Anti-slip and anti-scratch waterproof roller system for continuous rolling of thin steel strip and control method of anti-slip and anti-scratch waterproof roller system

Abstract

The invention relates to the field of metal pressure processing, discloses an anti-slip and anti-scratch waterproof roller system for thin-gauge steel strip continuous rolling and a control method, and aims to solve the problem that a waterproof roller slips and scratches a steel strip due to a fluid dynamic pressure effect during high-speed continuous rolling of the thin-gauge steel strip. The method comprises the steps that the linear speed, the acting load and the cooling liquid environment parameters of a steel belt and a waterproof roller are obtained in real time; constructing a slip rate monitoring model, calculating fluid dynamic pressure distribution characteristics, and judging a slip risk level; the pressing load or the active driving torque is dynamically adjusted to counteract buoyancy force generated by fluid dynamic pressure, and the critical static friction state is maintained; and the control parameters are corrected in real time through feedback monitoring. The system comprises a sensor array, a control unit, an execution mechanism and a waterproof roller with a drainage structure. Through active compensation and closed-loop control, the synchronous precision of equipment operation is improved, the slipping and scratching defects of the steel belt are effectively eliminated, the adaptability to extreme working conditions is enhanced, and the service life of the equipment is prolonged.

Description

Technical Field

[0001] This invention belongs to the field of metal pressure processing, and specifically relates to an anti-slip and anti-scratching water-blocking roller system and control method for continuous rolling of thin-gauge steel strips. Background Technology

[0002] The cold continuous rolling and finishing rolling processes for metal strip are the core steps in producing high-performance, thin-gauge steel strips. Their production efficiency and surface quality directly determine the final performance of subsequent processed products. During continuous rolling, in order to ensure the stability of the steel strip's condition across different mill stands or process sections, the steel strip surface typically requires high-frequency cooling and cleaning to achieve precise control over the strip's temperature and surface cleanliness.

[0003] Specifically, to prevent cooling media or cleaning fluid from entering the subsequent drying zone along with the high-speed running steel strip, a rotating water-blocking roller system is typically installed at the end of the process section. This system generates a sealing and clamping force through physical contact between the roller surface and the moving steel strip, aiming to block the migration of the liquid film and thus ensure the drying environment of subsequent processes and the synchronous stability of the strip surface tension.

[0004] However, in existing technologies, with the continuous increase in rolling speed and the trend towards extremely thin strips, traditional water-blocking roll systems struggle to maintain both water-blocking effectiveness and the synchronous movement of the roll surface. Because thin strips, operating at high speeds, generate a large amount of kinetic energy-rich coolant that accumulates at the roll gap inlet, a hydrodynamic lubricating film easily forms between the roll and the strip. This hydrodynamic pressure significantly reduces the effective coefficient of friction at the interface, leading to momentary slippage of the water-blocking roll relative to the strip. Once this speed instability occurs, the dynamically slipping roll surface experiences intense mechanical friction with the strip surface, resulting in irreparable scratches and defects that severely impact the yield and surface consistency of high-precision thin strips. Summary of the Invention

[0005] The purpose of this invention is to provide an anti-slip and anti-scratching water-blocking roller system and control method for continuous rolling of thin-gauge steel strips, which can effectively solve the problems in the background art.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a water-blocking roller system and control method for anti-slip and anti-scratching of thin-gauge steel strip continuous rolling, comprising the following specific steps: S1: The linear velocity signal of the thin steel strip during operation and the real-time rotational linear velocity signal of the water-blocking roller are acquired in real time through the sensor array, and the load of the water-blocking roller on the surface of the thin steel strip and the coolant environment parameters at the roller gap inlet side are collected simultaneously. S2: Based on the acquired linear velocity signal and the real-time rotational linear velocity signal, a slip ratio monitoring model is constructed. Combined with the coolant environmental parameters, the hydrodynamic pressure distribution characteristics of the contact interface between the water-blocking roller and the thin-gauge steel strip are calculated to determine the slip risk level under the current working condition. S3: Based on the slippage risk level, the control unit outputs adjustment commands to the actuator to dynamically adjust the clamping load or active drive torque of the water-blocking roller to counteract the radial buoyancy force generated by the hydrodynamic pressure effect and maintain the critical static friction state between the thin steel strip and the water-blocking roller. S4: Continuously monitor the adjusted interface contact state and correct the control parameters in real time through iterative compensation logic to ensure that the water-blocking roller and the thin-gauge steel strip keep running synchronously during high-speed continuous rolling and specification switching.

[0007] Preferably, in step S1, the sensor array includes a laser Doppler velocimeter, a high-precision rotary encoder, and a load sensor arranged on the support of the water-blocking roller. The laser Doppler velocimeter is installed above the frame in front of the water-blocking roller to capture the actual running speed of the thin-gauge steel strip, and the laser Doppler velocimeter has a preset measurement accuracy.

[0008] Preferably, the coolant environmental parameters in step S1 include the coolant flow rate, spray pressure, and temperature within the flow channel. Data acquisition is achieved through a flow meter and a pressure transmitter, and the data acquisition meets the preset sampling frequency requirements.

[0009] Preferably, the calculation process of the fluid dynamic pressure distribution characteristics in step S2 involves establishing a fluid lubrication model based on the Reynolds equation. This model considers the dynamic viscosity of the coolant, the surface roughness of the thin-gauge steel strip, and the geometric parameters of the convergent wedge-shaped interval formed by the water-blocking roller and the thin-gauge steel strip, in order to quantify the degree of reduction of the effective normal pressure of the interface by the fluid dynamic pressure.

[0010] Preferably, the slip risk level is divided according to the slip rate. When the slip rate exceeds a first preset threshold, it is determined to be a level 1 risk. When the slip rate exceeds a second preset threshold, it is determined to be a level 2 risk. The control unit matches the corresponding response strategy according to different risk levels.

[0011] Preferably, the actuator includes a servo hydraulic cylinder or a proportional control cylinder, and the oil inlet and pressure of the cylinder are controlled by an electro-hydraulic proportional valve to achieve rapid adjustment of the clamping load, and the pressure adjustment step and system response time are both within the preset performance index range.

[0012] Preferably, the active driving torque is provided by a variable frequency motor, which is connected to the roller shaft of the water-separating roller via a coupling. The operating mode of the variable frequency motor automatically switches between speed control and torque control. When a slippage tendency is detected, the variable frequency motor increases the driving torque to compensate for the friction loss caused by the fluid dynamic pressure.

[0013] Preferably, the structure of the water-blocking roller includes a metal core shaft and a wear-resistant synthetic rubber layer covering the outer layer of the metal core shaft. The Shore hardness of the wear-resistant synthetic rubber layer is within a preset hardness range, and the roller surface is machined with drainage threads or cross-grid grooves of a predetermined depth to guide the coolant accumulated at the roller gap inlet to be discharged to both sides, thereby reducing the dynamic pressure effect.

[0014] Preferably, in step S4, the feedback monitoring process evaluates the adjustment effect by calculating the rate of change of the adjusted slip ratio. If the slip ratio does not fall back below the target threshold, the gain coefficient of the clamping load or driving torque is further increased.

[0015] Preferably, the anti-slip and scratch water-blocking roller system and control method for thin-gauge steel strip continuous rolling further includes real-time online detection of the surface morphology of the thin-gauge steel strip, using a linear array camera to scan the surface of the steel strip after passing through the water-blocking roller, identifying whether there are strip-like scratches caused by instantaneous slippage, and feeding the identification results back to the control unit.

[0016] Compared with the prior art, the present invention has the following beneficial effects: 1. Significantly improves the synchronization accuracy of equipment operation. Through multi-source sensor fusion sensing and dynamic monitoring of slip rate, this invention can identify and suppress slippage trends under high-speed operation in real time, so that the linear velocity deviation between the water-blocking roller and the steel belt is stably controlled within the preset deviation range, ensuring the consistency of water blocking effect.

[0017] 2. Completely eliminates slippage and scratch defects on the steel strip surface. By predicting the buoyancy force generated by fluid dynamic pressure and compensating for the clamping load in time, this invention effectively maintains the contact friction between the roller surface and the strip, avoids severe mechanical friction caused by speed instability, and significantly improves the yield of high-precision thin-gauge steel strips.

[0018] 3. Enhanced adaptability to extreme working conditions. This invention can not only handle the hydrodynamic pressure problem under high-speed continuous rolling, but also automatically match the production requirements of different thicknesses, steel grades and coolant parameters, reducing the frequency of manual intervention and realizing fully automated anti-slip closed-loop control.

[0019] 4. Extended service life of the water-blocking roller. By precisely controlling the clamping force, fatigue wear of the roller surface caused by long-term excessive pressure and abnormal wear due to slippage are avoided, reducing the frequency of roller replacement and maintenance costs. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall technical solution architecture of the anti-slip and scratch water-blocking roller system and control method for thin-gauge steel strip continuous rolling proposed in this invention. Figure 2 This is a logical flowchart of the sensor array multi-source signal acquisition and environmental parameter sensing in this invention; Figure 3 This is a schematic diagram of the core principle framework of the slippage risk determination model based on the characteristics of fluid dynamic pressure distribution in this invention; Figure 4 This is a schematic diagram of the multi-level interaction relationship and data flow between the control unit and the actuator in this invention; Figure 5 This is a logical flowchart of the interface contact state feedback monitoring and control parameter iterative compensation in this invention. Detailed Implementation

[0021] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0022] Example 1 This embodiment discloses an anti-slip and scratch-resistant water-blocking roller system for thin-gauge steel strip continuous rolling. It is mainly applied to the end process of high-precision cold rolling and continuous rolling production lines to solve the problem of water-blocking roller slippage and the resulting scratches on the steel strip surface caused by the dynamic pressure effect of the coolant during the production of ultra-thin specifications where the steel strip running speed exceeds 800 meters / minute and the steel strip thickness is between 0.2 mm and 0.8 mm.

[0023] like Figure 1As shown, at the system physical architecture level, this embodiment constructs a highly integrated electromechanical-hydraulic operating platform. The core actuator of this platform is the water-blocking roller assembly, which spans the running path of the thin-gauge steel belt. The body of the water-blocking roller adopts a composite structure design, with a high-strength 45# steel metal mandrel inside, which is heat-treated to ensure sufficient dynamic stiffness and prevent radial runout under high-speed rotation. The outer layer of the metal mandrel is coated with a 20 mm thick wear-resistant synthetic rubber layer through a hot vulcanization process. The Shore hardness of this synthetic rubber layer is precisely controlled between 75 and 85 degrees. The design intent of this hardness range is to provide sufficient elastic deformation space to form an effective water-blocking contact width, while maintaining sufficient wear resistance to resist erosion under high-speed operation. To further reduce the hydrodynamic pressure at the inlet side of the roll gap, the rubber surface of the water-blocking roller is machined with drainage threads with a depth of 1.5 mm. These threads are rotated on both sides with the roller centerline as the symmetrical axis, thereby guiding the accumulated coolant to be forcibly discharged to both sides under the action of contact pressure, thus initially destroying the conditions for the formation of the fluid lubrication film from a physical structure perspective.

[0024] The system's sensing dimension consists of a precisely arranged sensor array. Above the thin-gauge steel strip, 500 mm in front of the water-retaining roller, is a laser Doppler velocimeter. This velocimeter uses the dual-beam interference principle to acquire the real-time linear velocity of the steel strip surface non-contactly, achieving a measurement accuracy of up to 0.01%. Its sampling frequency is set to 2000 Hz, ensuring the capture of microsecond-level velocity pulsations in the steel strip. Simultaneously, a high-precision rotary encoder with a resolution of 65,536 pulses per revolution is installed at the shaft end of the water-retaining roller, providing real-time feedback on the roller's rotation angle and the converted linear velocity. High-frequency response load sensors are embedded below the supports at both ends of the water-retaining roller. These load sensors, using the piezoelectric principle, can sense the combined radial force generated by steel strip tension fluctuations, hydrodynamic pressure rise, and mechanical vibration in real time. In addition, an environmental parameter sensing unit, including an ultrasonic flow meter, a pressure transmitter, and a thermal resistance temperature sensor, is deployed in the water collection tank area on the inlet side of the water separator roller to monitor the flow rate of the coolant flowing through the roller gap, the spray pressure, and its actual operating temperature in real time.

[0025] The core logic of the control system runs on a high-performance industrial control computer, which integrates a real-time control task processor and a digital signal processor (DSP) specifically for fluid simulation calculations. For the actuators, the system is equipped with an extremely fast-responding electro-hydraulic proportional servo system. This system includes a servo hydraulic cylinder whose piston rod is mechanically connected to the moving support frame of the water-separating roller. By precisely adjusting the oil flow and pressure of the servo hydraulic cylinder through an electro-hydraulic proportional valve, dynamic control of the water-separating roller's clamping load can be achieved. The minimum pressure adjustment step is set to 0.05 MPa, and the system response time of the entire hydraulic circuit is strictly controlled within 5 milliseconds. To provide active intervention, the water-separating roller's spindle is also connected to a high-power variable frequency motor via a coupling. This variable frequency motor has four-quadrant operation capability and can seamlessly switch between speed control mode and torque control mode.

[0026] Based on the above system architecture, the specific control method and workflow of this embodiment are as follows: Step S1: Synchronous acquisition and preprocessing of multi-source signals After the system starts, the control unit instructs the sensor array to enter full-time domain monitoring mode. For example... Figure 2 As shown, the laser Doppler velocimeter converts the collected linear velocity signal of the thin-gauge steel strip into a high-frequency pulse stream, which is transmitted to the counter module of the controller via shielded twisted-pair cable. Simultaneously, a high-precision rotary encoder provides real-time feedback of the pulse signal from the water-blocking roller. The controller's internal timestamp synchronization module aligns these two signals to ensure real-time speed comparison. The load sensor converts the sensed force signal into a standard 4-20 mA current signal in real time, which is then converted to an analog-to-digital converter (ADC) and input into the processor's logic unit. The flow meter, pressure transmitter, and temperature sensor continuously output coolant environmental parameters. Before the data enters the core algorithm, the system uses a Kalman filter algorithm to denoise the original signal, eliminating pseudo-random errors caused by frame vibration and electromagnetic interference, and extracting feature components reflecting the true state of the interface.

[0027] Step S2: Slip ratio monitoring and real-time calculation of fluid dynamic pressure characteristics like Figure 3 As shown, the control unit uses the processed linear velocity signal With rotational linear velocity signal Real-time calculation of the current slip ratio The calculation formula is: Meanwhile, the DSP processor invokes its built-in fluid lubrication analysis model. This model, based on the Reynolds equations and incorporating real-time data on coolant dynamic viscosity (temperature-dependent), spray pressure, flow rate, and the geometric parameters of the drainage threads on the water-blocking roller surface, establishes a model of the interfacial fluid dynamic pressure field distribution. Specifically, the system uses the finite difference method to iteratively solve for the pressure distribution in the convergent wedge-shaped section of the roller gap within each sampling period, quantifying the radial buoyancy force generated by the fluid dynamic pressure. This buoyancy is the root cause of the decrease in the effective clamping force of the water-blocking roller, which in turn induces slippage.

[0028] The system then determines the risk level of slippage. The control unit compares the real-time slip rate with preset thresholds: when the slip rate fluctuates between 0.2% and 0.5%, it is considered a normal operating condition; when the slip rate exceeds 0.5% and the rate of change of fluid buoyancy increases, it is considered a Level 1 risk; when the slip rate further climbs to above 1.5% and the actual effective positive pressure monitored by the load sensor decreases by more than 30%, it is considered a Level 2 risk. This classification mechanism provides a decision-making basis for subsequent classification control.

[0029] Step S3: Output and execution of multi-dimensional control commands like Figure 4 As shown, the control unit adopts different compensation strategies based on the determined risk level. Under Level 1 risk, the system primarily increases the clamping load by adjusting the servo hydraulic cylinders in the actuator. The control unit outputs incremental control current to the electro-hydraulic proportional valve, causing the cylinders to respond quickly and increase the normal pressure of the water-separating rollers on the thin steel strip to counteract the calculated fluid buoyancy force. This keeps the interfacial friction within a safe range that prevents slippage.

[0030] Under level 2 risk conditions, simply increasing the pressure may cause excessive heating of the rubber roller surface or plastic deformation of the thin steel strip. In this situation, the control unit activates a dual-dimensional "pressure-torque" compensation mechanism. In addition to continuing to optimize the hydraulic load, the controller instructs the variable frequency motor to switch from speed synchronization mode to torque enhancement mode. The variable frequency motor outputs an active drive torque in the same direction of operation, the magnitude of which precisely corresponds to the frictional loss torque caused by the fluid dynamic pressure. By actively outputting drive force, the water-blocking roller can maintain linear velocity synchronization with the steel strip even under extremely low friction coefficients, forcibly maintaining a critical static friction state.

[0031] Step S4: Closed-loop feedback monitoring and parameter iterative compensation like Figure 5As shown, after the adjustment is implemented, the system does not stop intervening but enters a high-frequency feedback loop. The control unit continuously monitors the trend of the slip ratio after adjustment. If the slip ratio drops rapidly to below 0.2% within 50 milliseconds, the system maintains the current control gain; if the slip ratio decreases slowly or oscillates, the iterative compensation logic inside the system will automatically correct the proportional and integral coefficients of the PID controller, further increasing the gain weight of the clamping load or drive torque.

[0032] To ensure effective control, the system also incorporates real-time online detection feedback of the steel strip surface. A linear array camera scans the surface of the steel strip after it passes through the water-blocking roller at a rate of 10,000 lines per second. The image processing module uses deep learning algorithms to identify the presence of striped, slippery scratches in real time. Once a suspected scratch is detected, the system instantly triggers the highest level alarm and applies extreme pressure. Simultaneously, the location of the defect is marked and recorded, and fed back to the central control system for process traceability.

[0033] Example 2 This embodiment, based on Embodiment 1, has undergone in-depth optimization for dynamic synchronization control under extremely thin specifications (thickness less than 0.15 mm) and high-speed, frequent acceleration and deceleration conditions. In terms of system hardware, this embodiment has miniaturized and upgraded the actuator for higher frequency operation.

[0034] In addition to retaining the servo hydraulic cylinders from Embodiment 1, the system also includes an additional set of piezoelectric ceramic actuators mounted on the support arm of the water-separating roller. These piezoelectric ceramic actuators have nanometer-level displacement resolution and response frequencies up to the kilohertz level, primarily used to compensate for the high-frequency impact loads generated when the steel strip joint passes over the roller.

[0035] At the methodological level, this embodiment introduces a predictive control algorithm. In step S2, the control unit does not only determine slippage based on current sensor data, but also establishes a pre-operational model based on a Long Short-Term Memory (LSTM) network. This model uses the velocity gradient, tension fluctuations, and coolant flow rate changes in historical production curves as input features to predict the possible peak fluid dynamic pressure within the next 200 milliseconds.

[0036] When a large-scale slippage risk is predicted, the control unit will apply a high-frequency oscillating pressure component in advance through the piezoelectric ceramic actuator before the slippage actually occurs (i.e., step S3 is executed in advance). This component can disrupt the continuity of the interfacial liquid film, similar to the reverse logic of the anti-lock braking system (ABS) in automobiles, and increase the engagement probability of micro-contact points through small-amplitude high-frequency pressure fluctuations.

[0037] Meanwhile, for the control of the variable frequency motor, this embodiment adopts direct torque control (DTC) technology. At the moment of detecting slippage tendency, the frequency converter can complete the change of magnetic field orientation and torque output within 1-2 milliseconds. By compensating for the hysteresis effect caused by rotational inertia, the angular acceleration of the water-blocking roller is perfectly matched with the linear acceleration change of the thin-gauge steel strip.

[0038] Furthermore, the feedback monitoring step S4 in this embodiment also includes monitoring the temperature rise of the rubber surface on the water-blocking roller. A non-contact infrared thermometer is used to monitor the roller surface temperature. When excessive heat generation due to frequent compensation is detected, the control unit automatically adjusts the distribution of the coolant spray array, using a portion of the coolant to directly cool the roller surface, ensuring the rubber layer remains within its optimal hardness range (75-85 degrees Celsius) and preventing water-blocking failure due to softening.

[0039] Example 3 This embodiment focuses on the system's adaptability in a multi-variety, small-batch production environment. For different steel grades (such as stainless steel, silicon steel, and carbon steel), their surface roughness and wettability vary significantly, directly affecting the formation characteristics of the fluid lubrication film.

[0040] In terms of hardware configuration, the sensor array in this embodiment adds a set of confocal laser scanning heads to scan the microscopic morphological features (Ra value) of the surface of each roll of steel strip in real time as it is loaded onto the line. The control unit's memory pre-stores a "materials-fluids-friction" expert database covering thousands of working conditions.

[0041] In the logical deduction of step S2, the system first reads the code of the steel grade currently being produced and the surface roughness parameters collected in real time. The controller automatically retrieves the correction coefficients from the expert database to reconstruct the fluid lubrication model in the Reynolds equation online. For example, for steel strips with relatively rough surfaces, the model automatically increases the weight of the effective contact area and reduces the force of fluid dynamic pressure compensation, thereby avoiding excessive clamping force from damaging the steel strip surface; for thin steel strips with mirror-like smoothness, the model significantly improves the prediction level of fluid dynamic pressure and activates the active drive torque in advance.

[0042] In the coordinated control step S3 of the actuator, this embodiment introduces a fuzzy neural network controller. This controller can handle the uncertainties and nonlinear characteristics in the sensor data. When the coolant environmental parameters (such as flow rate and temperature) fluctuate drastically, the fuzzy logic can provide a smooth control output based on empirical rules, avoiding high-frequency vibrations in the actuator, thereby extending the service life of the servo hydraulic cylinder and precision bearings.

[0043] In the feedback loop of step S4, this embodiment also integrates a digital twin mirror system. This system runs in parallel within a computer a mechanical model that is completely identical to the physical water-blocking roller. By comparing the simulated response of the digital twin with the measured physical response of the sensors, the control unit can diagnose in real time whether the sensors have experienced zero-point drift or whether the mechanical structure has fatigue loosening, thereby achieving full life-cycle health monitoring and precise compensation for the system.

[0044] Example 4 This embodiment optimizes energy efficiency and long-term system stability for large-scale industrial production. Structurally, the drainage structure of the water-blocking roller has been further improved. In addition to surface drainage threads, the metal mandrel features a hollow cooling channel that uses circulating cooling water to reduce high-speed frictional heat.

[0045] In terms of control methods, this embodiment introduces an energy-optimal control law when implementing the adjustment command in step S3. The system will evaluate the energy consumption ratio of the two methods, "increasing hydraulic load" and "increasing drive torque," in real time. Under the premise of ensuring anti-slip effect, the controller prioritizes the adjustment combination with lower power consumption and less wear on the equipment. For example, anti-slip is achieved by adjusting the hydraulic proportional valve in the low-speed range, while switching to the active auxiliary drive of the variable frequency motor in the extremely high-speed range.

[0046] In the feedback monitoring stage of step S4, this embodiment incorporates probabilistic prediction of scratch risk. The images acquired by the linear array camera are not only used to identify existing scratches, but also to assess the current anti-slip redundancy through thickness analysis of the residual liquid film at the roll gap exit (using optical interferometry). If the residual liquid film exceeds a critical value, the system will fine-tune the actuator even if slippage has not yet occurred, achieving true preventative control.

[0047] Furthermore, the sensor array in this embodiment also includes a spectrum analyzer for frame vibration. By performing real-time FFT transformation on the vibration spectrum in the 10 Hz to 5000 Hz frequency band, the system can identify the resonance phenomenon of the water-resistant roller caused by fluid excitation. Once a resonance trend is detected, the controller will fine-tune the speed bias of the variable frequency motor to make the system quickly jump away from the resonance zone, eliminating the risk of instantaneous slippage caused by mechanical instability from the physical source.

[0048] Example 5 This embodiment discloses an anti-slip system for continuous rolling of ultra-wide (over 1500 mm) thin-gauge steel strips. To address the problem of uneven lateral tension that easily occurs in wide steel strips, this embodiment employs a segmented design for the actuator.

[0049] The water-blocking rollers in the system are composed of multiple independent short roller sections combined by universal couplings, or a single roller structure with a flexible shaft. Each support node is equipped with an independent servo-hydraulic support and load sensor.

[0050] In terms of methodology, the linear velocity signal acquired in step S1 is now acquired at multiple points. The laser Doppler velocimeter sets velocity measurement points at three positions: left, center, and right of the steel strip. The hydrodynamic pressure model established in step S2 is also upgraded from a one-dimensional simplified model to a two-dimensional pressure field model, which can analyze the distribution of fluid pressure gradient in the transverse direction of the steel strip in real time.

[0051] In the control output phase of step S3, the controller executes differential compensation logic. If the hydrodynamic pressure on the left side of the steel strip is detected to be higher than that on the right side, the control unit will instruct the servo hydraulic support on the left side to output a larger clamping force. This refined lateral load distribution effectively prevents local slippage and strip warping caused by uneven lateral force on the steel strip.

[0052] The feedback monitoring process in step S4 also focuses on the shape and quality of the steel strip. The scanning results of the linear array camera not only provide feedback on scratch information, but also monitor whether there are local wrinkles in the steel strip caused by uneven pressure from the water-blocking roller. The system continuously optimizes the coordination coefficient of each actuator through iterative algorithms, ultimately achieving near-perfect synchronous coupling contact between the water-blocking roller and the steel strip under long-span, high-speed operating conditions.

[0053] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent changes, or alterations made by those skilled in the art using the above-disclosed technical content shall still fall within the scope of the present invention.

[0054] In the implementation of all the above embodiments, this system has successfully broken through the performance bottleneck of traditional water-blocking roll systems under high-speed continuous rolling conditions by highly integrating precision sensor technology, real-time fluid dynamics calculation technology and electro-hydraulic servo control technology.

[0055] From a signal processing perspective, the sampling frequency of over 1000 Hz used in step S1, combined with a 24-bit high-precision ADC acquisition card, enables the control system to capture extremely subtle physical fluctuations during the operation of the steel belt. These fluctuation data, after entering the control core, are not simply summed linearly, but rather subjected to multi-physics coupling calculations through a nonlinear fluid model in step S2. For example, the viscosity of the coolant... It is not a constant, but rather based on the real-time temperature fed back by the temperature sensor. It is adjusted in real time using the Arrhenius correction formula.

[0056] In the core computational logic, fluid dynamic pressure The distribution calculation follows the simplified Reynolds equation. This equation fully considers the microscopic morphological parameters of the water-blocking roller surface (such as the width of the drainage grooves). and depth By introducing these parameters, the fluid buoyancy force can be calculated. It can be accurate to the Newton level. This provides a solid theoretical basis for the precise application of force in step S3.

[0057] In terms of the coordination precision of the actuators, the collaborative operation between the servo hydraulic system and the variable frequency motor adopts an advanced "feedforward + feedback" control architecture. The feedforward part directly provides a preset output value based on the slippage risk level predicted in step S2, ensuring the system's response speed; the feedback part fine-tunes the system through the slip ratio closed loop and image recognition results in step S4, ensuring the system's steady-state accuracy. The control current of the electro-hydraulic proportional valve is modulated by PWM, exhibiting extremely high linearity and minimal hysteresis. This makes the adjustment process of the clamping load smooth and stable, effectively avoiding impact scratches on thin-gauge steel strips caused by sudden pressure changes.

[0058] From the perspective of data interaction and network topology, the entire system adopts a distributed architecture based on industrial Ethernet (such as ProfinetIRT or EtherCAT). Sensor data, control commands, and feedback image data are exchanged on a unified high-speed network bus. This architecture not only ensures the determinism of data transmission but also greatly enhances the system's scalability. For example, when the production line needs to add a steel strip surface quality analysis function, it is only necessary to connect a new linear array camera node to the bus and upgrade the image processing subroutine in step S4, without requiring large-scale changes to the underlying hardware logic of the entire system.

[0059] Safety design is incorporated throughout each embodiment. An independent hard-wired safety interlock circuit is installed within the control unit. Upon detecting a loss of load sensor signal, inverter malfunction, or abnormal hydraulic system pressure, the system will automatically raise the water-blocking roller to a safe position within 10 milliseconds and switch to emergency stop mode, maximizing protection of the expensive, thin-gauge steel belt from secondary damage.

[0060] In summary, this invention, through ingenious system architecture design and rigorous control methods, achieves effective control over fluid lubrication behavior under high-speed continuous rolling conditions. It not only significantly improves water-blocking performance but also fundamentally solves the long-standing technical problem of slippage and scratching in the production of thin-gauge steel strips. Experimental data show that after adopting this system and control method, the incidence of slippage and scratching defects on the steel strip surface is reduced by more than 95%, and the service life of the water-blocking roller is extended by more than 2 times, providing reliable equipment and technical support for the cold rolling process of high-precision metal strips.

[0061] In the future Industry 4.0 upgrade path, the digital modeling capabilities and adaptive control logic of this system can easily interface with the factory's MES system and big data center. By performing offline mining on the massive amount of operational data accumulated in step S4, the fluid dynamic pressure model in step S2 can be further optimized, realizing the evolution from "rule-based control" to "data-driven intelligent autonomy", thereby adapting to more extreme and complex future production needs.

[0062] In terms of detailed optimization of the mechanical structure, this invention also involves adjusting the damping characteristics of the water-blocking roller bearing housing. The bearing housing is filled with high-viscosity damping grease, which can effectively absorb the mechanical vibration energy caused by the high-speed operation of the thin-gauge steel belt. This microscopic physical design, together with the active control command in step S3, constructs a stable interface contact environment.

[0063] Furthermore, the sensor array in this invention also possesses self-diagnostic capabilities. The control unit periodically executes a self-test program, sending a small excitation signal to the actuator to observe the dynamic response characteristics of each sensor. If a response lag or abnormal amplitude is detected, the system automatically alerts maintenance personnel to calibrate or replace the sensors, ensuring the high reliability of the entire anti-slip control system during long-term continuous production.

[0064] Finally, to address the issue of media impurities arising from coolant recycling, the system integrates a laser scattering suspended matter monitor within the coolant parameter sensing unit. When the concentration of solid particles in the coolant exceeds a critical value, the system recognizes that these particles may alter the hydrodynamic characteristics of the fluid and increase the risk of scratches. At this point, the control unit automatically fine-tunes the friction coefficient weight in step S2 and increases the active drive torque output in step S3 to compensate for the interfacial dynamic instability caused by the particles. This detailed design fully demonstrates the systematic and meticulous nature of this invention in handling complex real-world operating conditions.

[0065] Through the combination of the above multi-level and multi-dimensional technical means, this invention not only provides a specific water-blocking roller system, but also establishes a complete and highly robust theoretical system for preventing slippage and scratches in continuous rolling of thin-gauge steel strips. Its superior technical performance and significant economic benefits make it a promising candidate for application in high-performance cold rolling production lines and highly valuable for widespread adoption.

[0066] It should be noted that the above embodiments are not isolated from each other. In practical applications, those skilled in the art can flexibly combine the hardware components and control logic in different embodiments according to the specific production line layout, steel strip specifications, and cost budget. For example, the piezoelectric ceramic actuator in Embodiment 2 can be introduced into the wide-width steel strip control system in Embodiment 5 to obtain better high-frequency response performance; or the expert database in Embodiment 3 can be applied to the general-purpose system in Embodiment 1 to improve its adaptability to multi-variety production. These combinations and modifications all fall within the scope of protection of the claims of this invention.

Claims

1. A method for controlling anti-slip and scratching water-blocking rollers in continuous rolling of thin-gauge steel strips, characterized in that, Includes the following steps: S1. The linear velocity signal of the thin steel strip during operation, the rotational linear velocity signal of the water-blocking roller, the load exerted by the water-blocking roller on the surface of the thin steel strip, and the coolant environment parameters at the inlet side of the water-blocking roller gap are acquired in real time through a sensor array. S2. Construct a slip ratio monitoring model based on the linear velocity signal and the rotational linear velocity signal, and calculate the hydrodynamic pressure distribution characteristics of the contact interface between the water-blocking roller and the thin-gauge steel strip in combination with the coolant environmental parameters, so as to determine the slip risk level under the current working condition; S3. Output adjustment commands to the actuator according to the slippage risk level, dynamically adjust the clamping load or active drive torque of the water-blocking roller to counteract the radial buoyancy force generated by the hydrodynamic pressure effect and maintain the critical static friction state between the thin steel strip and the water-blocking roller; S4. Continuously monitor the adjusted interface contact state, and correct the control parameters in real time according to the rate of change of the slip ratio through iterative compensation logic.

2. The method for controlling anti-slip and scratching water-blocking rollers for continuous rolling of thin-gauge steel strips according to claim 1, characterized in that, The sensor array in step S1 includes a laser Doppler velocimeter, a high-precision rotary encoder, and a load sensor arranged on the support of the water-blocking roller. The laser Doppler velocimeter is installed above the frame in front of the water-blocking roller and is used to capture the linear velocity of the thin-gauge steel strip.

3. The method for controlling anti-slip and scratching water-blocking rollers for continuous rolling of thin-gauge steel strips according to claim 1, characterized in that, The coolant environmental parameters mentioned in step S1 include the coolant flow rate, spray pressure, and temperature within the flow channel.

4. The method for controlling anti-slip and scratching water-blocking rollers for continuous rolling of thin-gauge steel strips according to claim 1, characterized in that, The process of calculating the fluid dynamic pressure distribution characteristics in step S2 includes: establishing a fluid lubrication model based on the Reynolds equation. The fluid lubrication model introduces the dynamic viscosity of the coolant, the surface roughness of the thin-gauge steel strip, and the geometric parameters of the convergent wedge interval formed by the water-blocking roller and the thin-gauge steel strip, in order to quantify the degree of reduction of the fluid dynamic pressure on the effective normal pressure of the interface.

5. The method for controlling anti-slip and scratching water-blocking rollers for continuous rolling of thin-gauge steel strips according to claim 1, characterized in that, In step S2, the slip risk level is divided according to the slip rate. When the slip rate exceeds the preset low-level threshold, it is determined to be the corresponding initial risk level. When the slip rate exceeds the preset high-level threshold, it is determined to be the corresponding high-level risk level. The control unit matches the corresponding response strategy according to the different risk levels.

6. The method for controlling anti-slip and scratching water-blocking rollers for continuous rolling of thin-gauge steel strips according to claim 1, characterized in that, The actuator in step S3 includes a servo hydraulic cylinder or a proportional control cylinder. The oil inlet and pressure of the servo hydraulic cylinder are controlled by an electro-hydraulic proportional valve to adjust the clamping load.

7. The method for controlling anti-slip and scratching water-blocking rollers for continuous rolling of thin-gauge steel strips according to claim 1, characterized in that, The active drive torque mentioned in step S3 is provided by a variable frequency motor. The working mode of the variable frequency motor switches between speed control and torque control. When a slippage trend is detected, the variable frequency motor increases the drive torque to compensate for the friction loss caused by the fluid dynamic pressure.

8. The method for controlling anti-slip and scratching water-blocking rollers for continuous rolling of thin-gauge steel strips according to claim 1, characterized in that, It also includes: using a linear array camera to scan the surface of the thin-gauge steel strip after passing through the water-blocking roller, identifying whether there are striped scratches caused by momentary slippage, and feeding the identification results back to the control unit.

9. A water-blocking roller system for continuous rolling of thin-gauge steel strips, characterized in that, include: A sensor array is used to acquire in real time the linear velocity signal of the thin-gauge steel strip during operation, the rotational linear velocity signal of the water-blocking roller, the load exerted by the water-blocking roller on the surface of the thin-gauge steel strip, and the coolant environment parameters at the inlet side of the water-blocking roller slot. A control unit, configured to perform the control method as described in any one of claims 1 to 8; The actuator, driven by the control unit, is used to dynamically adjust the clamping load or active driving torque of the water-blocking roller; The water-blocking roller includes a metal core and a wear-resistant synthetic rubber layer covering the outer layer of the metal core. The surface of the wear-resistant synthetic rubber layer is machined with drainage threads or cross-grid grooves of a predetermined depth.

10. The anti-slip and scratch-resistant water-blocking roller system for continuous rolling of thin-gauge steel strips according to claim 9, characterized in that, The actuator also includes a piezoelectric ceramic actuator mounted on the water-blocking roller support arm. The control unit applies a high-frequency oscillating pressure component through the piezoelectric ceramic actuator to disrupt the continuity of the interfacial liquid film.

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