Winding system and winding method of rolled product

Abstract

To provide a winding system that can be performed in an easier and more reliable mode while ensuring correct winding of a coil, and a winding management method.SOLUTION: A winder 10 includes: a distributor 13 that guides positioning of a rolled product with respect to a spool at an instantaneous winding point; and distributor movement means. A control instruction unit is configured to control spool rotation means 12 and distributor movement means in a cooperative manner according to a predetermined winding program. The predetermined winding program includes a predetermined reference operation parameter and detection means. The detection means includes at least one shape measurement device 31 of a laser triangulation type. A processing calculation unit is configured to feedback adjust a movement speed of the distributor on the basis of an actual operation parameter and theoretical data related to predetermined ideal winding of the coil. The actual operation parameter is calculated on the basis of a shape of a coil being formed, the shape being detected by the surface shape measurement device 31.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a system and method for coiling rolled products in the field of the steel industry.

[0002] In particular, the invention makes it possible to control, regulate and direct the hot or cold winding of semi-finished metal products (e.g. rods, wire, tubular elements, etc.) shipped from steel mills, which are used, for example, in the manufacture of metal structures to obtain reinforced concrete or other types of structures. [Background technology]

[0003] Winding systems are known that are suitable for producing coils of hot or cold semi-finished metal products, e.g. coming from a steel mill, i.e. coils of hot or cold fabricated products, such as rods, wire, tubular elements, sections, etc. In the following description, the various types of metal products will be referred to collectively as rods.

[0004] In some applications, the surface morphology of the rod is known to be non-uniform, with edges or corrugations that change the cross section of the rod, which affects coil winding.

[0005] The rod is often wound while still hot or very hot, which affects the area where the rod is wound and thus the winding of the coil.

[0006] Typically, the winding system comprises a rotating coiler around which the coil windings are formed, and a movable distributor which cooperates with the rotating coiler to guide the position of the rod along the height of the coil.

[0007] A rotating coiler typically includes a spindle associated with a number of retaining elements that define the width of the coil, with at least one retaining element being removable for removal of the coil.

[0008] The rotating coiler may be arranged so that its axis of rotation is vertical or horizontal, in either case the distributor is disposed on the side of the rotating coiler.

[0009] In use, the distributor is shuttled between the two axial ends of the coiler, such movement being in a plane parallel to the axis of rotation of the coiler, which may pass through the axis of rotation of the coiler or may be maintained tangent to the cylindrical surface of the varying diameter of the coil being formed.

[0010] The basic objective of the winding process is to wind the rod so that the rotating coiler is filled as evenly as possible, avoiding overlaps and / or gaps between the multiple turns of the coil.

[0011] As mentioned before, winding is definitely influenced by the cross section of the rod and its variations, so it is not enough to know only the nominal value of the rod cross section in order to control the coil formation accurately enough to optimize the filling speed and avoid overlaps and / or gaps between adjacent turns.

[0012] During winding, conventional types of winding systems do not allow optimal adjustment of the function of either the rotating coiler or the distributor so that the coil turns are arranged in the desired manner in relation to the above-mentioned optimization parameters depending on the cross-section and properties of the rod.

[0013] If the coil turns are improperly positioned during winding, the resulting coil will have imperfections, such as gaps and / or overlaps in some or all of the turns, which may result in coils from known systems having a low coil density factor, defined as the ratio of the effective volume of the coil to the total mounting area of ​​the coil.

[0014] Such imperfections are often reflected in the efficiency of the production process served by the resulting coil.

[0015] In order to improve the quality of the coil, several control and regulating devices have been proposed that can measure several parameters, including the rod distribution speed, and use the collected information to control and manage the winding. However, these known devices are unreliable in measuring the parameters, which are performed indirectly. This means that the adjustment of the rotation speed of the rotating coiler, the adjustment of the displacement speed and / or the adjustment of the distributor position are also inaccurate. Furthermore, these known devices are not only unable to detect the cross-section of the rod, but also need to be constantly coordinated with the distributor and need to be replaced and / or adjusted from time to time depending on the cross-section of the rod.

[0016] In order to overcome the aforementioned limitations, a winding management device and a winding management method based on direct detection of some winding parameters of the rod on the coil have been proposed, as disclosed in patent document 1 (EP 3362390).

[0017] More specifically, with reference to figures 1 and 2 of EP 3362390, said winding management device is intended to cooperate with a winding machine comprising a distributor B having a supply outlet C for hot or cold semi-finished metal products, and a spool D. The distributor B and the spool D are moved by suitable controlled moving and rotating means, respectively.

[0018] The winding management device comprises a video recording system E configured to acquire images of the semi-finished metal product, a processing and calculation unit F configured to process the images and continuously calculate the equivalent diameter of the semi-finished metal product and the tilt angle formed between the axis of the supply outlet C and the instantaneous winding point on the spool D of the semi-finished metal product, and a control command unit G configured to control the acquired operating parameters using previously provided reference operating parameters and to cooperatively control the moving and rotating means of the distributor B and the spool D.

[0019] The winding management method comprises the steps of inputting the reference operating parameters of the winding (desired inclination angle and equivalent diameter of the semi-finished metal product at the i-th revolution of the spool D and at the i-th layer of the coil being formed) into a control command unit G, collecting images by a video recording system during winding, the image collection being coordinated with the winding speed, processing the images by a processing and calculation unit F and continuously calculating at least the operating parameters (inclination angle and equivalent diameter of the semi-finished metal product), comparing the operating parameters obtained by image collection with the reference operating parameters input into the control command unit G, and converting the difference between the reference operating parameters and the obtained operating parameters into a coordinated change in the movement speed of the distributor and / or the rotation speed of the spool.

[0020] The winder management method disclosed in patent document 1 (EP 3362390) allows to significantly improve the quality of the spools, but is not easy to implement, since the step of detecting the control parameters has to be performed on the semi-finished metal product at the moment of winding it onto the spool D, at which moment the semi-finished metal product is more susceptible to vibrations than when it is wound onto the spool. The detection of the inclination angle is therefore influenced by vibration phenomena caused by the rotation of the winder and the feeding operation of the semi-finished product. To avoid a loss of accuracy, such a detection step has to be performed in a particularly precise manner. This complicates the winding management method.

[0021] Therefore, there is a need for a winding system and method of winding management that can be implemented in a simpler and more reliable manner while still ensuring correct winding of the coil. [Prior art documents] [Patent documents]

[0022] [Patent Document 1] European Patent No. 3362390 Summary of the Invention

[0023] It is therefore an object of the present invention to provide a system and method for winding rolled products in the steel industry, which allows correct winding of coils in a simple and reliable manner, thereby eliminating all or part of the drawbacks of the aforementioned problems of the prior art.

[0024] A further object of the present invention is to provide a system and method for coiling rolled products in the steel industry that is easy to manufacture or implement. [Brief description of the drawings]

[0025] The technical features of the present invention relating to the above-mentioned objects can be clearly understood from the contents of the appended claims. The advantages of the present invention will be further apparent from the following detailed description with reference to the accompanying drawings, which show one or more embodiments given as non-limiting examples, in particular as follows:

[0026] [Figure 1] FIG. 1 shows a perspective view of a winding management device disclosed in Patent Document 1 (EP 3362390). [Diagram 2] FIG. 2 is a plan view showing the winding management device of FIG. 1. [Diagram 3] FIG. 1 is a plan view of a winding system according to an embodiment of the present invention. [Figure 4] FIG. 4 shows an enlarged detail of FIG. [Diagram 5] FIG. 4 is a perspective view of a portion of the winding system shown in FIG. 3 with some parts removed and one winder shown so that the other parts can be more clearly seen. [Figure 6] 4 shows a plan view of one winder from directly above a portion of the winding system shown in FIG. 3. [Figure 7] 7A-7C are schematic cross-sectional side views illustrating steps of forming a coil within a spool of the winder of FIG. 6. [Figure 8]7A-7C are schematic cross-sectional side views illustrating another step of forming a coil in a spool of the winder of FIG. 6. [Figure 9] FIG. 7 is a schematic side cross-sectional view of a coil formed in a spool of the winder of FIG. 6, with spatial coordinates shown visually with reference to the scanning window of a laser profilometer. [Figure 10] FIG. 7 is a schematic side cross-sectional view of a coil formed in a spool of the winder of FIG. 6, with spatial coordinates shown visually with reference to the scanning window of a laser profilometer. [Figure 11] 1 shows a graph of the elongation trend over time of a forming multi-layer coil achievable with the winding system of the present invention. [Figure 12] 7A-7C are schematic side cross-sectional views of the coil being formed in the spool of the winder of FIG. 6 during certain operating conditions in the formation of the layer relative to theoretical reference conditions; [Figure 13] 7A-7C are schematic cross-sectional side views of the coil being formed in the spool of the winder of FIG. 6 during different operating situations in the formation of layers relative to theoretical reference conditions; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] With reference to the accompanying drawings, a coiling system for rolled products in the steel industry according to the invention is designated overall by the reference number 1.

[0028] For ease of explanation, the winding method according to the invention will be explained after and with reference to the description of the winding system.

[0029] In the following description and in the claims, reference is made to the winding system 1 in an in-use state. References to a lower or upper position, or to a horizontal or vertical orientation, should be understood in this sense.

[0030] 3, the winding system 1 is installed in a rolling line 100 (supply line) suitable for producing rolled products. More specifically, the winding system 1 is disposed at an end of such a rolling line 100.

[0031] As shown in FIG. 3, an end of the rolling line 100 may be branched into two or more branch portions, and each branch portion may be provided with a winding system 1 according to the present invention.

[0032] According to a general embodiment of the invention, a rolled product winding system 1 comprises a winder 10 .

[0033] The winder 10 itself is known to those skilled in the art and a detailed description of the winder 10 will be omitted, except that the winder 10 comprises the following components: a winding spool 11 and spool rotation means 12 suitable for rotating the spool 11 about a rotation axis Y at a spool rotation speed Vr.

[0034] More specifically, as shown, for example, in FIGS. 7 and 8, the spool 11 includes a spindle 110. The spindle 110 extends coaxially with a rotation axis Y. The rolled product P is gradually wound around the spindle 110 to form a wound coil (coil 2) of multiple layers (S1, S2, S3, . . . Sn). The rotation axis Y of the spool 11 may be arranged along the vertical direction or along the horizontal direction. The spindle 110 has a diameter D1 that defines the inner diameter of the coil 2 and a height H1 that defines the height of the coil 2. Preferably, the spool 11 is provided with two axial direction regulating elements 111, 112 that are located at both ends of the spindle 110 in the axial direction. Advantageously, as shown in FIG. 5, one of the two axial regulating elements 111, 112 (preferably the upper axial regulating element 112 in the case of a spool with a vertical axis of rotation) is removable and consists of a number of movable flaps 112'.

[0035] The winder 10 further includes a distributor 13 and a distributor moving means 15.

[0036] The distributor 13 is configured to guide the positioning of the rolled product P on the spool 11 at the instantaneous winding point W. The distributor 13 is provided with a product feed outlet 14.

[0037] The distributor moving means 15 is configured to move the distributor 13 relative to the spool 11. The movement of the distributor 13 by the distributor moving means (translation means) 15 causes the product supply outlet 14 to perform a reciprocating translational movement along the spool parallel to the axis of rotation Y so as to distribute the rolled product on the spool and to vary the instantaneous winding point W of the rolled product on the spool and on the forming coil parallel to the axis of rotation Y over time.

[0038] As shown in Figure 6, the instantaneous winding point W refers to the point (position) where a part of the rolled product first contacts the surface of the spool or the coil being formed. In other words, the instantaneous winding point W is the point (position) where the rolled product contacts the surface of the spool or the coil being formed.

[0039] The rolled product winding system 1 further comprises a control command unit 20. The control command unit 20 is configured to coordinately control the spool rotating means 12 and the distributor moving means 15 according to a predefined winding program. The winding program functions as a function of predefined operating reference parameters which can be stored by said control command unit 20 and of operating parameters which can be obtained in real time during winding by the control command unit 20 via detection means 31, 32 provided in the winding system 1.

[0040] According to the invention, said detection means 31, 32 include at least one laser triangulation profilometer 31 disposed diametrically on the spool 11 generally opposite the distributor 13. The laser triangulation profilometer 31 is configured to continuously detect the coil profile of the rolled product for each additional turn that is added along the height increase of the coil being formed.

[0041] The expression "located approximately diametrically opposite the distributor 13 with respect to the spool 11" means that it is located at any position in a half-plane opposite to the half-plane in which the distributor is located. These two half-planes are identified by a diametric plane PD that passes through the instantaneous winding point W and the rotation axis Y of the spool.

[0042] As shown in FIG. 6, the surface profiler 31 is oriented relative to the spool 11 so as to scan the surface of the coil about the axis of rotation Y at a position angularly offset from the instantaneous winding point W of the rolled product.

[0043] According to the present invention, instead of detecting the winding angle on the spool, the surface shape of the coil being formed is detected at a predetermined diametrical portion (circumferential position).

[0044] Furthermore, instead of being performed at the instantaneous winding point W (the area where the rolled product P is subjected to vibrations), the detection may be performed in another part of the coil downstream of the instantaneous winding point W (an area that is hardly subjected to vibrations because the rolled product is already stably wound onto the spool).

[0045] With the system 1 according to the invention, winding can be performed and managed more easily and reliably.

[0046] Preferably, the angular position of the surface profiler 31 relative to the spool for scanning the coil surface may be offset around the axis of rotation Y by an angle α between 75° and 105° relative to the instantaneous winding point W of the rolled product. More preferably, the angle α may be about 90° (as shown in FIG. 6).

[0047] The laser triangulation surface profile measuring device 31 and its operating principle are known to those skilled in the art, and a more detailed description of the surface profile measuring device 31 will be omitted, except as follows: The surface profile measuring device 31 comprises a laser emitter 310 configured to emit a laser beam, and a sensor 311 configured to detect reflected light generated by the laser beam.

[0048] In an advantageous embodiment, a laser beam emitted from a laser emitter 310 illuminates a target (the surface of the coil). Light reflected from the surface of the coil is detected by a sensor 311, thereby producing a profile of the illuminated surface.

[0049] Preferably, as shown in Figure 5, the profilometer 31 emits a laser beam LB which illuminates the spool and thus the coil being formed over its entire height (height H1). Advantageously, if the entire height of the spool cannot be illuminated by a single laser beam, more than one profilometer 31 may be provided, in which case the entire height of the spool is divided into a number of portions, each of which is illuminated by one profilometer 31.

[0050] Advantageously, the at least one laser triangulation profilometer 31 is adapted to detect, for each turn of the coil: the distance Xd from the coil turn itself to the profilometer 31 in a plane perpendicular to the spool axis of rotation Y, and the height position Yc along the axis of rotation Y relative to a reference plane RP perpendicular to the axis of rotation Y and located at one of the axial ends of the spool.

[0051] In an advantageous manner, the distance Xd for the turns belonging to the n-th layer of the coil is recorded, and since the diameter of the (n-1)th layer is known (e.g. previously calculated based on the diameter of the coil spindle, the number of layers already formed and the diameter of the rolled product (nominal or actual)), the radial distance Xc from the spool rotation axis Y to said turns is immediately calculated, and the diameter Dn of the n-th layer is calculated. Advantageously, such calculations may be performed by a processing and calculation unit 200 (provided in the system 1 so as to be preferably integrated in the control and instruction unit 20, as will be described below) or by a PLC (Programmable Logic Controller) directly on board the surface profile measuring device 31.

[0052] Therefore, by using the laser type surface shape measuring device 31, it becomes possible to determine the spatial coordinates (Xc (radial distance), Yc (height position)) for each turn of the coil in a coordinate system in which the rotation axis Y is the y-axis and the radial axis of the spool passing through the area of ​​the spool (coil) scanned by the surface shape measuring device 31 on the reference plane RP is the x-axis.

[0053] According to another embodiment of the invention, the surface profile measuring device 31 may be used to detect the surface profile of the wound coil, either as an alternative to or in addition to the position of the turns of the coil, in order to detect imperfections in the winding (consisting essentially of voids between the coils).

[0054] Advantageously, as shown in Figures 9 and 10, the at least one laser triangulation type surface shape measuring device 31 may be electronically operated to scan within a scanning window (scanning range) F having a height H along the rotation axis Y that is smaller than the height H1 of the spool 11.

[0055] In an advantageous manner, such a scan window F is generated by manipulation at the software level of the sensor, which limits the sensor reading to a given reading height (height H).

[0056] Preferably, at the software level, the method operates on the sensor 311 of the surface profiler 31 by limiting the reading of the sensor itself within a scanning window F to a predetermined intended reading depth D in the radial direction.

[0057] More specifically, such scanning window F is moved by software along the height H1 of the spool parallel to the axis of rotation Y, thereby allowing the scanning window F to follow the forming coil with each additional turn, while the sensor 311 remains fixed. In this way, vibrations of the profilometer 31 and the mechanical complications of moving the profilometer 31 are avoided.

[0058] Advantageously, such an approach allows the scan to be focused on the stretched region of the coil being formed, thereby avoiding interference that may result from light reflected from other parts of the coil or from imperfections present in the coil itself.

[0059] Preferably, the at least one laser triangulation based surface profilometer 31 is configured to update the position of the scan window with a delay of 10 to 50 milliseconds.

[0060] Preferably, the at least one laser triangulation surface profilometer 31 has a minimum scanning frequency of 300 Hz.

[0061] According to the invention, the winding system 1 further comprises a processing and computing unit 200 configured for feedback-adjusting the moving speed Vt of the distributor 13 (based on the surface profile of the coil of the rolled product detected by the surface profile measuring device 31 after each additional turn) in order to minimize the difference between the actual operating parameters calculated based on the profile of the coil during formation detected by said surface profile measuring device 31 and the same operating parameters calculated based on theoretical data associated with a predetermined ideal winding of the coil.

[0062] The winding system 1 for rolled products according to the invention thereby makes it possible to easily and reliably achieve a correct winding of the coil.

[0063] Furthermore, the rolled product coiling system 1 according to the invention is easy to manufacture and implement.

[0064] Preferably, the actual operating parameter calculated each time a turn of the coil is added based on the shape of the coil being formed detected by the surface shape measuring device 31 is the actual height Hr (from either end in the axial direction of the spool) of the nth layer of the coil being formed for each additional turn that is added, or the actual elongation speed (speed of increase in height) Vgr of each nth layer that increases in height for each additional turn that is added.

[0065] More specifically, as shown in Figures 7 and 8, the actual height Hr of the nth layer of the coil being formed for each additional turn corresponds to (is equal to) the height position Yc of the most recently added turn.

[0066] Furthermore, the actual extension speed Vgr of each nth layer for each additional turn of the coil is defined as the linear speed at which the height H1 (height position Yc) of the nth layer extends (increases) parallel to the rotation axis Y.

[0067] Figure 11 is a graph showing the change in height position of each turn of the nth layer over time. In the example of Figure 11, the trend is linear and the stretching speed is defined by the angle coefficient m of the line. The processing and calculation unit 200 calculates the actual stretching speed Vgr by relating the height position Yc of each turn over time, resulting in a graph as shown in Figure 11.

[0068] The actual elongation velocity Vgr of the nth layer changes direction depending on the elongation direction (upward or downward) of the layer.

[0069] According to a preferred embodiment of the invention, the predetermined winding program has the purpose of feedback-adjusting the distributor movement speed Vt so that the actual height Hr of the nth layer of the coil being formed for each additional turn is substantially equal to the theoretical height Ht.

[0070] In an ideally wound coil, adjacent turns are in contact with each other and thus there are no gaps between them. The theoretical height Ht of the nth layer (generally the coil) can be calculated as the sum of the diameters of the material cross-sections of the wound turns. In this calculation, the diameters of the turns along the same straight line parallel to the axis of rotation Y must be referenced. In an advantageous embodiment, the theoretical height Ht may be calculated as a function of the height of the spool, based on values ​​of the diameter of the rolled product previously provided to the processing and computing unit 200.

[0071] Typically, the cross-sectional area of ​​the rolled material (rolled product P) varies due to slight diameter changes caused by the upstream rolling process (e.g., due to wear, etc.). Therefore, the diameter of the rolled material (rolled product P) is not constant. Such variations affect the formation of the coil.

[0072] As will be described later, the calculation of the theoretical height Ht may be simplified by assuming that the diameter of the rolled material (rolled product P) is constant and equal to the nominal diameter.

[0073] Alternatively, the diameter of the rolled product being gradually fed to the coiling system 1 may be measured in real time to increase the accuracy of the calculation of the theoretical height Ht.

[0074] According to a further preferred embodiment of the invention, the predetermined winding program has the purpose of feedback-regulating the distributor 13 movement speed Vt so that it is substantially equal to the actual stretching speed Vgr of each nth layer in each turn of the coil to be further added, in order to avoid defects in the coil due to the distributor 13 being located in front of and / or behind the coil being formed.

[0075] According to a preferred embodiment of the invention, the detection means further comprise an on-line gauge 32 for measuring the diameter of the rolled product.

[0076] More specifically, as shown in Figure 3, the measuring instrument 32 is configured to continuously measure the diameter of the rolled product P and is arranged upstream of the distributor 13 along the supply line (rolling line 100) of the rolled product P. The processing and computing unit 200 is configured to use the measurement value of the diameter of the rolled product measured by the measuring instrument 32 as the value of the diameter of the rolled product.

[0077] Advantageously, the processing and computing unit 200 is configured to correlate each diameter measurement with a corresponding detection time, so that, knowing the linear feed speed of the rolled product, it is possible to correlate each diameter measurement with a particular portion of the rolled product.

[0078] According to such a preferred embodiment, the aforementioned predetermined reference operating parameters which can be stored by the control command unit 20 include the linear velocity VP of the rolled product along the supply line of the rolled product itself, the diameter D1 of the spool and the height H1 of the spool.

[0079] In an advantageous manner, having the above three predetermined operating parameters as input data, and having the diameter values ​​of the rolled product obtained in real time, the processing and calculation unit 200 can calculate the rotation speed Vr of the spool 11 and the movement speed Vt of the distributor 13, as will be explained in detail below.

[0080] According to an alternative embodiment of the invention, no online gauge 32 for measuring the diameter of the rolled product may be provided, in which case the processing and computing unit 200 is configured to use a default value, which can be stored by said control command unit 20, as the value of the diameter of the rolled product.

[0081] According to such an alternative embodiment, the aforementioned predetermined reference operating parameters which can be stored by the control command unit 20 include at least the linear velocity VP of the rolled product along the supply line of the rolled product itself, the diameter D1 of the spool, the height H1 of the spool and the nominal diameter φP of the rolled product.

[0082] In an advantageous embodiment, by having the aforementioned four predetermined operating parameters as input data, the processing and calculation unit 200 can calculate the rotation speed Vr of the spool 11 and the movement speed Vt of the distributor 13 as will be described in detail below.

[0083] Preferably, the processing and computing unit 200 is configured to initialize the moving speed Vt of the distributor 13 for each nth layer of the coil being formed with a theoretical moving speed Vtt, which is calculated as a function of the forming time Tfs of one turn (one revolution) in the nth layer and the number of turns (revolutions) Ns of the nth layer.

[0084] More specifically, the theoretical moving speed Vtt is calculated by dividing the coil height H1 by the formation time Tfl for one layer according to the following "Equation 1."

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[0085] The formation time for one layer, Tfl, is calculated by relating the formation time for one turn (one circumference) Tfs in the nth layer (nth diameter) to the number of turns (number of circumferences) Ns that can occupy one layer of the coil according to the following "Equation 2".

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[0086] To calculate the number of turns Ns of a coil within the coil height H1, it is necessary to know the diameter φP (nominal or actual diameter) of the rolled product and the coil height H1. This calculation is performed according to the following "Equation 3".

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[0087] To calculate the formation time Tfs of one turn (one revolution) on the nth layer (nth diameter), it is necessary to know the value of the circumferential length Cn (see formula 4 below, Dn: diameter of the nth layer) around which the rolled product is wound, and to use the input value of the linear speed VP of the supply line of the rolled product. This calculation is carried out according to formula 5 below.

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[0088] When a predetermined nominal value is used as the diameter φP of the rolled product, the diameter Dn of the nth layer is calculated according to the following "Equation 6", where Nln indicates the number of layers already formed including the nth layer (the nth layer number).

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[0089] When an actual value is used as the diameter φP of the rolled product, the diameter Dn of the nth layer is calculated according to the following "Equation 7".

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[0090] Here, a calculation example is shown assuming the four reference parameters VP=35 m / s, D1=900 mm, H1=900 mm, and φP=10 mm (nominal values). The calculation is for the nth layer of the coil being formed.

[0091] The method of the present embodiment begins by calculating the theoretical migration speed Vtt (see Equation 1 above and below).

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[0092] Here, it is assumed that the above-mentioned "Equation 2" below holds true.

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[0093] In this case, the above-mentioned "Formula 3", "Formula 4", "Formula 5", and "Formula 6" are used as shown below.

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[0094] Assuming that the number of layers already formed is Nln=2, the diameter Dn of the nth layer and the circumferential length Cn around which the rolled product is wound are calculated using the following "Equation 8" and "Equation 9."

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[0095] As a result, the formation time Tfs for one turn (one circumference) in the nth layer (nth diameter), the number of turns Ns of the coil within the coil height H1, and the formation time Tfl for one layer are calculated as shown in the following "Equation 10", "Equation 11", and "Equation 12".

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[0096] In conclusion, the theoretical moving speed Vtt of the distributor 13 in the nth layer is given by the following "Equation 13".

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[0097] The moving speed Vt of the distributor 13 is initialized at the value of the theoretical moving speed Vtt, and then feedback-adjusted according to two options ("first option" and "second option" below).

[0098] [First option] In the first option, the moving speed Vt of the distributor 13 is adjusted each time an additional turn of the coil is added so that the actual height Hr is substantially equal to the theoretical height Ht of the nth layer of the coil being formed. As shown in Figures 12 and 13, the adjustment criterion is as follows: (1) If the actual height Hr is lower than the theoretical height Ht, the moving speed Vt needs to be reduced. (2) If the actual height Hr is higher than the theoretical height Ht, the moving speed Vt needs to be increased.

[0099] In an advantageous manner, to ensure proper coil formation, the rolled product must be wound onto the spool in an orientation substantially perpendicular to the spool's axis of rotation Y, within a certain tolerance. Such a condition occurs when the product supply outlet 14 of the distributor 13 is aligned with the instantaneous winding point W. Such a condition is verified when the actual height Hr substantially coincides with the theoretical height Ht.

[0100] More specifically, if the actual height Hr is lower than the theoretical height Ht (as shown in FIG. 12), then the distributor 13 has passed above the instantaneous winding point W, and so the speed of the distributor 13 must be reduced (without taking into account the correction factor K) so that the rolled product is again parallel to the distributor outlet.

[0101] If (as shown in FIG. 13) the actual height Hr is higher than the theoretical height Ht, the distributor 13 has been retreated from the instantaneous winding point W, so that the speed of the distributor 13 must be increased (without taking into account the correction factor K) so that the rolled product is again parallel to the distributor outlet.

[0102] [2nd option] In a second option, the speed of movement Vt of the distributor 13 is adjusted each time an additional turn of the coil is added so that it is substantially equal to the stretching speed Vgr of the respective nth layer.

[0103] Advantageously, some calculation parameters may be modified by introducing the correction factor K, so that the coil winding characteristics can be adapted to specific requirements: in particular, the number of turns that can fit within the height of the coil (the number of turns Ns that can occupy one layer of the coil) can be modified using the correction parameter (correction factor K).

[0104] Advantageously, the moving speed Vt of the distributor 13 may be varied from the theoretical value (theoretical moving speed Vtt) by means of a correction parameter (correction factor K) so that a particular coil winding effect can be achieved by keeping the distributor 13 further back from the last wound turn.

[0105] Advantageously, for every nth layer of the coil being formed, the processing and computing unit 200 is configured to adjust the rotational speed Vr of the spool as a function of the linear speed VP of the rolled product along the supply line of the rolled product itself and either the diameter D1 of the spool or the diameter Dn of the (n-1)th layer of the coil being formed.

[0106] More specifically, the rotational speed of the spool, Vr, is calculated by Equation 14 below, where VPa is the angular velocity of the rolled product at a given nth layer diameter (rad / s), and is calculated by Equation 15 below, where VP is the speed of the rolled product (tangential velocity / linear velocity).

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[0107] Here, assuming that the speed of the rolled product is VP=35m / s and the diameter of the (n-1)th layer of the coil being formed is Dn=940mm (assuming Nln=2), the following "Formula 16" is shown as a calculation example. Therefore, the following "Formula 17" is obtained.

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[0108] Next, a method for winding a rolled product by the winding system 1 according to the present invention will be described.

[0109] The above explanation given with respect to the winding system 1 also applies to the winding method described below.

[0110] The winding method according to the present invention comprises the following operational steps (a) and (b). (a) The surface profile of the coil of the rolled product is continuously detected as each coil turn is added by the surface profile measuring device 31 oriented relative to the spool so as to scan the coil surface at positions angularly offset about the axis of rotation Y relative to the instantaneous winding point of the rolled product. (b) feedback adjusting the speed of movement Vt of the distributor 13 each time a turn of the coil is added so as to minimize the difference between actual operating parameters calculated based on the shape of the coil being formed detected by the surface shape measuring device 31 and the same operating parameters calculated based on theoretical data for a given ideal winding of the coil;

[0111] Preferably, the actual operating parameter calculated based on the shape of the coil being formed detected by the surface shape measuring device 31 each time a turn of the coil is added is the actual height Hr of the nth layer of the coil relative to either end of the axial direction of the spool each time a further turn of the coil is added, or the actual elongation velocity Vgr of each nth layer each time a further turn of the coil is added.

[0112] Advantageously, the moving speed Vt of the distributor 13 can be feedback adjusted so that the actual height Hr is substantially equal to the theoretical height Ht of the nth layer of the coil being formed as each further turn of the coil is added, the theoretical height Ht being calculated as a function of the height of the spool on the basis of values ​​of the diameter of the rolled product previously provided to the processing and computing unit 200.

[0113] Alternatively, the moving speed Vt of the distributor 13 may be feedback adjusted so that the moving speed Vt of the distributor 13 is substantially equal to the actual elongation speed Vgr of each nth layer each time an additional turn of the coil is added.

[0114] Advantageously, the laser triangulation surface profile measuring device 31 is configured to detect the radial distance from the axis of rotation Y of the spool and the height position along the axis of rotation Y for each turn.

[0115] The value of the diameter φP of the rolled product is obtained from continuous measurements on the rolled product P by an online measuring instrument 32 located in the rolled product supply line upstream of the distributor 13. Each diameter measurement is associated with a corresponding detection time.

[0116] In this case, preferably, the retrospective (post-facto) adjustment of the moving speed Vt of the distributor 13 uses predefined reference operating parameters which can be stored by the control command unit 20. In this case, the reference operating parameters include the linear speed of the rolled product along the supply line of the rolled product itself, the diameter of the spool and the height of the spool.

[0117] Alternatively, the value of the diameter φP of the rolled product is a predefined nominal value.

[0118] In this case, preferably, the retrospective (post-facto) adjustment of the distributor travel speed Vt uses predefined reference operating parameters which can be stored by the control command unit 20. In this case, the reference operating parameters include the linear speed of the rolled product along the supply line of the rolled product itself, the diameter of the spool, the height of the spool and the diameter of the rolled product.

[0119] Advantageously, the moving speed Vt of the distributor 13 is initialized for each nth layer of the coil being formed with a theoretical moving speed, which is calculated as a function of the winding time for one turn (one revolution) in said nth layer and the number of turns (number of revolutions) in said nth layer.

[0120] Advantageously, the rotational speed of the spool is adjusted for each nth layer of the coil being formed as a function of the linear speed of the rolled product along the supply line of the rolled product itself and either the diameter of the spool or the diameter of the (n-1)th layer of the coil being formed.

[0121] The advantages provided by the present invention previously described in the description of the winding system 1 also apply to the winding method, and therefore will not be repeated here for the sake of brevity.

[0122] The present invention provides many advantages, a few of which have already been mentioned.

[0123] The winding system 1 for rolled products according to the invention therefore makes it possible to easily and reliably achieve a correct winding of the coil.

[0124] Furthermore, the rolled product coiling system 1 according to the invention is easy to manufacture and implement.

[0125] Thus, the invention thus conceived achieves the objectives set forth.

[0126] Of course, in practice, the invention may take different shapes and configurations than those disclosed above without departing from the scope of the present protection.

[0127] Furthermore, all details may be replaced by technically equivalent elements and any size, shape and material may be used as required.

Claims

1. A coiling system (1) for a rolled product (P), comprising: The winder (10) and the control command unit (20) are provided. The winder (10) comprises: A take-up spool (11); a spool rotating means (12) configured to rotate said spool (11) about a rotation axis (Y); a distributor (13) adapted to guide the positioning of the rolled product (P) relative to the spool (11) at the instantaneous winding point and provided with a product feed outlet (14); a distributor moving means (15) configured to move the distributor (13) relative to the spool (11), During the movement of the distributor (13) by the distributor movement means (15), the product supply outlet (14) performs a reciprocating translational movement along the spool (11) parallel to the axis of rotation (Y) so as to distribute the rolled product (P) on the spool (11) and to vary over time the instantaneous winding point of the rolled product (P) on the spool (11) and on the coil being formed, the control command unit (20) is configured to cooperatively control the spool rotating means (12) and the distributor moving means (15) in accordance with a predetermined winding program; the predetermined winding program is a function of predetermined reference operating parameters that can be stored by the control command unit (20) and operating parameters that can be obtained in real time during winding by the control command unit (20) via detection means provided in the winding system (1), The detection means comprises at least one laser triangulation surface profile measuring device (31); the surface shape measuring device (31) is disposed on a substantially opposite side of the spool (11) from the distributor (13) in a diameter direction, and is configured to continuously detect a surface shape of the coil of the rolled product (P) for each additional turn; the surface profile measuring device (31) is oriented relative to the spool (11) so as to scan the surface of the coil at a position angularly offset from the instantaneous winding point of the rolled product (P) about the axis of rotation (Y); The winding system (1) comprises a processing and computing unit (200), The processing and computing unit (200) so as to minimize the difference between actual operating parameters calculated on the basis of the shape of the coil being formed detected by said surface profile measuring device (31) and the same operating parameters calculated on the basis of theoretical data for a given ideal winding of the coil. and a feedback adjustment of the moving speed of the distributor (13) is configured based on the surface shape of the coil of the rolled product (P) detected by the surface shape measuring device (31) for each additional turn. Winding system.

2. the actual operating parameters are calculated for each additional turn based on the shape of the coil being formed as detected by the surface profiler (31); The actual operating parameters are: the actual height (Hr) of the nth layer of the coil being formed relative to either axial end of the spool (11) for each additional turn; or is the actual elongation velocity (Vgr) of each nth layer per additional turn; The winding system of claim 1 .

3. The predetermined winding program or, so that the actual height (Hr) is substantially equal to the theoretical height (Ht) of the nth layer of the coil being formed as each coil turn is added; or so that the speed of movement of the distributor is substantially equal to the actual speed of elongation (Vgr) of each nth layer as each coil turn is added; The purpose of the present invention is to feedback adjust the moving speed of the distributor, said theoretical height (Ht) being calculated as a function of the height of said spool, based on values ​​of the diameter of said rolled product previously provided to said processing and computing unit (200); The winding system of claim 2.

4. the angular position of the surface profile measuring device (31) relative to the spool for scanning the coil surface is offset around the rotation axis (Y) by an angle between 75° and 105° relative to the instantaneous winding point of the rolled product; A winding system according to any one of claims 1 to 3.

5. The at least one laser triangulation type surface shape measuring device (31) is configured to detect the radial distance from the rotation axis (Y) of the spool and the height position along the rotation axis (Y) for each turn of the spool. A winding system according to any one of claims 1 to 4.

6. said at least one laser triangulation profilometer (31) being electronically operable to scan within a scanning window (F) having a height (H) along said axis of rotation (Y) that is smaller than the height of said spool (11), said scanning window (F) being preferably movable parallel to said axis of rotation (Y) to follow the forming coil with each additional turn; A winding system according to any one of claims 1 to 5.

7. the at least one laser triangulation surface profile measuring device (31) is configured to update the position of the scanning window (F) with a delay of at least 10 milliseconds and at most 50 milliseconds. The winding system according to claim 6.

8. said at least one laser triangulation surface profile measuring device (31) having a minimum scanning frequency of 300 Hz; A winding system according to any one of claims 1 to 7.

9. The detection means further comprises an online measuring instrument (32) for measuring a diameter (φP) of the rolled product, The measuring device (32) is configured to continuously measure the diameter (φP) of the rolled product, and is arranged upstream of the distributor (13) in the supply line of the rolled product, the processing and computing unit (200) is configured to use the measured value of the diameter of the rolled product measured by the gauge (32) as a value of the diameter of the rolled product. A winding system according to any one of claims 1 to 8.

10. The processing and computing unit (200) is configured to correlate each of the diameter measurements with a corresponding detection time. The winding system of claim 9.

11. The predetermined reference operating parameters that can be stored by the control command unit (20) are: the linear velocity of the rolled product along its own supply line; and a diameter of the spool; and a height of the spool. A winding system according to claim 9 or 10.

12. said processing and calculation unit (200) is configured to use a default value, memorizable by said control command unit (20), as the value of the diameter of said rolled product; A winding system according to any one of claims 1 to 8.

13. The predetermined reference operating parameters that can be stored by the control command unit (20) are: the linear velocity of the rolled product along its own supply line; and a diameter of the spool; and The height of the spool; and and a diameter of the rolled product. The winding system of claim 12.

14. the processing and calculation unit (200) is configured to initialize the moving speed of the distributor with a theoretical moving speed for every n-th layer of the coil being formed; The theoretical moving speed is calculated as a function of the formation time of one turn of the nth layer and the number of turns of the nth layer. A winding system according to any one of claims 1 to 13.

15. said processing and computing unit (200) being configured to adjust, for each n-th layer of the coil being formed, the rotational speed of the spool as a function of the linear speed of the rolled product along its own supply line and either the diameter of the spool or the diameter of the (n-1)-th layer of the coil being formed, A winding system according to any one of claims 1 to 14.

16. A method for winding a rolled product (P) into a coil by means of a winding system (1) according to any one of claims 1 to 15, comprising the steps of: As operation steps, (a) continuously detecting the surface profile of the coil of the rolled product (P) as each coil turn is added by a surface profile measuring device (31) oriented relative to the spool so as to scan the coil surface at positions angularly offset about the axis of rotation (Y) relative to the instantaneous winding point of the rolled product (P); (b) feedback adjusting the distributor travel speed (Vt) each time a turn of the coil is added so as to minimize the difference between actual operating parameters calculated based on the shape of the coil being formed detected by the surface shape measuring device (31) and the same operating parameters calculated based on theoretical data for a given ideal winding of the coil.

17. the actual operating parameters are calculated based on the shape of the coil being formed detected by the surface profile measuring device (31); The actual operating parameters are: the actual height (Hr) of the nth layer of the coil relative to either axial end of the spool as each coil turn is added; or is the actual elongation velocity (Vgr) of each nth layer as each turn of the coil is added; The winding method according to claim 16.

18. The moving speed (Vt) of the distributor is or, so that the actual height (Hr) is substantially equal to the theoretical height (Ht) of the nth layer of the coil being formed as each coil turn is added; or so that the speed of movement of the distributor (Vt) is substantially equal to the actual speed of extension (Vgr) of each nth layer as each coil turn is added; Feedback is adjusted, said theoretical height (Ht) being calculated as a function of the height of said spool, based on values ​​of the diameter of said rolled product previously provided to said processing and computing unit (200); The winding method according to claim 17.

19. The at least one laser triangulation surface profile measuring device (31) is configured to detect the radial distance from the rotation axis (Y) of the spool and the height position along the rotation axis (Y) for each turn of the spool. The winding method according to any one of claims 16 to 18.

20. the value of the diameter (φP) of the rolled product is obtained from continuous measurements of the rolled product by an online measuring device (32) arranged upstream of the distributor (13) in the supply line of the rolled product; Each diameter measurement is associated with a corresponding detection time. The winding method according to claim 18.

21. The retroactive adjustment of the distributor travel speed (Vt) uses predetermined reference operating parameters that can be stored by the control command unit (20); The reference operating parameters include the linear velocity of the rolled product along its own supply line, the diameter of the spool, and the height of the spool. The winding method according to claim 20.

22. The diameter (φP) of the rolled product is a predetermined nominal value. The winding method according to claim 18.

23. The retroactive adjustment of the distributor travel speed (Vt) uses predetermined reference operating parameters that can be stored by the control command unit (20); The reference operating parameters include a linear velocity of the rolled product along a feed line of the rolled product itself, a diameter of the spool, a height of the spool, and a diameter of the rolled product. The winding method according to claim 22.

24. The moving speed (Vt) of the distributor is initialized at a theoretical moving speed for every nth layer of the coil being formed; The theoretical moving speed is calculated as a function of the winding time for one turn in the nth layer and the number of turns in the nth layer. The winding method according to any one of claims 16 to 23.

25. the rotational speed of the spool is adjusted for each nth layer of the coil being formed as a function of the linear speed of the rolled product along its own feed line and either the diameter of the spool or the diameter of the (n-1)th layer of the coil being formed; The winding method according to any one of claims 16 to 24.

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