Continuous accumulative roll bonding apparatus and roll bonding method based on roughness on-line detection closed loop control

Abstract

The application provides a continuous accumulative roll bonding device based on roughness online detection closed-loop control and a roll bonding method, and relates to the technical field of metal plastic working and intelligent manufacturing. In the device, a surface steel brush device is used to brush and grind the inner surfaces of each group of metal coils towards another group of metal coils to form a bonding surface; a roughness online detector is used to detect the actual roughness of the two bonding surfaces after brushing and grinding in real time and feed back to a control unit; the control unit is configured to compare the actual roughness with a preset target roughness, generate an adjustment instruction to adjust at least one group of steel brush assemblies until the actual roughness reaches the target roughness in the case that the actual roughness does not reach the target roughness; a negative pressure dust collection device is used to collect the residual metal dust in the two groups of metal coils after brushing and grinding to reach the target roughness through negative pressure adsorption; a guide wheel is used to guide the two groups of metal coils to be centered and combined and then conveyed to a roller for accumulative roll bonding.

Description

Technical Field

[0001] This application relates to the fields of metal plastic processing and intelligent manufacturing technology, and in particular to a continuous cumulative rolling mill and rolling method based on online roughness detection and closed-loop control. Background Technology

[0002] Accumulative roll bonding (ARB) is an important process for preparing ultrafine-grained / nanocrystalline metal materials and layered metal composites through large plastic deformation. Its core principle is to repeatedly surface-treat, stack, and roll metal sheets to achieve metallurgical bonding of the sheets through large deformation, while refining the grains and improving the mechanical properties of the materials.

[0003] Traditional cumulative rolling processes are mostly offline and intermittent: the plates need to be cut, the surface is manually polished / brushed, cleaned, and stacked before being sent into the rolling mill for single rolling, and the above process is repeated after completion.

[0004] In realizing the inventive concept of this application, the inventors discovered at least the following problems in the related technology: Although there are some attempts at continuous rolling mill equipment in the prior art, they all have obvious technical defects. Existing cumulative rolling mill equipment all adopt an open-loop control mode: the process parameters for surface treatment (speed, feed rate, pressure) are preset fixed values, and during operation, they cannot sense and compensate for the actual roughness deviation caused by the following disturbance factors, thus leading to:

[0005] (1) Steel wire brushes inevitably wear down during continuous production, resulting in a gradual decrease in their brushing ability;

[0006] (2) The initial surface condition of the incoming board material varies from batch to batch, and the degree of surface oxidation and the original roughness are uneven;

[0007] (3) The impact of environmental factors such as equipment mechanical vibration and temperature changes.

[0008] This problem is particularly prominent when combining dissimilar metals (such as 1060 and 7075 aluminum alloys). 1060 aluminum alloy has good ductility and low hardness, while 7075 aluminum alloy has high strength and poor ductility, resulting in significant differences in their mechanical properties. An ideal process would require applying a larger roughness to the 7075 aluminum alloy side to increase mechanical interlocking anchor points, and a finer roughness to the 1060 aluminum alloy side to provide sufficient actual contact area; only through their combined action can coordinated deformation be achieved. However, open-loop control not only fails to accurately obtain this differentiated roughness during initial settings but also cannot stably maintain it within a precise range during long-term continuous production. In actual production, as the wire brush wears, the roughness gradually decreases; when incoming batches change, the initial settings cannot automatically adapt, leading to shear strain concentration at the interface, resulting in cracking, inclusions, and even delamination. Consequently, the product qualification rate has long struggled to break through the bottleneck of approximately 85%. Summary of the Invention

[0009] This application provides a continuous cumulative rolling equipment and rolling method based on online roughness detection and closed-loop control. It can solve the technical problems of existing cumulative rolling equipment, which adopts open-loop control mode and cannot detect and compensate for disturbances such as steel brush wear and material differences, resulting in surface treatment quality drift, large fluctuations in interface bonding strength when dissimilar metals are combined, and low product qualification rate.

[0010] This application provides a continuous cumulative rolling mill based on online roughness detection and closed-loop control for rolling two sets of metal coils. The mill includes a surface steel brush device, an online roughness detector, a negative pressure dust collection device, guide rollers, and rolls arranged sequentially along the feeding direction of the metal coils. It also includes a control unit electrically connected to both the surface steel brush device and the online roughness detector. The surface steel brush device comprises two independently adjustable wire brush assemblies for brushing the inner surface of each set of metal coils facing the other set, forming a mating surface. The online roughness tester is used to detect the actual roughness of the two surfaces to be joined after brushing and grinding in real time, and feeds it back to the control unit. The control unit is configured to compare the actual roughness with the preset target roughness, and generate an adjustment command if the actual roughness does not reach the target roughness, so as to adjust at least one set of wire brush assemblies until the actual roughness reaches the target roughness. The negative pressure dust collection device is used to adsorb the residual metal dust in the two sets of metal rolls that have reached the target roughness after brushing and grinding by negative pressure. The guide wheel is used to guide the two sets of metal rolls to be aligned and stacked and then transported to the roll for cumulative stacking.

[0011] According to the embodiments of this application, each wire brush assembly adopts a rotary wire brush with a wire diameter of 0.15mm to 0.30mm; at least one of the brush pressure, rotation speed and feed rate of the rotary wire brush can be independently adjusted.

[0012] According to the embodiments of this application, the negative pressure dust collection device adopts a negative pressure adsorption structure, the negative pressure is adjustable in the range of 0.075MPa~0.09MPa, and is equipped with an independent dust collection box for centralized collection of metal dust.

[0013] According to an embodiment of this application, the guide wheel includes two sets of guide wheels, an upper set of guide wheels corresponding to the lower surface of the upper metal coil and a lower set of guide wheels corresponding to the upper surface of the lower metal coil; the two sets of guide wheels can ensure that the overlap edge deviation of the upper and lower metal coils is no greater than 0.5mm.

[0014] According to embodiments of this application, the online roughness inspection instrument employs a laser confocal displacement sensor or a surface topography inspection unit based on machine vision; the online roughness inspection instrument has multiple inspection points in the width direction of each group of metal rolls and is equipped with a cleaning air curtain to remove loose abrasive debris adhering to the surface of each group of metal rolls before inspection.

[0015] According to an embodiment of this application, the rolls include upper and lower paired work rolls, made of alloy material, and provide 50%-80% of the single rolling pressure; the surface roughness of the rolls is 0.4μm~0.8μm.

[0016] According to an embodiment of this application, two sets of metal coils are arranged symmetrically, and are metal sheet raw materials of the same or different materials; the material of each set of metal coils includes aluminum alloy, magnesium alloy, copper alloy, and steel; each set of metal coils is equipped with an unwinding mechanism with adjustable feeding speed, the unwinding mechanism is used to adjust the feeding speed of the metal coils so that the feeding speed is matched with the brushing feed speed of the surface steel brush device and the rolling speed of the rolls.

[0017] This application also provides a continuous cumulative rolling method, applied to the aforementioned continuous cumulative rolling equipment based on online roughness detection and closed-loop control. The method includes: Step S1, the control unit acquires the material parameters of the upper and lower sets of metal coils to be rolled, and calculates the target roughness of the two surfaces to be joined according to the preset mapping model; Step S2, the surface steel brush device is activated to brush the inner surface of each set of metal coils facing the other set of metal coils to form the surfaces to be joined; the online roughness detector detects the actual roughness of the two surfaces to be joined after brushing and grinding in real time and feeds it back to the control unit. The control unit compares the actual roughness with the preset target roughness. If the actual roughness does not reach the target roughness, an adjustment command is generated to adjust at least one set of steel wire brush assemblies until the actual roughness reaches the target roughness; Step S3, the negative pressure dust collection device adsorbs the residual metal dust in the two sets of metal coils that have reached the target roughness after brushing and grinding by negative pressure; Step S4, the guide wheel guides the two sets of metal coils to be aligned and stacked and then transported to the rolls for cumulative rolling.

[0018] According to an embodiment of this application, in the upper and lower sets of metal coils, the upper and lower sets of metal coils are made of different materials, the upper set of metal coils has higher plasticity than the lower set of metal coils, and the upper set of metal coils has lower strength than the lower set of metal coils.

[0019] According to an embodiment of this application, in step S1, the first target roughness of the surface to be bonded corresponding to the upper group of metal coils is less than the second target roughness of the surface to be bonded corresponding to the lower group of metal coils.

[0020] According to an embodiment of this application, in step S1, the first target roughness is 1.8μm~2.2μm, the second target roughness is 2.8μm~3.2μm, and the difference between the first target roughness and the second target roughness is 0.8μm~1.2μm.

[0021] According to an embodiment of this application, in step S2, adjusting at least one set of wire brush assemblies includes at least one of the following, and is performed sequentially in the following priority: Method 1: Increase the rotation speed of the wire brush assembly on the side that has not reached the target roughness by 5% to 20% based on the current rotation speed; Method 2: If the target roughness is still not reached after adjusting the rotation speed, increase the pressure of the wire brush assembly on the metal roll surface on the corresponding side; Method 3: If the target roughness is still not reached after increasing the brush pressure, reduce the feeding speed of the metal roll on the corresponding side through the unwinding mechanism to extend the brushing time of the metal roll.

[0022] According to an embodiment of this application, in step S4, after the two sets of metal coils are aligned and stacked and before being conveyed to the rolls, the method further includes: locally preheating the two sets of stacked metal coils, with the preheating temperature controlled at 80°C to 120°C.

[0023] Compared with the prior art, the continuous cumulative rolling equipment and rolling method based on online roughness detection and closed-loop control provided in this application have at least the following beneficial effects:

[0024] 1. Achieving a technological leap: For the first time, closed-loop feedback control was introduced into the surface treatment process of cumulative rolling. Through the real-time sensing of the online roughness detector and the automatic adjustment of the control unit, the problem of process drift caused by disturbance factors such as steel brush wear and material differences was solved, realizing a technological leap from open-loop experience operation to closed-loop intelligent control in cumulative rolling.

[0025] 2. Achieving high-quality composite of dissimilar metals: For material combinations with significant performance differences, such as 1060 and 7075 aluminum alloys, a mapping model was established, and the differentiated roughness was precisely executed and stably maintained through a closed-loop system;

[0026] 3. Achieve continuous and intelligent production: Integrate the entire process of feeding, surface treatment, online detection and closed-loop control, dust collection, and centering and stacking rolling, replacing traditional intermittent manual operation and significantly improving production efficiency. Process parameters are automatically sensed and adjusted, reducing manual intervention and reliance, and adapting to large-scale industrial production;

[0027] 4. Ensure surface treatment quality stability: A controllable rotary wire brush is used in conjunction with online detection and closed-loop control to accurately control and maintain stable surface roughness; combined with a negative pressure dust collection device to thoroughly remove dust, ensuring the cleanliness and activation state of the surfaces to be bonded, thus guaranteeing batch consistency of board bonding strength and product performance from the source.

[0028] 5. Strong process controllability: Through the mapping model, the target roughness can be automatically calculated for metal sheets of different materials and thicknesses. The closed-loop control scheme can automatically realize and maintain the roughness, which has strong process adaptability and can quickly switch between different products.

[0029] 6. Excellent environmental performance: It integrates a negative pressure dust collection device and is equipped with a pulse back-flushing filter cartridge to achieve centralized collection and treatment of dust, avoid workshop environmental pollution, and improve the working environment of operators;

[0030] 7. Compact structure and high reliability: The overall structure of the equipment is rationally laid out along the production line, with good synergy among the functional modules, low maintenance costs, and is suitable for industrial promotion and application. Attached Figure Description

[0031] The above and other objects, features and advantages of this application will become clearer from the following description of embodiments with reference to the accompanying drawings, in which:

[0032] Figure 1 This schematic diagram illustrates the structure of a continuous cumulative rolling mill based on online roughness detection closed-loop control according to an embodiment of this application.

[0033] Figure 2 The illustration schematically shows the metallographic microscopy morphology of the interface after lamination of two different grades of aluminum alloys using a continuous cumulative lamination rolling apparatus according to an embodiment of this application.

[0034] Figure 3 A flowchart illustrating a continuous cumulative rolling method according to an embodiment of this application is shown schematically.

[0035] Explanation of reference numerals in the attached figures:

[0036] 1-Upper group of metal coils, 2-Lower group of metal coils, 3-Surface steel brush device, 4-Surface to be bonded, 5-Negative pressure dust collection device, 6-Guide roller, 7-Roller, 8-Online roughness detector, 9-Control unit, 10-Local heater. Detailed Implementation

[0037] The embodiments of this application will now be described with reference to the accompanying drawings. However, it should be understood that these descriptions are exemplary only and are not intended to limit the scope of this application. In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the embodiments of this application for ease of explanation. However, it will be apparent that one or more embodiments may be implemented without these specific details. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concepts of this application.

[0038] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. The terms “comprising,” “including,” etc., as used herein indicate the presence of features, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, or components.

[0039] All terms used herein (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0040] like Figure 1 As shown, this embodiment of the continuous cumulative rolling mill based on online roughness detection and closed-loop control is used to roll two sets of metal coils. The mill includes a surface steel brush device 3, an online roughness detector 8, a negative pressure dust collection device 5, a guide roller 6, and a rolling mill roll 7 arranged sequentially along the feeding direction of the metal coils. It also includes a control unit 9, which is electrically connected to the surface steel brush device 3 and the online roughness detector 8.

[0041] Two sets of metal coils are formed by rolling two types of metal sheet raw materials into coils, and are arranged vertically at the feed end of the entire equipment. The two sets of metal coils include an upper metal coil 1 and a lower metal coil 2, which are arranged symmetrically vertically.

[0042] The two sets of metal coils can be made of the same or different materials, such as aluminum alloy, magnesium alloy, copper alloy, or steel, depending on the requirements. Taking the upper and lower sets of metal coils as an example where they are made of different materials, the upper set of metal coils can be selected to have higher plasticity and lower strength than the lower set. Specifically, the two sets of metal coils are suitable for combinations of 1060 grade aluminum alloy and 7075 grade aluminum alloy. More specifically, upper set 1 can be a 1060 grade aluminum alloy coil, and lower set 2 can be a 7075 grade aluminum alloy coil. Therefore, this equipment is suitable for the continuous cumulative rolling composite of two or more metal sheets, and can efficiently prepare layered metal composite materials, especially suitable for the preparation of layered composites of different grades of aluminum alloys.

[0043] The surface steel brush device 3 includes two independently adjustable sets of steel wire brush assemblies, used to brush the inner surfaces of each group of metal coils facing the other, forming the surfaces to be bonded 4. Specifically, the surface steel brush device 3 includes an upper steel wire brush assembly and a lower steel wire brush assembly. The upper steel wire brush assembly is used to brush the lower surface of the upper metal coil 1, and the lower steel wire brush assembly is used to brush the upper surface of the lower metal coil 2. In this way, the surface steel brush device 3 precisely brushes the inner surfaces of the two groups of metal coils, forming two rough surfaces to be bonded 4.

[0044] The online roughness detector 8 is used to detect the actual roughness of the two surfaces 4 to be joined after brushing and grinding in real time, and feeds it back to the control unit 9.

[0045] The control unit 9 is configured to compare the actual roughness fed back by the online roughness detector 8 with the preset target roughness, and generate an adjustment command to adjust at least one set of wire brush assemblies until the actual roughness reaches the target roughness if the actual roughness does not reach the target roughness.

[0046] It should be noted that "actual roughness not reaching the target roughness" means that the actual roughness is greater than the target roughness, in which case the mating surface 4 is relatively rough; conversely, "actual roughness not reaching the target roughness" means that the actual roughness is less than or equal to the target roughness, in which case the mating surface 4 is sufficiently smooth. Furthermore, the target roughness can be a roughness point value or a roughness range. This roughness range can be an open range including the upper limit point value or a closed range including both the upper and lower limit point values. If the target roughness is a roughness point value, "actual roughness not reaching the target roughness" specifically means that the actual roughness reaches the target roughness within the allowable error range. If the target roughness is a roughness range, "actual roughness not reaching the target roughness" specifically means that the actual roughness is higher than the upper limit value of that roughness range.

[0047] The negative pressure dust collection device 5 is used to adsorb the residual metal dust in the two sets of metal rolls that have reached the target roughness after brushing and grinding by negative pressure; the guide wheel 6 is used to guide the two sets of metal rolls after passing through the negative pressure dust collection device 5 to be aligned and stacked, and then conveyed to the roll 7 for cumulative stacking.

[0048] To address the challenges of open-loop control in traditional roll forming processes, where surface treatment suffers from roughness drift and significant bond strength fluctuations due to steel brush wear and material variations, the equipment described in this application incorporates an online roughness detector between the surface steel brush assembly and the negative pressure dust collection device. This detector, along with the control unit and independently adjustable wire brush assembly, forms a closed-loop control system, providing closed-loop feedback control for the surface treatment process. Through this closed-loop control scheme, the equipment automatically detects the actual roughness decrease trend caused by wire brush assembly wear and promptly adjusts the surface steel brush assembly to compensate, ensuring that the actual roughness of the two surfaces and their difference remain stable near the preset target roughness. This significantly improves bond strength and yield.

[0049] In some embodiments, each group of metal coils is equipped with an unwinding mechanism with adjustable feeding speed. The unwinding mechanism is used to adjust the feeding speed of the metal coils so that the feeding speed matches the brushing feed speed of the surface steel brush device 3 and the rolling speed of the roll 7, respectively, to ensure uniform cycle time throughout the entire process.

[0050] The following provides a detailed description of the surface steel brush device 3, the online roughness detector 8, the negative pressure dust collection device 5, the guide wheel 6, the roller 7, and the control unit 9.

[0051] In some embodiments, each group of wire brush assemblies in the surface steel brush device 3 is a rotary wire brush with a wire diameter of 0.15mm to 0.30mm, adaptable to the brushing requirements of metal sheets of different materials. At least one of the following—the brush pressure (i.e., the cylinder pressure of the wire brush against the surface of the metal coil), the rotation speed, and the feed rate—can be independently adjusted to control the surface roughness of the surfaces to be bonded 4 in real time. Therefore, precise brushing can be performed separately according to the differences in mechanical properties between the two sets of metal coils to be stacked, resulting in a uniform micro-rough structure (e.g., ...) on the surfaces to be bonded 4. Figure 1 The enlarged structure of the surface 4 to be bonded (shown in the figure) provides sufficient real contact area and bonding anchor points for mechanical interlocking and diffusion bonding in subsequent large deformation rolling.

[0052] The online roughness tester 8 is fixedly installed between the surface steel brush device 3 and the negative pressure dust collection device 5 to ensure that each group of metal rolls undergoes roughness testing immediately after brushing and before dust removal. The test results are directly used to control the surface steel brush device 3 and provide feedback adjustment to the relevant parameters that can be independently adjusted in the surface steel brush device 3 (i.e., at least one of the above-mentioned steel brush pressure, rotation speed and feed rate).

[0053] For example, the online roughness inspection instrument 8 can employ a laser confocal displacement sensor or a machine vision-based surface morphology inspection unit. The online roughness inspection instrument 8 has multiple inspection points along the width direction of each group of metal rolls, enabling non-contact, real-time multi-point inspection along the width direction of the metal rolls, comprehensively reflecting the microstructure of the surfaces to be bonded 4. The online roughness inspection instrument 8 can also be equipped with a cleaning air curtain to remove loose abrasive debris adhering to the surface of each group of metal rolls before inspection, ensuring that the inspection data is not interfered with by residues and is accurate and reliable.

[0054] The detection data (i.e., actual roughness) of the online roughness detector 8 can be transmitted to the control unit 9 in real time via the industrial bus. The transmission delay of the industrial bus is no more than milliseconds, which meets the real-time control requirements of high-speed continuous production lines.

[0055] For example, control unit 9 can use a PID (Proportional-Integral-Derivative) control algorithm or a fuzzy logic algorithm for control. Based on the deviation between the actual roughness and the target roughness of the two surfaces 4 to be joined, detected by the online roughness detector 8, control unit 9 dynamically adjusts at least one of the aforementioned steel brush pressure, rotational speed, and feed rate to achieve precise closed-loop control.

[0056] The control unit 9 is based on a programmable logic controller (PLC) or an industrial computer, and is connected in communication with the online surface roughness detector 8, the surface steel brush device 3 and the unwinding mechanism to form a complete closed-loop control system.

[0057] In some embodiments, the negative pressure dust collection device 5 adopts a negative pressure adsorption structure, with an adjustable negative pressure range of 0.075MPa to 0.09MPa. The adsorption vent covers the bonding surfaces 4 of the two sets of metal rolls, and the negative pressure adsorbs the residual metal dust in the two sets of metal rolls that have achieved the target roughness after brushing and grinding. During the continuous feeding process of the metal rolls, dynamic adsorption is performed at a negative pressure of 0.075MPa to 0.09MPa, which efficiently removes residual metal dust and oxide film fragments from the brushing and testing process, avoiding dust residue from affecting the bonding strength of the plates.

[0058] The negative pressure dust collection device 5 can also be equipped with an independent dust collection box for centralized collection of residual metal dust. The dust collection box is also equipped with a pulse backflushing filter cartridge to achieve periodic cleaning and centralized recycling of dust, avoid workshop environmental pollution, and improve the working environment for operators.

[0059] In some embodiments, the guide roller 6 includes upper and lower sets of guide rollers, wherein the upper set of guide rollers corresponds to the lower surface of the upper metal coil, and the lower set of guide rollers corresponds to the upper surface of the lower metal coil. The upper and lower sets of guide rollers ensure that the overlap edge deviation of the upper and lower metal coils is no greater than 0.5 mm. Thus, the guide roller 6 can accurately guide the upper and lower metal coils to center and overlap, ensuring overlap accuracy. The guide roller 6 can achieve bidirectional centering adjustment, ensuring that the overlap edge deviation is no greater than 0.5 mm, avoiding skewness of the two metal coils that could lead to uneven loading and unilateral wear during the rolling process, affecting the composite quality.

[0060] In some embodiments, the roll 7 includes paired upper and lower work rolls, which are high-rigidity rolling mill structures made of high-strength alloy material, and provide 50%-80% of the single rolling reduction to meet the large deformation requirements of cumulative stacking rolling, achieving stable metallurgical bonding of the two sets of metal coils, while refining grains and improving material properties. The surface roughness of the roll 7 is 0.4μm~0.8μm to ensure uniform rolling pressure distribution and consistent bonding of the composite plate along the width direction. It should be noted that the surface roughness evaluation parameter can be Ra (arithmetic mean deviation of profile).

[0061] In some embodiments, a local heater 10 is provided in the inlet region of the roll 7 to control the temperature of the two sets of metal coils passing through the inlet region at 80°C to 120°C. The local heater 10 may be of the induction heating or infrared heating type.

[0062] In summary, the embodiments of this application provide a continuous cumulative rolling mill based on online roughness detection and closed-loop control, which can detect and control the surface treatment quality in real time, thereby stably realizing the continuous production of dissimilar metals with high bonding strength. This is of great significance for promoting the industrial application of cumulative rolling technology, especially the large-scale production of aluminum alloy layered composite materials.

[0063] Based on the same inventive concept, this application also provides a continuous cumulative rolling method, which will be combined with the following. Figures 2-3 The method is described in detail.

[0064] Figure 2 A flowchart illustrating a continuous cumulative rolling method according to an embodiment of this application is shown schematically.

[0065] like Figure 2 As shown, the continuous cumulative rolling method of this embodiment is applied to the continuous cumulative rolling equipment based on online roughness detection closed-loop control in any of the above embodiments. The method includes the following steps S1 to S4.

[0066] Step S1: The control unit acquires the material parameters of the upper and lower sets of metal coils to be stacked and calculates the target roughness of the two surfaces to be joined according to the preset mapping model.

[0067] This step is used for target roughness setting. The control unit acquires the material parameters of the upper and lower groups of metal coils to be accumulatively roll-bonded, and the material parameters include grade and mechanical property parameters (such as hardness, yield strength, tensile strength, etc.).

[0068] The mapping model may be a model that establishes a mapping relationship among the material parameters, the roughness difference and the bonding strength, and the differentiated target roughness that the two surfaces to be bonded should reach is solved based on the mapping model.

[0069] In step S2, the surface steel brush device is started to respectively brush and grind the inner surface of each group of metal coils facing the other group of metal coils, so as to form the surfaces to be bonded. The on-line roughness detector detects the actual roughness of the two brushed surfaces to be bonded in real time, and feeds back the actual roughness to the control unit. The control unit compares the actual roughness with the preset target roughness, and generates an adjustment instruction when the actual roughness does not reach the target roughness, so as to adjust at least one group of steel wire brush assemblies until the actual roughness reaches the target roughness.

[0070] This step forms closed-loop feedback control for the surface treatment process of the metal coils, ensuring that both groups of metal coils reach the target roughness after brushing and grinding.

[0071] In step S3, the negative pressure dust collection device adsorbs the residual metal dust in the two groups of metal coils that have reached the target roughness after brushing and grinding through negative pressure.

[0072] This step is dynamic negative pressure follow-up cleaning. The two groups of metal coils that have reached the target roughness in step S2 immediately enter the negative pressure dust collection device, and the residual metal dust on the surface is completely removed through negative pressure adsorption during the continuous feeding process to obtain a clean surface. The pulse back-blow filter cartridge matched with the dust collection device can perform periodic cleaning and centralized recovery of the collected dust.

[0073] In step S4, the guide wheels guide the two groups of metal coils to be centered and stacked and then conveyed to the rolls, where accumulative roll bonding is performed at the rolls.

[0074] This step is centering stacking and roll bonding. The two groups of cleaned metal coils are subjected to bidirectional centering adjustment through the guide wheels, are centered and stacked with the precision that the deviation of the stacked edge is not greater than 0.5mm, and are synchronously fed into the rolls, and accumulative roll bonding is completed under the condition that the single rolling reduction is 50% to 80%, so as to realize the metallurgical bonding of the two groups of metal coils.

[0075] For example, before step S1, for the upper and lower groups of metal coils to be accumulatively roll-bonded, the upper group of metal coils and the lower group of metal coils may be of different materials, the plasticity of the upper group of metal coils is higher than that of the lower group of metal coils, and the strength of the upper group of metal coils is lower than that of the lower group of metal coils. Specifically, the upper group of metal coils may be 1060 grade aluminum alloy coils, and the lower group of metal coils may be 7075 grade aluminum alloy coils.

[0076] In step S1, the control unit can calculate, based on the mapping model, that the first target roughness Ra1 corresponding to the upper metal coil with higher plasticity and lower strength is less than the second target roughness Ra2 corresponding to the lower metal coil with lower plasticity and higher strength. For example, the first target roughness Ra1 is 1.8μm~2.2μm, the second target roughness Ra2 is 2.8μm~3.2μm, and the difference ΔRa between the first target roughness Ra1 and the second target roughness Ra2 is 0.8μm~1.2μm.

[0077] In step S1 above, the mapping model can be established through prior system experiments: For the target material combinations of two sets of metal coils (such as material grade combinations like 1060 / 7075, 1060 / AZ31, T2 / Q235, etc.), under fixed rolling conditions (such as single rolling reduction of 60%-70%, rolling speed of 3m / min~8m / min, and surface roughness Ra of the rolls of 0.4μm~0.8μm), different roughness difference gradients ΔRa are set, ΔRa=0, 0.5, 1.0, 1.5, 2.0μm. Then, under each set of parameters, multiple stacking tests are performed on the two sets of metal coils (such as no less than 5 times). The interfacial bonding strength of each set of metal coils is tested using the peeling method or shearing method. The experimental data are fitted into a regression formula or database table and stored in the control unit. For a new material combination of two sets of metal coils, only the material parameters such as hardness and yield strength of the two new materials need to be input. The control unit can automatically output the appropriate roughness difference and the target roughness corresponding to the two surfaces to be bonded by interpolation calculation or formula solution.

[0078] In step S2, the control unit receives the actual roughness of each of the two surfaces to be bonded, detected by the online roughness detector, and compares it with the preset target roughness. For a certain surface to be bonded, if the corresponding actual roughness does not reach the target roughness, an adjustment command is generated, and the control unit controls the adjustment of the relevant parameters (i.e., at least one of the above-mentioned brush pressure, rotation speed, and feed rate) of the wire brush assembly on the corresponding side of the surface to be bonded according to the adjustment command.

[0079] In some embodiments, in step S2, adjusting at least one set of wire brush assemblies includes at least one of the following, and is performed sequentially in the following priority:

[0080] Method 1: Increase the rotational speed of the wire brush assembly on the side that has not reached the target roughness by 5% to 20% from the current speed;

[0081] Method 2: If the target roughness is still not achieved after adjusting the rotation speed, increase the pressure of the wire brush assembly on the metal roll surface on the corresponding side.

[0082] Method 3: If the target roughness is not achieved after increasing the pressure of the steel brush, the feeding speed of the metal roll on the corresponding side is reduced by the unwinding mechanism to extend the brushing time of the metal roll.

[0083] Therefore, the control unit adjusts the surface steel brush device according to the following priority order to increase the force: first, increase the rotation speed, which has the shortest response time (usually <1 second) and has the least impact on the overall production line cycle time; if it is still not up to standard, increase the steel brush pressure; if the first two methods are still insufficient, control the unwinding mechanism to appropriately reduce the feeding speed (for example, reduce it by 10%~30%), extend the brushing time, and ensure that the actual roughness reaches the target roughness before restoring the normal feeding speed.

[0084] After adjusting the surface steel brush device to achieve the target roughness after brushing and polishing the two sets of metal coils, the current parameters are maintained for stable operation. This closed-loop control process continues throughout the entire production cycle, automatically compensating for process drift caused by factors such as wear of the steel wire brush assembly and differences in the surface condition of the incoming materials, ensuring that the actual roughness of the mating surface of each section of metal coil accurately meets the standard.

[0085] Thus, the control unit, with a PLC or industrial computer as its core, communicates with the online surface roughness detector, the surface steel brush device, and the unwinding mechanism to form a complete closed-loop control system.

[0086] In some embodiments, in step S4, after the two sets of metal coils are stacked and before they are conveyed to the roll 7, the two sets of stacked metal coils are locally preheated. The preheating temperature is controlled at 80°C to 120°C to reduce the deformation resistance, increase the degree of interfacial plastic deformation, and further improve the bonding quality.

[0087] Based on the content disclosed in the above embodiments, this application also provides three more specific operation procedures for the continuous cumulative rolling method as follows.

[0088] Example 1: Closed-loop controlled continuous stacking rolling of aluminum alloys and magnesium alloys, the specific operation process includes steps 1.1 to 1.5.

[0089] 1.1 Raw material preparation: 2mm thick 1060 aluminum alloy coils are selected as the upper group of metal coils 1, and 2mm thick AZ31 magnesium alloy coils are selected as the lower group of metal coils 2. The two are arranged symmetrically at the feeding end of the equipment. 1060 aluminum alloy has good plasticity but low strength, while AZ31 magnesium alloy has high strength but relatively poor plasticity.

[0090] 1.2 Target Setting: Based on the mapping model and the hardness difference between the two materials, control unit 9 calculates the target roughness Ra_AZ31 = 3.0 μm on the magnesium alloy coil side and Ra_1060 = 1.8 μm on the aluminum alloy coil side, with a difference ΔRa = 1.2 μm. The allowable error range for the target roughness is ±0.1 μm.

[0091] 1.3 Closed-Loop Control Brushing: The surface steel brush device 3 is started, with an initial rotation speed of 1500 r / min and a wire diameter of 0.2 mm. The online roughness detector 8 provides real-time feedback of the detection data, revealing that the magnesium alloy coil side has a roughness of only 2.5 μm due to slight wear of the steel brush assembly from previous batches, failing to meet the standard (not reaching 3.0 μm). The control unit 9 prioritizes increasing the rotation speed of the steel brush assembly on this side to 1680 r / min (an increase of 12%), and the actual roughness gradually increases, stabilizing at 3.0 ± 0.1 μm after approximately 3 seconds. The aluminum alloy coil side is maintained at 1.8 ± 0.1 μm through fine-tuning.

[0092] 1.4 Dust removal: Start the negative pressure dust collection device 5, set the negative pressure adsorption pressure to 0.08MPa, and fully adsorb the aluminum powder and magnesium powder remaining on the surface of the metal roll to obtain a clean surface.

[0093] 1.5 Centering, Overlapping, and Rolling: After cleaning, the two sets of metal coils are precisely centered and overlapped by guide rollers 6, and then fed into rolls 7 for cumulative overlapping. The single rolling pressure is set to 60%, the rolling speed is 5 m / min, and the surface roughness Ra of rolls 7 is 0.6 μm. After testing, the resulting composite plate of aluminum alloy coil and magnesium alloy coil showed no cracks at the interface, and the bonding strength stably reached 178 MPa.

[0094] Example 2: Closed-loop control of continuous rolling of copper and steel, the specific operation process includes steps 2.1 to 2.5.

[0095] 2.1 Raw material preparation: 1.5mm thick T2 grade copper coils are selected as the upper group of metal coils 1, and 1.5mm thick Q235 grade steel coils are selected as the lower group of metal coils 2. The two are symmetrically arranged at the feed end. Copper has excellent ductility, and Q235 steel has high strength.

[0096] 2.2 Target setting: The control unit 9 calculates the target roughness Ra_Q235=5.0μm on the steel coil side and the target roughness Ra_T2=3.0μm on the copper coil side according to the mapping model, with a difference ΔRa=2.0μm.

[0097] 2.3 Closed-loop control of brushing: The initial rotation speed of the wire brush assembly in the surface steel brush device 3 is 1200 r / min. During production, the online roughness detector 8 detected that the actual roughness of a local area on one side of the steel coil was as low as 4.2 μm (because the surface hardness of this batch of steel coils was slightly higher). The control unit 9 first increased the rotation speed on that side to 1350 r / min, and the actual roughness increased to 4.6 μm, but still did not meet the standard. Then, the second priority was activated to increase the steel brush pressure, and the actual roughness reached the target roughness of 5.0 μm. The actual roughness on one side of the copper coil was detected to be too high, at 3.5 μm. The control unit 9 slightly reduced the rotation speed and steel brush pressure on that side to restore it to 3.0 μm.

[0098] 2.4 Dust removal: The negative pressure adsorption pressure of the negative pressure dust collection device 5 is set to 0.09MPa to thoroughly remove copper powder and iron powder residues from the surface of the metal roll.

[0099] 2.5 Rolling: After the guide roller 6 guides the two sets of metal coils to be aligned and stacked, they are fed into the roll 7. The single rolling pressure is set to 70%, and the rolling speed is 3m / min. After testing, the resulting copper-steel composite plate showed excellent interfacial bonding with no cracks or inclusions.

[0100] Example 3: Closed-loop controlled continuous stacking rolling of 1060 aluminum alloy and 7075 aluminum alloy, the specific operation process includes steps 3.1 to 3.5.

[0101] 3.1 Raw Material Preparation: A 2.0mm thick 1060 grade aluminum alloy coil is selected as the upper metal coil 1, and a 2.0mm thick 7075-T6 grade aluminum alloy coil is selected as the lower metal coil 2. The two are symmetrically arranged at the feeding end of the equipment. 1060 aluminum has high plasticity and good ductility, serving as the toughening layer of the composite plate; 7075 aluminum is a high-strength, heat-treatable aluminum alloy, providing high strength. The combination of the two can achieve a synergistic improvement in strength and toughness, but the composite process is extremely difficult.

[0102] 3.2 Target Setting: Based on the mapping model and the hardness parameters of the two materials, control unit 9 calculates the appropriate target roughness: the target roughness Ra = 3.0 μm for the 7075 side and Ra = 2.0 μm for the 1060 side, with a difference ΔRa = 1.0 μm. This difference is set based on a large amount of experimental data. If the difference is too small, insufficient interlocking on the 7075 side will result in low bonding strength; if the difference is too large, excessive thinning on the 1060 side will lead to strain concentration at the interface. The allowable error range for the target roughness is ±0.1 μm.

[0103] 3.3 Closed-Loop Controlled Brush Grinding: The surface steel brush device 3 is started, with a steel brush filament diameter of 0.2 mm, an initial rotation speed of 1500 r / min, and a brushing feed speed of 6 m / min. The online roughness detector 8 (using laser confocal microscopy) continuously monitors the surface in real time. After approximately 15 minutes of continuous production, the online roughness detector 8 detects that the actual roughness of the 7075 side slowly decreases from 3.0 μm to 2.7 μm. At this point, it is determined that the steel brush has begun normal wear. The control unit 9 immediately issues an adjustment command, increasing the rotation speed of the steel brush on this side to 1620 r / min (an 8% increase) with the highest priority. The actual roughness quickly recovers to 3.0 ± 0.1 μm and remains stable throughout the process. The 1060 side is maintained at 2.0 ± 0.1 μm through independent closed-loop adjustment. Throughout the entire production process, the difference in actual roughness between the two surfaces, ΔRa, remains stable within a precise range of 1.0 ± 0.15 μm.

[0104] 3.4 Metal Dust Removal: Activate the negative pressure dust collection device 5, employing a negative pressure adsorption pressure of -0.08MPa. The adsorption vents are directly facing the upper and lower surfaces of the metal coil, fully covering the brushing and grinding area. The negative pressure dust collection device 5 efficiently adsorbs 1060 aluminum powder, 7075 aluminum powder, and oxide film fragments generated during brushing and grinding, preventing aluminum powder residue and oxide film from being trapped at the rolling interface. The negative pressure dust collection device 5 is equipped with a pulse-jet filter cartridge to achieve periodic cleaning and centralized recovery of dust.

[0105] 3.5 Plate Alignment, Lamination, and Rolling: The upper and lower sets of metal coils are aligned bidirectionally via guide rollers 6 to ensure that the overlap edge deviation of 1060 aluminum and 7075 aluminum is no greater than 0.3mm. Rolls 7 are adjusted to: single-pass rolling pressure of 65%, rolling speed of 6m / min, and surface roughness Ra of rolls 7 of 0.6μm. Before lamination rolling, an infrared heater is used to preheat the inlet temperature of the laminated plate to 100±5℃ to reduce deformation resistance and increase the degree of interfacial plastic deformation.

[0106] 3.6 Results and Performance: After 100 consecutive batches of production, the average interfacial bond strength was 188 MPa, with a standard deviation of only ±4 MPa, far superior to traditional processes. The elongation of the 1060 aluminum alloy layer was ≥27%, and the tensile strength of the 7075 aluminum alloy layer was ≥515 MPa, achieving a synergistic improvement in both strength and toughness. Figure 3 As shown, the upper part represents the morphology of 7075 aluminum, and the lower part represents the morphology of 1060 aluminum. After cumulative rolling, the metallographic images of the 1060 and 7075 aluminum alloys show a flat interface with no obvious pores, cracks, or inclusions, and no clear interface distinction between the two materials. Therefore, this method is applicable to high-end applications such as aerospace structural components and high-strength lightweight sheet metal.

[0107] To clarify the specific roles of the online roughness inspector 8 and the control unit 9 in the entire continuous cumulative rolling mill, a comparative example is provided, contrasting with Embodiment 3 described above. This comparative example uses the exact same equipment and initial settings as Embodiment 3 (e.g., brush speed 1500 r / min), but the feedback loop between the online roughness inspector 8 and the control unit 9 is disconnected, allowing the system to operate continuously with fixed initial parameters without any automatic adjustments based on actual roughness. This comparative example represents an open-loop control mode.

[0108] The results of the comparative experiments are summarized in Table 1 below.

[0109]

[0110] As shown in Table 1, in the open-loop control mode, the actual roughness of the 7075 side gradually decreased from approximately 3.0 μm to approximately 2.3 μm due to continuous wear of the wire brush assembly as production time progressed (after approximately 15 minutes). The actual roughness of the 1060 side also showed significant drift. The difference in actual roughness between the two surfaces fluctuated greatly, and the initially set differential treatment effect was gradually lost. The bonding strength of the products showed a significant downward trend: the bonding strength of the initial products could reach 180 MPa, but the bonding strength of the later products was as low as approximately 135 MPa, with drastic fluctuations between batches (standard deviation ±18 MPa). Furthermore, metallographic examination revealed discontinuous dotted unbonded areas and microcracks at the interface of the later products.

[0111] The aforementioned embodiment 3, through a closed-loop control scheme, can automatically sense the actual roughness decrease trend caused by the wear of the wire brush assembly and promptly compensate by increasing the rotation speed and wire brush pressure, ensuring that the actual roughness of the two surfaces and their difference remain stable near the preset target roughness, thereby achieving a significant improvement in bonding strength and yield. Thus, this method is the first to introduce closed-loop feedback control into the surface treatment process of cumulative rolling. Through real-time sensing by the online roughness detector and automatic adjustment by the control unit, it solves the process drift problem caused by disturbances such as wire brush wear and material differences, realizing a process leap from open-loop experience-based operation to closed-loop intelligent control in cumulative rolling.

[0112] It should also be noted that the embodiments of the device part are similar to those of the method part, and the technical effects achieved are also similar. Please refer to each other for specific details, which will not be repeated here.

[0113] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in a block diagram or flowchart, and combinations of blocks in a block diagram or flowchart, may be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0114] Those skilled in the art will understand that the features described in the various embodiments of this application can be combined and / or combined in various ways, even if such combinations or combinations are not explicitly described in this application. In particular, the features described in the various embodiments of this application can be combined and / or combined in various ways without departing from the spirit and teachings of this application. All such combinations and / or combinations fall within the scope of this application.

Claims

1. A continuous cumulative rolling mill based on online roughness detection and closed-loop control, used for rolling two sets of upper and lower metal coils; characterized in that, The equipment includes a surface steel brush device (3), an online roughness detector (8), a negative pressure dust collection device (5), a guide wheel (6), and a roll (7) arranged sequentially along the feeding direction of the metal coil. It also includes a control unit (9), which is electrically connected to the surface steel brush device (3) and the online roughness detector (8), respectively. The surface steel brush device (3) includes two sets of independently adjustable steel wire brush assemblies, which are used to brush the inner surface of each set of metal coils facing the other set of metal coils to form a bonding surface (4). The online roughness detector (8) is used to detect the actual roughness of the two surfaces (4) to be joined after brushing and grinding in real time, and feed it back to the control unit (9). The control unit (9) is configured to: compare the actual roughness with the preset target roughness, and generate an adjustment command when the actual roughness does not reach the target roughness, so as to adjust at least one set of the wire brush assemblies until the actual roughness reaches the target roughness. The negative pressure dust collection device (5) is used to adsorb the residual metal dust in the two sets of metal rolls that have reached the target roughness after brushing and grinding by negative pressure; the guide wheel (6) is used to guide the two sets of metal rolls to be aligned and stacked and then transported to the roll (7) for cumulative stacking.

2. The device according to claim 1, characterized in that, Each of the aforementioned wire brush assemblies uses a rotary wire brush with a wire diameter of 0.15mm to 0.30mm; At least one of the brush pressure, rotation speed, and feed rate of the rotary wire brush can be independently adjusted.

3. The device according to claim 1, characterized in that, The negative pressure dust collection device (5) adopts a negative pressure adsorption structure, with an adjustable negative pressure range of 0.075MPa~0.09MPa, and is equipped with an independent dust collection box for centralized collection of the metal dust.

4. The device according to claim 1, characterized in that, The guide wheel (6) includes two sets of guide wheels, an upper set of guide wheels corresponding to the lower surface of the upper metal coil and a lower set of guide wheels corresponding to the upper surface of the lower metal coil. The upper and lower sets of guide wheels can ensure that the overlap edge deviation of the upper and lower sets of metal coils is no more than 0.5mm.

5. The device according to claim 1, characterized in that, The online roughness detector (8) uses a laser confocal displacement sensor or a surface morphology detection unit based on machine vision; The online roughness tester (8) has multiple test points in the width direction of each group of metal rolls and is equipped with a cleaning air curtain to remove loose abrasive debris attached to the surface of each group of metal rolls before testing.

6. The device according to claim 1, characterized in that, The roll (7) includes upper and lower paired work rolls, made of alloy material, and provides 50%-80% of the single rolling pressure. The surface roughness of the roll (7) is 0.4μm to 0.8μm.

7. The device according to any one of claims 1-6, characterized in that, The two sets of metal coils are arranged symmetrically above and below, and are metal sheet raw materials of the same or different materials. The materials used in each set of metal coils include aluminum alloy, magnesium alloy, copper alloy, and steel.

8. A continuous cumulative rolling method, characterized in that, The method, applied to the device according to any one of claims 1-7, comprises: Step S1, the control unit (9) obtains the material parameters of the upper and lower sets of metal coils to be stacked and calculates the target roughness of the two surfaces (4) to be joined corresponding to the material parameters according to the preset mapping model. Step S2: Start the surface steel brush device (3) to brush the inner surface of each group of metal rolls facing the other group of metal rolls to form a bonding surface (4); the online roughness detector (8) detects the actual roughness of the two bonding surfaces (4) after brushing and grinding in real time and feeds it back to the control unit (9). The control unit (9) compares the actual roughness with the preset target roughness. If the actual roughness does not reach the target roughness, it generates an adjustment command to adjust at least one group of steel wire brush assemblies until the actual roughness reaches the target roughness. Step S3, the negative pressure dust collection device (5) adsorbs the residual metal dust in the two sets of metal rolls that have reached the target roughness after brushing and grinding by negative pressure; In step S4, the guide wheel (6) guides the two sets of metal coils to be aligned and stacked, and then conveys them to the roll (7) for cumulative stacking.

9. The method according to claim 8, characterized in that, In the two sets of metal coils, the upper and lower sets of metal coils are made of different materials. The upper set of metal coils has higher plasticity than the lower set of metal coils, and lower strength than the lower set of metal coils.

10. The method according to claim 9, characterized in that, In step S1, the first target roughness of the bonding surface (4) corresponding to the upper group of metal rolls is less than the second target roughness of the bonding surface (4) corresponding to the lower group of metal rolls.

11. The method according to claim 10, characterized in that, In step S1, the roughness of the first target is 1.8μm~2.2μm, the roughness of the second target is 2.8μm~3.2μm, and the difference between the roughness of the first target and the roughness of the second target is 0.8μm~1.2μm.

12. The method according to claim 8, characterized in that, In step S2, the adjustment of at least one set of the wire brush assemblies includes at least one of the following, and is performed sequentially in the following priority: Method 1: Increase the rotational speed of the wire brush assembly on the side that has not reached the target roughness by 5% to 20% from the current rotational speed; Method 2: If the target roughness is still not achieved after adjusting the rotation speed, increase the pressure of the wire brush assembly on the metal roll surface on the corresponding side. Method 3: If the target roughness is not achieved after increasing the pressure of the steel brush, the feeding speed of the metal roll on the corresponding side is reduced by the unwinding mechanism to extend the brushing time of the metal roll.

13. The method according to claim 8, characterized in that, In step S4, after the two sets of metal coils are stacked together and before being conveyed to the roll (7), the following steps are also included: The two sets of metal coils after being stacked are locally preheated, and the preheating temperature is controlled at 80℃~120℃.

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