Physical parameter online detection system for engineering materials

Abstract

The invention relates to the technical field of engineering material detection, and discloses a physical parameter online detection system for engineering materials, which comprises a load signal acquisition module for acquiring a torque signal, a roller rotating speed signal, a rack outlet tension signal and an engineering material outlet speed signal; a frequency domain feature extraction module peels off a periodic load component in the torque signal, extracts a non-periodic pulsating load, calculates an energy integral, and determines an interface friction power consumption weight; the geometric boundary judgment module determines an instantaneous horizontal position of a neutral surface by utilizing a slip deviation vector based on a flow conservation relationship; the dynamic compensation correction module calculates dynamic inertial energy consumption and corrects roller thermal expansion geometric increment and rack elastic flattening displacement; according to the device and the method, load noise generated by extrinsic resistance is stripped through multi-dimensional load decoupling, a drift path generated by external sensing hardware under a severe working condition is cut off, and accurate measurement of the rheological resistance is realized.

Description

Technical Field

[0001] This invention belongs to the field of engineering material testing technology, and in particular relates to an online testing system for the physical parameters of engineering materials. Background Technology

[0002] In the current continuous rolling production process of metal materials, real-time monitoring of physical parameters such as yield strength and rheological stress of the rolled parts is a fundamental requirement for ensuring product quality consistency and achieving automated control. The current mainstream technical solution mainly adopts external sensors such as X-ray thickness gauges or ultrasonic flaw detectors placed outside the stand. By using the signal penetration and reflection characteristics, the mechanical state characteristics of the material are obtained. This solution has high measurement resolution under standard working conditions and constitutes the common method in the current industrial inspection field. However, with the increase in production load and the application of high-strength engineering materials, the above method faces the constraints of environmental tolerance and long-term reliability. The intense cooling water spray, high-temperature iron oxide dust, and high-strength magnetic field interference in the rolling zone constitute a complex physical environment, which causes distortion of the signal transmission path of external sensors and induces irregular drift in measurement accuracy. In order to maintain system operation, constant temperature protection and high-frequency offline calibration are usually required. This hidden cost has evolved into a technical burden in long-term continuous operation.

[0003] To address measurement errors, conventional approaches primarily involve enhancing sensor shielding or introducing mathematical compensation models. However, these methods only address the issue at the signal transmission end, failing to address the fundamental contradiction between the measurement reference and the physical process. Simply increasing the density of sensing hardware or the complexity of the fitting algorithm not only leads to system redundancy but also, by ignoring the energy balance logic during rolling, results in a time lag between the detection results and the actual plastic deformation state of the material. The existing architecture, in its physical principles, struggles to reconcile the contradiction between detection frequency and environmental adaptability. For hardware measurement errors, conventional approaches involve enhancing hardware shielding or introducing mathematical compensation at the signal end. With the development of control theory, the focus of technology has shifted from hardware improvement to algorithm optimization. Interference is shielded through model coupling. For example, Chinese invention patent CN121211932A discloses a rolling force prediction method based on a deformation resistance rolling force coupling model of a cold continuous rolling mill. It uses a differential evolution algorithm to optimize parameters and attempts to improve accuracy by iterating the deformation zone length. However, this post-processing prediction method relies on a preset prior dataset and the algorithm's convergence process. It cannot isolate non-intrinsic power consumption such as mechanical loss of the drive system, interface friction, and tension traction in real time under millisecond-level dynamic working conditions, resulting in a time lag between the output results and the actual plastic deformation state of the material.

[0004] Therefore, the technical problem to be solved by this invention is how to utilize the dynamic response of the rolling mill stand itself to directly extract the real-time physical parameters of the material from the energy balance dimension, while utilizing the existing hardware in the system. Summary of the Invention

[0005] This invention provides an online detection system for physical parameters of engineering materials, comprising: The load signal acquisition module is used to acquire the torque sampling signal of the main drive motor, the roll speed signal, the stand outlet tension signal, and the engineering material outlet speed signal; The frequency domain feature extraction module is used to extract the non-periodic pulsating load characterizing the interface friction characteristics based on the periodic load component caused by the rotation of the roll in the stripping torque sampling signal of the digital bandpass filter, and to calculate the energy integral of the non-periodic pulsating load in the frequency band from 0.5Hz to 50Hz to determine the instantaneous weight of the interface friction power consumption in the total deformation work. The geometric boundary determination module is used to determine the instantaneous horizontal position of the neutral surface in the deformation zone based on the flow rate conservation relationship in the deformation zone and the slip deviation vector between the roll speed signal and the exit velocity signal of the engineering material. The instantaneous horizontal position of the neutral surface is used as the dynamic geometric boundary of the energy decoupling equation. The dynamic compensation and correction module is used to obtain the angular acceleration of the main drive motor to calculate the dynamic inertial energy consumption, and to calculate the geometric increment of the thermal expansion of the roll and the elastic flattening displacement of the frame based on the preset interface friction heat equivalent coefficient. The physical parameter calculation module is used to perform load decoupling calculation on the torque sampling signal based on instantaneous weights, dynamic geometric boundaries, dynamic inertial energy dissipation, geometric increment of roll thermal expansion, and elastic flattening displacement of the frame, so as to remove load noise generated by non-intrinsic resistance and output physical parameters characterizing the rheological properties of engineering materials.

[0006] Preferably, the frequency domain feature extraction module is also used to extract harmonic energy features in the torque sampling signal that are unrelated to the mechanical period, to characterize the load stability of the plastic rheological process of the engineering material by calculating the uniformity of energy distribution of the load pulsation signal in the frequency domain, and to output an evaluation index characterizing the uniformity of the internal structure of the engineering material based on the energy distribution uniformity and the preset microstructure consistency mapping logic.

[0007] Preferably, when determining the instantaneous horizontal position of the neutral surface, the geometric boundary determination module uses the fluctuation of the frame outlet tension signal to correct the offset value of the neutral surface in the horizontal axis, thereby realizing the closed-loop constraint of the kinematic slip characteristics on the dynamic energy consumption distribution.

[0008] Preferably, the dynamic compensation correction module is also used to construct a compensation matrix that covers the accumulation of thermal effects and the load step response. By analyzing the response frequency of the main drive motor, the periodic load fluctuations introduced by the roll eccentricity are removed, and the net load after removal is input into the physical parameter calculation module.

[0009] Preferably, the load signal acquisition module includes a high-frequency data acquisition card for acquiring torque sampling signals at a sampling frequency of not less than 2kHz, in order to capture transient load fluctuations caused by sudden changes in material interface stress.

[0010] Preferably, the frequency domain feature extraction module follows the following rules when calculating the energy distribution uniformity H: ,in, For non-periodic pulsating loads at a specific frequency The normalized power spectral density at the point is N, where N is the number of frequency domain samples. The physical parameter calculation module determines whether there are component segregation defects inside the engineering material based on the numerical offset of the energy distribution uniformity H.

[0011] Preferably, when performing load decoupling calculations, the physical parameter calculation module deducts the interface friction power consumption from the total load and calculates the average unit pressure within the deformation zone in conjunction with the dynamic geometric boundary.

[0012] Preferably, the frequency domain feature extraction module identifies the hidden material strengthening features in the non-periodic pulsating load by constructing a residual autoregressive model of the torque signal, and supplements the material strengthening features into the energy decoupling equation in real time.

[0013] Preferably, the system further includes a correction unit for acquiring offline mechanical testing data of engineering materials and dynamically adjusting the calculation ratio of instantaneous weights based on the deviation between the offline mechanical testing data and physical parameters.

[0014] Preferably, the physical parameters output by the physical parameter calculation module include the yield strength, rheological stress, and work hardening index of the engineering material.

[0015] Compared with existing technologies, the online detection system for physical parameters of engineering materials of this invention has the following advantages: 1. In online detection of physical parameters, a physical parameter identification path based on the power difference characteristics of the frame is established. The energy transfer characteristics are obtained by utilizing the physical tension bridge formed between adjacent frames. By gradually stripping the system mechanical loss, interface friction power consumption and tension traction power consumption from the main drive energy flow, the pure plastic deformation work of the rolled piece in the deformation zone is extracted. The direct causal image between the intrinsic mechanical state of the material and the inherent energy consumption distribution of the system is established, which solves the problem of uncontrollable drift of external sensing hardware caused by the harsh measurement environment under extreme conditions.

[0016] 2. By utilizing the kinematic constraint that the workpiece satisfies the constant flow rate per second within the deformation zone, and by monitoring the minute slip vectors of the roll speed and the workpiece exit speed, the instantaneous position of the neutral surface within the deformation zone is inverted and used as the dynamic geometric boundary of the energy decoupling equation. This achieves a closed-loop constraint of the kinematic slip characteristics on the distribution of dynamic energy consumption, cuts off the interference path of interface lubrication condition fluctuations or oxide scale state evolution on the material yield strength detection, and ensures that the physical parameter output depends only on the material's own rheological properties.

[0017] 3. Construct a multi-dimensional compensation mechanism covering thermal effect accumulation, inertial energy consumption difference, and pressure step response. By analyzing the angular acceleration vector of the main drive system to remove the virtual power consumption in the unsteady state stage, and combining the frictional heat-work conversion rate and pressure pulsation response characteristics, the geometric increment of roll thermal expansion and the elastic flattening amount of the frame are corrected in real time. This eliminates nonlinear noise introduced by equipment mechanical fatigue, thermal distortion, and speed regulation under operating conditions, achieving logical isolation between the material property perception process and the evolution of the equipment's physical state, and realizing the detection stability of the entire process from the biting stage to the tailing stage. Attached Figure Description

[0018] Figure 1 This is a flowchart illustrating the principle of multidimensional load decoupling and rheological parameter calculation in this invention. Figure 2 This is a schematic diagram of the functional modules and core task branches of the system of the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0020] It should be noted that all directional and positional terms used in this invention, such as: up, down, left, right, front, back, vertical, horizontal, inner, outer, top, bottom, transverse, longitudinal, center, etc., are only used to explain the relative positional relationship and connection between components in a specific state (as shown in the accompanying drawings). They are only for the convenience of describing this invention and do not require that this invention be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention. In addition, the descriptions of "first," "second," etc., in this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated.

[0021] In the description of this invention, unless otherwise explicitly specified and limited, the terms installation, connection, and linking should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0022] In the description of this specification, references to the terms "an embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example, and the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0023] The following specific examples illustrate the implementation of this application. Those skilled in the art can understand the advantages and effects of this application from the content disclosed in this specification. It should be noted that the following embodiments are intended to explain the present invention and are not intended to limit the scope of protection of the present invention. The directional and positional indications involved in this application are only used to explain the relative positional relationship between the components in a specific state and are not a limitation of the present invention. In addition, in the description of this application, unless otherwise explicitly specified and limited, the terms installation and connection should be interpreted broadly. For those skilled in the art, the specific meaning of the above terms in the present invention can be understood according to the specific circumstances.

[0024] This invention provides an online physical parameter detection system for engineering materials. By performing multi-dimensional decoupling of the main drive energy flow of a rolling mill, the system removes load components generated by non-intrinsic resistance, enabling the determination of the rheological resistance of engineering materials under rolling production conditions. The system includes: a load signal acquisition module, a frequency domain feature extraction module, a geometric boundary determination module, a dynamic compensation and correction module, and a physical parameter calculation module. The load signal acquisition module acquires torque, speed, and tension signals during the rolling process. The system captures transient load fluctuations caused by sudden changes in material interface stress within a millisecond timescale. By utilizing existing drive system feedback signals, the system eliminates the influence of harsh environments on the external sensing path. This system acquires raw physical signals through a high-frequency data acquisition card and performs unified dimensional processing: the dimension of the torque sampling signal M is N·m, the dimension of the roll speed signal n is r / min, the dimension of the stand exit tension signal T is kN, and the dimension of the engineering material exit speed signal... The unit of measurement is m / s; the system has a preset time synchronization clock to ensure that the data acquired by each module within the same sampling period t have phase consistency; the frequency domain feature extraction module identifies interface friction features and determines power consumption weights; the geometric boundary determination module locates the neutral surface of the deformation zone; the dynamic compensation correction module calculates the inertia and thermodynamic geometric compensation; the physical parameter calculation module finally calculates and outputs the physical parameters characterizing the rheological properties of the engineering material; during continuous rolling, due to the presence of cooling water spray, high-temperature iron dust and electromagnetic interference in the rolling zone, it is difficult for external sensors to maintain a stable measurement benchmark; to address this challenge, the present invention uses a load signal acquisition module to acquire the inherent dynamic signals of the system, including a high-frequency data acquisition card with a sampling frequency of not less than 2kHz, used to synchronously acquire the torque sampling signal M of the main drive motor, the roll speed signal n, the stand exit tension signal T, and the engineering material exit speed signal in a high-frequency sampling manner. The system captures transient load fluctuations caused by sudden changes in material interface stress within a millisecond timescale, and eliminates the impact of harsh environments on the external sensing path by utilizing existing drive system feedback signals.

[0025] Based on the trend of interfacial friction coefficient drift caused by changes in lubrication conditions and workpiece surface condition during long-process production, the frequency domain feature extraction module extracts the friction component by analyzing the energy spectrum distribution of the torque signal. A digital bandpass filter is used to filter the torque sampling signal M, removing the periodic component caused by mechanical rotation, and extracting the aperiodic pulsating load characterizing the interfacial friction. The energy integral of the aperiodic pulsating load in the 0.5Hz to 50Hz frequency band is then calculated. Based on this, the frequency domain feature extraction module determines the instantaneous weight of the interfacial friction power consumption by calculating the proportion of the energy integral value in the total deformation energy consumption. First, the angular velocity is determined based on the torque sampling signal M and the roll speed. Calculate total power The frequency domain feature extraction module determines the instantaneous weights based on the energy proportion formula. : ,in, This represents the instantaneous weight of interface frictional power consumption in the total deformation work; The torque sampling signal is then subjected to a Fast Fourier Transform at a frequency of... The power spectral density value at that point; the numerator is the energy integral within the frictional characteristic frequency band from 0.5 Hz to 50 Hz; the denominator is from 0 Hz to the upper limit of the entire frequency domain. The total energy integral; simultaneously, the frequency domain feature extraction module also evaluates tissue consistency by calculating the energy distribution uniformity H of the load pulsation signal in the frequency domain; specifically, the formula for calculating the energy distribution uniformity H is as follows: Where H represents the uniformity of energy distribution. For non-periodic pulsating loads at a specific frequency The normalized power spectral density at the location is N, where N is the number of frequency domain samples. When the calculated value H deviates from the preset range, the system outputs an evaluation index characterizing the internal uniformity of the engineering material, thereby converting the load noise into a quantitative description of the material's micro-rheological smoothness.

[0026] The organization consistency mapping logic selects 20 standard samples with grain sizes ranging from 1μm to 12μm, collects a reference torque sequence with no less than 4096 sampling points under no-load conditions to determine the background noise distribution, rolls the standard samples under a preset reduction rate condition, and calculates the energy distribution uniformity H of each group using the physical parameter calculation module, taking the arithmetic mean to determine the reference entropy value. And calculate the standard deviation relative to that value. The offset threshold for determining the segregation defects of internal components in the material is set as follows: The real-time energy distribution uniformity H and the baseline entropy value When the absolute value of the difference exceeds the offset threshold, the output is an evaluation index for tissue non-uniformity, where the baseline entropy value is... The standard deviation is the expected value of the energy distribution of the standard sample in a steady rheological state. The range of fluctuation of the expected value is represented by H, which is the normalized power spectral density distribution calculated by the algorithm. Given the determined entropy parameters, the rotational frequency of the roll base is determined based on the roll speed signal n from the main drive motor. Identifying gear meshing characteristic frequencies by reducing gear ratio The lower cutoff frequency limit of the digital bandpass filter is set to 0.2× And the upper limit is 10× To ensure the cutoff frequency covers the interfacial friction characteristic frequency band from 0.5Hz to 50Hz, a Hanning window with 512 sampling points is used to slide and truncate the torque sampling signal M, maintaining a 50% window overlap. The non-periodic pulsating load within the truncation window is calculated at the following frequencies. Normalized power spectral density distribution at ... Determine the energy integral value, and then determine the instantaneous weight of the interface friction power consumption based on the proportion of this value in the total deformation work. As input parameters for solving physical parameters, among which This refers to the number of revolutions per second of the rolling mill. The frequency of mechanical vibration generated by the meshing of transmission chain gears. For non-periodic loads at frequency The energy percentage at that location Quantify the contribution of triboelectric energy to total energy consumption.

[0027] During the rolling process of high-strength materials, the geometric boundary of the deformation zone is not constant due to the dynamic impact and slippage evolution during the instantaneous biting of the workpiece. To address this challenge, the geometric boundary determination module is based on the conservation relationship of the flow rate per second in the deformation zone, utilizing the roll speed signal n and the exit velocity signal of the engineering material. Slip deviation vector between Determine the instantaneous horizontal position of the neutral surface within the deformation zone. ; Slip deviation vector The calculation method is as follows: ,in, The slip deviation vector, This is a signal indicating the export speed of engineering materials. The circumferential linear velocity of the roll is calculated based on the roll rotation speed signal n; the geometric boundary determination module determines the instantaneous horizontal position of the neutral surface. As the dynamic geometric boundary of the energy decoupling equation, the slip deviation vector is used. The nonlinear mapping relationship with the geometry of the deformation zone is used to deduce the physical coordinates of the material at the same speed as the roll, and the calculation follows the mapping function: ,in, R is the instantaneous horizontal position of the neutral surface (horizontal distance from the ingress contact point as the origin); R is the roll radius. This is the total bite angle corresponding to the contact arc; This is the slip deviation vector; this module will adjust the offset correction amount. Superimposed on the slip deviation vector The initial position is calculated to determine the instantaneous horizontal position of the corrected neutral surface. Using the dynamic geometric boundary as the energy decoupling equation, the calculation benchmark of the contact area of ​​the deformation zone is dynamically adjusted according to the rolling state by establishing a closed-loop constraint on the dynamic energy consumption distribution by kinematic slip characteristics.

[0028] To address the rotational inertia loss and geometric errors caused by roll thermal expansion during mill speed regulation, the dynamic compensation and correction module constructs a compensation matrix to quantify and correct the rotational inertia torque and roll thermal evolution errors generated by mill speed regulation. This module differentiates the roll speed signal n to obtain the angular acceleration. And according to the preset frame rotational inertia Calculate the components of dynamic inertial moment ,Right now ,in, Here, J represents the dynamic inertial torque component, and J represents the frame rotational inertia. The angular acceleration is used; the dynamic compensation and correction module determines the geometric increment of the roll's thermal expansion based on the interface frictional heat equivalent coefficient. And determine the elastic flattening displacement of the frame based on the step response characteristics of the hydraulic cylinder pressure signal. The inertial load of the equipment body and the geometric distortion components caused by the evolution of the physical state are subtracted from the original load signal, thus decoupling the sensing process of physical parameters from the motion state of the equipment. A load step calibration procedure is executed under the condition that the rolls are in contact with each other and no material is passing through. The hydraulic system drives the rolls to generate a pressure step from 0kN to 20000kN, and the torque sampling signal M of the main drive motor is collected simultaneously. Based on the torque sampling signal... The linear mapping relationship between the increment and the pressure increment determines the static stiffness coefficient. The thermal expansion ratio determined based on the integral of frictional power consumption is used. Real-time correction of geometric increment of thermal expansion of rolls With frame elastic flattening displacement Using the slip deviation vector Correcting the instantaneous horizontal position of the neutral surface And it is determined as the dynamic geometric boundary of the energy decoupling equation, where The torque response coefficient caused by a unit pressure change. Characterizing the proportional relationship between frictional heat generation and the radial elongation of the roll. The change in the radius of the roll due to heat. This refers to the elastic displacement caused by the force applied to the frame. This represents the coordinate position where the material and the roll speed are equal within the deformation zone.

[0029] The physical parameter calculation module is based on the instantaneous weights output by the above modules. Dynamic geometric boundaries Components of dynamic inertial torque Geometric increment of thermal expansion of rolls and the amount of elastic flattening displacement of the frame The module performs load decoupling operations on the torque sampling signal M; it subtracts the dynamic inertial torque component from the torque sampling signal M. The tensile component is calculated, and after considering the frictional power consumption at the peeling interface, the pure plastic deformation work of the engineering material in the deformation zone is extracted. The average unit pressure in the deformation zone is calculated using the corrected contact arc length parameter, and physical parameters characterizing the rheological properties of the engineering material are output. These physical parameters include the yield strength of the engineering material. Rheological stress and work hardening index To determine the work hardening index, which characterizes the deformability of a material. The physical parameter calculation module obtains the rheological stress within a continuous sampling period. With equivalent plastic strain A power-law characteristic model of the rheological curve is established using a linear regression algorithm, wherein the work hardening index... The calculation method is as follows: ,in, The work hardening index, For rheological stress, The equivalent plastic strain is used; this module outputs quantitative parameters characterizing the plastic deformation capacity of engineering materials by updating the model regression coefficients in real time; under this calculation process, the physical parameters are obtained from the energy balance during the material deformation process, ensuring that the test results have physical consistency.

[0030] Example 1: In the continuous rolling of high-strength steel strip with a thickness of 0.1mm to 0.3mm, this technical solution implements an online detection procedure to address the nonlinear abrupt change in interface lubrication state and high-frequency load impact. Under this condition, the engineering material generates interface stress fluctuations at the moment of biting, accompanied by periodic noise interference from roll rotation and reducer meshing, causing the material's plastic deformation power consumption and interface friction power consumption to couple in the torque sampling signal M. The load signal acquisition module acquires the torque sampling signal M and the roll speed signal n at a sampling frequency of 2kHz, and the frequency component stripping is performed by the frequency domain feature extraction module. Specifically, this module sets the cutoff frequency in the range of 0.5Hz to 50Hz, extracts the non-periodic pulsating load from the torque sampling signal M, and calculates the normalized power spectral density distribution. To determine the instantaneous weight of interface friction power consumption. ,in, For non-periodic pulsating loads at a specific frequency Normalized power spectral density at , This is the frequency index for frequency domain sampling.

[0031] Among them, the geometric boundary determination module is based on the slip deviation vector. Calculate the instantaneous horizontal position of the neutral surface The slip deviation vector The calculation formula is as follows: ,in, The slip deviation vector, This is a signal indicating the export speed of engineering materials. The circumferential linear velocity of the roll is calculated based on the roll rotation speed signal n; the instantaneous weights are extracted by the frequency domain feature extraction module. The geometric boundary determination module provides a dynamic reference, and the instantaneous horizontal position of the neutral surface is determined by the geometric boundary determination module. The area of ​​application of frictional stress is modified to resolve the coupling between interfacial frictional disturbances and geometric boundary drift within the energy balance logic; angular acceleration is generated when the rolling mill performs speed regulation operations. At that time, the dynamic compensation and correction module calls the preset frame rotational inertia J to calculate the dynamic inertial torque components. ,Right now ,in, Here, J represents the dynamic inertial torque component, and J represents the frame rotational inertia. The angular acceleration is used, and simultaneously, the dynamic compensation and correction module determines the geometric increment of the roll's thermal expansion based on the frictional heat equivalent coefficient. The elastic flattening displacement of the frame is determined based on the step response characteristics of the hydraulic cylinder pressure signal. The physical parameter calculation module removes the instantaneous weighted values ​​from the total load. The determined friction term and the angular acceleration The determined inertial components are derived from the instantaneous horizontal position of the neutral surface. and the amount of elastic flattening displacement of the frame The defined effective contact arc length is used to calculate the dynamic yield strength of the material. This processing method converts the disturbance components generated by equipment operation into energy balance components, enabling the system to output rheological stress reflecting the uniformity of the material's internal structure during the unsteady-state stage when the rolling speed changes abruptly. .

[0032] Example 2: A rheological resistance detection accuracy verification test was performed on a four-roll cold rolling test platform for high-strength steel plates. The platform integrates a torque sensor, encoder, and exit speedometer. The data source is the torque sampling signal M installed on the mill drive shaft. The sampling frequency was set to 2kHz. The selection of the sampling frequency was based on a balance between the signal spectrum bandwidth and the system processing load. The upper limit of the spectrum bandwidth of the reducer meshing component is around 800Hz. According to the Nyquist sampling theorem, the sampling frequency must be at least 2.5 times the highest frequency of the signal to avoid signal aliasing and ensure the capture of load fluctuation characteristics. Therefore, the sampling frequency value for this test was determined. To simulate non-ideal working conditions in an industrial environment, Gaussian white noise with a signal-to-noise ratio of 18dB was superimposed on the torque sampling signal M, and a 50Hz power frequency interference harmonic was introduced. This test design includes the sample group and control group of this invention. The sample group of this invention adopts a multi-dimensional load decoupling scheme, that is, the instantaneous weight is determined through a frequency domain feature extraction module. Calculate the rheological stress after stripping the interface frictional power consumption. The control group used a fixed constant friction coefficient compensation method. During the experiment, the rolling mill speed gradient was changed and the system's sensing response to rheological resistance was observed synchronously. Specific experimental data are shown in Table 1.

[0033] Table 1: Test data of physical parameters under different rolling conditions

[0034] According to the test results in Table 1, when the rolling speed increases from 1.0 m / s to 15.0 m / s, the instantaneous weighting is affected by the change in the surface condition of the rolled piece. The stress value increased from 0.082 to 0.224. In the control group, due to the inability to identify the dynamic proportion of interface friction power consumption in real time, the output stress value showed a trend of drift with increasing speed, and the deviation rate increased from 6.7% to 28.7%. In contrast, the sample group of this invention, through a frequency domain feature extraction module, used a digital bandpass filter to remove periodic components and extract the non-periodic pulsating load characterizing interface friction, thus improving the rheological stress... The calculation results remain near the intrinsic resistance values ​​of the material; as the rolling thickness decreases, the geometric boundary determination module determines the boundary by adjusting the slip deviation vector. Real-time correction of the instantaneous horizontal position of the neutral surface To compensate for the calculation error caused by the evolution of the contact area in the deformation zone of the rolled piece; through nonlinear characteristic analysis of the data in Table 1, it can be seen that when the rolling speed exceeds 12.0 m / s, the error growth rate of the control group accelerates. This phenomenon corresponds to the dynamic inertial moment component under high-speed conditions. To address the severe fluctuations, the present invention utilizes a dynamic compensation correction module to introduce angular acceleration in the sample group. The correction item offsets the virtual power consumption caused by the inertia of the equipment system, and realizes the isolation between the material rheological parameters and the rolling mill motion state. In the sample group where the material composition has segregation, the calculated energy distribution uniformity H value deviates by 16.4% from the normal reference value. Based on this, the physical parameter calculation module outputs the organization non-uniformity evaluation index. The experimental conclusion confirms that the detection system has the ability to perceive the physical characteristics of engineering materials.

[0035] Example 3: This example combines Figures 1 to 2 This describes an online physical parameter detection system for engineering materials, such as... Figure 1 As shown, the load signal acquisition module uses high-frequency acquisition of torque signals, roll speed signals, stand exit tension signals, and engineering material exit velocity signals. The acquired data streams are then transmitted in parallel to the feature processing unit. The frequency domain feature extraction module is used to remove the periodic load components from the torque signals and calculate the energy integral to determine the interface friction power consumption weight. The geometric boundary determination module uses the slip deviation vector to determine the instantaneous horizontal position of the neutral surface based on the second flow rate conservation relationship, thereby outputting the dynamic geometric boundary. The dynamic compensation and correction module calculates the dynamic inertia power consumption and corrects the geometric increment of roll thermal expansion and the elastic flattening displacement of the stand, outputting the dynamic inertia and geometric increment. Finally, the physical parameter calculation module gathers the interface friction power consumption weight, dynamic geometric boundary, and dynamic inertia and geometric increment to perform load decoupling calculation. After removing load noise and calculating rheological property parameters, it outputs the rheological properties of the engineering material, including yield strength and rheological stress.

[0036] like Figure 2As shown, the system takes online detection of physical parameters of engineering materials as its core and unfolds into five main components through a branch structure. The load signal acquisition module is responsible for high-frequency acquisition of raw physical data and includes multi-dimensional data sources such as torque, rotation speed and tension. The geometric boundary determination module determines the neutral surface based on the conservation of flow rate per second and calculates the forward and backward slip deviation. The physical parameter solution module performs load decoupling, outputs rheological properties and removes load noise. The frequency domain feature extraction module removes periodic loads, determines friction weights and performs energy integration calculations. The dynamic compensation and correction module is used to calculate inertial energy dissipation and geometric deformation increment and correct thermal expansion and flattening displacement.

[0037] Example 4: When the rolling mill is in an operating condition where mechanical wear causes signal substrate evolution, the system adopts a calibration procedure based on dynamic benchmark correction for uniformity of the structure. Under no-load operation, a baseline torque sequence with 4096 sampling points is acquired. The initial energy spectrum distribution under no-load conditions is calculated as a compensation component. The physical parameter calculation module uses a Hanning window with 512 sampling points to slide and truncate the torque sampling signal M, setting the overlap rate between windows to 50%. This ensures that each discrete calculation cycle covers the stress cycle characteristics corresponding to one rotation of the roll. A discrete Fourier transform is performed on the time-domain signal within the window, and the normalized power spectral density distribution is calculated. ,in, For discrete calculation of specific frequencies within a period The power value at a given point is the ratio of the total power in that window. Before production, the system conducts 10 rolling tests on qualified reference samples, collects the corresponding torque sampling signal M, and calculates the energy distribution uniformity. The arithmetic mean of the test results is defined as the reference entropy value. Calculate the entropy value of each sample group relative to the baseline. Standard deviation During online detection, the physical parameter calculation module sets the deviation threshold for determining tissue abnormalities to the standard deviation. Three times that of the baseline entropy value, if the energy distribution uniformity H calculated in real time is equal to the baseline entropy value. If the absolute value of the difference exceeds the deviation threshold, the system outputs an evaluation index characterizing the unevenness of the microstructure; taking the detection of high-strength alloy strip as an example, if the calibrated reference entropy value The standard deviation is 4.25. If the value is 0.12, then the judgment threshold value is 0.36. When a coarse-grained structure is detected inside the material and the real-time entropy value H shifts to 4.78, the physical parameter calculation module identifies the material defect because the deviation of 0.53 exceeds the judgment threshold.

[0038] To address the interference caused by the decrease in roll surface roughness with increasing rolling mileage, the dynamic compensation and correction module introduces a time-weighted decay factor to automatically update the benchmark. The system is calibrated every 24 hours, and the average energy distribution uniformity value of the aforementioned 100 sets of grid samples is included in the new benchmark entropy value with a weight of 0.8. To compensate for the energy spectrum center shift, the physical parameter calculation module automatically updates the corrected reference entropy value using the reference. As a zero point, combined with instantaneous weights The compensated plastic deformation energy consumption data outputs a quantitative index of the microstructure uniformity of engineering materials. This method transforms the evaluation of microstructure consistency into a measurement of the deviation of the system's energy spectrum.

[0039] Example 5: When the aluminum alloy sheet is in the initial rolling condition, the system executes a pre-calibration program to determine the reference value of the energy distribution uniformity H. This program collects the torque sampling signal M of the main drive motor under no-load conditions of the rolling mill. The frequency domain feature extraction module performs a discrete Fourier transform on the torque sampling signal M to identify the mechanical characteristic frequencies caused by gear meshing. This was defined as a background noise component. For the reference sample, 20 sets of load spectra with a sampling length of 8192 data points were collected under a preset compression rate. The reference entropy value was determined by calculating the arithmetic mean of the energy distribution uniformity of each set of samples. .

[0040] When the system faces a motor speed adjustment condition, the frequency domain feature extraction module executes the follow-up calibration procedure for the filter cutoff frequency and calculates the roll rotation frequency based on the roll speed signal n. ,in, The unit is The frequency domain feature extraction module sets the lower cutoff frequency limit of the digital bandpass filter to 0.2× And the upper limit is set at 10× The system maintains the instantaneous weight of interface friction power consumption when the rolling speed fluctuates. The calculation accuracy was improved, and the calculated energy distribution uniformity H was detected to deviate from the reference entropy value. The absolute value reaches 3 times the standard deviation. At that time, the physical parameter calculation module outputs technical indicators characterizing the uniformity of the internal structure of the material.

[0041] Example 6: During the on-site commissioning and operation of the six-roll cold rolling mill, the system executes the initial calibration procedure of the geometric compensation matrix to determine the elastic flattening displacement of the stand. and the geometric increment of thermal expansion of the rolls The calculation benchmark operates with the rolls in contact and no material passing through. A hydraulic cylinder drives the rolls to press together and applies a load step from 0 kN to 20000 kN. Simultaneously, the torque sampling signal M of the main drive motor and the pressure signal of the hydraulic system are acquired. The static stiffness coefficient is determined based on the mapping relationship between the torque increment and the pressure increment. The dynamic compensation and correction module monitors the correlation between temperature fluctuations and torque values ​​in the roll bearing housing by rolling 50 reference coils, and establishes a geometric increment of roll thermal expansion based on the integral of frictional power consumption. The calculation model for the geometric increment of thermal expansion of the rolls. The calculation method is as follows: ,in, This is the geometric increment of thermal expansion of the roll. It is the proportionality coefficient of thermal expansion. Here, n represents the interface friction torque component, t represents the roll speed signal, t represents the sampling point index, and T represents the total number of sampling points. The system incorporates the physical compliance of the frame into the compensation matrix, ensuring that the geometric boundary determination module determines the instantaneous horizontal position of the neutral surface. When, the contact area deviation caused by mechanical deformation is deducted.

[0042] When the detection system encounters a tension sensor malfunction or loss of the outlet speed measurement signal, the load signal acquisition module executes a redundancy check and fault-tolerant sensing procedure to maintain the continuity of physical parameter output. The system uses the current feedback signal from the main drive motor and the torque sampling signal M for correlation analysis. When the consistency coefficient between the two is lower than 0.85, the physical parameter calculation module switches to a calculation path based on motor electrical parameters. Simultaneously, the geometric boundary determination module detects the loss of the engineering material outlet speed signal. In this state, the instantaneous horizontal position of the neutral surface is utilized. The historical mean is used to estimate the boundary value, and the estimated value is corrected based on the rate of change of the energy distribution uniformity H output by the frequency domain feature extraction module. If the fluctuation of the energy distribution uniformity H exceeds 3 times the standard deviation... The system determines that the slip state of the deformation zone has changed and locks the output value of the physical parameters. This procedure ensures that the detection system maintains the closed calculation logic when the external sensing link is damaged, and achieves the stability of the detection results under sensor failure conditions.

[0043] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit of this application and the scope of protection of this invention, and all of these forms are within the protection scope of this application.

Claims

1. An online detection system for physical parameters of engineering materials, characterized in that, include: The load signal acquisition module is used to acquire the torque sampling signal of the main drive motor, the roll speed signal, the stand outlet tension signal, and the engineering material outlet speed signal; The frequency domain feature extraction module is used to extract the non-periodic pulsating load characterizing the interface friction characteristics based on the periodic load component caused by the rotation of the roll in the stripping torque sampling signal of the digital bandpass filter, and to calculate the energy integral of the non-periodic pulsating load in the frequency band from 0.5Hz to 50Hz to determine the instantaneous weight of the interface friction power consumption in the total deformation work. The geometric boundary determination module is used to determine the instantaneous horizontal position of the neutral surface in the deformation zone based on the flow rate conservation relationship in the deformation zone and the slip deviation vector between the roll speed signal and the exit velocity signal of the engineering material. The instantaneous horizontal position of the neutral surface is used as the dynamic geometric boundary of the energy decoupling equation. The dynamic compensation and correction module is used to obtain the angular acceleration of the main drive motor to calculate the dynamic inertial energy consumption, and to calculate the geometric increment of the thermal expansion of the roll and the elastic flattening displacement of the frame based on the preset interface friction heat equivalent coefficient. The physical parameter calculation module is used to perform load decoupling calculation on the torque sampling signal based on instantaneous weights, dynamic geometric boundaries, dynamic inertial energy dissipation, geometric increment of roll thermal expansion, and elastic flattening displacement of the frame, so as to remove load noise generated by non-intrinsic resistance and output physical parameters characterizing the rheological properties of engineering materials.

2. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, The frequency domain feature extraction module is also used to extract harmonic energy features in the torque sampling signal that are unrelated to the mechanical cycle. By calculating the uniformity of energy distribution of the load pulsation signal in the frequency domain, it characterizes the load stability of the plastic rheological process of the engineering material. Based on the energy distribution uniformity and the preset microstructure consistency mapping logic, it outputs evaluation indexes that characterize the internal microstructure uniformity of the engineering material.

3. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, When determining the instantaneous horizontal position of the neutral surface, the geometric boundary determination module uses the fluctuation of the tension signal at the frame outlet to correct the offset value of the neutral surface in the horizontal axis, thereby realizing the closed-loop constraint of the kinematic slip characteristics on the distribution of dynamic energy consumption.

4. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, The dynamic compensation correction module is also used to construct a compensation matrix that covers the accumulation of thermal effects and the load step response. By analyzing the response frequency of the main drive motor, the periodic load fluctuations introduced by the roll eccentricity are removed, and the net load after removal is input into the physical parameter calculation module.

5. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, The load signal acquisition module includes a high-frequency data acquisition card, which is used to acquire torque sampling signals at a sampling frequency of not less than 2kHz in order to capture transient load fluctuations caused by sudden changes in material interface stress.

6. The online detection system for physical parameters of engineering materials according to claim 2, characterized in that, The frequency domain feature extraction module follows these rules when calculating the energy distribution uniformity H: ,in, For non-periodic pulsating loads at a specific frequency The normalized power spectral density at the point is N, where N is the number of frequency domain samples. The physical parameter calculation module determines whether there are component segregation defects inside the engineering material based on the numerical offset of the energy distribution uniformity H.

7. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, When performing load decoupling calculations, the physical parameter calculation module deducts the interface friction power consumption from the total load and calculates the average unit pressure within the deformation zone in conjunction with the dynamic geometric boundary.

8. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, The frequency domain feature extraction module identifies the hidden material strengthening features in non-periodic pulsating loads by constructing a residual autoregressive model of the torque signal, and adds the material strengthening features to the energy decoupling equation in real time.

9. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, The system also includes a correction unit, which acquires offline mechanical testing data of engineering materials and dynamically adjusts the calculation ratio of instantaneous weights based on the deviation between the offline mechanical testing data and physical parameters.

10. The online detection system for physical parameters of engineering materials according to claim 1, characterized in that, The physical parameters output by the physical parameter calculation module include the yield strength, rheological stress, and work hardening index of engineering materials.

Images