A roughing vertical roll wear compensation method

Abstract

The present application relates to the field of rolling steel, and more particularly to a rough rolling vertical roll wear compensation method, which collects the average value of actual wear amount of different vertical roll materials and different on-machine positions in a rolling cycle; according to the rolling block number of the vertical roll in the rolling cycle, the on-machine position of the vertical roll and the vertical roll material, a vertical roll wear compensation function F(x) is constructed; the vertical roll wear compensation amount calculated by the vertical roll wear compensation function F(x) is applied to the vertical roll set gap to correct the final vertical roll set gap. The present application has the advantages that: according to the wear characteristic difference of different material vertical rolls, the actual wear data is collected to construct the vertical roll wear compensation function F(x), the original Timken model is dynamically corrected; taking the actual application of a certain hot rolling 2150 production line as an example, after the present application is adopted, the wear amount prediction accuracy of E1 and E2 vertical rolls is significantly improved, the width control accuracy of the strip steel is improved, the width hit rate is improved, and the width out-of-tolerance products caused by wear prediction deviation are effectively reduced.

Description

Technical Field

[0001] This invention relates to the field of steel rolling, and more particularly to a method for compensating for wear on roughing mill vertical rolls. Background Technology

[0002] In hot-rolled strip steel production, width accuracy is one of the key indicators for measuring product quality. In the 2150 production line of a hot-rolled strip steel plant, the control of coil width accuracy mainly relies on the vertical roll equipment in the roughing zone. The roughing rolls adjust the strip width through lateral pressure, and their setting accuracy directly affects the width quality of the final product.

[0003] During roughing, the vertical rolls come into direct contact with the high-temperature strip, bearing significant rolling forces and thermal shocks, leading to gradual and cumulative wear on the roll surface. Changes in the amount of vertical roll wear alter the actual roll gap, thus affecting the accuracy of strip width control. Therefore, accurate prediction of vertical roll wear is a crucial component of the width control model, and the accuracy of vertical roll wear prediction directly impacts strip width accuracy.

[0004] Currently, the TMEIC model algorithm is used to calculate the vertical roll wear in the mathematical model of the 2150 hot rolling line. This algorithm considers the rolling force, rolling length, and other production conditions of rolls of different materials during each strip rolling process within the rolling cycle, and calculates the wear amount through iterative accumulation to form the final predicted value of total wear. This model has a certain degree of stability and reliability in long-term applications.

[0005] However, in actual production applications, with the continuous development of roll manufacturing technology, vertical roll manufacturers frequently change, and new materials are constantly being introduced into use. Field practice has revealed significant differences in the wear resistance of vertical rolls made of different materials, and there is a large deviation between the actual wear of new material rolls and the values ​​predicted by the original models. For example, after a material change, the actual wear of E1 and E2 vertical rolls reached 20mm and 12mm respectively, while the original model predictions were only 1.7mm and 2.5mm, a difference of several times. This deviation leads to a mismatch between the set roll gap and the actual wear, resulting in fluctuations in strip width control and affecting the stability of product quality.

[0006] Existing technologies lack adaptive compensation mechanisms for the wear characteristics of vertical rolls made of different materials. They cannot dynamically adjust the wear prediction value based on factors such as changes in vertical roll material, differences in the roll's position on the mill, and the number of rolls in the rolling cycle, making it difficult to guarantee the accuracy of width control.

[0007] Therefore, there is an urgent need to develop a compensation method that can adapt to the wear characteristics of vertical rolls made of different materials, so as to improve the prediction accuracy of vertical roll wear, stabilize strip width control, and improve product quality. Summary of the Invention

[0008] The purpose of this invention is to provide a method for compensating for wear of vertical rolls in roughing mills. By collecting the average actual wear of vertical rolls made of different materials, and combining the rolling force data and rolling length data of the first pass in the rolling process, a vertical roll wear compensation function F(X) is constructed. This function uses the number of vertical rolls rolled, the position on the mill, and the material of the vertical roll as independent variables to calculate the wear compensation amount and apply it to the set roll gap of the vertical roll. At the same time, a regional boundary limiting mechanism is set to prevent abnormal data interference, and a partial debugging strategy is adopted to ensure that the algorithm is smoothly integrated into the production control.

[0009] To achieve the above objectives, the present invention provides the following technical solution: A method for compensating wear on roughing mill vertical rolls includes: Collect the average actual wear amount of different vertical roll materials and different mounting positions within one rolling cycle; The average value of the actual wear was collected and compared with the wear predicted by the existing mathematical model. The influence of the vertical roll material, the position on the mill, and the number of rolling blocks on the vertical roll wear prediction error was analyzed and determined. Based on the number of rolling blocks, the position of the vertical roll on the mill, and the material of the vertical roll in this rolling cycle, a vertical roll wear compensation function F(X) is constructed. The vertical roll wear compensation amount calculated by the vertical roll wear compensation function F(X) is applied to the vertical roll set gap to correct the final set gap of the vertical roll.

[0010] The vertical roll wear compensation function F(X) is a dependent variable function related to the number of vertical rolls rolled, the vertical roll's position on the mill, and the vertical roll's material. Its expression is: ①; in: Indicates the number of blocks rolled within a vertical roll cycle; This indicates the maximum number of blocks that can be rolled on a vertical roll in one rolling cycle; This indicates the upper limit of wear on the vertical roll within one rolling cycle; The vertical roll wear compensation function F(X) is used to predict the amount of compensation for vertical roll wear during the current rolling cycle.

[0011] The formula for calculating the final roll gap of the vertical roll is: The final roll gap setting for vertical rolls is calculated as follows: roll gap = roll thermal expansion effect + original model vertical roll wear effect + vertical roll wear compensation amount × compensation amount input weight.

[0012] It also includes setting regional boundary limits for the wear compensation amount of the vertical rollers; The limiting parameters include: the number of rolled blocks within the cycle, the preset total wear amount for the cycle, and the final predicted vertical roll wear compensation amount. By using the limiting parameters, the vertical roll wear compensation amount is controlled within the set range to prevent abnormal data from causing fluctuations in width control.

[0013] This also includes phased commissioning: after the vertical roller is replaced, the wear compensation for the vertical roller is gradually applied, following these steps: E2 vertical roller compensation is performed at a set ratio; After the E2 vertical roll compensation is put into stable operation, it will be gradually extended to the E1 vertical roll compensation, and the vertical roll compensation ratio will be gradually increased.

[0014] The collection of the average actual wear amount includes classifying and statistically analyzing wear data for different vertical roller materials and different mounting positions, forming comparative data with the wear calculated by the original model.

[0015] The rolling force data and rolling length data are both based on the actual data of the first pass vertical roll as the evaluation sample, and are used to analyze wear trends and as a basis for compensation.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. To address the differences in wear characteristics of vertical rolls made of different materials, a vertical roll wear compensation function F(x) is constructed by collecting actual wear data, thereby achieving dynamic correction of the original Timmerman model. Taking a hot-rolled 2150 production line as an example, after adopting this invention, the accuracy of wear prediction for E1 and E2 vertical rolls is significantly improved, thereby increasing the strip width control accuracy, improving the width hit rate, and effectively reducing the number of products with out-of-tolerance widths caused by wear prediction deviations. 2. By introducing the vertical roller material parameter code m as the independent variable of the compensation function, the wear compensation amount can be automatically adjusted according to the different material characteristics. Field practice shows that when the vertical roller manufacturer changes and the new material vertical roller is put into use, there is no need to modify the original model core algorithm. The new material wear characteristics can be quickly adapted by the compensation function alone, avoiding the width control fluctuation caused by material changes and greatly shortening the process adjustment cycle. 3. Set the area boundary limiting parameters, including the number of rolling blocks in the cycle, the preset total wear in the cycle, and the final predicted vertical roll wear compensation amount, etc., to control the compensation amount within a reasonable range. When sensor failure, communication abnormality or extreme working conditions occur, the limiting mechanism will automatically take effect to prevent abnormal compensation values ​​from causing drastic fluctuations in width control, thereby improving the robustness and safety of the system. 4. Design a phased debugging plan. After the vertical roller is replaced, the compensation amount is first applied to the E2 vertical roller with a small weight (e.g., 30%). After the compensation algorithm is running stably, it is gradually extended to the E1 vertical roller, and the compensation ratio is gradually increased until the full amount is applied. This strategy effectively reduces the technical risks brought about by the new algorithm, ensures a smooth transition in the production process, and avoids batch quality accidents caused by algorithm switching. 5. Without changing the core architecture of the original Timac model, wear correction is achieved by adding a compensation function, avoiding large-scale software reconstruction and hardware upgrades. Field engineers only need to add a compensation calculation module in the secondary system (L2 level) to realize the function deployment. It has the characteristics of low investment, quick results and easy promotion. 6. Wear data of vertical rolls of different materials accumulated in practical applications can be fed back into the roll management system, providing a scientific basis for roll material selection, machine cycle optimization, and roll grinding strategy formulation, realizing refined management of the entire life cycle of rolls and further reducing roll consumption costs. Detailed Implementation

[0017] The present invention will now be described in detail, but it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0018] The following embodiments are implemented based on the technical solution of the present invention, providing detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments. Unless otherwise specified, the methods used in the following embodiments are conventional methods. Example 1:

[0019] A method for compensating wear on roughing mill vertical rolls includes: S1. Collect the average actual wear amount of different vertical roll materials and different mounting positions within one rolling cycle.

[0020] Taking a hot-rolled 2150 production line as an example, the actual wear data of E1 and E2 vertical rolls under different material conditions were collected and compared with the wear calculated by the original model to form the data statistics shown in Table 1.

[0021] Table 1 compares the average wear of vertical rollers of different materials at different machine positions.

[0022] As shown in Table 1, the actual wear of the original material vertical roller is significantly higher than the value calculated by the original model, while the wear of the new material vertical roller is even higher. This indicates that the original model can no longer accurately predict the wear of the new material vertical roller and wear compensation is required.

[0023] S2. Collect vertical roll wear data during the rolling cycle.

[0024] The correlation between vertical roll wear and the number of rolled blocks was analyzed to correct the accuracy of the vertical roll wear compensation algorithm during rolling. Utilizing the rolling line downtime during maintenance and roll changes in the finishing mill, the vertical roll diameter was manually measured on-machine using an outside micrometer at a specific moment within the rolling cycle to determine the actual wear amount of the vertical roll at the current number of rolled blocks. Through multiple measurements, the true wear values ​​at different rolling block positions within the rolling cycle were obtained.

[0025] S3. Based on the number of rolling blocks, the position of the vertical roll on the mill, and the material of the vertical roll in this rolling cycle, construct the vertical roll wear compensation function F(X)); The vertical roll wear compensation function F(X) is a dependent variable function related to the number of vertical rolls rolled, the vertical roll's position on the mill, and the vertical roll's material. Its expression is: ①; in: Indicates the number of blocks rolled within a vertical roll cycle; This indicates the maximum number of blocks that can be rolled on a vertical roll in one rolling cycle; This indicates the upper limit of wear on the vertical roll within one rolling cycle; The vertical roll wear compensation function F(X) is used to predict the amount of compensation for vertical roll wear during the current rolling cycle.

[0026] Based on the data in Table 1 and combined with actual rolling data from the field, the following empirical formula is established: For the new material of vertical rollers: ①; in: Indicates the number of blocks rolled within a vertical roll cycle; This indicates the maximum number of blocks that can be rolled on a vertical roll in one rolling cycle; This indicates the upper limit of wear on the vertical roll within one rolling cycle.

[0027] S4. Apply the vertical roll wear compensation amount calculated by the vertical roll wear compensation function F(X) to the vertical roll set gap, correct the final set gap of the vertical roll, and form the mathematical model (i.e., the TMEIC model) setting data for width control. The mathematical model setting data for width control refers to the final set value for roll gap execution, which is sent to the basic automation level (L1 level) after wear compensation correction. This data is the control parameter output by the process control level (L2 level) mathematical model and is directly used to drive the position control of the vertical roll hydraulic cylinder, thereby achieving precise adjustment of the strip width.

[0028] The formula for calculating the final roll gap of the vertical roll is: The final roll gap setting for vertical rolls is calculated as follows: roll gap = roll thermal expansion effect + original model vertical roll wear effect + vertical roll wear compensation amount × compensation amount input weight.

[0029] Calculate the roll gap: The basic roll gap value is calculated based on process parameters such as the target width of the strip, temperature, and steel grade; Effect of thermal expansion of rolls: Consider the change in roll gap caused by the thermal expansion of vertical rolls during the rolling process; The original model's vertical roll wear effect: The original Timmac model calculates the wear amount of a single piece of steel by factors such as the wear rate of the roll base, the rolling force per unit width, and the rolling length. The calculation is repeated iteratively to obtain the wear amount of the vertical roll after several pieces have been rolled. Vertical roller wear compensation amount: an additional wear correction value calculated by the compensation function F(X) of this invention; Compensation input weight: A coefficient used to control the magnitude of compensation input during the debugging phase, with a value range of 0 to 1.

[0030] Taking a certain strip of steel as an example: The calculated roll gap is 1230.5 mm; The effect of thermal expansion of the rolls is +0.3 mm; The wear effect of the existing vertical rollers is +0.8mm; The vertical roll wear compensation amount F(X) = 8 * 6000 / 15000 = 3.2 mm (calculated based on the current number of rolled blocks n = 6000). The compensation input weight is set to 0.5 (during the debugging phase); Therefore: The final set roll gap of the vertical roll is 1230.5 + 0.3 - 0.8 - 3.2 × 0.5 = 1228.4 mm.

[0031] 1228.4mm is the final mathematical model setting data sent to the basic automation system. The vertical roller will use this as the target value to adjust the roll gap to ensure that the strip width meets the preset accuracy requirements.

[0032] S5. Set the regional boundary limit for the wear compensation amount of the vertical roller; The limiting parameters include: the number of rolled blocks within the cycle, the upper and lower limits of the final predicted wear compensation amount for the vertical rolls of the new material, and the upper and lower limits of the final predicted wear compensation amount for the vertical rolls of the original material. These limiting parameters control the vertical roll wear compensation amount within a set range to prevent abnormal data from causing fluctuations in width control.

[0033] The set limit range is: Maximum number of blocks rolled within a cycle: 15,000 blocks; The final forecast for the upper limit of wear compensation for the original material vertical roller is: 8mm (E1) and 5mm (E2). The final forecast for the lower limit of wear compensation for the original material vertical roller is 0mm (to prevent negative compensation). The final forecast for the upper limit of wear compensation for the new material vertical roller is: 25mm (E1) and 15mm (E2). The final forecast for the lower limit of wear compensation for the new material vertical roller is 0mm (to prevent negative compensation). When the calculated result of F(X) exceeds the above range, the boundary value is automatically taken as the actual compensation amount.

[0034] S6. Partial commissioning: After replacing the vertical roller, gradually apply the vertical roller wear compensation amount, following these steps: After the E2 vertical roller was replaced during the maintenance period on July 26, 2023, partial commissioning began: Step 1: Perform E2 vertical roll compensation under the set ratio; With the compensation amount weight set to 0.3, the width control stability was observed after one continuous production cycle of the vertical roller, and no abnormal fluctuations were found.

[0035] Step 2: After the E2 vertical roller is running stably, the compensation will be extended to the E1 vertical roller. Set the weight of the E1 vertical roller compensation amount to 0.3 and run it synchronously with E2.

[0036] Step 3: Gradually increase the vertical roller compensation ratio; After each cycle of vertical roll use, the compensation amount is increased by 0.1 to 0.2 in weight until full compensation is achieved (weight = 1.0). The entire process took 5 months, during which more than 87,000 strip steel pieces were produced, and the width control accuracy was improved by about 2%, with no width fluctuations caused by the switching of the compensation algorithm.

[0037] Through the above-mentioned segmented debugging steps, the algorithm was smoothly integrated into the production control, achieving a smooth transition and effective application of the vertical roller wear compensation method.

[0038] This invention addresses the differences in wear characteristics of vertical rolls made of different materials. By collecting actual wear data, a vertical roll wear compensation function F(X) is constructed to dynamically correct the original Timmerman model. Taking a hot-rolled 2150 production line as an example, after adopting this invention, the accuracy of wear prediction for E1 and E2 vertical rolls is significantly improved, increasing the strip width control accuracy, improving the width hit rate, and effectively reducing width deviations caused by wear prediction errors. By introducing the vertical roll material parameter code m as the independent variable of the compensation function, the wear compensation amount can be automatically adjusted according to the characteristics of different materials. Field practice shows that when the vertical roll manufacturer changes and new material vertical rolls are put into use, there is no need to modify the core algorithm of the original model. The compensation function alone can quickly adapt to the wear characteristics of the new material, avoiding width control fluctuations caused by material changes and significantly shortening the process adjustment cycle. Setting area boundary limiting parameters, including the number of rolling blocks within the cycle, the preset total wear amount for the cycle, and the final predicted vertical roll wear compensation amount, controls the compensation amount within a reasonable range. When sensor failure, communication abnormality, or extreme operating conditions occur, the limiting is activated. The mechanism automatically takes effect, preventing abnormal compensation values ​​from causing drastic fluctuations in width control and improving the system's robustness and safety. A phased debugging scheme is designed: after vertical roll replacement, compensation is initially applied to the E2 vertical roll with a smaller weight (e.g., 30%). Once the compensation algorithm stabilizes, it is gradually extended to the E1 vertical roll, with the compensation ratio gradually increased until full coverage. This strategy effectively reduces the technical risks associated with the new algorithm's implementation, ensuring a smooth transition in production and avoiding batch quality incidents caused by algorithm switching. Without altering the core architecture of the original TIMAG model, wear correction is achieved by adding a compensation function, avoiding large-scale software refactoring and hardware upgrades. Field engineers only need to add a compensation calculation module to the secondary system (L2 level) to deploy the function, featuring low investment, quick results, and easy promotion. Wear data of vertical rolls made of different materials accumulated in practical applications can feed back into the roll management system, providing a scientific basis for roll material selection, on-machine cycle optimization, and roll regrinding strategy formulation, achieving refined management of the entire roll lifecycle and further reducing roll consumption costs.

Claims

1. A method for compensating wear on roughing mill vertical rolls, characterized in that, include: Collect the average actual wear amount of different vertical roll materials and different mounting positions within one rolling cycle; Based on the number of rolling blocks, the position of the vertical roll on the mill, and the material of the vertical roll in this rolling cycle, a vertical roll wear compensation function F(X) is constructed. The vertical roll wear compensation amount calculated by the vertical roll wear compensation function F(X) is applied to the vertical roll set gap to correct the final set gap of the vertical roll.

2. The method for compensating wear on roughing mill vertical rolls according to claim 1, characterized in that, The aforementioned vertical roll wear compensation function F(X) is a dependent variable function related to the number of vertical rolls, the vertical roll's position on the mill, and the vertical roll's material. Its expression is: ①； in: Indicates the number of blocks rolled within a vertical roll cycle; This indicates the maximum number of blocks that can be rolled on a vertical roll in one rolling cycle; This indicates the upper limit of wear on the vertical roll within one rolling cycle; The vertical roll wear compensation function F(X) is used to predict the amount of compensation for vertical roll wear during the current rolling cycle.

3. The method for compensating wear on roughing mill vertical rolls according to claim 1, characterized in that, The formula for calculating the final roll gap of the vertical roll is as follows: The final roll gap setting for vertical rolls is calculated as follows: roll gap = roll thermal expansion effect + original model vertical roll wear effect + vertical roll wear compensation amount × compensation amount input weight.

4. The method for compensating wear on roughing mill vertical rolls according to claim 1, characterized in that, It also includes setting regional boundary limits for the wear compensation amount of the vertical rollers; The limiting parameters include: the number of rolled blocks within the cycle, the preset total wear amount for the cycle, and the final predicted vertical roll wear compensation amount. By using the limiting parameters, the vertical roll wear compensation amount is controlled within the set range to prevent abnormal data from causing fluctuations in width control.

5. The method for compensating wear on roughing mill vertical rolls according to claim 1, characterized in that, This also includes phased commissioning: after the vertical roller is replaced, the wear compensation for the vertical roller is gradually applied, following these steps: E2 vertical roller compensation is performed at a set ratio; After the E2 vertical roll compensation is put into stable operation, it will be gradually extended to the E1 vertical roll compensation, and the vertical roll compensation ratio will be gradually increased.

6. The method for compensating wear on roughing mill vertical rolls according to claim 1, characterized in that, The collection of the average actual wear amount includes classifying and statistically analyzing wear data for different vertical roller materials and different mounting positions, forming comparative data with the wear calculated by the original model.

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