Rolling Mill Coiler Force Control for Coil Protrusions
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Solution Overview
Problem
During the rolling of metal strips into coils, air entrapment between laps can cause issues like scratch-gouge defects and coil scoping, due to varying radial forces exerted by protrusions in the coil on the roll.
Innovation Solution
A control scheme using sensors to capture data on radial forces and coil positions, combined with a hydraulic cylinder system, adjusts the roll force to counteract the radial force of the coil, maintaining a constant force throughout the coiling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a roll contacts the coil surface to prevent air entrapment, then air entrapment between laps is reduced, but force consistency deteriorates due to protrusions causing radial force variations
Solution Approach 1:
The system uses load cells to continuously measure the radial force between the roll and coil, and a control system automatically adjusts the roll position or applied force based on these measurements to maintain constant force despite protrusions
Solution Approach 2:
The roll positioning system transitions from a static fixed position to a dynamic adjustable position, allowing real-time modification of roll-to-coil contact force to compensate for varying coil surface geometry
2Stability of the object's composition
If the roll applies constant force to the coil, then force consistency is maintained, but protrusions cause radial force variations that affect coiling quality
Solution Approach 1:
Load cells provide real-time feedback on the actual radial force, and the control system uses this information to dynamically adjust the roll positioning or hydraulic cylinder output to maintain both force consistency and coiling quality
Solution Approach 2:
The system dynamically changes the roll position or applied force parameters in response to detected protrusions, allowing the force magnitude or application point to be adjusted to maintain quality standards
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces the impact of protrusions on the force consistency between the roll and the coil, preventing defects and ensuring a stable coiling process.
Implementation Method 1
transmitting, to a hydraulic cylinder coupled to the roll, the signal, wherein after the signal is received by the hydraulic cylinder, the hydraulic cylinder causes the roll to exert the roll force
Implementation Method 2
capturing, by a first sensor during the coil forming operation, first coil data associated with the coil while the strip of metal is being rolled into the coil, wherein the first coil data includes data corresponding to a radial force from the coil applied to an roll
Implementation Method 3
capturing, by a second sensor during the coil forming operation, second coil data associated with the coil while the strip of metal is being rolled into the coil, wherein the second coil data includes data corresponding to a position of the coil
Data Source
AI summary
Systems and methods directed to rolling mill coilers are disclosed. Systems and methods are disclosed for a control scheme to maintain a constant force between a roll and a coil's surface. Example systems and methods may include forming a portion of a coil, capturing a first coil data corresponding to force of the coil while the strip of metal is being rolled into the coil, capturing second coil data corresponding to position of the coil while the strip of metal is being rolled into the coil, determining a signal that corresponds to a roll force of the roll and a position of the protrusion, and transmitting the signal to a hydraulic cylinder coupled to the roll, the hydraulic cylinder causing the roll to exert the roll force counter to the radial force of the coil.