High frequency vibration rolling method, system and apparatus for multi-pass copper rod rolling

Abstract

The present application relates to copper rod production technical field, especially to the high frequency vibration rolling method, system and equipment of multi-pass copper rod continuous rolling, method includes: obtaining copper rod expected index, according to the copper rod expected index establishes rolling process flow and according to the rolling process flow distribution continuous rolling pass;For each the continuous rolling pass calculates the corresponding high frequency vibration frequency and rolling force of setting;The hardness detection is carried out to the production result of each the continuous rolling pass, and the physical structure and performance of copper rod in production process are calculated according to the result of hardness detection;According to the physical structure and performance of copper rod, and based on the copper rod expected index, the high frequency vibration frequency and rolling force are corrected to the fixed continuous rolling pass feedback correction the high frequency vibration frequency and rolling force. Through the present application, effectively solve the problems such as unstable surface quality, uneven grain, energy waste and other problems in traditional copper rod production.

Description

Technical Field

[0001] The present invention relates to the technical field of copper rod production, and in particular to a high-frequency vibration rolling method, system and equipment for multi-pass continuous rolling of copper rods. Background Art

[0002] During the continuous rolling process of copper rod production, traditional production methods face problems such as unstable surface quality and uneven material properties. Cracks, scratches, and other defects often appear on the surface of the copper rod. Furthermore, due to the high energy consumption during the processing, energy cannot be effectively recovered and utilized, which increases production costs. Furthermore, during the multiple rolling passes of the copper rod, its grain structure and mechanical properties may become uneven. Especially during the large deformation stage, grain coarsening or unevenness seriously affects the performance and quality of the copper rod.

[0003] High-frequency vibration can effectively reduce surface defects, promote grain refinement, improve the uniformity and mechanical properties of copper rods, and reduce friction and improve deformation efficiency during the rolling process, thereby reducing energy consumption. Although high-frequency vibration technology has been applied in some fields, the precise adjustment of vibration frequency and rolling force, as well as the optimization of grain structure, remain challenges in copper rod production.

[0004] The information disclosed in this background technology section is only intended to deepen the understanding of the overall background technology of the present disclosure and should not be regarded as an admission or any form of suggestion that the information constitutes the prior art known to those skilled in the art. Summary of the Invention

[0005] The present invention provides a high-frequency vibration rolling method, system and equipment for multi-pass copper rod continuous rolling, which can effectively solve the problems in the background technology.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is:

[0007] A high-frequency vibration rolling method for multi-pass copper rod continuous rolling, characterized in that the method comprises:

[0008] Obtaining expected indicators of the copper rod, establishing a rolling process according to the expected indicators of the copper rod, and allocating continuous rolling passes according to the rolling process;

[0009] Calculating and setting corresponding high-frequency vibration frequency and rolling force for each of the continuous rolling passes;

[0010] Performing hardness testing on the production results of each continuous rolling pass, and inferring the physical structure and performance of the copper rod during the production process based on the results of the hardness testing;

[0011] According to the physical structure and performance of the copper rod and based on the expected indicators of the copper rod, the high-frequency vibration frequency and the rolling force are corrected by feedback of the fixed continuous rolling passes.

[0012] Furthermore, the corresponding high-frequency vibration frequency and rolling force are set, including:

[0013] Obtaining copper rod processing parameters, and establishing a rolling vibration parameter model based on the expected indicators of the copper rod;

[0014] determining the copper rod deformation stage according to the rolling vibration parameter model and based on the continuous rolling passes;

[0015] Establishing a parameter matching relationship between the high-frequency vibration frequency and the rolling force range based on historical production data;

[0016] The high-frequency vibration frequency and the rolling force of different continuous rolling passes are calculated and determined according to the copper rod deformation stage and the parameter ratio relationship.

[0017] Furthermore, calculating and determining the high-frequency vibration frequency and the rolling force of different continuous rolling passes includes:

[0018] Obtaining a material constitutive relationship, and calculating the equivalent strain rate and stress distribution of the copper rod in each of the continuous rolling passes based on the copper rod processing parameters;

[0019] Establishing a stress distribution model based on the copper rod processing parameters, and calculating the stress distribution of the copper rod in each rolling pass;

[0020] Calculating the rolling force of each of the continuous rolling passes according to the stress distribution, in combination with the material constitutive relationship and the roller contact condition;

[0021] The high-frequency vibration frequency is calculated according to the rolling force and the equivalent strain rate in combination with the rolling vibration parameter model.

[0022] Furthermore, calculating the high-frequency vibration frequency includes:

[0023] Calculating the local strain rate of the copper rod in each of the continuous rolling passes and its corresponding vibration response requirements based on the copper rod processing parameters;

[0024] Analyzing the nonlinear strain vibration frequency relationship based on the local strain rate and the deformation stage of the copper rod;

[0025] Calculating and determining a preliminary range of the high-frequency vibration frequency required for each of the continuous rolling passes based on the vibration response requirement and the nonlinear strain-vibration-frequency relationship;

[0026] The coupling effect of the stress distribution and the deformation stage of the copper rod is calculated to narrow the preliminary range of the high-frequency vibration frequency to a certain value.

[0027] Furthermore, hardness testing is performed on the production results of each continuous rolling pass, including:

[0028] Performing a surface hardness test on the copper rod of each continuous rolling pass to obtain a hardness test value, wherein the hardness test value is used to infer the grain size and grain structure of the copper rod;

[0029] Calculating the grain size and structural characteristics of the copper rod in each of the continuous rolling passes based on the known relationship between the hardness test value and the grain size and the copper rod processing parameters during the copper rod processing;

[0030] According to the grain size and the structural characteristics, the uniformity and distribution of the grains are identified to determine whether there is an uneven grain structure or a potential defect area.

[0031] Furthermore, the grain size and structural characteristics of the copper rod in each of the continuous rolling passes are calculated, including:

[0032] Based on the hardness test values, a hardness grain size relationship model is established, and the grain size of each pass is calculated according to the deformation stage and stress distribution of the copper rod;

[0033] Acquiring real-time monitoring data, calculating the structural characteristics of the copper rod grains in combination with the copper rod processing parameters, and calibrating the hardness-grain size relationship model based on the real-time monitoring data;

[0034] Based on the grain size and the structural characteristics, identifying the grain distribution pattern of the copper rod in different continuous rolling passes, and detecting whether there are areas with uneven or oversized grains;

[0035] The copper rod processing parameters of the subsequent continuous rolling passes are adjusted according to the feedback of the detection results, and the high-frequency vibration frequency and the rolling force are corrected.

[0036] Furthermore, an energy recovery mechanism is established, including:

[0037] Collecting the electrical energy consumption, mechanical energy conversion and heat energy loss of each continuous rolling pass to generate energy usage information;

[0038] Calculating the energy input and consumption ratio of each of the continuous rolling passes based on the energy usage information, and identifying the source of high-frequency vibration and energy loss during the rolling process based on the calculation results;

[0039] Determine an energy recovery method suitable for the high-frequency vibration process and the rolling process based on the energy loss source;

[0040] An energy recovery path is set based on the energy recovery method, and the remaining kinetic energy, frictional heat energy and mechanical energy are recovered, stored and redistributed.

[0041] Furthermore, setting an energy recovery path based on the energy recovery method includes:

[0042] Analyzing the energy consumption characteristics of each of the continuous rolling passes based on the energy usage information, and identifying the energy recovery method for energy generation and consumption in each pass;

[0043] Identifying the starting point and the end point of the energy flow based on the energy consumption characteristics, and defining and determining the key nodes of the energy recovery path;

[0044] Analyze and design the energy recovery flow based on the energy recovery method and the key nodes;

[0045] The energy recovery path is generated according to the energy recovery flow direction and the key nodes, and the energy recovery flow direction in the energy recovery path is adjusted in real time according to dynamic changes in the production process.

[0046] A high-frequency vibration rolling system for multi-pass copper rod continuous rolling, the system comprising:

[0047] The process establishment module obtains the expected indicators of copper rods, establishes the rolling process according to the expected indicators of copper rods, and allocates continuous rolling passes according to the rolling process;

[0048] Parameter calculation module, which calculates and sets the corresponding high-frequency vibration frequency and rolling force for each continuous rolling pass;

[0049] The detection and calculation module performs hardness testing on the production results of each continuous rolling pass and calculates the physical structure and performance of the copper rod during the production process based on the hardness test results;

[0050] The feedback correction module corrects the high-frequency vibration frequency and rolling force of the fixed continuous rolling pass according to the physical structure and performance of the copper rod and based on the expected indicators of the copper rod.

[0051] The invention discloses a high-frequency vibration rolling device for continuous multi-pass copper rod rolling, wherein the device is used to implement the high-frequency vibration rolling method for continuous multi-pass copper rod rolling.

[0052] The technical solution of the present invention can achieve the following technical effects:

[0053] By optimizing the rolling process, recovering energy, and promoting grain refinement, the surface quality, material property uniformity, energy efficiency, and production efficiency of the copper rod are improved, thereby enhancing the overall quality and production benefits of the copper rod. This solves the problems of unstable surface quality, energy waste, uneven grains, and low production efficiency in traditional copper rod production.

[0054] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0056] Figure 1 Schematic diagram of the process of high-frequency vibration rolling method for multi-pass continuous copper rod rolling;

[0057] Figure 2 A schematic diagram of the process for setting the high-frequency vibration frequency and rolling force;

[0058] Figure 3 Schematic diagram of the structure for calculating high-frequency vibration frequency;

[0059] Figure 4 This is a flowchart of hardness testing;

[0060] Figure 5 Schematic diagram of the energy recovery mechanism. DETAILED DESCRIPTION

[0061] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0062] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used in this specification are for the purpose of describing specific embodiments only and are not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0063] Embodiment 1;

[0064] like Figure 1 As shown, the present application provides a high-frequency vibration rolling method for multi-pass copper rod continuous rolling, the method comprising:

[0065] S10: obtaining expected indicators of the copper rod, establishing a rolling process according to the expected indicators of the copper rod, and allocating continuous rolling passes according to the rolling process;

[0066] S20: Calculate and set the corresponding high-frequency vibration frequency and rolling force for each continuous rolling pass;

[0067] S30: Perform hardness testing on the production results of each continuous rolling pass, and infer the physical structure and performance of the copper rod during the production process based on the results of the hardness testing;

[0068] S40: According to the physical structure and performance of the copper rod and based on the expected indicators of the copper rod, the high-frequency vibration frequency and rolling force are corrected for the fixed continuous rolling pass feedback.

[0069] Specifically, first, according to production needs, the expected indicators of the copper rod are obtained, such as the diameter, strength, ductility, surface finish and other technical requirements of the copper rod. According to the expected indicators of the copper rod, a rolling process flow is established. The rolling process flow includes the specific steps, temperature control, rolling speed, etc. of each continuous rolling pass. By analyzing the processing characteristics of the copper rod, the most suitable process conditions for each continuous rolling pass are determined. According to the rolling process flow, the work handled by each continuous rolling pass is reasonably allocated to ensure that each continuous rolling pass can be processed under the best process conditions, thereby meeting the technical requirements of copper rod production; for each continuous rolling pass, the required high-frequency vibration frequency and rolling force are calculated based on factors such as the position in the rolling process flow, the material and temperature of the copper rod. In the initial rolling stage, due to the large initial size of the copper rod, the temperature is set to 0.05. A low vibration frequency and high rolling force are set to promote the initial plastic deformation of the copper rod. During the final rolling stage, a higher vibration frequency and moderate rolling force are set to further optimize the surface quality and grain refinement. During each continuous rolling pass, the surface hardness of the copper rod is detected in real time using hardness testing equipment. The hardness test value is closely related to the physical structural characteristics of the copper rod, such as grain size, grain boundary density, and stress state. Based on the hardness test results, the actual physical structure and mechanical properties of the copper rod are inferred using the known relationship between hardness and physical properties such as grain size and strength. The inferred results are used to evaluate the processing quality of the copper rod in each pass and determine whether it meets the expected mechanical performance requirements. The inferred physical structure and performance of the copper rod are compared with the preset expected indicators of the copper rod to analyze the differences. If there is a deviation between the actual quality of the copper rod and the expected indicators of the copper rod, the copper rod process parameters are adjusted according to the test feedback information, and the high-frequency vibration frequency and rolling force are corrected based on the feedback to optimize the process conditions for the next continuous rolling pass. For example, if a hardness test shows that the copper rod has uneven grains or defects, the vibration frequency can be adjusted appropriately to improve the uniformity of the material and the final surface quality. This correction process ensures that the rolling parameters of each pass are precisely adjusted based on real-time monitoring of the process data of each pass, thereby improving the stability of the entire production process and the quality of the copper rod.

[0070] The technical solution of the present invention solves the problems of unstable surface quality, energy waste, uneven grains and low production efficiency in traditional copper rod production. By optimizing the rolling process, recovering energy and promoting grain refinement, the surface quality, material property uniformity, energy utilization efficiency and production efficiency of the copper rod are improved, thereby improving the overall quality and production benefits of the copper rod.

[0071] Further, if Figure 2 As shown, the corresponding high-frequency vibration frequency and rolling force are set, including:

[0072] Obtain copper rod processing parameters and establish a rolling vibration parameter model based on the expected copper rod indicators;

[0073] Determine the copper rod deformation stage based on the rolling vibration parameter model and the continuous rolling passes;

[0074] Establish the parameter ratio relationship between high-frequency vibration frequency and rolling force range based on historical production data;

[0075] The high-frequency vibration frequency and rolling force of different continuous rolling passes are calculated and determined according to the deformation stage of the copper rod and the parameter ratio relationship.

[0076] As a preferred embodiment of the above, the copper rod processing parameters, including the initial size (such as diameter and length), material, temperature, rolling speed, processing stress, etc. of the copper rod, are collected. Based on the expected indicators of the copper rod (such as strength, ductility, surface finish, etc.), the changing characteristics of the copper rod in different processing stages are analyzed. For example, in the initial rolling stage, the temperature of the copper rod is high and the deformation is large, so the vibration frequency is set relatively low. In the final rolling stage, the temperature and deformation of the copper rod gradually decrease, and a higher vibration frequency is required to optimize the surface quality. Based on the above copper rod processing parameters and expected indicators, a rolling vibration parameter model is established to describe the relationship between vibration frequency, amplitude, rolling force, etc. and the mechanical properties and material properties during the copper rod processing; according to the rolling vibration parameter model, combined with the process conditions in the actual production process, the copper rod deformation stage in each continuous rolling pass is determined. For example, in the initial rolling stage, the copper rod undergoes a large plastic deformation, while in the middle pass, the deformation of the copper rod is moderate; in the final rolling stage, the copper rod mainly achieves the predetermined performance standard by fine-tuning the surface quality and grain refinement. If the deformation of the copper rod is large at a certain stage, the appropriate low-frequency vibration setting can be inferred, and if in another stage If the deformation is small, a higher frequency vibration can be selected. Based on historical production data, the relationship between the high-frequency vibration frequency and rolling force of the copper rod under different rolling conditions (such as different copper rod deformation stages and different temperatures) is analyzed. Through regression analysis, a parameter ratio relationship between the vibration frequency and rolling force is established. Through the analysis and optimization of multi-pass production data, the parameter ratio relationship between the high-frequency vibration frequency and rolling force can be continuously improved through machine learning algorithms, so that it can more accurately adapt to the needs of different production environments and copper rod materials. According to the copper rod deformation stage and the established parameter ratio relationship between the high-frequency vibration frequency and rolling force, the high-frequency vibration frequency and rolling force of each continuous rolling pass are calculated. For example, in the initial rolling pass, a suitable lower vibration frequency and higher rolling force are calculated; in the final rolling pass, the frequency is adaptively adjusted to ensure grain refinement and optimize surface quality. In actual applications, you may encounter situations where temporary adjustments need to be made based on temperature changes or material properties on site. For example, if the copper rod overheats during rolling, the frequency is adjusted to avoid excessive plastic deformation and ensure that the performance of the finished product meets expectations.

[0077] Furthermore, the high-frequency vibration frequency and rolling force of different continuous rolling passes are calculated and determined, including:

[0078] Obtain the material constitutive relationship and calculate the equivalent strain rate and stress distribution of the copper rod in each continuous rolling pass based on the copper rod processing parameters;

[0079] A stress distribution model is established based on the copper rod processing parameters to calculate the stress distribution of the copper rod in each rolling pass;

[0080] Calculate the rolling force of each continuous rolling pass based on stress distribution, combined with the material constitutive relationship and roll contact conditions;

[0081] The high-frequency vibration frequency is calculated based on the rolling force and equivalent strain rate combined with the rolling vibration parameter model.

[0082] As a preferred embodiment of the above, the material constitutive relationship of the copper rod is obtained. The material constitutive relationship describes the mechanical response of the copper rod under different stress and strain conditions. According to the material, temperature, strain rate and other parameters of the copper rod, an appropriate constitutive model (such as an elastic model, a plastic flow model, etc.) is selected, and the model is used to predict the stress-strain behavior of the copper rod in each continuous rolling pass. Based on the copper rod processing parameters (such as rolling speed, temperature, deformation, etc.), the equivalent strain rate of the copper rod in each continuous rolling pass is calculated. The equivalent strain rate is the rate at which the material deforms during the processing, which directly affects the plastic deformation behavior and mechanical properties of the material. According to the material constitutive relationship, the stress distribution of the copper rod in each pass is calculated. Through the calculation of the stress distribution, the internal stress state of the copper rod during the rolling process can be understood, especially in the area where the rolling force is applied and the contact interface; a stress distribution model is constructed according to the copper rod processing parameters, and the model describes the stress changes of the copper rod during the rolling process. The law, especially the difference in stress distribution in different passes, can be further optimized through finite element analysis or experimental data fitting according to the data in the actual processing process to ensure that the stress distribution of each continuous rolling pass can truly reflect the actual processing state of the copper rod; according to the calculated stress distribution, combined with the material constitutive relationship and the roller contact conditions (such as the surface roughness and contact angle of the roller), the rolling force of each continuous rolling pass is calculated. The rolling force is an important parameter acting on the copper rod, which directly affects the deformation process, grain structure and surface quality of the copper rod; according to the calculated rolling force and equivalent strain rate, combined with the established rolling vibration parameter model, the high-frequency vibration frequency of each continuous rolling pass is calculated. The high-frequency vibration frequency is closely related to the deformation characteristics of the copper rod. Usually, a lower vibration frequency is required in the initial rolling stage to assist large deformation, and a higher vibration frequency is required in the final rolling stage to refine the grains and improve the surface quality.

[0083] Further, if Figure 3 As shown, the high-frequency vibration frequency is calculated, including:

[0084] Calculate the local strain rate of the copper rod in each continuous rolling pass and its corresponding vibration response requirements based on the copper rod processing parameters;

[0085] Analyze the nonlinear strain-vibration-frequency relationship based on the local strain rate and the deformation stage of the copper rod;

[0086] According to the vibration response requirements and the nonlinear strain-vibration-frequency relationship, the preliminary range of high-frequency vibration frequency required for each continuous rolling pass is calculated and determined;

[0087] The stress distribution and the coupling effect of the copper rod deformation stage are calculated to narrow the preliminary range of high-frequency vibration frequency to a certain value.

[0088] As a preferred embodiment of the above, the local strain rate of each continuous rolling pass is calculated based on the copper rod processing parameters (such as temperature, rolling speed, material properties, etc.). The local strain rate is the rate at which the copper rod deforms in each pass, which directly affects the stress state and deformation behavior of the material. When calculating, it is necessary to consider the local deformation areas of the copper rod in different passes, especially the areas with large deformation amounts, which are treated as key areas. By analyzing the strain rate, the vibration response requirements of the copper rod in each pass are evaluated, that is, the copper rod has different requirements for high-frequency vibration in different local deformation areas; based on the local strain rate and the deformation stage of the copper rod, the relationship between nonlinear strain and vibration frequency is analyzed. The relationship between strain and vibration frequency in copper rods at different deformation stages is typically nonlinear, especially under large strain or high stress conditions. These nonlinear factors must be considered when adjusting the vibration frequency. By analyzing the copper rod's response under different deformation states during actual rolling, a suitable mathematical model for the relationship between strain and vibration frequency was developed. This model helps determine the optimal vibration frequency range for each pass, ensuring that vibration plays an optimal role in the material deformation process. Based on the local strain rate and the nonlinear strain-vibration frequency relationship, a preliminary range of high-frequency vibration frequencies required for each continuous rolling pass was calculated. This preliminary range aims to meet the copper rod's deformation requirements while ensuring that the vibration frequency effectively promotes deformation and optimizes its grain structure and surface quality. The calculation of this preliminary range takes into account factors such as the specific deformation characteristics, temperature changes, and deformation rate of the copper rod at each pass to ensure that the vibration frequency can adapt to the rolling requirements at different stages. By calculating the stress distribution of the copper rod and the coupling effect of the deformation stage, the preliminary range of vibration frequencies was further narrowed to a specific value. Stress distribution is a key factor in determining the material response in different regions during the copper rod's deformation process. The vibration frequency range was optimized by combining the stress distribution with the specific conditions of the copper rod's deformation stage. For example, in areas with greater stress, the vibration frequency may need to be appropriately reduced to avoid excessive local stress concentration; in areas with smaller stress, the vibration frequency may need to be increased to promote grain refinement and surface quality optimization. By comprehensively analyzing the interaction between stress distribution and deformation stages, the most appropriate high-frequency vibration frequency is determined to ensure that the vibration frequency of each continuous rolling pass can meet all requirements in the copper rod production process.

[0089] Further, if Figure 4 As shown, the hardness test is performed on the production results of each continuous rolling pass, including:

[0090] The surface hardness of the copper rod in each continuous rolling pass is tested to obtain the hardness test value, and the hardness test value is used to infer the grain size and grain structure of the copper rod;

[0091] Based on the known relationship between hardness test value and grain size, combined with the copper rod processing parameters during the copper rod processing, the grain size and structural characteristics of the copper rod in each continuous rolling pass are calculated;

[0092] Based on the grain size and structural characteristics, the uniformity and distribution of the grains can be identified to determine whether there is an uneven grain structure or potential defect areas.

[0093] As a preferred embodiment of the above, during the production process of each continuous rolling pass, a hardness testing device (such as a Rockwell hardness tester, a Vickers hardness tester, etc.) is used to test the hardness of the copper rod surface. The hardness test value is closely related to the grain size and grain structure of the copper rod. By measuring the hardness values ​​of the copper rod surface in different passes, the degree of grain refinement, the distribution of grain boundaries, and the strength characteristics of the material can be indirectly inferred. To ensure the representativeness of the data, multi-point hardness testing is required for each continuous rolling pass to avoid the influence of local data deviation on the overall result. Based on the known relationship between hardness and grain size, the grain size of the copper rod is inferred from the hardness value. The specific relationship can be based on an empirical formula or a model established by previous experimental data, such as the Hall-Petch relationship, which is used to describe the quantitative relationship between grain size and hardness. Combined with the copper rod processing parameters such as temperature, deformation, and rolling speed during the processing, the relationship between the hardness value and the grain structure characteristics is further analyzed to calculate the grain size and grain structure characteristics of the copper rod in each pass. In addition, the different processing stages of the copper rod can also be considered. The impact on grain size, such as the possibility of larger grains in the initial rolling stage, and obvious grain refinement in the final rolling stage; based on the calculated grain size and structural characteristics, further analysis of grain uniformity and distribution is carried out. By comparing the grain characteristics of different passes and different regions, the presence of grain inhomogeneity or potential defect areas can be identified. Image processing technology or other surface inspection methods are used to evaluate the grain distribution and identify possible abnormal areas, such as areas with excessively large grains or uneven distribution. During the inspection process, microscopy, scanning electron microscopy (SEM) and other technologies can also be combined to conduct a more detailed grain analysis to ensure that the estimated results obtained through hardness testing accurately reflect the actual grain structure of the copper rod; based on the grain uniformity analysis results, further judgment is made on whether there is an uneven grain structure or potential defect areas. By comparing the grain distribution and hardness distribution, the copper rod is evaluated to see whether it meets the predetermined quality standards. If the test results show the presence of grain inhomogeneity or defect areas, corrections can be made by adjusting the subsequent rolling process (such as increasing the vibration frequency, adjusting the rolling force, etc.).

[0094] Specifically, the grain size and structural characteristics of the copper rod are calculated for each continuous rolling pass, including:

[0095] Based on the hardness test values, a hardness-grain-size relationship model is established, and the grain size of each pass is calculated according to the copper rod deformation stage and stress distribution;

[0096] Obtain real-time monitoring data, combine it with copper rod processing parameters, calculate the structural characteristics of the copper rod grains, and calibrate the hardness-grain size relationship model based on the real-time monitoring data;

[0097] Identify the grain distribution pattern of copper rods in different continuous rolling passes based on grain size and structural characteristics, and detect whether there are areas of uneven or oversized grains;

[0098] According to the feedback of the test results, the copper rod processing parameters of the subsequent continuous rolling passes are adjusted to correct the high-frequency vibration frequency and rolling force.

[0099] As a preferred embodiment of the above embodiment, a hardness-grain size relationship model is established based on the known relationship between the hardness test value and the grain size (such as the Hall-Petch relationship, etc.). The grain size of the copper rod is inferred from the hardness value. Taking into account the changes in the deformation stage and stress distribution of the material, it is ensured that the model can accurately reflect the grain size in different processing stages (such as initial rolling, intermediate rolling, and final rolling). In areas with large deformation stages and high stress distribution, the grains may be coarser. Through model correction, the grain size of each pass can be accurately calculated based on the hardness test value. The hardness-grain size relationship model can be further optimized based on historical production data so that it can more accurately adapt to actual production conditions, especially when the copper rod temperature, deformation rate and stress distribution change. During the production process, the copper rod processing parameters (such as temperature, rolling speed, deformation amount, stress distribution, etc.) are monitored in real time and compared with the hardness test values. Combined with the real-time monitoring data obtained, the hardness-grain size relationship model is dynamically adjusted through a feedback mechanism. The real-time monitoring data provides key information such as the actual stress state and deformation stage of each pass, thereby ensuring the accuracy of the hardness grain size relationship model in actual production. Accuracy, the calibrated hardness-grain size relationship model will be revised in real time according to the new production data; based on the revised hardness-grain size relationship model and real-time monitoring data, the grain structure characteristics of the copper rod in each pass are calculated. The structural characteristics include the size, shape, distribution of grain boundaries, uniformity of grains, etc. Through image processing and data analysis technology, the grain distribution pattern of the copper rod in different passes is identified, and whether there is an uneven or oversized grain area is detected. Especially in the area of ​​uneven deformation or stress concentration, the grains may become larger or unevenly distributed, affecting the mechanical properties and Quality, by analyzing the grain characteristics of each continuous rolling pass, potential quality problems can be identified, such as areas of grain coarsening or uneven grains; according to the detection results of grain distribution, the copper rod processing parameters of subsequent continuous rolling passes are adjusted. If the grain distribution is uneven or too large, the copper rod process parameters such as temperature, rolling force, rolling speed, etc. are adjusted. In particular, the deformation process of the copper rod is optimized by adjusting the high-frequency vibration frequency and rolling force. The grain refinement is promoted by increasing or decreasing the vibration frequency, and the rolling force is adjusted to ensure uniform material deformation and avoid grain coarsening caused by local excessive deformation.

[0100] Further, if Figure 5 As shown, an energy recovery mechanism is established, including:

[0101] Collect the power consumption, mechanical energy conversion and heat loss of each continuous rolling pass to generate energy usage information;

[0102] Calculate the energy input and consumption ratio of each continuous rolling pass based on energy usage information, and identify the sources of high-frequency vibration and energy loss during the rolling process based on the calculation results;

[0103] Determine the energy recovery method suitable for high-frequency vibration and rolling processes based on the source of energy loss;

[0104] The energy recovery path is set based on the energy recovery method, and the remaining kinetic energy, frictional heat energy and mechanical energy are recovered, stored and redistributed.

[0105] As a preferred embodiment of the above, in the production process of each continuous rolling pass, sensors and monitoring equipment are used to collect data on electric energy consumption, mechanical energy conversion and heat energy loss in the copper rod rolling process in real time. The electric energy consumption data can be obtained through an electric meter or a power metering device, the mechanical energy conversion can be measured by a force sensor to measure the mechanical power consumption during the rolling process, and the heat energy loss can be monitored by a temperature sensor to monitor the temperature change in the rolling area, and then the heat energy loss caused by friction and other factors is calculated. All these data will be summarized as energy usage information, which includes the actual energy consumption and conversion efficiency of each continuous rolling pass, helping to accurately evaluate the energy utilization status in the rolling process; based on the collected energy usage information, the energy input (such as power supply, mechanical drive, etc.) and energy consumption ratio (such as friction loss, heat energy dissipation, etc.) of each pass are calculated, and by comparing the input and consumed energy, the source of energy loss is further analyzed, for example, whether there is excessive energy consumption when mechanical energy is converted into vibration energy during high-frequency vibration; or heat energy loss caused by friction and plastic deformation of materials during rolling; based on the identified energy loss source , determine the energy recovery method suitable for the high-frequency vibration process and rolling process. For example, for mechanical energy loss, the excess mechanical energy can be converted into electrical energy and re-input into the system by feeding back electrical energy; for thermal energy loss, the waste heat can be recovered through a heat exchange device and converted into usable energy, such as heating rolling equipment or providing a heating power supply. In addition, other suitable energy recovery technologies can be adopted, such as using a vibration energy conversion device to recover vibration energy and convert it into electrical energy or use it for other purposes to reduce energy waste and improve overall energy efficiency; based on the determined energy recovery method, set the energy recovery path. The energy recovery path refers to how to collect, convert and store excess energy (such as residual kinetic energy, frictional heat, etc.) during the production process, including through power devices, heat exchange systems, energy storage devices and other methods. The collected energy can be stored in batteries, thermal energy storage systems or other energy storage devices, and redistributed as needed in subsequent production processes. For example, in certain rolling processes, the stored energy can be mobilized to supplement the required power or temperature, reducing the consumption of external energy.

[0106] Furthermore, the energy recovery path is set based on the energy recovery method, including:

[0107] Based on the energy usage information, the energy consumption characteristics of each continuous rolling pass are analyzed, and the energy recovery method of energy generation and consumption in each pass is identified;

[0108] Identify the starting and ending points of energy flow based on energy consumption characteristics, and define and determine the key nodes of the energy recovery path;

[0109] Analyze and design energy recovery flow based on energy recovery methods and key nodes;

[0110] An energy recovery path is generated according to the energy recovery flow direction and key nodes, and the energy recovery flow direction in the energy recovery path is adjusted in real time according to dynamic changes in the production process.

[0111] As a preferred embodiment of the above embodiment, in the production process of each continuous rolling pass, based on the collected energy usage information, the energy consumption characteristics of the copper rod production process are analyzed. The energy consumption characteristics include the electrical energy consumption, mechanical energy conversion, heat energy loss, etc. of each pass. The energy utilization efficiency in each process is specifically analyzed. By identifying the energy generation and consumption at different stages of each pass, it is determined which part of the energy can be recovered, and the specific energy recovery method of each pass is identified to ensure that different processes adopt different energy recovery methods. According to the energy consumption characteristics obtained by analysis, the starting point and end point of the energy flow are identified. The starting point can be the source of energy generation, such as the electrical energy input of the vibration system, the conversion of mechanical energy during the rolling process, etc. The end point is the target of energy recovery and redistribution, such as storage equipment, energy reuse system, etc. According to the starting point and end point of the energy flow, the key nodes in the energy recovery path are defined. These key nodes may include energy recovery devices, storage equipment, heat exchange equipment, etc., and the purpose of determining the key nodes is determined. It is to build a complete energy recovery path to ensure that the energy flow in each link is not hindered; based on the identified energy recovery methods and key nodes, further analyze the energy recovery flow between different processes, and consider the possible flow direction of energy in the production process, such as conducting heat energy from the high-temperature area to the heat exchange device, or converting mechanical energy from the vibration system into electrical energy and then feeding it back to the power system; based on the identified energy recovery flow direction and key nodes, generate a complete energy recovery path. The energy recovery path includes the flow process from energy generation to the energy recovery device, ensuring the continuity and efficiency of the energy recovery process. During the production process, according to the dynamically changing production conditions (such as the processing temperature, strain rate, production speed, etc. of the copper rod), the energy recovery flow in the energy recovery path is adjusted in real time. For example, when the energy consumption of a certain pass is large, the energy recovery flow can be dynamically adjusted to transfer more surplus energy from the heat exchange system or mechanical energy recovery system to the energy storage device to meet the energy needs of future passes.

[0112] Embodiment 2;

[0113] Based on the same inventive concept as the high-frequency vibration rolling method for multi-pass continuous copper rod rolling in the aforementioned embodiment, the present invention also provides a high-frequency vibration rolling system for multi-pass continuous copper rod rolling, the system comprising:

[0114] The process establishment module obtains the expected indicators of copper rods, establishes the rolling process according to the expected indicators of copper rods, and allocates continuous rolling passes according to the rolling process;

[0115] Parameter calculation module, which calculates and sets the corresponding high-frequency vibration frequency and rolling force for each continuous rolling pass;

[0116] The detection and calculation module performs hardness testing on the production results of each continuous rolling pass and calculates the physical structure and performance of the copper rod during the production process based on the hardness test results;

[0117] The feedback correction module corrects the high-frequency vibration frequency and rolling force of the fixed continuous rolling pass according to the physical structure and performance of the copper rod and based on the expected indicators of the copper rod.

[0118] The above-mentioned adjustment system in the present invention can effectively realize the high-frequency vibration rolling method of multi-pass copper rod continuous rolling, and the technical effects that can be achieved are as described in the above-mentioned embodiments and will not be repeated here.

[0119] Embodiment 3;

[0120] Based on the same inventive concept as the high-frequency vibration rolling method for multi-pass copper rod continuous rolling in the aforementioned embodiment, the present invention also provides high-frequency vibration rolling equipment for multi-pass copper rod continuous rolling, which is used to implement the high-frequency vibration rolling method for multi-pass copper rod continuous rolling.

[0121] Specifically, the high-frequency vibration rolling equipment for multi-pass copper rod continuous rolling includes a roller unit, a control unit, a sensor unit and an energy recovery unit. The rolling unit includes at least one set of rollers for copper rod rolling. Each roller is equipped with a vibration device. The vibration device can generate high-frequency vibrations through an electromagnetic exciter, piezoelectric ceramic elements, or other appropriate vibration generating devices. The frequency and amplitude of the vibrations are adjustable to meet the rolling requirements of different continuous rolling passes. During each continuous rolling pass, the vibration frequency and amplitude are adjusted in real time based on factors such as the material, processing temperature, and deformation of the copper rod. The control unit adjusts the vibration device of each roller based on real-time feedback data to optimize the processing effect of the copper rod. The control unit is used to monitor the rolling parameters of each pass in real time, including key parameters such as temperature, rolling force, rolling speed, surface quality of the copper rod, vibration frequency, and amplitude. The control unit automatically adjusts the high-frequency vibration frequency, rolling force, and other key process parameters by processing this real-time data. The control unit evaluates the current rolling effect based on feedback data from the sensor unit and dynamically adjusts relevant parameters according to the processing status of the copper rod. The sensor unit includes multiple sensors arranged on the rolling stand, the surface of the copper rod, and the vibration device. These sensors are used to collect process parameters generated during the rolling process and feed real-time data back to the control unit. Common sensors include temperature sensors, force sensors, strain sensors, acceleration sensors, displacement sensors, etc. These sensors are placed on the surface of the rollers, the surface of the copper rods, and the vibration device to monitor key process data such as rolling force, vibration frequency, temperature changes, and deformation in real time. The sensors send this data to the control unit via wireless or wired means for real-time adjustment of process parameters. The energy recovery unit is responsible for recovering the remaining mechanical and thermal energy during the rolling process and includes a mechanical energy recovery system (such as a generator and energy storage equipment) and a thermal energy recovery system (such as a heat exchanger). During high-frequency vibration rolling, mechanical energy is converted into thermal energy or kinetic energy through the vibration device. The energy recovery unit converts the remaining mechanical energy into electrical energy through a mechanical energy conversion device (such as a generator). The heat exchanger can recover excess thermal energy from the rolling equipment and convert it into reusable thermal energy.

[0122] The above-mentioned equipment in the present invention can effectively realize the high-frequency vibration rolling method of multi-pass copper rod continuous rolling, and the technical effects that can be achieved are as described in the above-mentioned embodiments and will not be repeated here.

[0123] Although the present application has been described with reference to specific features and embodiments thereof, it is apparent that various modifications and combinations may be made thereto without departing from the spirit and scope of the present application. Accordingly, this specification and drawings are merely illustrative of the present application as defined herein and are deemed to cover any and all modifications, variations, combinations or equivalents within the scope of the present application. Obviously, those skilled in the art may make various modifications and variations to the present application without departing from the scope of the present application. Thus, the present application is intended to include such modifications and variations as fall within the scope of the present application and its equivalents.

Claims

1. A high-frequency vibration rolling method for multi-pass copper rod continuous rolling, characterized in that: The method comprises: Obtaining expected indicators of the copper rod, establishing a rolling process according to the expected indicators of the copper rod, and allocating continuous rolling passes according to the rolling process; Calculating and setting corresponding high-frequency vibration frequency and rolling force for each of the continuous rolling passes; Performing hardness testing on the production results of each continuous rolling pass, and inferring the physical structure and performance of the copper rod during the production process based on the results of the hardness testing; According to the physical structure and performance of the copper rod and based on the expected indicators of the copper rod, the high-frequency vibration frequency and the rolling force are corrected by feedback of the fixed continuous rolling passes.

2. The high-frequency vibration rolling method for multi-pass copper rod continuous rolling according to claim 1, characterized in that: Set the corresponding high-frequency vibration frequency and rolling force, including: Obtaining copper rod processing parameters, and establishing a rolling vibration parameter model based on the expected indicators of the copper rod; determining the copper rod deformation stage according to the rolling vibration parameter model and based on the continuous rolling passes; Establishing a parameter matching relationship between the high-frequency vibration frequency and the rolling force range based on historical production data; The high-frequency vibration frequency and the rolling force of different continuous rolling passes are calculated and determined according to the copper rod deformation stage and the parameter ratio relationship.

3. The high-frequency vibration rolling method for multi-pass copper rod continuous rolling according to claim 2, characterized in that: Calculating and determining the high-frequency vibration frequency and the rolling force of different continuous rolling passes includes: Obtaining a material constitutive relationship, and calculating the equivalent strain rate and stress distribution of the copper rod in each of the continuous rolling passes based on the copper rod processing parameters; Establishing a stress distribution model based on the copper rod processing parameters, and calculating the stress distribution of the copper rod in each of the continuous rolling passes; Calculating the rolling force of each of the continuous rolling passes according to the stress distribution, in combination with the material constitutive relationship and the roller contact condition; The high-frequency vibration frequency is calculated according to the rolling force and the equivalent strain rate in combination with the rolling vibration parameter model.

4. The high-frequency vibration rolling method for multi-pass copper rod continuous rolling according to claim 3, characterized in that: Calculating the high frequency vibration frequency includes: Calculating the local strain rate of the copper rod in each of the continuous rolling passes and its corresponding vibration response requirements based on the copper rod processing parameters; Analyzing the nonlinear strain vibration frequency relationship based on the local strain rate and the deformation stage of the copper rod; Calculating and determining a preliminary range of the high-frequency vibration frequency required for each of the continuous rolling passes based on the vibration response requirement and the nonlinear strain-vibration-frequency relationship; The coupling effect of the stress distribution and the deformation stage of the copper rod is calculated to narrow the preliminary range of the high-frequency vibration frequency to a certain value.

5. The high-frequency vibration rolling method for multi-pass copper rod continuous rolling according to claim 1, characterized in that: Performing hardness testing on the production results of each continuous rolling pass, including: Performing a surface hardness test on the copper rod of each continuous rolling pass to obtain a hardness test value, wherein the hardness test value is used to infer the grain size and grain structure of the copper rod; Calculating the grain size and structural characteristics of the copper rod in each of the continuous rolling passes based on the known relationship between the hardness test value and the grain size and the copper rod processing parameters during the copper rod processing; According to the grain size and the structural characteristics, the uniformity and distribution of the grains are identified to determine whether there is an uneven grain structure or a potential defect area.

6. The high-frequency vibration rolling method for multi-pass copper rod continuous rolling according to claim 5, characterized in that: Calculating the grain size and structural characteristics of the copper rod in each of the continuous rolling passes, including: Based on the hardness test values, a hardness grain size relationship model is established, and the grain size of each pass is calculated according to the deformation stage and stress distribution of the copper rod; Acquiring real-time monitoring data, calculating the structural characteristics of the copper rod grains in combination with the copper rod processing parameters, and calibrating the hardness-grain size relationship model based on the real-time monitoring data; Based on the grain size and the structural characteristics, identifying the grain distribution pattern of the copper rod in different continuous rolling passes, and detecting whether there are areas with uneven or oversized grains; The copper rod processing parameters of the subsequent continuous rolling passes are adjusted according to the feedback of the detection results, and the high-frequency vibration frequency and the rolling force are corrected.

7. The high-frequency vibration rolling method for multi-pass continuous copper rod rolling according to claim 1, characterized in that: Establish energy recovery mechanisms, including: Collecting the electrical energy consumption, mechanical energy conversion and heat energy loss of each continuous rolling pass to generate energy usage information; Calculating the energy input and consumption ratio of each of the continuous rolling passes based on the energy usage information, and identifying the source of high-frequency vibration and energy loss during the rolling process based on the calculation results; Determine an energy recovery method suitable for the high-frequency vibration process and the rolling process based on the energy loss source; An energy recovery path is set based on the energy recovery method, and the remaining kinetic energy, frictional heat energy and mechanical energy are recovered, stored and redistributed.

8. The high-frequency vibration rolling method for multi-pass copper rod continuous rolling according to claim 7, characterized in that: Setting an energy recovery path based on the energy recovery method includes: Analyzing the energy consumption characteristics of each of the continuous rolling passes based on the energy usage information, and identifying the energy recovery method for energy generation and consumption in each pass; Identifying the starting point and the end point of the energy flow based on the energy consumption characteristics, and defining and determining the key nodes of the energy recovery path; Analyze and design the energy recovery flow based on the energy recovery method and the key nodes; The energy recovery path is generated according to the energy recovery flow direction and the key nodes, and the energy recovery flow direction in the energy recovery path is adjusted in real time according to dynamic changes in the production process.

9. High-frequency vibration rolling system for multi-pass copper rod continuous rolling, characterized in that: The system comprises: The process establishment module obtains the expected indicators of copper rods, establishes the rolling process according to the expected indicators of copper rods, and allocates continuous rolling passes according to the rolling process; Parameter calculation module, which calculates and sets the corresponding high-frequency vibration frequency and rolling force for each continuous rolling pass; The detection and calculation module performs hardness testing on the production results of each continuous rolling pass and calculates the physical structure and performance of the copper rod during the production process based on the hardness test results; The feedback correction module corrects the high-frequency vibration frequency and rolling force of the fixed continuous rolling pass according to the physical structure and performance of the copper rod and based on the expected indicators of the copper rod.

10. High-frequency vibration rolling equipment for multi-pass copper rod continuous rolling, characterized in that: The device is used to implement the method according to any one of claims 1 to 8.

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