Rolling force closed-loop control method
By using a closed-loop rolling force control method, traditional position sensors are removed, a closed-loop rolling force signal is constructed, and differential rolling force control is switched to solve the problems of high cost and electromagnetic interference in foil rolling mills, thus achieving stable production and high-quality products.
Patent Information
- Application Number
- CN202511322652.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-16
- Publication Date
- 2025-11-14
AI Technical Summary
Existing foil rolling mill control systems rely on position sensors, resulting in high costs, susceptibility to electromagnetic interference, frequent and difficult-to-handle malfunctions, and impacting production stability and product quality.
A closed-loop rolling force control method is adopted. The Sony magnetostrictive displacement sensor and ET200 counting module are removed, and a closed-loop control logic based on the rolling force signal is constructed. The shape control is switched to differential rolling force control, and the bypass logic is activated when the sensor fails, the fault signal is shielded, and the system switches to pure rolling force control mode.
Reduce equipment and maintenance costs, improve production stability and safety, enhance product quality, ensure continuous production, and effectively address sensor failures.
Smart Images
Figure CN120940398A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of metal rolling technology, specifically a closed-loop control method for rolling force. Background Technology
[0002] In foil rolling production, the TCS (rolling mill control system) is the core system ensuring rolling accuracy and stability. Traditional technical solutions have long relied on position sensors to achieve control functions. Existing standard TCS control systems are generally equipped with four sets of Sony magnetostrictive displacement sensors and four corresponding ET200 counting modules for position detection and position control.
[0003] However, on the one hand, the core control requirements of foil rolling mills are concentrated on rolling force control, and position control is not a necessary function. The configuration of the aforementioned sensors and counting modules creates redundancy, which not only directly increases the initial equipment cost by about RMB 500,000, but also requires bearing subsequent maintenance costs, resulting in high equipment life cycle costs. On the other hand, traditional systems are heavily dependent on position sensors, and the control logic is deeply bound to the position signal. Once the sensor fails to work properly, the entire rolling control system is prone to paralysis.
[0004] In cold rolling mill applications equipped with electromagnetic edge heaters, the insufficient anti-interference capability of existing technologies is particularly prominent. The electromagnetic compatibility (EMC) noise generated during the operation of the electromagnetic edge heaters easily interferes with Sony magnetostrictive displacement sensors, leading to frequent sensor malfunctions. Even with conventional protective measures, noise interference is difficult to eliminate, and sensor failures can have serious consequences: from instability in the rolling process to foil breakage, and even potential safety accidents such as mill stand fires. Some customers have therefore requested the return of electromagnetic edge heater systems, severely impacting production continuity and safety.
[0005] Traditional foil shape control relies heavily on tilt control, which is closely linked to position sensor signals. When sensors fail or are removed, the accuracy of shape control drops significantly, making it difficult to effectively compensate for foil shape deviations. This results in insufficient product flatness and affects final product quality. Furthermore, existing systems lack adaptive mechanisms to handle sensor failures. When a sensor malfunctions, the system cannot quickly switch to an alternative control mode, often forcing an interruption of the rolling process and further exacerbating production losses. These shortcomings make traditional technical solutions insufficient in terms of cost control, anti-interference capabilities, fault handling, and product quality assurance to meet the actual production needs of foil finishing mills.
[0006] To address this, those skilled in the art have proposed a closed-loop control method for rolling force, which aims to reduce equipment costs and improve rolling stability, effectively address sensor failures, and meet the actual production needs of foil finishing mills. Summary of the Invention
[0007] To address the aforementioned technical problems, this invention provides a closed-loop control method for rolling force, thereby resolving the issues raised in the background art.
[0008] A closed-loop control method for rolling force includes the following steps:
[0009] S1. In the foil finishing mill using the TCS control system, remove all Sony magnetostrictive displacement sensors and corresponding ET200 counting modules.
[0010] S2. Switch the frame control and thickness control from position control to rolling force control, and build a closed-loop control logic based solely on real-time rolling force signals. Regulate the foil rolling process by monitoring the rolling force reference value.
[0011] S3. Switch the plate shape control from tilt control to differential rolling force control, set the position reference value and tilt reference value to zero, and control the plate shape through differential rolling force distribution;
[0012] S4. Real-time monitoring of the rolling status during the rolling process. When a cold rolling mill with a position sensor detects a position sensor failure, the bypass logic is immediately activated.
[0013] Preferably, in step S1, the number of Sony magnetostrictive displacement sensors removed is 4 sets, and the corresponding number of ET200 counting modules is 4 sets.
[0014] Preferably, in step S2, the rolling force reference value is the GCS1:WFRd.Diff.RF parameter in the TCS control system, with the unit being N.
[0015] Preferably, in step S2, the foil rolling process specifically involves rolling from an initial thickness to a target thickness, wherein the initial thickness is 0.023 mm and the target thickness is 0.013 mm.
[0016] Preferably, in step S3, controlling the plate shape through differential rolling force distribution specifically involves dynamically adjusting the rolling force distribution on both sides of the mill based on real-time monitored rolling force reference values, and controlling the straightness through different rolling forces.
[0017] Preferably, in step S4, the position sensor fault is specifically a fault caused by electromagnetic compatibility interference in the Sony magnetostrictive displacement sensor.
[0018] Preferably, in step S4, after the bypass logic is activated:
[0019] S401, shield the faulty sensor signal;
[0020] S402, Switch to pure rolling force closed-loop control mode to maintain rolling, so that the stand continues rolling;
[0021] S403. When the rolling mill stops and rolling ceases, it is forced to enter the Q-Stop state until all position sensor faults are repaired.
[0022] Compared with the prior art, the present invention has the following beneficial effects:
[0023] 1. This invention reduces the initial equipment cost and subsequent maintenance cost of foil finishing mill by removing the four sets of Sony magnetostrictive displacement sensors and the corresponding four sets of ET200 counting modules in the traditional standard configuration. It breaks through the control framework of traditional TCS system that relies on position sensors, and replaces position control with rolling force control, thereby achieving cost optimization while meeting the core requirements of foil mill.
[0024] 2. This invention fully switches the frame control and thickness control from position control to rolling force control, and changes the shape control from tilt control to differential rolling force control, forming an integrated closed-loop control system based on real-time rolling force signals. Stable rolling can be achieved through rolling force closed-loop control logic in the absence of Sony position sensors.
[0025] 3. This invention addresses sensor malfunctions caused by EMC noise generated by the electromagnetic edge heater. By bypassing logic, the fault signal can be shielded and the system can switch to a pure rolling force control mode, avoiding serious consequences such as strip breakage and mill fire. Furthermore, after shutdown, the system maintains a Q-Stop state until the fault is repaired, ensuring production continuity and safety, and achieving safe and controllable production under fault conditions.
[0026] 4. The present invention sets the position reference value and the tilt reference value to zero, and dynamically adjusts the rolling force on both sides of the rolling mill through differential rolling force distribution, effectively compensating for plate shape deviation, improving foil flatness, and improving product quality. Attached Figure Description
[0027] Figure 1 This is a screenshot of the actual production application of the present invention;
[0028] Figure 2 The present invention applies the tilt position and roll gap calculation to the deviation rolling force and rolling force;
[0029] Figure 3 This is a data recording diagram of the present invention;
[0030] Figure 4 The present invention provides an example of an automatic switching screen where the control system automatically identifies the signal channel of a faulty sensor and cuts off the signal input of that channel during the operation of a configured magnetic ruler system, thus avoiding erroneous signals. Detailed Implementation
[0031] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.
[0032] Example: Figure 1 As shown, this invention provides a closed-loop control method for rolling force, applied to a foil finishing mill using a TCS control system. The specific steps are as follows:
[0033] S1. In the TCS control system of the foil finishing mill, the traditional standard configuration of 4 sets of Sony magnetostrictive displacement sensors and corresponding 4 sets of ET200 counting modules were removed; thereby eliminating sensor procurement costs and EMC failure sources, and reducing subsequent investment in sensor installation and maintenance.
[0034] S2. By modifying the software control program and logic of the TCS control system, the stand control mode and thickness control mode are switched from the original position control to rolling force control, and a closed-loop control logic based solely on real-time rolling force signals is constructed.
[0035] Using the GCS1:WFRd.Diff.RF parameter in the TCS control system as the reference value for rolling force (in N), the changes in this parameter are monitored in real time, and the rolling process is adjusted according to its deviation from the target rolling force. In actual rolling, this method successfully rolled the foil from an initial thickness of 0.023 mm to a target thickness of 0.013 mm, with a stable rolling process and accuracy meeting production requirements.
[0036] S3, such as Figure 2 and Figure 3 As shown, the plate shape control mode is switched from the original tilt control to differential rolling force control, and the position reference value and tilt reference value are set to 0 through the TCS control system.
[0037] Based on the real-time monitored rolling force reference value (GCS1:WFRd.Diff.RF), the rolling force distribution between the drive side (DS) and the operating side (OS) of the mill is dynamically adjusted. The difference in rolling force between the two sides compensates for the foil's shape deviation, thereby achieving flatness control. For example, when a wavy defect is detected on the operating side of the foil, the rolling force on the operating side is appropriately increased to correct the shape through the difference in rolling force.
[0038] S4, such as Figure 4 As shown, in a cold rolling mill equipped with an electromagnetic edge heater, the operating status of the position sensor is monitored in real time. When a Sony magnetostrictive displacement sensor is detected to have malfunctioned due to electromagnetic compatibility (EMC) noise interference, the TCS control system immediately activates the bypass logic, which includes the following sub-steps:
[0039] S401, Shielding fault sensor signals: The control system automatically identifies the signal channel of the fault sensor and cuts off the signal input of that channel to prevent erroneous signals from affecting rolling control.
[0040] S402. Switch to pure rolling force closed-loop control mode: Completely switch the stand control, thickness control, and shape control to a rolling force-based closed-loop control mode to maintain continuous rolling on the mill stand. Testing showed that even after manually triggering the failure of each of the four Sony sensors, the mill still maintained a stable rolling state.
[0041] S403, Q-Stop Status Retention After Shutdown: When the rolling mill stops due to production needs or other reasons, and the rolling process stops, the control system forces the mill to enter the rapid stop (Q-Stop) state and locks the state until all position sensor faults are repaired, ensuring that rolling is not restarted before the fault is eliminated, thus avoiding secondary risks.
[0042] Through the above implementation methods, the cold rolling mill successfully solved the rolling instability problem caused by sensor failure in the case of EMC noise interference in the electromagnetic edge heater.
[0043] For cold rolling mill systems equipped with Sony magnetostrictive displacement sensors and corresponding ET200 counting modules, the core objective of this invention is to achieve intelligent identification and isolation of faulty magnetic scale sensors, preventing erroneous signals from interfering with the rolling process. The specific logic is as follows:
[0044] The TCS control system monitors the operating status of each magnetic scale sensor in real time and continuously collects parameters on the integrity, stability and consistency of sensor signals.
[0045] When a magnetic ruler sensor is detected to malfunction due to electromagnetic compatibility (EMC) interference, hardware damage, or other reasons (such as signal jumps, no feedback, or deviation exceeding the threshold), the control system can automatically locate the signal channel where the faulty sensor is located.
[0046] Once the faulty channel is identified, the bypass logic is immediately activated to cut off the signal input of the faulty channel, prevent the erroneous signal from entering the control loop, and ensure that the rolling control logic operates only based on valid signals.
[0047] The system simultaneously switches the stand control, thickness control, and shape control to a pure rolling force closed-loop control mode to maintain stable mill operation and prevent rolling interruptions or product quality defects caused by sensor malfunctions. This design has been verified in practice; when a magnetic scale malfunction is manually triggered, the system can respond quickly and achieve a seamless switchover.
[0048] For the design of aluminum foil rolling mills, Sony magnetostrictive displacement sensors (magnetic scales) may not be required, based on the following reasons:
[0049] The core control requirements of aluminum foil rolling mills focus on the accuracy and stability of rolling force, and traditional position control relying on magnetic rulers is not a necessary function. This invention constructs a closed-loop control logic based solely on real-time rolling force signals (step S2), completely switching the stand control and thickness control from position control to rolling force control, which can accurately realize the rolling process of foil from initial thickness (e.g., 0.023mm) to target thickness (e.g., 0.013mm).
[0050] By switching the plate shape control from tilt control to differential rolling force control (step S3), setting the position reference value and tilt reference value to zero, and dynamically adjusting the rolling force distribution on both sides of the mill based on the real-time rolling force reference value (GCS1:WFRd.D i ff.RF parameter in the TCS control system), the plate shape deviation can be effectively compensated and the flatness of the aluminum foil can be guaranteed without relying on the magnetic ruler signal.
[0051] Removing the magnetic scale and its corresponding ET200 counting module (step S1) directly reduces initial equipment costs and subsequent maintenance costs. It also eliminates potential sources of failure due to EMC interference, improving the long-term reliability of the system. Practice shows that aluminum foil rolling mills using this design can still achieve stable and high-precision rolling production even without a magnetic scale, fully meeting actual production needs.
[0052] In summary, this invention, through a differentiated design approach, not only solves the problem of fault signal interference in the already configured magnetic scale system, but also provides a low-cost, high-stability control scheme for aluminum foil rolling mills without magnetic scales, comprehensively improving the adaptability and economy of the rolling mill control system.
[0053] It is important to note that the constructions and arrangements of this application shown in several different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who consult this disclosure will readily understand that many modifications are possible without substantially departing from the novel teachings and advantages of the subject matter described in this application. Other substitutions, modifications, alterations, and omissions may be made in the design, operation, and arrangement of the exemplary embodiments without departing from the scope of the invention. Therefore, the invention is not limited to the particular embodiments but extends to a variety of modifications that still fall within the scope of the appended claims.
[0054] Furthermore, in order to provide a concise description of exemplary embodiments, not all features of actual embodiments (i.e., those features that are not relevant to the best mode of carrying out the invention as currently considered, or those features that are not relevant to implementing the invention) may be omitted.
[0055] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.
Claims
1. A closed-loop control method for rolling force, characterized in that, Includes the following steps: S1. In the foil finishing mill using the TCS control system, remove all Sony magnetostrictive displacement sensors and corresponding ET200 counting modules. S2. Switch the frame control and thickness control from position control to rolling force control, and build a closed-loop control logic based solely on real-time rolling force signals. Regulate the foil rolling process by monitoring the rolling force reference value. S3. Switch the plate shape control from tilt control to differential rolling force control, set the position reference value and tilt reference value to zero, and control the plate shape through differential rolling force distribution; S4. Real-time monitoring of the rolling status during the rolling process. When a cold rolling mill with a position sensor detects a position sensor failure, the bypass logic is immediately activated.
2. The rolling force closed-loop control method as described in claim 1, characterized in that: In step S1, four sets of Sony magnetostrictive displacement sensors are removed, and four sets of corresponding ET200 counting modules are removed.
3. The rolling force closed-loop control method as described in claim 1, characterized in that: In step S2, the rolling force reference value is the GCS1:WFRd.Diff.RF parameter in the TCS control system, with the unit being N.
4. The closed-loop control method for rolling force as described in claim 1, characterized in that: In step S2, the foil rolling process specifically involves rolling from an initial thickness to a target thickness, wherein the initial thickness is 0.023 mm and the target thickness is 0.013 mm.
5. The closed-loop control method for rolling force as described in claim 1, characterized in that: In step S3, controlling the plate shape through differential rolling force distribution specifically involves dynamically adjusting the rolling force distribution on both sides of the mill based on the real-time monitored rolling force reference value, and controlling the straightness through different rolling forces.
6. The closed-loop control method for rolling force as described in claim 1, characterized in that: In step S4, the position sensor fault specifically refers to a fault in the Sony magnetostrictive displacement sensor caused by electromagnetic compatibility interference.
7. The closed-loop control method for rolling force as described in claim 1, characterized in that, In step S4, after the bypass logic is activated: S401, shield the faulty sensor signal; S402, Switch to pure rolling force closed-loop control mode to maintain rolling, so that the stand continues rolling; S403. When the rolling mill stops and rolling ceases, it is forced to enter the Q-Stop state until all position sensor faults are repaired.