressing balance device 7. The output end of the motor 5 is connected to the working roll 6 through a torque sensor 1. The torque sensor 1 is used to detect the motor torque.

[0109] An oil film bearing 61 and a rolling bearing 62 are provided on the roll shaft of the working roll 6. The working roll is supported by two sets of oil film bearings and one set of rolling bearings. The output end of the pressing balance device 6 is connected to the working roll 6. The pressure sensor 2 is provided on the pressing balance device 6. The pressure sensor 2 is used to detect the pressure (i.e., rolling force) output by the pressing balance device 6.

[0110] The torque sensor 1 and the pressure sensor 2 are both electrically connected to the acquisition card 3 , and the acquisition card 3 is used to collect detection data of the torque sensor 1 and the pressure sensor 2 , and transmit the detection data to the host computer 4 .

[0111] The speed data of the motor 5 / working roll 6 can generally be obtained on the industrial control panel of the rolling mill. If rolling cannot provide the speed data, it is necessary to add a speed sensor at the output end of the motor 5 to obtain the speed data of the motor 5 / working roll 6.

[0112] The above is an example of the best implementation of the present invention, and the parts not described in detail are common knowledge of ordinary technicians in the field. The protection scope of the present invention shall be based on the content of the claims, and any equivalent transformation based on the technical enlightenment of the present invention is also within the protection scope of the present invention.

Claims

1. A method for measuring rolling force of bars and wires based on energy flow, characterized in that: The following steps are involved: Build an experimental platform to obtain the motor torque and rolling force of the rolling mill; Based on the energy flow of the rolling mill, a rolling force calculation model with unknown parameters, namely, the arm coefficient and the friction coefficient, is established. Record the motor torque and rolling force of the rolling mill at different rolling pressures when the rolling mill is rolling a preset material, and obtain several sets of motor torque and rolling force data; Importing several groups of motor torque and rolling force data into the rolling force calculation model, deriving a group of arm coefficients and friction coefficients, and calculating the average values ​​of the arm coefficients and friction coefficients, respectively, to obtain the arm coefficients and friction coefficients when rolling the preset materials; Applying the force arm coefficient and the friction coefficient when rolling the preset material to the rolling force calculation model to obtain the rolling force calculation model for calculating the rolling of the preset material; When rolling a preset material, the motor torque is introduced into a rolling force calculation model used to calculate the rolling force when rolling the preset material, and the real-time rolling force can be output.

2. The method for measuring rolling force of bars and wires based on energy flow according to claim 1, characterized in that: The establishment of a rolling force calculation model with unknown parameters of the force arm coefficient and friction coefficient includes the following steps: It is determined that the energy source of the rolling mill is provided by the motor. The energy input by the motor is consumed by the work done by the rolling force and the thermal work at each support of the roller shaft. The power calculation formula is obtained: P M =P Z +P fb Where P M is the output power of the motor, P Z is the power consumption of the vertical downward rolling of the working roll, P fb The heat consumption power of all bearings on the roller shaft of the working roll; According to the calculation formula of the motor output power, the calculation formula of the vertical downward rolling power consumption and the calculation formula of the bearing heat consumption power, the undetermined parameters of the power calculation formula including the arm coefficient and the friction coefficient are determined to obtain the rolling force calculation model.

3. The method for measuring rolling force of bars and wires based on energy flow according to claim 2, characterized in that: Motor output power P M The calculation formula is: Where M m is the motor torque, n is the speed; Power consumption P of vertical downward rolling of working rolls Z The calculation formula is: Where M P is the vertical downward rolling torque; M P The calculation formula is: Where P is the rolling force, R is the radius of the working roll, β is the angle between the rolling pressure point and the center line of the roll axis, ψ is the force arm coefficient, and Δh is the thickness difference before and after rolling. Heat consumption power P of all bearings on the roll shaft of the working roll fb The calculation formula is: In the formula, F fi is the support force of the ith bearing, μ i is the friction coefficient of the ith bearing, r i is the roller radius at the i-th bearing; the function of converting the supporting force into the rolling force P is F fi =f i (P); According to the above formula, the rolling force calculation model can be obtained: Among them, the friction coefficient μ i and the lever arm coefficient ψ are unknown parameters.

4. The method for measuring rolling force of bars and wires based on energy flow according to claim 3, characterized in that: The bearings used to support the working rolls include oil film bearings and rolling bearings. The friction coefficient includes the oil film bearing friction coefficient μ 油膜 and rolling bearing friction coefficient μ 滚动 ; Friction coefficient of oil film bearing μ 油膜 The calculation formula is: Where η is the dynamic viscosity of the lubricating oil, is the relative clearance of the oil film bearing, ξ is the correlation coefficient of the aspect ratio of the oil film bearing, when B / d<1, When B / d≥1, ξ=1, B and d are the width and inner diameter of the oil film bearing respectively; P m is the average pressure of the oil film bearing, P m The calculation formula is According to the above formula, the calculation model of rolling force is further obtained: Among them, the rolling bearing friction coefficient μ 滚动 and the lever arm coefficient ψ are unknown parameters.

5. The method for measuring rolling force of bars and wires based on energy flow according to claim 4, characterized in that: The arm coefficient ψ is approximately calculated using the following formula: Furthermore, the modified adjustment coefficient λ is introduced to obtain the actual value calculation formula of the lever arm coefficient ψ: According to the above formula, the calculation model of rolling force is further obtained: Among them, the rolling bearing friction coefficient μ 滚动 and adjustment coefficient λ are unknown parameters.

6. A bar and wire rolling force measuring device based on energy flow, characterized in that: Including torque sensor, pressure sensor, acquisition card and host computer, The torque sensor is used to detect the motor torque of the rolling mill. The pressure sensor is used to detect the rolling force of the rolling mill. The acquisition card is used to collect the detection data of the torque sensor and the pressure sensor, and transmit the data to the host computer.

7. The method for measuring rolling force of bars and wires based on energy flow according to claim 6, characterized in that: It also includes a rotation speed sensor, which is used to detect the motor rotation speed of the rolling mill.

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