Inter-Stand Torque Adjustment for Uniform Bar Drawing
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Solution Overview
Problem
Existing methods for adjusting inter-stand drawing action in metal bar rolling and finishing processes fail to precisely match torque values to specific bar conditions, leading to non-homogeneous product quality, deformations, and inefficiencies, particularly for bars with smaller cross-sections, due to slow adjustment processes that require significant inter-stand distances.
Innovation Solution
A method and device that dynamically adjust the torque of individual stands by determining reference torque values during the initial bar feed, using a PI adjustment algorithm to maintain consistent torque values across stands, allowing for rapid adjustments and minimizing inter-stand distances, even for bars with smaller cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional torque adjustment methods are used with significant inter-stand crossing times, then bars with larger cross sections (greater than 40 mm) can be processed, but the production speed is limited and plant space requirements increase
Solution Approach 1:
The patent implements dynamic adjustment of torque values during the bar feeding process rather than using static pre-set values. The control system continuously monitors actual torque values and adjusts them in real-time based on feedback from load cells and processing conditions, enabling rapid adaptation without requiring long inter-stand crossing times
Solution Approach 2:
The system employs feedback control by measuring actual torque values using load cells during bar processing and comparing them against target values. The control unit automatically adjusts torque values based on this feedback, allowing precise control with minimal inter-stand distance and enabling faster production cycles
2Device complexity
If predefined reference torque values are used without considering specific operating conditions, then the adjustment process is simplified, but product quality becomes non-homogeneous and defects increase
Solution Approach 1:
The patent applies local quality by tailoring torque values to specific local conditions of each bar and processing stage. Instead of using uniform predefined values, the system adjusts torque values based on individual bar characteristics, position in the sequence, and real-time processing conditions, ensuring optimal quality for each specific case
Solution Approach 2:
The system dynamically changes torque parameters based on specific operating conditions including bar material, cross-section, position in the processing sequence, and measured load values. This continuous parameter adjustment ensures high manufacturing precision while adapting to varying conditions without requiring complex manual reconfiguration
3Device complexity
If torque adjustment is performed in a consequential manner after the bar exits the stand, then the adjustment process is simpler to implement, but repeated adjustments generate consequential stresses that cause deformations and neckings
Solution Approach 1:
The system performs preliminary torque adjustments before the bar enters each stand by calculating and setting appropriate torque values in advance based on bar characteristics and processing requirements. This prevents the need for consequential adjustments during bar transit, eliminating the generation of harmful stresses that cause deformations and neckings
Solution Approach 2:
The control system applies preliminary anti-action by pre-compensating for potential torque variations and establishing optimal torque values before processing begins. This anticipatory adjustment prevents the development of consequential stresses that would otherwise lead to bar deformations, neckings, and quality defects
Data Source
AI summary
A method to adjust the drawing action on a bar in a rolling and/or finishing train is provided, as well as an adjustment device associated with the train to implement the method. A metal product is made using the method.