Cold Rolling Condition Prediction for Stable High-Speed Steel Sheet Rolling
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Solution Overview
Problem
Existing cold rolling methods struggle to maintain productivity and stability when rolling difficult-to-roll materials with high loads, as operating conditions can be adversely affected by factors like lubrication state and thermal expansion, leading to issues such as mill vibration and sheet thickness variations.
Innovation Solution
A cold rolling mill rolling condition calculation method and device that uses a prediction model trained with past rolling performance data to estimate and adjust rolling conditions, ensuring stability and productivity by predicting steady rolling speeds and constraints, even during non-steady conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rolling speed is increased to improve productivity, then the output increases, but the operating condition changes due to lubrication state changes, thermal expansion, and temperature rise, making it difficult to maintain rolling stability
Solution Approach 1:
The patent implements a feedback control system that continuously monitors rolling conditions (lubrication state, temperature, roll expansion) and adjusts rolling parameters in real-time. The control system receives data from sensors measuring these parameters and automatically modifies rolling speed and other operating conditions to maintain stability, thereby resolving the contradiction between increased productivity and maintained rolling stability.
Solution Approach 2:
The patent dynamically changes operating parameters (rolling speed, lubrication flow rate, coolant temperature) based on real-time monitoring of the rolling process. By adjusting these parameters in response to detected changes in lubrication state, thermal expansion, and temperature, the system maintains optimal rolling conditions even at higher speeds, thus improving productivity while preserving stability.
2Strength
If the rolling load is increased to roll difficult-to-roll materials, then the material strength and thin gauge are achieved, but the operating condition reaches the specification limit of the cold rolling mill, requiring careful setting of pass schedule and rolling speed
Solution Approach 1:
The patent performs preliminary calculations and simulations to determine the optimal pass schedule and rolling speed before actual rolling operations. By pre-planning the rolling parameters based on material properties and mill capabilities, the system ensures that difficult-to-roll materials can be processed at high loads without exceeding facility constraints, thereby achieving high strength while maintaining ease of operation.
Solution Approach 2:
The patent employs dynamic adjustment of rolling parameters during the rolling process to accommodate varying loads and material properties. The system continuously monitors rolling conditions and automatically adjusts pass schedule and speed to optimize both material strength achievement and facility utilization, eliminating the need for conservative manual settings.
3Reliability
If the rolling speed is set to avoid mill vibration and chattering, then the facility constraint is satisfied, but the productivity is reduced due to lower operating speed
Solution Approach 1:
The patent uses feedback control to continuously monitor vibration levels and lubrication conditions, adjusting rolling speed in real-time to avoid mill vibration and chattering. This allows the system to operate at higher speeds when conditions are favorable and reduce speed only when necessary to prevent vibration, thereby maximizing productivity while maintaining reliability.
Solution Approach 2:
The patent implements periodic monitoring and adjustment of rolling parameters to prevent mill vibration and chattering. By detecting early signs of vibration and applying corrective actions at regular intervals, the system maintains stable operation at higher speeds, improving productivity while controlling vibration through periodic control cycles.
Data Source
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AI summary
A cold rolling mill rolling condition calculation method according to the present invention includes: an estimation step of estimating a rolling constraint condition with respect to a target steady rolling condition of a roll target material, the estimation performed by training a prediction model using first multi-dimensional data generated based on non-steady rolling performance data, among past rolling performance in rolling a roll material by a cold rolling mill, as an explanatory variable, and using steady rolling performance data and rolling constraint condition data during steady rolling, as a response variable, and then inputting second multi-dimensional data generated based on the non-steady rolling performance data of the roll target material; and a change step of changing the target steady rolling condition so that the estimated rolling constraint condition satisfies a predetermined condition.