A method and apparatus for measuring the rolling force of bar and wire rods based on energy flow.

Abstract

This invention relates to a method and apparatus for measuring the rolling force of bar and wire rods based on energy flow. The method includes the following steps: constructing an experimental platform to acquire the motor torque and rolling force of the rolling mill; establishing a rolling force calculation model with undetermined parameters, such as the lever arm coefficient and friction coefficient, based on the energy flow of the rolling mill; recording the motor torque and rolling force under different rolling pressures when the rolling mill is rolling a preset material, obtaining several sets of motor torque and rolling force data; importing the several sets of motor torque and rolling force data into the rolling force calculation model respectively, deriving a set of lever arm coefficient and friction coefficient, and calculating the average value of the lever arm coefficient and friction coefficient respectively. Compared with direct measurement methods, this invention can be implemented on any bar and wire rod rolling equipment. After determining the lever arm coefficient and friction coefficient of the rolling-related material, there is no need to modify the structure of the old equipment; only the motor torque needs to be detected to obtain the rolling force in real time, making its application scenarios universal.

Description

Technical Field

[0001] This invention relates to the field of bar and wire rolling technology, specifically to a method and apparatus for measuring bar and wire rolling force based on energy flow. Background Technology

[0002] Bar and wire rod rolling plays a vital role in industry and society, serving as an indispensable core process in modern manufacturing. It is widely used in construction, machinery manufacturing, the automotive industry, power transmission, and daily life. With social development and advancements in science and technology, the demand for both the quantity and quality of rolled bar and wire rod products is continuously increasing.

[0003] During the rolling process, the choice of rolling force significantly affects the quality of the rolled product. Insufficient rolling force leads to poor surface quality and uneven deformation; excessive rolling force increases rolling scrap, energy and material consumption, and may even damage the rolled product. Determining the appropriate rolling force is crucial for improving product quality, production efficiency, and energy conservation. However, most companies currently lack devices to measure rolling force, making it impossible to directly obtain the rolling force. They must rely on trial and error or empirical methods to determine the rolling process parameters, resulting in low efficiency and inconsistent product quality.

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

[0005] (1) Direct measurement method: Pressure sensors are arranged at three positions: hydraulic positioner, lower support bearing seat, frame base and pressing 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 bar and wire rod rolling equipment that has been put into operation is difficult to modify and install, and it is impossible to arrange a measurement system.

[0006] (2) Rolling force prediction model: Traditional rolling force prediction models adopt certain simplification methods, assume the stress and deformation state of the rolling part, and calculate the rolling force required for rolling by combining material theory with 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 value. Nowadays, data-driven methods are used to predict rolling force using neural network models, but the training process of neural networks requires the acquisition of measured rolling force. Therefore, rolling force prediction models cannot solve the problem of the difficulty in obtaining the actual rolling force.

[0007] Methods commonly used in steel rolling mills are difficult to apply to bar and wire rod rolling mills. For example, Chinese invention patent application number 202410707047.5 discloses a method and apparatus for determining rolling force. This method can determine the rolling force during the dynamic rolling process from thin to thick, but like traditional rolling force prediction models, the relevant parameters are difficult to obtain, and the apparatus described in the patent is difficult to install and implement. Patents 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 assessment and energy-saving optimization. Chinese invention patent application number CN111250544B discloses a method for predicting the electrical energy consumption of a pickling and rolling mill unit based on a cold rolling mathematical model, establishing a rolling torque calculation model, but the method for obtaining the rolling force is not explained. Chinese invention patent application CN111250544B discloses a method for predicting the power consumption of a combined pickling and rolling mill based on a cold rolling mathematical model. The rolling force calculation model it establishes is for plate rolling and is based on materials theory calculation methods. According to existing literature and patents, there are currently no methods or devices that use the concept 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 bar and wire rods based on energy flow, in order to address the above-mentioned shortcomings.

[0009] To solve the above technical problems, the present invention adopts the following technical solution:

[0010] A method for measuring the rolling force of bar and wire rods based on energy flow includes the following steps:

[0011] An experimental platform was built 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 undetermined parameters such as lever arm coefficient and friction coefficient is established;

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

[0014] Several sets of motor torque and rolling force data are imported into the rolling force calculation model to derive a set of lever arm coefficients and friction coefficients. The average values ​​of the lever arm coefficients and friction coefficients are then calculated to obtain the lever arm coefficients and friction coefficients when rolling the preset material.

[0015] By applying the lever arm coefficient and friction coefficient when rolling the preset material to the rolling force calculation model, a rolling force calculation model for calculating the rolling force when rolling the preset material is obtained.

[0016] When rolling a preset material, the motor torque can be imported into the 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 undetermined parameters such as the lever arm coefficient and the friction coefficient includes the following steps:

[0018] The energy source of the rolling mill is determined to be provided by an electric motor. The energy input to the motor is consumed by the work done by the rolling force and the heat at each support of the roll shaft. The power calculation formula is obtained as follows:

[0019] P M =P Z +P fb

[0020] In the formula, P M P is the output power of the motor. Z P is the power consumed in vertical downward rolling of the work rolls. fb This refers to the heat dissipation power of all bearings on the work roll shaft;

[0021] Based on the formulas for calculating the output power of the motor, the power consumption of vertical downward rolling, and the heat consumption of the bearing, the parameters to be determined in the power calculation formula, including the lever arm coefficient and the friction coefficient, are used to obtain the rolling force calculation model.

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

[0023]

[0024] In the formula, M m n is the motor torque, and n is the speed.

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

[0026]

[0027] In the formula, M P M is the vertically downward rolling torque; P The calculation formula is:

[0028]

[0029] In the formula, P is the rolling force, R is the radius of the work roll, β is the angle between the rolling pressure application point and the line connecting the roll axis center, ψ is the lever arm coefficient, and Δh is the thickness difference before and after rolling.

[0030] The heat dissipation power P of all bearings on the work roll shaft fb The calculation formula is:

[0031]

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

[0033] Based on the above formula, the rolling force calculation model can be obtained:

[0034]

[0035] Wherein, the friction coefficient μ i The lever arm coefficient ψ is a parameter to be determined.

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

[0037] Oil film bearing friction coefficient μ 油膜 The calculation formula is:

[0038]

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

[0040] Based on the above formula, the calculation model for rolling force is further obtained:

[0041]

[0042] Among them, the friction coefficient μ of rolling bearings 滚动 The lever arm coefficient ψ is a parameter to be determined.

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

[0044]

[0045] Furthermore, by introducing a modified adjustment coefficient λ, we obtain the formula for calculating the actual value of the lever arm coefficient ψ:

[0046]

[0047] Based on the above formula, the calculation model for rolling force is further obtained:

[0048]

[0049] Among them, the friction coefficient μ of rolling bearings 滚动 The adjustment coefficient λ is a parameter to be determined.

[0050] A rod and wire rolling force measurement device based on energy flow includes a torque sensor, a pressure sensor, a data 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 data acquisition card is used to acquire detection data from the torque sensor and pressure sensor and transmit it to the host computer.

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

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

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

[0057] (2) Compared with existing prediction models, the present invention requires fewer key parameters. It only needs to determine the lever arm coefficient and friction coefficient of the rolling equipment when rolling related materials. Moreover, the above parameters can be obtained through the test device of this application, making it highly feasible.

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

[0059] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. Attached Figure Description

[0060] Figure 1 This is a schematic diagram of the measurement method of the present invention;

[0061] Figure 2 This is a stress analysis diagram of the rolling process;

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

[0063] The attached diagram lists the components represented by each number as follows:

[0064] 1. Torque sensor; 2. Pressure sensor; 3. Data acquisition card; 4. Host computer; 5. Motor; 6. Work roller; 61. Oil film bearing; 62. Rolling bearing; 7. Pressing balance device. Detailed Implementation

[0065] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0066] In the description of this invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", "clockwise" and "counterclockwise" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

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

[0068] (1) Design of experimental platform:

[0069] Based on the existing rolling mill equipment's work roll section, a torque sensor is installed between the motor's output shaft and the work roll's rotating shaft. The torque sensor is used to detect the motor torque. A pressure balancing device and a pressure sensor are installed on the work roll. The pressure sensor is used to detect the rolling force.

[0070] (2) Establish a rolling force calculation model:

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

[0072] The energy source of the rolling mill is determined to be provided by an electric motor. The energy input to the motor is consumed by the work done by the rolling force and the heat work at each support of the roll shaft. Given that the energy supply and consumption are equal at any given time, the power calculation formula can be obtained:

[0073] P M =P Z+P fb

[0074] In the formula, P M P is the output power of the motor. Z P is the power consumed in vertical downward rolling of the work rolls. fb This refers to the heat dissipation power of all bearings on the work roll shaft;

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

[0076]

[0077] In the formula, M m n is the motor torque, and n is the speed. The motor torque is obtained by a torque sensor installed on the motor output end (i.e., the motor output shaft), and the speed is obtained by a speed sensor installed on the motor output end.

[0078] P Z The power consumed by vertical downward rolling of the work rolls is P. The vertical downward rolling force includes the pressure from the contact point to the axis of the bar / wire and the frictional force between the work rolls and the bar / wire at the contact point. Z The calculation formula is:

[0079]

[0080] In the formula, M P M is the vertically downward rolling torque; P The calculation formula is:

[0081]

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

[0083] P fb To support the heat dissipation at the bearings, the work roll is generally supported by both oil film bearings and rolling bearings. The total heat dissipation power P of all bearings on the work roll shaft is... fb The calculation formula is:

[0084]

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

[0086] Oil film bearing friction coefficient μ 油膜 The calculation formula is:

[0087]

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

[0089] Based on the above formula, the calculation model for 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 lever arm coefficient ψ and the friction factor μ of the rolling bearing are relatively independent. 滚动 Since it cannot be directly measured, the lever arm coefficient ψ is approximated using the following formula:

[0092]

[0093] Introducing a corrected adjustment factor λ, we obtain the formula for calculating the actual value of the lever arm coefficient ψ:

[0094]

[0095] The final calculation model for rolling force is obtained as follows:

[0096]

[0097] The final rolling force calculation model only requires obtaining the mill lever arm coefficient ψ (i.e., determining the aforementioned adjustment coefficient λ) and the rolling bearing friction factor μ. 滚动 This allows us to determine the calculation model for the rolling force.

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

[0099] The material to be rolled is determined, and multiple rolling processes are performed using a rolling mill and a test platform, with each rolling process involving a different reduction (i.e., the thickness difference Δh before and after rolling). The pressure value from the pressure sensor (i.e., the rolling force P) and the torque value from the torque sensor (i.e., the motor torque M) are then read. mThis process yields multiple sets of pressure and torque values. These values ​​are then imported into the rolling force calculation model to solve for multiple adjustment coefficients λ and the friction factor μ of the rolling bearing. 滚动 The average values ​​are then taken 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] Substitute the average value of the adjustment coefficient and the average value of the friction factor of the rolling bearing into the rolling force calculation model to determine the rolling force calculation model when rolling this 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, based on the energy flow of the rolling mill, the above calculation model was designed. Once the parameters to be determined are established, it can be put into use on the rolling production line. During use, only the motor torque needs to be monitored to export 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 generation of defective rolled products.

[0105] like Figure 2 The figure shows the stress analysis during the rolling process (specifically, the cross-sectional view at the two work rolls).

[0106] The test platform design needs to consider the acquisition of rolling force and motor drive torque. Pressure sensors are installed in the reduction balancing device to acquire rolling force in real time. Sensor data is read by the host computer via a data acquisition card. By simulating the rolling process on the test platform, the rolling force and drive motor torque corresponding to different rolling reduction amounts Δh are recorded. These values ​​are then substituted into the rolling force calculation model to derive a set of lever arm adjustment coefficients λ and rolling bearing friction coefficients μ. 滚动 The average of the data in the same group is taken 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 specification, only the real-time drive torque of the motor needs to be collected and input into 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 measurement device based on energy flow includes a torque sensor 1, a pressure sensor 2, a data acquisition card 3, and a host computer 4.

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

[0109] The work roll 6 is equipped with an oil film bearing 61 and a rolling bearing 62 on its roller shaft. The work 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 work roll 6. The pressure sensor 2 is set 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] Torque sensor 1 and pressure sensor 2 are both electrically connected to data acquisition card 3. Data acquisition card 3 is used to acquire the detection data of torque sensor 1 and pressure sensor 2 and transmit the detection data to host computer 4.

[0111] The rotational speed data of motor 5 / work roll 6 can usually be obtained from the industrial control panel of the rolling mill. If the rolling mill cannot provide rotational speed data, a rotational speed sensor needs to be added to the output end of motor 5 to obtain the rotational speed data of motor 5 / work roll 6.

[0112] The above description provides examples of the preferred embodiments of the present invention. Parts not detailed herein are common knowledge to those skilled in the art. The scope of protection of the present invention is determined by the claims. Any equivalent modifications based on the technical teachings of the present invention are also within the scope of protection of the present invention.

Claims

1. A method for measuring the rolling force of bar and wire rods based on energy flow, characterized in that, Includes the following steps: An experimental platform was built 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 undetermined parameters such as lever arm coefficient and friction coefficient is established; Record the motor torque and rolling force under different rolling pressures when the rolling mill is rolling the preset material, and obtain several sets of motor torque and rolling force data; Several sets of motor torque and rolling force data are imported into the rolling force calculation model to derive a set of lever arm coefficients and friction coefficients. The average values ​​of the lever arm coefficients and friction coefficients are then calculated to obtain the lever arm coefficients and friction coefficients when rolling the preset material. By applying the lever arm coefficient and friction coefficient when rolling the preset material to the rolling force calculation model, a rolling force calculation model for calculating the rolling force when rolling the preset material is obtained. When rolling a preset material, the motor torque can be imported into the rolling force calculation model used to calculate the rolling force when rolling the preset material, and the real-time rolling force can be output. Establishing a rolling force calculation model that includes undetermined parameters such as the lever arm coefficient and the friction coefficient involves the following steps: The energy source of the rolling mill is determined to be provided by an electric motor. The energy input to the motor is consumed by the work done by the rolling force and the heat at each support of the roll shaft. The power calculation formula is obtained as follows: P M =P Z +P fb In the formula, P M P is the output power of the motor. Z P is the power consumed in vertical downward rolling of the work rolls. fb This refers to the heat dissipation power of all bearings on the work roll shaft; Based on the formulas for calculating the output power of the motor, the power consumption of vertical downward rolling, and the heat consumption of the bearing, the parameters to be determined in the power calculation formula, including the lever arm coefficient and the friction coefficient, are determined to obtain the rolling force calculation model. Motor output power P M The calculation formula is: In the formula, M m n is the motor torque, and n is the speed. Power consumption P in vertical downward rolling of work rolls Z The calculation formula is: In the formula, M P M is the vertically downward rolling torque; P The calculation formula is: In the formula, P is the rolling force, R is the radius of the work roll, β is the angle between the line connecting the rolling pressure application point and the center of the roll shaft and the line connecting the centers of the two work rolls, ψ is the lever arm coefficient, and Δh is the thickness difference before and after rolling. The heat dissipation power P of all bearings on the work roll shaft fb The calculation formula is: In the formula, F fi μ is the supporting force of the i-th bearing. i Let r be the coefficient of friction of the i-th bearing. i Let F be the roller diameter radius at the i-th bearing; the function of the support force converted into the rolling force P is F. fi =f i (P); Based on the above formula, the rolling force calculation model can be obtained: Wherein, the friction coefficient μ i The lever arm coefficient ψ is a parameter to be determined.

2. The method for measuring the rolling force of bar and wire rods based on energy flow according to claim 1, characterized in that, Bearings used to support the work rolls include oil film bearings and rolling bearings, with friction coefficients including the oil film bearing friction coefficient μ. 油膜 and the coefficient of friction μ of rolling bearings 滚动 ; Oil film bearing friction coefficient μ 油膜 The calculation formula is: In the formula, η is the dynamic viscosity of the lubricating oil. Let B / d be the relative clearance of the oil film bearing, and ξ be the correlation coefficient of the width-to-diameter ratio of the oil film bearing. When B / d < 1, When B / d ≥ 1, ξ = 1, where B and d are the width and inner diameter of the oil film bearing, respectively; P m P is the average pressure of the oil film bearing. m The calculation formula is Based on the above formula, the calculation model for rolling force is further obtained: Among them, the friction coefficient μ of rolling bearings 滚动 The lever arm coefficient ψ is a parameter to be determined.

3. The method for measuring the rolling force of bar and wire rods based on energy flow according to claim 2, characterized in that, The lever arm coefficient ψ is approximately calculated using the following formula: Furthermore, by introducing a modified adjustment coefficient λ, we obtain the formula for calculating the actual value of the lever arm coefficient ψ: Based on the above formula, the calculation model for rolling force is further obtained: Among them, the friction coefficient μ of rolling bearings 滚动 The adjustment coefficient λ is a parameter to be determined.

4. The method for measuring the rolling force of bar and wire rod based on energy flow according to any one of claims 1 to 3, characterized in that, The test platform includes a torque sensor, a pressure sensor, a data acquisition card, and a 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 data acquisition card is used to acquire detection data from the torque sensor and pressure sensor and transmit it to the host computer.

5. The method for measuring the rolling force of bar and wire rods based on energy flow according to claim 4, characterized in that, It also includes a speed sensor, which is used to detect the motor speed of the rolling mill.

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