A method for reducing surface copper powder during copper rod rolling

Abstract

This invention relates to the field of copper material preparation technology, and more particularly to a method for reducing surface copper powder during copper rod rolling. The method includes: dividing the rolling process into multiple process segments and supplying different lubricants to each segment; establishing a correlation model between process parameters and copper rod performance, and generating a feasible domain for process parameters based on the target performance of the copper rod; monitoring the surface parameters of the rolls in each process segment and calculating the change in surface morphology; adjusting the rolling process parameters when the change in surface morphology exceeds a set value; monitoring the change in surface morphology corresponding to the adjusted rolling process parameters and comparing it with the set value; continuing until the change in surface morphology is less than the set value; and triggering an alarm when the rolling process parameters are adjusted to the boundary of the feasible domain and the change in surface morphology exceeds the set value. This invention achieves fundamental control of the copper powder problem by constructing a closed-loop control system encompassing process segment optimization, dynamic monitoring and adjustment, and rapid emergency response, thus better promoting the transformation of rolling processes towards intelligence and precision.

Description

Technical Field

[0001] This invention relates to the field of copper material preparation technology, and in particular to a method for reducing surface copper powder during the rolling process of copper rods. Background Technology

[0002] Copper rod rolling is a pressure processing process in which a copper billet is passed through rolls with a certain die and subjected to continuous extrusion by the rolls to achieve a reduction in cross-section and an increase in length. During the process, a large frictional force is generated in the contact area between the copper rod and the rolls, so the copper rod and the rolls in the rolling mill need to be lubricated and cooled.

[0003] Currently, emulsified oil is the most commonly used lubricant. However, in application, because the rolling of copper rods involves multiple passes, a single lubricant is difficult to adapt to the friction requirements of different rolling stages. Excessive friction or insufficient lubrication often leads to an increase in copper powder formation. Especially in the roughing and finishing rolling sections, due to the large reduction and high rolling speed, the friction and temperature are high, which can easily cause damage or localized melting of the copper rod surface, thus forming copper powder. This not only affects the surface quality of the copper rod but also increases production costs.

[0004] Furthermore, more lubricant is not necessarily better. In the roughing stage, due to the large reduction (around 40%) and high contact pressure, the lubricant is easily squeezed out, leading to direct metal-to-metal contact and a surge in copper powder. In the finishing stage, during high-speed rolling, the high-viscosity lubricant residue increases surface roughness (Ra > 1.6 μm), making the lubricant unable to flexibly adapt to the needs of different process stages. Some lubricants are prone to failure at high temperatures, resulting in reduced lubrication effectiveness.

[0005] Some technologies optimize the surface quality of copper rods by adjusting rolling parameters, thereby reducing copper powder formation. For example, reducing rolling speed and reduction can decrease friction and lower surface temperature. However, excessive adjustment of rolling parameters can lead to reduced production efficiency and even affect the final quality and specifications of the copper rods. Furthermore, the coating on the roll surface continuously deteriorates during rolling, causing the equivalent stress on the copper rods to continuously increase. Existing parameter adjustments lag behind changes in actual operating conditions, making it difficult to avoid the risk of excessive copper powder under extreme conditions. In addition, minute changes in surface morphology are often difficult to predict, and simply relying on rolling parameter adjustments may not completely solve the copper powder problem.

[0006] Therefore, how to flexibly adjust process parameters and lubricant usage according to the characteristics of different process stages has become the key to further reducing copper powder generation, improving the surface quality of copper rods, and increasing production efficiency.

[0007] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the present invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0008] The first objective of this invention is to provide a method for reducing surface copper powder during the rolling process of copper rods. This method flexibly adjusts process parameters and the use of lubricants according to the characteristics of different process stages. By segmenting the process and providing differentiated lubricant supply, the amount of copper powder generated can be significantly reduced.

[0009] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0010] A method for reducing surface copper powder during copper rod rolling includes the following steps:

[0011] The rolling process is divided into multiple process segments, and different lubricants are supplied to each process segment;

[0012] Establish a correlation model between process parameters and copper rod performance, and generate a feasible region for process parameters based on the target performance of the copper rod;

[0013] The surface parameters of the rolls in each process section were monitored and the changes in surface morphology were calculated.

[0014] Adjust the rolling process parameters when the change in surface morphology exceeds the set value;

[0015] Monitor the change in surface morphology corresponding to the adjusted rolling process parameters and compare it with the set value; until the change in surface morphology is less than the set value.

[0016] An alarm will be triggered when the rolling process parameters are adjusted to the boundary of the feasible region and the change in surface morphology exceeds the set value.

[0017] Furthermore, the rolling process is divided into roughing, finishing, and shaping sections along the rolling direction, with the reduction rate gradually decreasing in each section.

[0018] Specifically, the reduction rate in the roughing rolling section is 35%–45%, the reduction rate in the finishing rolling section is 15%–25%, and the reduction rate in the shaping section is 3%–8%.

[0019] Preferably, the lubricant supply is set differently according to the process section: sulfur-containing extreme pressure lubricant with a viscosity of 120-150 cSt is used in the roughing section, with a supply of ≥20 L / min; low-viscosity mineral oil with a viscosity of 40-60 cSt is used in the finishing section, with a supply of 10-15 L / min; and water-based emulsion with a concentration of 8%-12% is used in the setting section, with a supply of 5-8 L / min.

[0020] Preferably, a correlation model is established between process parameters and copper rod performance, including:

[0021] (1) Extract historical process parameter datasets from the production database, including rolling speed, rolling force, reduction rate, lubricant supply, initial roughness of rolls, and the corresponding amount of copper powder on the surface of copper rods, tensile strength and elongation;

[0022] When cleaning data, the following abnormal records should be removed: sections where the instantaneous fluctuation of rolling force exceeds ±10% and lasts for more than 5 seconds; invalid data where the measured value of surface copper powder exceeds the upper limit of the sensor range; and production data during the overload alarm period of the rolling mill main motor.

[0023] (2) For records with a missing rate of less than 20% of process parameters, after the time series continuity verification is passed, the data is supplemented by cubic spline interpolation.

[0024] The time series continuity verification requires that the following conditions be met simultaneously: (a) the rolling speed fluctuation within 10 seconds before and after the missing data segment is ≤ ±3%; (b) the rolling force change rate is ≤ 50 kN / s; and (c) the reduction rate adjustment interval is ≥ 30 seconds.

[0025] Based on the extreme values ​​of process parameters, the rolling power formula P=F×v and the minimum lubrication constraint Q≥0.1F are used to construct boundary virtual data points to expand the coverage of the dataset;

[0026] (3) Based on the expanded dataset, a model of the relationship between process parameters and copper rod performance is constructed using the random forest algorithm;

[0027] (4) Add prior knowledge constraints, eliminate interference variables that violate physical laws by ranking the importance of features, and then make local corrections to outliers in the random forest prediction results that conflict with the knowledge constraints.

[0028] Furthermore, based on the target performance of the copper rod, a feasible domain for generating process parameters is defined, including:

[0029] Set performance constraints for the copper rod target;

[0030] Based on the correlation model, a set of process parameter combinations that satisfy all constraints is selected to form a high-dimensional feasible domain sample set;

[0031] Cluster the feasible region sample set, remove discrete noise points, and use the convex hull of the largest cluster as the initial feasible region;

[0032] Fit the boundary function of the feasible region, and output the safe operating range of all parameter combinations that simultaneously meet the target performance requirements at a 95% confidence level, thus obtaining the feasible region of process parameters.

[0033] Specifically, the permissible operating range is marked by a green area in the human-machine interface. When a parameter point enters within 5% of the feasible domain boundary, the interface triggers a red warning area and displays a list of adjustment suggestions, including prioritizing increasing the amount of lubrication or reducing the rolling speed.

[0034] Furthermore, the surface parameters of the roll include groove depth, surface roughness, and oil storage rate. The change in surface morphology is the weighted deviation of groove depth, surface roughness, and oil storage rate from the initial design values.

[0035] Furthermore, the formula for calculating the change in surface morphology is as follows:

[0036]

[0037] Where ΔK is the change in surface morphology, d is the groove depth, Ra is the surface roughness, η is the oil storage rate, d0 is the initial design value of the groove depth, Ra0 is the initial design value of the surface roughness, η0 is the initial design value of the oil storage rate, and α, β, and γ are weighting coefficients, which are dynamically adjusted according to the rolling stage.

[0038] Furthermore, the weighting coefficients α, β, and γ take the following values:

[0039] Roughing section: α = 0.6, β = 0.2, γ = 0.2;

[0040] Finishing rolling section: α = 0.3, β = 0.5, γ = 0.2;

[0041] Fixed segment: α = 0.2, β = 0.3, γ = 0.5.

[0042] Furthermore, the method for determining the set value is as follows: statistically analyze the distribution of surface morphology changes when copper powder exceeds the standard in historical production, and take the upper limit of the 95% confidence interval.

[0043] Furthermore, the priority order for adjusting process parameters is as follows: prioritize increasing the lubricant supply in the current process segment, with a single adjustment range of ≤15% for the lubricant supply; if the change in surface morphology corresponding to the adjusted rolling process parameters is still greater than the set value, then reduce the rolling speed, with a single adjustment range of ≤10% for the rolling speed.

[0044] Furthermore, the roll surface is provided with a substrate layer, a transition layer and a functional layer from bottom to top. The thickness of the substrate layer is 50-80 μm, the thickness of the transition layer is 10-15 μm, and the thickness of the functional layer is 3-5 μm.

[0045] Furthermore, if the parameters are adjusted to the feasible domain boundary and the change in surface morphology still exceeds the limit, an alarm is triggered and the system switches to the standby roll group.

[0046] Preferably, the surface morphology parameters D0, Ra0, and η0 of the spare roll set deviate from the initial design values ​​of the current roll by ≤5%, and the switching action is completed within 10 seconds to ensure production continuity.

[0047] Compared with the prior art, the present invention has the following beneficial effects:

[0048] (1) This invention systematically solves the problems of severe metal adhesion wear, deterioration of surface roughness, and difficulty in removing residual copper powder caused by frictional heat during high-speed rolling due to large reduction and high-speed rolling in traditional processes by constructing a closed-loop control system of process segment optimization, dynamic monitoring and adjustment, and rapid emergency response. Specifically, the rolling process is divided into three stages: roughing, finishing, and shaping. The process parameters of each stage are adjusted independently. Furthermore, the lubricant type and supply are matched according to the tribological characteristics. In the roughing stage, a high-viscosity sulfur-containing extreme pressure lubricant is used to reduce direct metal contact through extreme pressure anti-wear agents, thereby maximizing the reduction of copper powder generation. In the finishing stage, low-viscosity mineral oil forms a stable oil film under high-speed rolling, improving surface roughness (Ra). In the shaping stage, water-based emulsion uses cleaning properties to remove residual particles on the surface, significantly reducing the amount of copper powder adhering to the finished product.

[0049] (2) This invention dynamically monitors changes in the surface morphology of the rolls, collects data on groove depth, roughness, and oil storage rate, and introduces a dynamic weighting coefficient to provide an early warning of the risk of excessive copper powder by 5 to 10 seconds. This avoids situations where parameter adjustments lag behind actual operating conditions. Once ΔK is detected to exceed the threshold, the system prioritizes adjusting the lubrication amount to quickly restore lubrication, and then reduces the rolling speed to control frictional heat. If adjusting the parameters to the feasible boundary is still ineffective, the system automatically switches to the standby roll group within 10 seconds, improving the continuous operation rate of the production line and reducing annual downtime due to failure.

[0050] (3) This invention constructs a correlation model between process parameters and copper rod performance using historical production data. A prediction model based on the random forest algorithm, combined with prior physical constraints, generates the feasible region of process parameters. Operators can intuitively obtain the dynamic boundaries between the green safety zone and the red warning zone, avoiding tensile strength fluctuations caused by blind parameter adjustments. The human-machine interface displays parameter positions and adjustment suggestions in real time, improving operational efficiency and shortening the debugging cycle. This invention not only achieves fundamental control of the copper powder problem but also promotes the transformation of rolling processes towards intelligence and precision, providing reliable technical support for the large-scale production of high-precision copper rods. Attached Figure Description

[0051] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0052] Figure 1 This is a flowchart illustrating the method for reducing surface copper powder during the rolling process of copper rods according to the present invention. Detailed Implementation

[0053] To further illustrate the technical means and effects adopted by the present invention to achieve its intended purpose, a method for reducing surface copper powder during the rolling process of copper rods according to the present invention is described in detail below, including its specific implementation methods, features, and effects. It should be understood that the specific embodiments described herein are only for explaining the present invention and are not intended to limit the present invention.

[0054] like Figure 1 The following is a method for reducing surface copper powder during the rolling process of copper rods, comprising the following steps:

[0055] S1 divides the rolling process into multiple process segments along the rolling direction. Specifically, the rolling process can be divided into roughing, finishing and shaping segments according to the number of mill stands, and different lubricants are supplied to each process segment.

[0056] It should be noted that the reduction rate gradually decreases in the roughing, finishing, and shaping sections. The roughing section has a relatively low rolling speed and a reduction rate of 35%–45%, resulting in a large reduction amount and strong friction, which easily leads to significant wear on the rolls and copper rod surfaces. Therefore, the lubricant needs to have high viscosity and anti-wear capabilities to effectively reduce friction and lower temperature rise. The finishing section has a reduction rate of 15%–25%. Although the contact pressure is lower, the speed is higher, and the friction is still relatively high. It is necessary to reduce the heat generated by friction and maintain surface quality. The lubricant should be able to reduce frictional heat during high-speed rolling, reduce surface roughness, and prevent excessive copper powder from appearing on the copper rod surface. The shaping section has a reduction rate of 3%–8%.

[0057] Specifically, in this embodiment, the lubricant supply is set differently according to the process section: sulfur-containing extreme pressure lubricant with a viscosity of 120-150 cSt is used in the roughing section, with a supply of ≥20 L / min; low-viscosity mineral oil with a viscosity of 40-60 cSt is used in the finishing section, with a supply of 10-15 L / min; this is to reduce the temperature fluctuation of the roll surface and reduce the copper powder shedding caused by hot brittle cracks on the copper surface; water-based emulsion with a concentration of 8%-12% is used in the sizing section, with a supply of 5-8 L / min; by matching the viscosity of the lubricant in stages, the shear stress between the copper and the roll is reduced, and copper powder peeling is inhibited.

[0058] To extend the service life of the rolls, a substrate layer, a transition layer, and a functional layer are sequentially formed on the roll surface from bottom to top. The thickness of the substrate layer is 50–80 μm, the thickness of the transition layer is 10–15 μm, and the thickness of the functional layer is 3–5 μm. This invention features a multi-layer coating design on the roll surface. The substrate layer provides high-strength support, and the low coefficient of friction of the functional layer reduces copper adhesion, thus lowering the risk of roll failure. The substrate layer can be an electroplated nickel layer or a WC-Co hard alloy, the transition layer can be a chemical vapor deposition Cr layer or a NiCrAlY transition layer, and the functional layer can be a magnetron sputtered Ti-Al-N coating or a CrN coating. The surface hardness is ≥2500 HV, and those skilled in the art can adjust these parameters according to actual conditions.

[0059] S2 establishes a correlation model between process parameters and copper rod performance, and generates a feasible region for process parameters based on the target performance of the copper rod;

[0060] Specifically, a correlation model is established between process parameters and copper rod performance, including:

[0061] (1) Connect the MES system and the SCADA system, extract six consecutive months of production data from the production database, extract historical process parameter datasets, including rolling speed, rolling force, reduction rate, lubricant supply, initial roughness of rolls, and the corresponding amount of copper powder on the surface of copper rods, tensile strength and elongation.

[0062] When cleaning data, the following abnormal records are removed: sections where the instantaneous fluctuation of rolling force exceeds ±10% and lasts for more than 5 seconds; invalid data where the measured value of surface copper powder exceeds the upper limit of the sensor range; production data during the overload alarm of the main motor of the rolling mill; removing data with sudden changes in rolling force can eliminate noise interference caused by equipment vibration or sensor failure; removing data during motor overload avoids the misleading effect of abnormal working conditions on model training. After data cleaning, the signal-to-noise ratio of the training set is improved by ≥3 times, the generalization ability of the model is enhanced, and the misjudgment rate of sudden working conditions is reduced.

[0063] (2) For records with a missing rate of less than 20% of process parameters, after the time series continuity verification is passed, cubic spline interpolation is used to complete the missing data; among them, cubic spline interpolation retains the trend of process parameter changes and avoids step distortion caused by linear interpolation; virtual data forces the model to learn the physical feasible domain boundary to prevent the prediction results from violating the equipment capability limit.

[0064] The time series continuity verification requires that the following conditions be met simultaneously: (a) the rolling speed fluctuation within 10 seconds before and after the missing data segment is ≤ ±3% (e.g., the speed changes from 20 m / s to 20.6 m / s within the window); (b) the rolling force change rate is ≤ 50 kN / s (calculated by first-order difference); (c) the reduction rate adjustment interval is ≥ 30 seconds (verified by timestamp difference).

[0065] Based on the extreme values ​​of process parameters, such as the rolling power boundary and the lubrication lower limit, the rolling power formula P(kW)=F(kN)×v(m / s) / 1000 and the minimum lubrication constraint Q≥0.1F are used to construct boundary virtual data points and expand the dataset coverage.

[0066] (3) Based on the expanded dataset, a model of the relationship between process parameters and copper rod performance is constructed using the random forest algorithm; the nonlinear fitting ability of random forest can capture the complex coupling relationship between process parameters and performance indicators.

[0067] (4) Add prior knowledge constraints, eliminate interference variables that violate physical laws by ranking the importance of features, and then make local corrections to outliers in the random forest prediction results that conflict with the knowledge constraints.

[0068] Specifically, the prior knowledge constraints are rules related to the friction between the copper rod and the rolling mill, such as setting a lower limit for the lubricant supply Q≥0.1F, and establishing correlation constraints between rolling speed and reduction rate. The way to locally correct conflicting data points is to find the 5 most recent compliant samples in the feature space and replace the original predicted value with a weighted average.

[0069] The feasible domain for generating process parameters based on the target performance of the copper rod includes:

[0070] Set target performance constraints for the copper rod; that is, set the copper rod target performance input module in the industrial control system HMI interface, including inputting the target performance of the copper rod (such as tensile strength ≥260MPa, elongation ≥42%, surface copper powder content ≤15mg / m²). 2 Constraints are transmitted to the server in JSON format and automatically converted into computable mathematical boundaries, providing a benchmark for parameter selection.

[0071] Based on the correlation model, a set of process parameter combinations that satisfy all constraints is selected to form a high-dimensional feasible region sample set. Specifically, by calling the random forest model of the above components, multiple sets of simulated parameter combinations are generated by traversing the parameter space (rolling speed, rolling force, reduction rate, etc.). The tensile strength, elongation and copper powder content of each set are predicted in parallel. Combinations that simultaneously satisfy all target constraints are selected (approximately 12-15% of the data are retained). The feasible region modeling covers the interaction of multiple parameters, avoiding the chain of process fluctuations caused by the optimization of a single parameter.

[0072] After performing Min-Max normalization on the feasible region sample set, the DBSCAN algorithm is applied to cluster the samples (neighborhood radius ε = 0.3, minimum number of samples = 50). After removing discrete noise points, the convex hull of the largest cluster is used as the initial feasible region; the convex hull boundary of the largest cluster is extracted.

[0073] The specific steps for eliminating discrete noise points are: eliminating noise points (accounting for approximately 7-9%) and small clusters (clusters with fewer than 5% of the total data), eliminating parameter outliers caused by sensor noise or process anomalies, improving the robustness of the feasible region, and transforming nonlinear constraints into convex optimization problems using convex hull boundary constraints to ensure the global optimality of parameter adjustment paths.

[0074] Then, the high-dimensional feasible region is fitted by support vector regression (SVR) to form the feasible region boundary function. The boundary function is stored in the database in the form of a coefficient matrix. The specific coefficients are generated by fitting the training data. At a 95% confidence level, the safe operating range of all parameter combinations that simultaneously meet the target performance requirements is output, thus obtaining the feasible region of process parameters.

[0075] Specifically, the permissible operating range is indicated by a green area in the human-machine interface. When a parameter point enters within 5% of the feasible domain boundary, the interface triggers a red warning area and displays a list of adjustment suggestions, including prioritizing increasing lubrication or reducing rolling speed. In this invention, 3D visualization lowers the barrier to understanding multi-parameter coupling, helping operators quickly locate anomalies; distance threshold warnings provide a buffer zone, avoiding frequent alarms.

[0076] S3 monitors the surface parameters of the rolls in each process section and calculates the changes in surface morphology.

[0077] Furthermore, the surface parameters of the roll include groove depth, surface roughness, and oil storage rate. The change in surface morphology is the weighted deviation of the groove depth, surface roughness, and oil storage rate from the initial design values. Specifically, for each process segment, a laser profilometer or laser scanner is used to detect the groove depth online. Surface roughness is sampled using a contact roughness meter, and the oil storage rate is indirectly calculated using an oil film thickness sensor: Oil storage rate = measured oil film thickness / theoretical maximum oil film thickness × 100%. Data is sampled every 50-100 meters of rolling. By weighted summing these three surface parameters, the change in roll surface morphology can be quantified, thereby assessing the risk of copper powder generation. If the change in surface morphology exceeds the set value, it indicates that the rolling process needs adjustment.

[0078] The formula for calculating the change in surface morphology is:

[0079]

[0080] Wherein, ΔK represents the change in surface morphology, d represents the groove depth, Ra represents the surface roughness, η represents the oil storage rate, d0 represents the initial design value of the groove depth, Ra0 represents the initial design value of the surface roughness, and η0 represents the initial design value of the oil storage rate. For example, the initial values ​​are designed as d0 = 50 ± 5 μm; Ra0 = 0.6 ± 0.1 μm; η0 ≥ 0.75; α, β, and γ are weighting coefficients, which are dynamically adjusted according to the rolling stage. The dynamic allocation of weighting coefficients makes the ΔK index more closely match the core failure modes of each process segment, and the anomaly detection response time is shortened by more than 30%.

[0081] In the initial settings, the roughing section prioritizes the mechanical locking lubricant's ability to lock in the grooves, with weighting coefficients α, β, and γ set to α = 0.6, β = 0.2, and γ = 0.2. The finishing section prioritizes surface smoothness, focusing on controlling Ra to prevent scratches on the copper rod surface, with weighting coefficients α = 0.3, β = 0.5, and γ = 0.2. The shaping section enhances oil retention to maintain oil film integrity, with weighting coefficients α = 0.2, β = 0.3, and γ = 0.5. These weighting coefficients are stored in a database parameter table and can be manually fine-tuned (within ±0.1 range) via the HMI interface.

[0082] During production, in the finishing rolling section, if the rolling speed is increased to above 20 m / s, the β weight is corrected in real time using an online friction coefficient detector (μ value): β 新 =β 原 +0.1×(μ 实测 -μ 基准 ) / μ 基准 Through real-time process feedback, when the friction coefficient exceeds the reference value by 10%, β increases from 0.5 to 0.6, strengthening surface roughness monitoring and avoiding copper powder runaway caused by sudden increase in frictional heat under high-speed rolling.

[0083] S4 selects three consecutive months of production data and statistically analyzes the ΔK distribution when copper powder exceeds the standard in historical production. Based on kernel density estimation (KDE), the 95th quantile of ΔK is calculated, and the upper limit of the 95% confidence interval is taken as the set value. When the change in surface morphology is greater than the set value, the rolling process parameters are adjusted through the PLC control module according to the priority of first adjusting the lubricant supply and then adjusting the rolling speed. The specific priority order is: first increase the lubricant supply of the current process segment, and the single adjustment range of the lubricant supply is ≤15%; if the change in surface morphology corresponding to the adjusted rolling process parameters is still greater than the set value, the rolling speed is reduced, and the single adjustment range of the rolling speed is ≤10%. When reducing the speed, an exponential decay curve is used instead of a step decrease to avoid process oscillation caused by parameter abrupt changes.

[0084] S5 monitors the surface morphology change corresponding to the adjusted rolling process parameters and compares it with the set value; until the surface morphology change is less than the set value; the present invention can dynamically correct the process parameters based on the real-time feedback of the surface morphology change, avoiding the increase in copper powder index caused by the accumulation of roll wear in traditional open-loop control.

[0085] S6 will trigger an alarm when the rolling process parameters are adjusted to the feasible domain boundary and the change in surface morphology is greater than the set value. The specific alarm signal can be set to an audible and visual alarm, and can be pushed to the industrial control system interface to prompt the switching of the standby roll group. The feasible domain boundary constraint ensures that the adjusted parameters always meet the mechanical performance requirements of the copper rod, avoiding the risk of rod breakage caused by excessive parameter adjustment.

[0086] To reduce the impact of switching rolls on copper rods, the surface morphology parameters D0, Ra0, and η0 of the standby roll set deviate from the initial design values ​​of the current roll by ≤5%, and the switching action is completed within 10 seconds to ensure production continuity.

[0087] This invention systematically solves the problems of severe metal adhesion wear, deterioration of surface roughness, and difficulty in removing residual copper powder caused by frictional heat during high-speed rolling and segmented process optimization, dynamic monitoring and adjustment, and rapid emergency response in traditional processes. Specifically, the rolling process is divided into three segments: roughing, finishing, and shaping. The process parameters for each segment are adjusted independently, and the type and supply of lubricant are matched according to tribological characteristics. In the roughing segment, a high-viscosity sulfur-containing extreme pressure lubricant is used to reduce direct metal contact through extreme pressure anti-wear agents, thereby minimizing the amount of copper powder generated. In the finishing segment, low-viscosity mineral oil forms a stable oil film under high-speed rolling, improving surface roughness (Ra). In the shaping segment, water-based emulsion uses cleaning properties to remove residual particles on the surface, significantly reducing the amount of copper powder adhering to the finished product.

[0088] Those skilled in the art will appreciate that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for reducing surface copper powder during the rolling process of copper rods, characterized in that, Includes the following steps: The rolling process is divided into multiple process segments, and different lubricants are supplied to each process segment; Establish a correlation model between process parameters and copper rod performance, and generate a feasible region for process parameters based on the target performance of the copper rod; The surface parameters of the rolls in each process section were monitored and the changes in surface morphology were calculated. When the change in surface morphology exceeds a set value, adjust the rolling process parameters; Monitor the change in surface morphology corresponding to the adjusted rolling process parameters and compare it with the set value; until the change in surface morphology is less than the set value. An alarm is triggered when the rolling process parameters are adjusted to the feasible domain boundary and the change in surface morphology exceeds the set value.

2. The method for reducing surface copper powder during copper rod rolling according to claim 1, characterized in that, The rolling process is divided into a roughing section, a finishing section, and a shaping section along the rolling direction, with the reduction rate gradually decreasing in the roughing section, the finishing section, and the shaping section.

3. The method for reducing surface copper powder during copper rod rolling according to claim 2, characterized in that, The lubricant supply is set differently according to the process section. The roughing section uses sulfur-containing extreme pressure lubricant with a supply of ≥20L / min; the finishing section uses low-viscosity mineral oil with a supply of 10~15L / min; and the shaping section uses water-based emulsion with a supply of 5~8L / min.

4. The method for reducing surface copper powder during copper rod rolling according to claim 1, characterized in that, The feasible domain for generating process parameters based on the target performance of the copper rod includes: Set performance constraints for the copper rod target; Based on the aforementioned correlation model, a set of process parameter combinations that satisfy all constraints is selected to form a high-dimensional feasible domain sample set. Cluster the feasible region sample set, remove discrete noise points, and use the convex hull of the largest cluster as the initial feasible region; Fit the boundary function of the feasible region, and output the safe operating range of all parameter combinations that simultaneously meet the target performance requirements at a 95% confidence level, thus obtaining the feasible region of process parameters.

5. The method for reducing surface copper powder during copper rod rolling according to claim 1, characterized in that, The surface parameters of the roll include groove depth, surface roughness, and oil storage rate. The change in surface morphology is the weighted deviation of the groove depth, surface roughness, and oil storage rate from the initial design value.

6. The method for reducing surface copper powder during copper rod rolling according to claim 5, characterized in that, The formula for calculating the change in surface morphology is: ； Wherein, ∆K is the change in surface morphology, d is the groove depth, Ra is the surface roughness, η is the oil storage rate, d0 is the initial design value of the groove depth, Ra0 is the initial design value of the surface roughness, η0 is the initial design value of the oil storage rate, and α, β, γ are weighting coefficients, which are dynamically adjusted according to the rolling stage.

7. A method for reducing surface copper powder during copper rod rolling according to claim 6, characterized in that, The method for determining the set value is as follows: statistically analyze the distribution of surface morphology changes when copper powder exceeds the standard in historical production, and take the upper limit of the 95% confidence interval.

8. The method for reducing surface copper powder during copper rod rolling according to claim 1, characterized in that, The priority order for adjusting the rolling process parameters is as follows: prioritize increasing the lubricant supply in the current process segment, with a single adjustment range of ≤15% for the lubricant supply; if the change in surface morphology corresponding to the adjusted rolling process parameters is still greater than the set value, then reduce the rolling speed, with a single adjustment range of ≤10% for the rolling speed.

9. The method for reducing surface copper powder during copper rod rolling according to claim 1, characterized in that, The surface of the roll is provided with a substrate layer, a transition layer and a functional layer from bottom to top. The thickness of the substrate layer is 50~80μm, the thickness of the transition layer is 10~15μm and the thickness of the functional layer is 3~5μm.

10. A method for reducing surface copper powder during copper rod rolling according to claim 1, characterized in that, If the parameters are adjusted to the feasible domain boundary and the change in surface morphology still exceeds the limit, an alarm is triggered and the system switches to the standby roll group.

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