Cold rolling mill with dynamic target shape control

Abstract

A cold rolling mill (100) for a metal substrate (102) such as aluminum or aluminum alloys may include a control system (108) for controlling the flatness of the metal substrate (102). The control system (108) may dynamically change a target flatness to which an actual flatness is compared to over the course of rolling the metal substrate (102) and control one or more flatness control actuators (118) based on a difference between the actual flatness and the target flatness. A method of rolling the metal substrate (102) with the cold mill includes providing a target flatness and dynamically changing the target flatness during rolling of the metal substrate (102).

Description

COLD ROLLING MILL WITH DYNAMIC TARGET SHAPE CONTROLREFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit ofU.S. Provisional Patent Application No. 63 / 580,584, filed on September 5, 2023, and entitled COLD ROLLING MILL WITH DYNAMIC TARGET SHAPE CONTROL, the content of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] This application relates to the processing of metal substrates, such as but not limited to aluminum or aluminum alloy metal sheets, and more particularly to systems and methods for controlling flatness of the metal substrate.BACKGROUND

[0003] Metal rolling can be used for forming metal strips (e.g., plates, sheets, foils, slabs, etc.) (hereinafter “metal substrates”) from stock such as ingots or thicker metal strips. Depending on the desired properties of the final metal product, the metal substrate may be hot rolled, cold rolled, and / or warm rolled. Hot rolling generally refers to a rolling process where the temperature of the metal is above the recrystallization temperature of the metal. Cold rolling generally refers to a rolling process where the temperature of the metal is below the recrystallization temperature of the metal. Warm rolling generally refers to a rolling process where the temperature of the metal is below the recrystallization temperature but above the temperature during cold rolling.

[0004] Flatness of the metal substrate refers to the ability of the metal substrate to lay flat when placed on a level surface and without externally applied forces. Deviations from flatness, also referred to as off-flatness, may take various forms in the metal substrate such as edge waves, center waves, and / or buckles, and may cause issues in productivity, material handling, downstream processing, and / or customer processing. As a non-limiting example, metal substrates with off- flatness may be difficult to process at high speeds, and the poor shape of the metal substrate may cause strip breaks or other issues decreasing the productivity of the rolling mill and / or overall process. A metal substrate with off-flatness may also cause various issues with the handling of the metal substrate, such as but not limited to coil build-up, steering problems, off-centered positioning in the rolling mill, difficulty to trim and / or slit, and / or difficulty threading of the metal substrate.SUMMARY

[0005] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0006] According to certain embodiments, a cold rolling mill includes a flatness control actuator for controlling flatness of the metal substrate at the work stand and a controller communicatively coupled to the flatness control actuator. The controller may provide a dynamically changing target flatness during rolling of the metal substrate and based on a stage of rolling and control the flatness control actuator to control the flatness of the metal substrate based on the dynamically changing target flatness.

[0007] According to some embodiments, a rolling mill for a metal substrate includes a control system with a sensor for measuring a flatness of the metal substrate and a controller communicatively coupled to the sensor. The controller may receive a measured flatness from the sensor and compare the measured flatness to a target flatness, where the controller dynamically changes the target flatness during rolling of the metal substrate and based on a stage of rolling. The controller may generate a control response for a flatness control actuator of the rolling mill based on a difference between the measured flatness and the target flatness.

[0008] According to some embodiments, a method of rolling a metal substrate with a cold mill includes providing a target flatness and dynamically changing the target flatness during rolling of the metal substrate and based on a stage of rolling, receiving a measured flatness of a metal substrate, comparing the measured flatness to the target flatness, and controlling a flatness control actuator based on a difference between the measured flatness and the target flatness.

[0009] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed descriptionand accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0011] FIG. 1 illustrates a rolling system with a flatness control system according to embodiments.

[0012] FIG. 2 illustrates dynamic target flatness control using the flatness control system of FIG. 1 and comparing an acceleration stage of rolling with a regime stage of rolling according to embodiments.

[0013] FIG. 3 illustrates dynamic target flatness control using the flatness control system of FIG. 1 and comparing a deceleration stage of rolling with the regime stage of rolling according to embodiments.

[0014] FIG. 4 illustrates a process for controlling flatness of a metal substrate using the rolling system of FIG. 1 according to embodiments.DETAILED DESCRIPTION

[0015] Described herein are flatness control systems and methods for controlling flatness of a metal substrate during rolling of the metal substrate. Rolling systems may include, but are not limited to, hot rolling mills, cold rolling mills, and warm rolling mills. In certain embodiments, the systems and methods described herein may be particularly useful with cold rolling mills. As such, while the following description refers to cold rolling mills, the embodiments described herein may be used with hot and warm rolling mills and are also not limited to rolling systems and may be utilized in various other types of metal processing systems as desired. Compared to traditional approaches to flatness control that utilize a static or fixed target flatness over the course of rolling, the flatness control systems described herein dynamically change and / or control a target flatness for the metal substrate over the course of rolling of the metal substrate. Dynamically changing the target flatness over the course of rolling of the metal substrate accommodates the various physical phenomena due to differences between various stages of rolling, such as but not limited to anacceleration stage, a regime (or steady-state) stage, and a deceleration stage, thereby providing a rolled metal substrate with improved flatness control and a process with increased material recovery (or conversely decreased waste) and increased productivity. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0016] FIG. 1 illustrates an example of a rolling system 100 for a metal substrate 102 according to embodiments. In various embodiments, the metal substrate 102 may be various metals as desired, including but not limited to aluminum, aluminum alloys, steel, or other metals as desired. In some examples, metal substrate 102 may be aluminum or an aluminum alloy in the Ixxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, 8xxx series and / or any other aluminum or aluminum alloy. The rolling system 100 may include a rolling mill 104 with at least one work stand 106 and a flatness control system 108.

[0017] In the example illustrated in FIG. 1, the rolling mill 104 is a cold rolling mill, although in other examples, the rolling mill 104 may be a warm rolling mill and / or a hot rolling mill as desired. The rolling mill 104 may have any number of work stands 106 as desired. As such, while two work stands 106A-B are illustrated in FIG. 1, in other examples the rolling mill 104 may include a single work stand 106 or plurality of work stands 106, such as two work stands 106, three work stands 106, four work stands 106, or any other desired number of work stands 106.

[0018] Each work stand 106 includes a pair of vertically aligned work rolls 112A-B. In the example of FIG. 1, each work stand 106A-B also includes backup rolls 114A-B that support the work rolls 112A-B. In other examples, the work stands 106A-B may also include intermediate rolls. A roll gap 1 16 of each work stand 106 is defined between the work rolls 112A-B, and the metal substrate 102 such as an aluminum or aluminum alloy sheet is passed through the roll gap 116 along a passline in a processing direction (represented by arrow 110).

[0019] In certain embodiments, one or more of the work stands 106 includes one or more flatness control actuators 118. The one or more flatness control actuators 118 may be various devices, mechanisms, and / or systems for controlling a flatness of the metal substrate 102 by controlling one or more characteristics of the work rolls 112A-B. Non-limiting examples of flatness control actuators 118 include work roll bending actuators, work roll tilting actuators, and coolant or temperature actuators. In certain embodiments, work roll bending actuators control roll bendingforces and may be utilized to control a symmetrical shape of the metal substrate 102. Work roll tilting actuators control a tilt of the work rolls (e.g., inclination across a width of the metal substrate 102) and may be utilized to control an asymmetrical shape of the metal substrate 102. In certain embodiments, the one or more flatness control actuators 118 may be at least one or more mechanical actuators, although they need not be in other embodiments. Other flatness control actuators 118 or mechanisms for influencing the geometry of the roll gap 116 may be utilized as desired.

[0020] The flatness control system 108 may include a one or more flatness sensors 120 and a controller 122.

[0021] The one or more flatness sensors 120 may be various devices for measuring the flatness of the metal substrate 102. The location, type, and number of flatness sensors 120 should not be considered limiting. In the example illustrated, the flatness sensor 120 is a shapemeter roll or a multi-zone flatness measuring roll; however, in other embodiments, the flatness sensor 120 may be other types of flatness measuring rolls, other sensors that measure flatness via contact, and / or other sensors that measure flatness without contacting the metal substrate 102. As a non-limiting example, in other embodiments, the flatness control system 108 additionally or alternatively includes an optical sensor and / or a camera for measuring the flatness of the metal substrate 102.

[0022] The controller 122 may include a computer system and / or one or more processing units and / or one or more memory devices. The processing unit may be various suitable processing devices or combinations of devices including but not limited to one or more application specific integrated circuits, digital signal processors, digital signal processing devices, programmable logic devices, field programmable gate arrays, processors, controllers, micro-controllers, microprocessors, other electronic units, and / or a combination thereof. The one or more memory devices may be any machine-readable medium that can be accessed by the processor, including but not limited to any type of long term, short term, volatile, nonvolatile, or other storage medium, and is not to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored. Moreover, as disclosed herein, the term “storage medium,” “storage” or “memory” can represent one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and / or other machine readablemediums for storing information. The term “machine-readable medium” includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or various other storage mediums capable of storing that contain or carry instruction(s) and / or data.

[0023] The controller 122 may be provided at various locations within the rolling system 100. While illustrated as separate from the flatness sensors 120 and the flatness control actuators 118, in some embodiments, the controller 122 (or sub-components thereof such as one or more processing units and / or one or more memory devices) may be components of the flatness sensors 120 and / or the flatness control actuators 118.

[0024] In certain embodiments, the controller 122 optionally includes an associated user interface, including but not limited to a graphical user interface or a human machine interface, such that the controller 122 may obtain information from a user and / or provide information to the user. In such embodiments, the user interface and / or human machine interface may be on the controller 122 itself or may be at a location remote from the controller 122, such as on a user device, a dedicated user interface device, an operations control center remote from the rolling system 100, combinations thereof, and / or as otherwise desired.

[0025] The controller 122 may be communicatively coupled to the flatness sensors 120 and the flatness control actuators 118. The controller 122 may also be communicatively coupled to various other components of the rolling system 100 such as but not limited to components controlling rolling speed, tension in the metal substrate, combinations thereof, and / or other components as desired. In various embodiments, and as discussed in detail below, the controller 122 may generate a control signal for controlling the one or more flatness control actuators 118 based at least partially on data related to the flatness of the metal substrate 102 from the flatness sensors 120.

[0026] In certain embodiments, the controller 122 may receive and / or determine an initial target flatness for the metal substrate 102. The target flatness of the metal substrate 102 is generally the shape or profile of the metal substrate 102 across the width of the metal substrate 102. The initial target flatness may be determined based on various control parameters such as but not limited to a type of rolling process, a type of alloy, an exit thickness of the metal substrate, a reduction in the metal substrate, combinations thereof, and / or other parameters as desired. Over the course of rolling, the controller 122 may compare the actual or measured flatness from the flatness sensors 120 to the target flatness and may generate control signals for controlling the one or more flatnesscontrol actuators 118 based on any differences between the actual flatness and the target flatness. As non-limiting examples, the controller 122 may generate a control signal for controlling a work roll tilt actuator, a work roll bending actuator, and / or a temperature control actuator based on differences between the actual flatness and the target flatness.

[0027] While traditionally the target flatness has remained static over the course of rolling, the controller 122 may dynamically change and / or control the target flatness over the course of rolling. The controller 122 may dynamically change and / or control the target flatness based on various parameters as desired, such as but not limited to the type of rolling process, the type of alloy, the exit thickness of the metal substrate, the reduction in the metal substrate, the stage of rolling, the rolling speed, combinations thereof, and / or other parameters as desired. As non-limiting examples, the controller 122 may adjust and / or control the target flatness for the metal substrate 102 based on the stage of rolling (e.g., an acceleration stage, a regime or steady-state stage, or a deceleration stage), and the target flatness during one stage (e.g., acceleration) may be different from the target flatness during another stage (e.g., regime). Dynamically controlling the target flatness may accommodate the different physical phenomena that the metal substrate 102 is subjected to during the various stages, thereby providing a metal substrate 102 with improved flatness and a process with improved recovery and productivity. In some embodiments, the controller 122 dynamically controls the target flatness over the course of rolling such that a target shape during the acceleration stage is different from at least a target shape during the regime stage and optionally different from a target shape during the deceleration stage. Similarly, the controller 122 may dynamically control the target flatness such that the target shape during the deceleration stage is different from at least the target shape during the regime stage and optionally different from the target shape during the acceleration stage.

[0028] FIGS. 2 and 3 illustrate non-limiting examples of dynamic control of the target flatness by the controller 122 according to embodiments. In FIGS. 2 and 3, the same dynamically controlled target flatness is represented by the target map 201, where the x-axis is time and the y-axis represents distance from a first edge of the metal substrate 102. The red areas of target map 201 represent compensation via the flatness control actuators 118 for making the portion of the metal substrate loose and blue areas represent compensation via the flatness control actuators 118 for making the portion of the metal substrate tight.

[0029] FIG. 2 illustrates an acceleration target shape 203 at time 205 during an acceleration stage of rolling as compared to a regime target shape 207 at time 209 during a regime stage of rolling. The regime target shape 207 generally has a positive (or “frown”) shape profile, while the acceleration target shape 203 is a modified negative (or “smile”) shape profile. As illustrated by comparing the acceleration target shape 203 with the regime target shape 207, the acceleration target shape 203 makes the center of the metal substrate 102 looser and the edges tighter compared to the regime target shape 207. In various embodiments, the adjusted acceleration target shape 203 may facilitate bending of the metal substrate 102 to the desired shape (e.g., the positive shape profile) and may decrease the time required for acceleration ramp up.

[0030] FIG. 3 illustrates a deceleration target shape 211 at time 213 during a deceleration stage of rolling as compared to a regime target shape 215 at time 217 during the regime stage of rolling. The regime target shape 215 is similar to the regime target shape 207 and generally has a positive (or “frown”) shape profile, and the deceleration target shape 211 is closer to the negative shape profile than the regime target shape 215 (or a “modified frown” for discussion purposes). As illustrated by comparing the deceleration target shape 211 with the regime target shape 215, the deceleration target shape 211 makes the center of the metal substrate 102 looser and the edges tighter compared to the regime target shape 215, which may facilitate bending of the metal substrate 102 to the desired positive shape.

[0031] As generally represented by target map 201, over the course of rolling, the target profile is dynamically controlled and adjusted. While the target map 201 illustrates a changing target profile from a modified negative shape profile to a positive shape profile to a modified frown shape profile, this target profile should not be considered limiting. In other examples, the controller 122 may dynamically control the target shape over the course of rolling as desired and based on the aforementioned parameters such as but not limited to the type of process, the type of alloy, the exit thickness, the desired reduction, the rolling speed, etc.

[0032] FIG. 4 illustrates an example of a process for controlling a flatness of the metal substrate 102 with the rolling system 100. The method may be at least partially performed by the controller 122, and in some embodiments, may be fully performed by the controller 122.

[0033] In a block 402, the method includes receiving or determining an initial target flatness. Block 402 may be based on various parameters such as but not limited to a type of rolling process,a type of alloy, an exit thickness of the metal substrate, a reduction in the metal substrate, combinations thereof, and / or other parameters as desired. In various embodiments, a user may provide the initial target flatness and / or the controller 122 may determine the target flatness.

[0034] In a block 404, the method includes dynamically controlling the target flatness. Dynamically controlling the target flatness may be based on various parameters as desired, such as but not limited to the type of rolling process, the type of alloy, the exit thickness of the metal substrate, the reduction in the metal substrate, the stage of rolling, the rolling speed, combinations thereof, and / or other parameters as desired. As non-limiting examples, block 404 may include adjusting and / or controlling the target flatness for the metal substrate 102 based on the stage of rolling (e.g., the acceleration stage, the regime or steady-state stage, and / or the deceleration stage). In some embodiments, dynamically controlling the target flatness may be based on data from one or more system sensors measuring one or more characteristics of the rolling system 100 and / or the metal substrate 102, although it need not be in other embodiments. In some embodiments, the data from the one or more systems sensors may correspond with various stages of rolling, and the data may be utilized to determine the stage of rolling. As a non-limiting example, the system sensor may measure a rolling speed, a temperature, and / or other information that may correspond with stages of rolling.

[0035] In some embodiments, block 404 includes dynamically controlling the target flatness by adjusting the target flatness such that the target flatness during one stage of rolling (e.g., the acceleration stage) may be different from the target flatness during another stage of rolling (e.g., the regime stage and / or the deceleration stage). In some examples, block 404 optionally includes providing a static target flatness during one stage of rolling and dynamically changing the target flatness during another stage of rolling. As a non-limiting example, block 404 may include providing a static target flatness during the regime stage of rolling and a changing target flatness during the acceleration stage and / or the deceleration stage. In one non-limiting example, block 404 may include controlling the target flatness such that the target flatness during one stage may be a positive target flatness and the target flatness during another stage may be a negative target flatness.

[0036] In a block 406, the method includes receiving the measured flatness of the metal substrate 102 using the one or more flatness sensors 120. In certain embodiments, block 406 includesreceiving the measured flatness from one or more optical sensors, a shapemeter roll, and / or other flatness sensors 120 as desired.

[0037] In a block 408, the method includes determining an error or difference between the measured flatness received in block 406 and the dynamically controlled target flatness from block 404.

[0038] Based on the measured flatness being within acceptable tolerances of the target flatness, the method may proceed to block 410, and based on the rolling process continuing, the process returns to block 404. The acceptable tolerances in block 408 may be provided by the user and / or determined by the controller 122 based on the type of process, the type of alloy, the exit thickness, the desired reduction, and / or as otherwise desired.

[0039] In various embodiments, based on a difference between the measured flatness and the target flatness being outside of acceptable tolerances, in block 412, the method includes determining a control response for one or more flatness control actuators 118. In certain embodiments, block 412 may include determining a control response for one or more of a work roll bending actuator, a work roll tilting actuator, and / or a coolant or temperature actuator. In various embodiments, block 412 may include determining the control response based on the type of error determined in block 408. As non-limiting examples, a symmetrical error or difference identified in block 408 may result in determining a control response for a work roll bending actuator and / or any other symmetrical flatness actuator in block 412 while an asymmetrical error or difference in block 408 may result in determining a control response for a work roll tilting actuator and / or any other asymmetrical flatness actuator in block 412. In some embodiments, block 412 may include determining a control response for addressing both symmetrical and asymmetrical errors. Non-limiting examples of a control response for the one or more flatness control actuators 118 may include increasing a bending force, decreasing a bending force, increasing a tilt of the work roll towards a first side, increasing a tilt of the work roll towards a second side, combinations thereof, and / or other control responses as desired.

[0040] In a block 414, the controller 122 may generate a control signal for controlling the one or more flatness control actuators 118 based on the determined control response from block 412 to modify the flatness of the metal substrate 102 and such that the measured flatness is within the acceptable tolerances of the target flatness.

[0041] The above method is for illustrative purposes, and various other operations and / or combinations of operations related to controlling flatness of at least the material head region of the metal substrate may be performed as desired.

[0042] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0043] Illustration 1. A cold rolling mill comprising: a flatness control actuator for controlling flatness of the metal substrate at a work stand of the cold rolling mill; and a controller communicatively coupled to the flatness control actuator, wherein the controller is configured to: provide a dynamically changing target flatness during rolling of the metal substrate and based on a stage of rolling; and control the flatness control actuator to control the flatness of the metal substrate based on the dynamically changing target flatness.

[0044] Illustration 2. The cold rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the flatness control actuator comprises at least one of a roll bending actuator, a roll tilt actuator, or a coolant actuator.

[0045] Illustration 3. The cold rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to dynamically control the target flatness based on the cold rolling mill being in an acceleration stage or rolling, a regime stage of rolling, or a deceleration stage of rolling.

[0046] Illustration 4. The cold rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to dynamically change the target flatness such that a target flatness during an acceleration stage of rolling is different from a target flatness during a regime stage of rolling.

[0047] Illustration 5. The cold rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to dynamically change the targetflatness based on a type of cold rolling process, a type of metal of the metal substrate, and / or an exit thickness of the metal substrate.

[0048] Illustration 6. The cold rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to dynamically change the target flatness such that the target flatness is static during a regime stage of a rolling process.

[0049] Illustration 7. The cold rolling mill of any preceding or subsequent illustration or combination of illustrations, further comprising a system sensor communicatively coupled with the controller, wherein the system sensor measures at least one characteristic of the rolling mill corresponding to the stages of rolling, and wherein the controller is configured to dynamically change the target flatness based at least partially on information from the system sensor.

[0050] Illustration 8. A rolling mill for a metal substrate, the rolling mill comprising a control system, the control system comprising: a sensor for measuring a flatness of the metal substrate; and a controller communicatively coupled to the sensor and configured to: receive a measured flatness from the sensor; compare the measured flatness to a target flatness, wherein controller dynamically changes the target flatness during rolling of the metal substrate and based on a stage of rolling; and generate a control response for a flatness control actuator of the rolling mill based on a difference between the measured flatness and the target flatness.

[0051] Illustration 9. The rolling mill of any preceding or subsequent illustration or combination of illustrations, further comprising: a work stand comprising at least one work roll for rolling the metal substrate; and the flatness control actuator for controlling the at least one work roll to control the flatness of the metal substrate.

[0052] Illustration 10. The rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the flatness control actuator comprises at least one of a roll bending actuator for controlling bending of the at least one work roll, a roll tilt actuator for controlling a tilt of the at least one work roll, or a coolant actuator for controlling an application of coolant on the at least one work roll.

[0053] Illustration 11. The rolling mill of any preceding or subsequent illustration or combination of illustrations, further comprising a system sensor communicatively coupled with the controller, wherein the system sensor measures at least one characteristic of the rolling mill corresponding tothe stages of rolling, and wherein the controller is configured to dynamically change the target flatness based at least partially on information from the system sensor.

[0054] Illustration 12. The rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to dynamically control the target flatness to have a plurality of shapes during rolling of the metal substrate.

[0055] Illustration 13. The rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to dynamically change the target flatness such that a target flatness during an acceleration stage of rolling is different from a target flatness during a regime stage of rolling.

[0056] Illustration 14. The rolling mill of any preceding or subsequent illustration or combination of illustrations, wherein the controller is configured to dynamically change the target flatness such that a target flatness during an acceleration stage of rolling is different from a target flatness during a deceleration stage of rolling.

[0057] Illustration 15. A method of rolling a metal substrate with a cold mill, the method comprising: providing a target flatness and dynamically changing the target flatness during rolling of the metal substrate and based on a stage of rolling; receiving a measured flatness of a metal substrate; comparing the measured flatness to the target flatness; and controlling a flatness control actuator based on a difference between the measured flatness and the target flatness.

[0058] Illustration 16. The method of any preceding or subsequent illustration or combination of illustrations, wherein dynamically changing the target flatness comprises providing a target flatness during an acceleration stage of rolling that is different from a target flatness during a deceleration stage of rolling.

[0059] Illustration 17. The method of any preceding or subsequent illustration or combination of illustrations, wherein dynamically changing the target flatness comprises providing a static target flatness during a regime stage of rolling.

[0060] Illustration 18. The method of any preceding or subsequent illustration or combination of illustrations, wherein dynamically changing the target flatness comprises providing a target flatness during an acceleration stage of rolling and a target flatness during a deceleration stage of rolling that are different from a target flatness during a regime stage of rolling.

[0061] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations, wherein controlling the flatness control actuator comprises dynamically controlling a tilt of a work roll or a bending force of the work roll during at least one of an acceleration stage of rolling or a deceleration stage of rolling.

[0062] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, wherein dynamically changing the target flatness comprises providing a negative target flatness during at least one stage of rolling and a positive target flatness during another stage of rolling.

[0063] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0064] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0065] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0066] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and“back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

[0067] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0068] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

CLAIMSThat which is claimed:

1. A cold rolling mill comprising: a flatness control actuator for controlling flatness of a metal substrate at a work stand of the cold rolling mill; and a controller communicatively coupled to the flatness control actuator, wherein the controller is configured to: provide a dynamically changing target flatness during rolling of the metal substrate and based on a stage of rolling; and control the flatness control actuator to control the flatness of the metal substrate based on the dynamically changing target flatness.

2. The cold rolling mill of claim 1, wherein the flatness control actuator comprises at least one of a roll bending actuator, a roll tilt actuator, or a coolant actuator.

3. The cold rolling mill of claim 1, wherein the controller is configured to dynamically control the target flatness based on the cold rolling mill being in an acceleration stage of rolling, a regime stage of rolling, or a deceleration stage of rolling.

4. The cold rolling mill of claim 1, wherein the controller is configured to dynamically change the target flatness such that a target flatness during an acceleration stage of rolling is different from a target flatness during a regime stage of rolling.

5. The cold rolling mill of claim 1, wherein the controller is configured to dynamically change the target flatness based on a type of cold rolling process, a type of metal of the metal substrate, and / or an exit thickness of the metal substrate.

6. The cold rolling mill of claim 1, wherein the controller is configured to dynamically change the target flatness such that the target flatness is static during a regime stage of a rolling process.

7. The cold rolling mill of claim 1, further comprising a system sensor communicatively coupled with the controller, wherein the system sensor measures at least one characteristic of the cold rolling mill corresponding to the stages of rolling, and wherein the controller is configured to dynamically change the target flatness based at least partially on information from the system sensor.

8. A rolling mill for a metal substrate, the rolling mill comprising a control system, the control system comprising: a sensor for measuring a flatness of the metal substrate; and a controller communicatively coupled to the sensor and configured to: receive a measured flatness from the sensor; compare the measured flatness to a target flatness, wherein controller dynamically changes the target flatness during rolling of the metal substrate and based on a stage of rolling; and generate a control response for a flatness control actuator of the rolling mill based on a difference between the measured flatness and the target flatness.

9. The rolling mill of claim 8, further comprising: a work stand comprising at least one work roll for rolling the metal substrate; and the flatness control actuator for controlling the at least one work roll to control the flatness of the metal substrate.

10. The rolling mill of claim 9, wherein the flatness control actuator comprises at least one of a roll bending actuator for controlling bending of the at least one work roll, a roll tilt actuator for controlling a tilt of the at least one work roll, or a coolant actuator for controlling an application of coolant on the at least one work roll.

11. The rolling mill of claim 8, further comprising a system sensor communicatively coupled with the controller, wherein the system sensor measures at least one characteristic of the rolling mill corresponding to the stages of rolling, and wherein the controller is configured todynamically change the target flatness based at least partially on information from the system sensor.

12. The rolling mill of claim 8, wherein the controller is configured to dynamically control the target flatness to have a plurality of shapes during rolling of the metal substrate.

13. The rolling mill of claim 8, wherein the controller is configured to dynamically change the target flatness such that a target flatness during an acceleration stage of rolling is different from a target flatness during a regime stage of rolling.

14. The rolling mill of claim 8, wherein the controller is configured to dynamically change the target flatness such that a target flatness during an acceleration stage of rolling is different from a target flatness during a deceleration stage of rolling.

15. A method of rolling a metal substrate with a cold mill, the method comprising: providing a target flatness and dynamically changing the target flatness during rolling of the metal substrate and based on a stage of rolling; receiving a measured flatness of a metal substrate; comparing the measured flatness to the target flatness; and controlling a flatness control actuator based on a difference between the measured flatness and the target flatness.

16. The method of claim 15, wherein dynamically changing the target flatness comprises providing a target flatness during an acceleration stage of rolling that is different from a target flatness during a deceleration stage of rolling.

17. The method of claim 15, wherein dynamically changing the target flatness comprises providing a static target flatness during a regime stage of rolling.

18. The method of claim 15, wherein dynamically changing the target flatness comprises providing a target flatness during an acceleration stage of rolling and a target flatness during adeceleration stage of rolling that are different from a target flatness during a regime stage of rolling.

19. The method of claim 15, wherein controlling the flatness control actuator comprises dynamically controlling a tilt of a work roll or a bending force of the work roll during at least one of an acceleration stage of rolling or a deceleration stage of rolling.

20. The method of claim 19, wherein dynamically changing the target flatness comprises providing a negative target flatness during at least one stage of rolling and a positive target flatness during another stage of rolling.

Images