Roll unit, roll equipment, data measuring method, and product manufacturing method

Abstract

This roll unit comprises: a roll 100 configured to be capable of spinning about an axis of rotation; chocks 110, 110A and 110B respectively provided outward of both end portions, in an axial direction, of the roll 100; and sensors 120, 120A, 120B provided respectively on surfaces of the chocks 110, 110A and 110B, for acquiring information relating to the chocks 110, 110A and 110B. As a result, the present invention provides a roll unit equipped with a sensor that is easier to replace than in the past, roll equipment, a data measuring method, and a product manufacturing method.

Description

Roll unit, roll equipment, data measurement method, and product manufacturing method

[0001] The present invention relates to a roll unit, a roll facility, a data measurement method, and a product manufacturing method.

[0002] Patent Document 1 describes that a rolling mill having at least a pair of upper and lower work rolls and backup rolls is provided with a strain measuring means for measuring elastic strain in the rolling direction occurring in each of the work-side roll chocks and drive-side roll chocks of the work rolls, and a strain conversion means for converting the measured elastic strain into a rolling direction force acting on each of the work-side roll chocks and drive-side roll chocks of the work rolls corresponding to the elastic strain using a relational equation between elastic strain and rolling direction force that has been identified in advance.

[0003] Patent Document 2 describes that a four-row cylindrical roller bearing is incorporated between the inner peripheral surface of the housing and the outer peripheral surface of the backup roll, and that a sensor device is held in part of a flange ring provided at the axial end of this four-row cylindrical roller bearing, and that this sensor device comprises a detection unit for detecting temperature and vibration, and a transmission unit for transmitting a signal as a wireless signal after processing an output signal extracted from this detection unit, and that a receiving antenna, which is part of the receiving unit for receiving the wireless signal emitted by the transmission unit, is provided in part of a retaining cover, which is a member separate from the flange ring.

[0004] Japanese Patent No. 5811048 Japanese Patent Application Laid-Open No. 2003-83352

[0005] If vibration occurs during the rolling process, stripes will appear on the surface of the rolled material, resulting in a decrease in surface quality, and stripes will appear on the surface of the rolling rolls, increasing costs due to increased roll grinding frequency and reducing manufacturing efficiency, so there are circumstances in which it is desirable to avoid this.In particular, when rolling high-strength materials and thin materials, which require a high rolling load, large rolling vibrations are likely to occur, so it is desirable to suppress vibrations or measure them accurately.

[0006] A conventional technique for measuring elastic strain in the rolling direction occurring in a roll unit is disclosed, for example, in Patent Document 1. Patent Document 1 discloses a configuration in which a strain measuring means is inserted into the bottom of a hole formed in a chock of a work roll, and the hole is closed and fixed with a bolt.

[0007] Furthermore, Patent Document 2 discloses that a four-row cylindrical roller bearing is provided with a sensor device for detecting temperature or vibration on a flange ring at the axial end thereof.

[0008] In a typical rolling mill, the rolls are called roll units and are replaced periodically together with the bearing housings. For this reason, sensors such as wired vibration accelerometers installed to measure vibration during rolling must be removed and installed every time the rolls are replaced. In this invention, the combination of a roll and a chock is referred to as a roll unit.

[0009] However, if the sensor is installed inside the chock or in the bearing, the structure around the sensor becomes complex, which means that it takes time to replace the sensor. However, if it takes time to install the sensor, this leads to a corresponding decrease in work efficiency.

[0010] For this reason, it is desirable to make it easier to remove the sensor and improve work efficiency.

[0011] The present invention provides a roll unit, a roll facility, a data measurement method, and a product manufacturing method that are equipped with a sensor that can be replaced more easily than conventional sensors.

[0012] The present invention includes a number of means for solving the above-mentioned problems, and one example thereof is a roll configured to be rotatable around a rotation axis, chocks provided on the outside of both ends of the roll in the axial direction, and sensors provided on the surface of each of the chocks for acquiring information about the chocks.

[0013] According to the present invention, it is possible to mount a sensor that is easier to replace than conventional sensors. Problems, configurations, and effects other than those described above will become apparent from the following description of the embodiments.

[0014] FIG. 1 is a diagram showing a schematic configuration of a roll facility including a roll unit of an embodiment. FIG. 2 is a control block diagram of a control device in the roll facility of an embodiment. FIG. 3 is a diagram showing a schematic configuration of a roll unit of an embodiment. FIG. 4 is a diagram showing a schematic configuration of a roll unit of an embodiment when viewed from the rolling direction. FIG. 5 is a diagram showing a schematic configuration of a roll unit of an embodiment when viewed from a direction perpendicular to the rolling direction. FIG. 6 is a diagram showing a schematic configuration of another form of a roll unit of an embodiment when viewed from the rolling direction. FIG. 7 is a diagram showing a schematic configuration of another form of a roll unit of an embodiment when viewed from a direction perpendicular to the rolling direction. FIG. 8 is a diagram showing a schematic configuration of yet another form of a roll unit of an embodiment when viewed from the rolling direction. FIG. 9 is a diagram showing a schematic configuration of yet another form of a roll unit of an embodiment when viewed from the rolling direction.

[0015] Examples of the roll unit, roll equipment, data measurement method, and product manufacturing method of the present invention will be described with reference to Figures 1 to 9. In the drawings used in this specification, identical or corresponding components are designated by identical or similar reference numerals, and repeated explanations of these components may be omitted.

[0016] First, the overall configuration of a roll facility equipped with a roll unit and the configuration of a main controller for the operation will be described with reference to Figures 1 and 2. Figure 1 is a diagram showing a schematic configuration of a roll facility equipped with a roll unit of the embodiment, and Figure 2 is a control block diagram of a control device in the roll facility of the embodiment.

[0017] In the following embodiments, an example will be described in which the roll unit of the present invention is provided in roll equipment. However, the roll unit of the present invention is not limited to roll equipment, and can also be applied to equipment that uses a roll set having a chock, such as an edger, a leveler guide roll, or a pinch roll, and is not particularly limited thereto.

[0018] 1, a rolling facility 1 for rolling a metal material 5 includes an F1 stand 10, an F2 stand 20, an F3 stand 30, an F4 stand 40, a control device 60, a display device 70, etc. The F1 stand 10, the F2 stand 20, the F3 stand 30, the F4 stand 40, the control device 60, and the display device 70 are connected to each other by communication lines (not shown for convenience of illustration).

[0019] The rolling equipment 1 is not limited to a configuration in which four rolling stands are installed as shown in Fig. 1, but may have at least one stand. In addition, either hot rolling or cold rolling may be used, and there is no particular limitation.

[0020] The F1 stand 10 comprises an upper work roll unit 11, a lower work roll unit 12, an upper backup roll unit 13 and a lower backup roll unit 14 which contact and support the upper work roll unit 11 and the lower work roll unit 12, respectively, and a housing 15 which holds these. Note that a six-stage configuration can be achieved by providing an intermediate roll between each work roll and each backup roll.

[0021] The F2 stand 20, the F3 stand 30, and the F4 stand 40 each have substantially the same configuration as the F1 stand 10, and therefore details thereof will be omitted.

[0022] As shown in FIG. 2 , the control device 60 includes a measurement data collection unit 61, a judgment unit 62 having a single data judgment unit 62 a and a multiple data judgment unit 62 b, a comparison value calculation unit 63, a processing unit 64, and an operation control unit 65 that controls the operation of each device in the rolling equipment 1.

[0023] The control device 60 can be configured as a computer having a display device 70 such as a liquid crystal display described below, input devices, a storage device, a CPU, memory, an external power source (whether wired or wireless), etc., and may be configured as one computer or as separate computers, and is not particularly limited.

[0024] The control of the operation of each device and each function by the control device 60 is executed based on various programs recorded in the storage device. The control processing of the operation executed by the control device 60 may be integrated into one program, or may be separated into multiple programs, or a combination thereof. Furthermore, some or all of the programs may be realized by dedicated hardware or may be modularized.

[0025] The functional configuration of the control device 60 will be described below with reference to FIG.

[0026] The measurement data collection unit 61 collects various data measured by sensors 120 provided on the surfaces of the chocks 110, 110A, 110B described below, which acquire information about the chocks 110, 110A, 110B, and related data, such as timing data.

[0027] The comparison value calculation unit 63 calculates comparison values ​​in the single-data judgment unit 62a and the multiple-data judgment unit 62b, which will be described later. The comparison values ​​may be, for example, abnormality judgment values ​​obtained from the accumulated experience and track record of a manufacturer performing rolling operation using the rolling equipment 1 or a manufacturer of the rolling equipment, values ​​obtained by statistically processing these, comparison values ​​calculated based on an analytical model, comparison values ​​calculated by machine learning such as deep learning, etc., but are not limited to these.

[0028] The single data judgment unit 62a of the judgment unit 62 is a part that judges whether each piece of data measured by the sensor 120 is abnormal or normal, etc. It decides which comparison value to use from among the comparison values ​​calculated by the comparison value calculation unit 63, and makes instantaneous (one-time) judgments and trend judgments over time.

[0029] Of the judgment unit 62, the multiple data judgment unit 62b is a part that judges whether the data measured by the sensor 120 is normal or abnormal as a whole by combining the data measured by the sensor 120 with external data such as the load and rolling speed. As with the single data judgment unit 62a, it decides which comparison value to use from among the comparison values ​​calculated by the comparison value calculation unit 63, and makes instantaneous (one-time) judgments and trend judgments over time.

[0030] The processing unit 64 processes the results of the judgments made by the single data judgment unit 62 a and the multiple data judgment unit 62 b, compares the measurement data with a threshold value, and if a deviation occurs, determines countermeasures such as reducing the rolling speed, and performs processing such as displaying the countermeasures as operator guidance on the display device 70, outputting an alarm, calculating a correction amount for optimizing control, and outputting a countermeasure processing signal to the operation control unit 65.

[0031] Returning to FIG. 1 , the display device 70 is a display device such as a display or an audio device such as an alarm. For example, when it is determined that a rolling abnormality has occurred, the display is often used in a device for informing an operator of the necessary countermeasures.

[0032] During operation, the operator can check the rolling status of the metal material 5 by visually checking the display screen of the display device 70, each stand itself, and the spaces between each stand.

[0033] It should be noted that the present invention is not limited to a configuration in which the occurrence of a rolling abnormality is notified to an operator and an operation to improve the rolling abnormality that has occurred is automatically performed by the control device 60, but may be a configuration in which the information is only displayed on the display device 70, or a configuration in which the display on the display device 70 is omitted and the operation to improve the rolling abnormality is only automatically performed by the control device 60.

[0034] Although the control device 60 has been exemplified as a device that controls the operation of the rolling equipment 1, it is not limited to this form and can also be one or more of a mobile terminal such as a smartphone or tablet, or even an edge PC.

[0035] Next, the configuration of the roll unit of this example will be described in detail with reference to Figures 3 to 5. Figure 3 is a diagram showing the schematic configuration of the roll unit of this example, Figure 4 is a diagram showing the schematic configuration of the roll unit when viewed from the rolling direction, and Figure 5 is a diagram showing the schematic configuration of the roll unit when viewed from a direction perpendicular to the rolling direction.

[0036] In Figures 3 to 5, the upper work roll unit 11 of the F1 stand 10 is shown as a representative example, but the structures of the other units such as the lower work roll unit 12, upper backup roll unit 13, and lower backup roll unit 14 are approximately the same, and details thereof will be omitted.

[0037] The upper work roll unit 11 shown in Figures 3 to 5 is composed of a roll 100, chocks 110 provided on the drive side and operation side of the roll 100, a sensor 120, and bearings 130 provided inside the chock 110 and supporting the roll 100 so that it can rotate.

[0038] The sensor 120 is provided on the surface of each of the chocks 110 on the driving side and the operating side, inside a recess 113 provided on the surface of the chock 110, in a position visible from the outside, and acquires information about the chock 110.

[0039] There are no particular limitations on the method of fixing the sensor 120 to the recess 113, and various fixing methods can be used, such as a fitting structure between one or more recesses or protrusions on the surface of the sensor 120 and one or more protrusions or recesses in the recess 113, bolt fastening, magnets, adhesives, etc.

[0040] Although an example is shown in which a portion of the sensor 120 protrudes from the surface of the chock 110 around the recess 113, the entire sensor 120 may be located at a position recessed further from the recess 113 on the surface of the chock 110, or the entire sensor 120 may protrude from the surface of the chock 110.

[0041] For example, as shown in FIG. 3, if both the drive-side sensor 120 and the operation-side sensor 120 are provided, it is possible to measure three-dimensional cases where the vibration mode is torsion, etc., and it is desirable because more data can be collected.

[0042] The sensor 120 is composed of a sensing unit 121, an amplifier 122, a storage device (memory) 123, a transmitter 124, a power supply 125, and the like.

[0043] It is desirable that this sensor 120 be a package specification in which the necessary components of the sensing unit 121 and the like are modularized, and that it can be replaced all at once when replacing the power supply 125, when the sensor 120 breaks down, or when replacing the upper work roll unit 11 itself. This makes it possible to simply replace it with a new module, making the replacement process extremely easy. It is also more desirable that it be integrated with various covers for waterproofing, dustproofing, etc., which can improve the accuracy of data acquisition and reduce the probability of equipment failure.

[0044] Furthermore, it is desirable that the measurement timing of the sensing unit 121 of this sensor 120 be known by a timestamp or the like. In this case, synchronization with external data such as load and rolling speed can be achieved, so that data from the sensing unit 121 mounted on the chock can be compared and combined with other data. This allows for more accurate examination.

[0045] The sensing unit 121 is composed of various sensor components, such as one or a combination of two or more of a displacement sensor that measures the vibration of the chock 110, a speed sensor, an acceleration sensor, an inclination angle sensor, a temperature sensor, a strain gauge, a piezoelectric element, a microphone, an acoustic emission sensor, a thermometer, etc., and these can be added or removed as appropriate according to the data to be measured. For example, if a thermometer is provided, it can be determined during vibration analysis whether or not there is an effect due to temperature, such as a gap becoming smaller due to expansion caused by a temperature rise.

[0046] The amplifier 122 amplifies the data measured by the sensing unit 121 as necessary, and outputs the amplified sensor data to a storage device 123 or to an external storage device via a transmitter 124 .

[0047] The storage device 123 is composed of a memory that stores the measurement results of the sensing unit 121 for a certain period of time. This allows the information to be stored and examined later even if the measurement data cannot be transmitted externally during measurement. Furthermore, even if it is difficult to transmit data wirelessly, the data can be retrieved externally.

[0048] The transmitter 124 is a device that outputs the measurement results measured by the sensing unit 121 and amplified by the amplifier 122 as necessary directly, or outputs the measurement results temporarily stored in the storage device 123, to an externally connected device such as the control device 60. This transmitter 124 may be connected wirelessly or by wire, and is not particularly limited.

[0049] The power supply 125 is a means for supplying power for driving the sensing unit 121, etc. This makes it possible to collect data for a certain period of time without an external power supply. Furthermore, since power supply from an external power source is no longer required, the configuration can be more suitable for integrated packaging.

[0050] This power supply 125 may be rechargeable or non-rechargeable, and is not particularly limited. If rechargeable, charging may be by either a wired or wireless method, and is not particularly limited. Furthermore, power may be generated by vibration or temperature, and is not particularly limited. This allows the battery to be used continuously without replacement, further reducing the frequency of replacement and further improving productivity.

[0051] Next, other forms of the roll unit will be described with reference to Figure 6 onwards. Figure 6 is a diagram showing the schematic configuration of another form of the roll unit when viewed from the rolling direction, Figure 7 is a diagram showing the schematic configuration of another form of the roll unit when viewed from a direction perpendicular to the rolling direction, Figure 8 is a diagram showing the schematic configuration of yet another form of the roll unit when viewed from the rolling direction, and Figure 9 is a diagram showing the schematic configuration of yet another form of the roll unit when viewed from a direction perpendicular to the rolling direction.

[0052] In the upper work roll unit 11A shown in Figures 6 and 7, the sensor 120A is a recess 113A provided on the surface of each of the chocks 110A on the drive side and the operation side, and is provided in a position visible from the outside, and is provided outside the outer wall surface of the housing 15 in the direction of the central axis of the housing 15.

[0053] The chock 110A also has flanges 111 that protrude from both radial sides of the roll 100. Furthermore, a roll facility having the upper work roll unit 11A is further provided with a bending cylinder 112 that applies a vertical force to the flanges 111. In addition, the sensor 120A is provided between the flanges 111 at a position away from the bearings 130, i.e., at a position that does not contact the bearings 130.

[0054] In the upper work roll unit 11B shown in Figures 8 and 9, the sensor 120B is a recess 113B provided on the surface of the chock 110A, one of the surfaces of the chocks 110B on the drive side and the operation side, and is provided in a position visible from the outside, and is provided outside the outer wall surface of the housing 15 in the direction of the central axis of the housing 15.

[0055] 8 and 9 show an example in which a portion of the sensor 120B is recessed from the surface of the chock 110B around the recess 113B, but at least a portion of the sensor 120B may protrude from the surface of the chock 110A.

[0056] In addition, in the upper work roll unit 11B, the sensor 120B is provided axially outward from the housing 15 and at a position away from the bearing 130, and is also provided on the axial side surface of the chock 110B.

[0057] Although the recesses 113, 113A, 113B are exposed on the surface of the chocks 110, 110A, 110B and are visible from the outside, a configuration in which they are not directly visible from the outside may be adopted by providing a cover or the like to prevent dirt.

[0058] When rolling metal material 5 using such upper work roll units 11, 11A, 11B, lower work roll unit 12, upper backup roll unit 13, and lower backup roll unit 14, information on the operating status can be measured using sensors 120, 120A, and 120B.

[0059] Furthermore, the timing for replacing the roll can be determined using the measured signals and data.

[0060] Furthermore, the operating conditions can be changed appropriately using the measured signals and data to roll the metal material 5.

[0061] Next, the effects of this embodiment will be described.

[0062] The upper work roll unit 11, lower work roll unit 12, upper backup roll unit 13, and lower backup roll unit 14 of the above-described embodiment comprise a roll 100 configured to be rotatable around its rotation axis, chocks 110, 110A, and 110B respectively provided on the outside of both axial ends of the roll 100, and sensors 120, 120A, and 120B provided on the surface of each chock 110, 110A, and 110B to acquire information about the chocks 110, 110A, and 110B.

[0063] Since the sensors 120, 120A, 120B are provided on the surfaces of the chocks 110, 110A, 110B in this manner, even if the surrounding structure is complex, when access is required to replace the sensors 120, 120A, 120B, the access is easy and the work is simplified, thereby improving work efficiency.

[0064] Furthermore, since the side of the chock 110B remains exposed to the outside even after the roll unit is installed in the equipment, the sensor 120B is provided on the axial side of the chock 110B, making it possible to easily access the sensor 120 even when not replacing the roll unit.

[0065] Furthermore, the sensors 120, 120A, 120B are recesses 113, 113A, 113B provided on the surfaces of the chocks 110, 110A, 110B, and are provided in positions that are visible from the outside. This means that the sensors 120, 120A, 120B do not interfere with other parts when the roll unit is installed in the equipment, and therefore the sensors 120, 120A, 120B are less likely to be subjected to load, thereby reducing the probability of failure.

[0066] Furthermore, the sensors 120, 120A, and 120B can obtain various pieces of information relating to the operating state by measuring the vibrations of the chocks 110, 110A, and 110B.

[0067] Furthermore, the device further includes a bearing 130 that is provided inside the chock 110A and supports the roll 100 so that it can rotate about its axis. The sensor 120A is provided at a position away from the bearing 130, so that the sensor 120A does not come into contact with the bearing 130. This allows the sensor 120A to detect vibrations of the entire device in which the roll unit is incorporated without being significantly affected by the vibrations of the bearing 130.

[0068] Furthermore, the sensors 120, 120A, and 120B are configured to be able to transmit the acquired information of the chocks 110, 110A, and 110B to the outside wirelessly or via a wired connection, so that data can be transmitted to the outside even during measurement, making it possible to change the operating conditions during operation to more appropriate conditions.

[0069] Furthermore, the roll equipment includes an upper work roll unit 11, a lower work roll unit 12, an upper backup roll unit 13, a lower backup roll unit 14, and a housing 15 in which the upper work roll unit 11, the lower work roll unit 12, the upper backup roll unit 13, and the lower backup roll unit 14 are provided, and the sensors 120A and 120B are provided axially outside the housing 15, making them easier to access.

[0070] Furthermore, the roll 100 is a roll 100 that rolls the metal material 5, and the chock 110A has flange portions 111 that protrude on both radial sides of the roll 100, and further includes a bending cylinder 112 that applies a vertical force to the flange portions 111, and the sensor 120A is provided between each of the flange portions 111, so that it can be positioned so as not to interfere with the bending cylinders 112, and therefore the sensor 120A is less likely to be subjected to load, and failures can be further prevented.

[0071] Furthermore, the sensors 120, 120A, 120B are recesses 113, 113A, 113B provided on the surfaces of the chocks 110, 110A, 110B, and are provided in positions that are visible from the outside, so that they do not interfere with the chocks of other rolls, and therefore the sensors 120, 120A, 120B are less likely to be subjected to load, thereby reducing the probability of failure.

[0072] Furthermore, in the data measurement method, when operating using the upper work roll unit 11, lower work roll unit 12, upper backup roll unit 13, and lower backup roll unit 14, information on the operating state is measured by the sensor 120, making it possible to detect abnormalities and roll malfunctions early, thereby optimizing the roll replacement cycle, optimizing the timing of maintenance, and enabling the units to be used for a long period of time without problems, which is effective in improving quality control and productivity.

[0073] Furthermore, in a product manufacturing method, the information measured by the above-mentioned data measurement method can be used to adjust operating conditions as needed, thereby improving product quality and increasing production volume.

[0074] <Others> The present invention is not limited to the above-described embodiments, and various modifications and applications are possible. The above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those having all of the described configurations.

[0075] DESCRIPTION OF SYMBOLS 1...Rolling equipment 5...Metal material 10...F1 stand 11, 11A, 11B...Upper work roll unit 12...Lower work roll unit 13...Upper backup roll unit 14...Lower backup roll unit 15...Housing 20...F2 stand 30...F3 stand 40...F4 stand 60...Control device 61...Measurement data collection unit 62...Judgment unit 62a...Single data judgment unit 62b...Multiple data judgment unit 63...Comparison value calculation unit 64...Processing unit 65...Operation control unit 70...Display device 100...Roll 110, 110A, 110B...Chock 111...Flange portion 112...Bending cylinder 113, 113A, 113B...Depression 120, 120A, 120B...Sensor 121...Sensing unit 122...Amplifier 123...Storage device 124...Transmitter 125...power source 130...bearing

Claims

1. A roll configured to be rotatable about a rotation axis; Chocks are provided on the outside of both ends of the roll in the axial direction, A sensor provided on a surface of each of the chocks to acquire information about the chocks; The sensor includes a storage device that stores the acquired information for a certain period of time. Roll unit.

2. 2. The roll unit according to claim 1, The sensor includes a power source for supplying power for driving the sensor. Roll unit.

3. 3. The roll unit according to claim 1, The sensor is a depression provided on the surface of the chock and is provided at a position visible from the outside. Roll unit.

4. 3. The roll unit according to claim 1, The sensor measures vibration of the chock. Roll unit.

5. The roll unit according to claim 4, A bearing is provided inside the chock and supports the roll rotatably, The sensor is provided at a position away from the bearing. Roll unit.

6. 3. The roll unit according to claim 1, The sensor is configured to be able to transmit the acquired information of the chock to the outside wirelessly or via wire. Roll unit.

7. A roll unit according to claim 1 or 2; a housing in which the roll unit is provided, The sensor is provided on the outer side of the housing in the axial direction. Roll equipment.

8. 8. The roll installation according to claim 7, The roll is a roll for rolling a metal material, The chock has flanges protruding from both sides in the radial direction of the roll, The bending cylinder further applies a vertical force to the flange, The sensor is provided between each of the flanges. Roll equipment.

9. 9. The roll installation according to claim 8, The sensor is a depression provided on the surface of the chock and is provided at a position visible from the outside. Roll equipment.

10. When the roll unit according to claim 1 or 2 is used for operation, the information on the operation state is measured by the sensor. Data measurement method.

11. The information measured by the data measuring method according to claim 10 is used to adjust operating conditions as necessary. Product manufacturing method.