Flexible Rolling of Wide Metal Strips With Learning-Based Flatness Control
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Solution Overview
Problem
Existing methods for manufacturing metal strips with widths over 650 mm are challenging due to limitations in controlling flatness and thickness variations, particularly in achieving consistent profiles across the length of the strip, and require significant adjustments in rolling mills and control systems.
Innovation Solution
A two-step process for flexible rolling that includes a 'learning phase' to store parameter values for thickness and flatness data, followed by a 'program-loop' phase for optimizing and controlling the rolling process, where the bending of work rolls is influenced by rolling forces rather than roll gap settings, allowing for dynamic changes in thickness and flatness across the strip length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ordinary mills are used to manufacture metal strips with width more than 650 mm, then the manufacturing process is simple, but it becomes difficult to achieve consistent thickness and flatness profiles across the strip length
Solution Approach 1:
The rolling process is divided into two distinct phases: a learning phase where thickness and flatness data are collected and stored, and a program-loop phase where pre-determined control parameters are applied. This segmentation allows the system to optimize for both precision and operational simplicity.
Solution Approach 2:
The learning phase performs preliminary measurements and data collection to establish thickness and flatness profiles before actual production. This preliminary action enables the program-loop phase to execute rolling operations with pre-optimized parameters, achieving consistent results without requiring complex real-time adjustments during manufacturing.
2Adaptability or versatility
If flexible rolling with quarto or duo mill is used, then different thickness profiles can be achieved, but the control system becomes complex requiring advanced control engineering and measurement systems
Solution Approach 1:
The system performs self-characterization during the learning phase by automatically measuring and storing its own thickness and flatness data. This self-service approach eliminates the need for complex external measurement systems and control engineering, as the mill learns and optimizes its own parameters through automated data collection and analysis.
Solution Approach 2:
The invention changes the control approach from complex real-time parameter adjustments to using pre-determined parameters established during the learning phase. By storing and reusing optimized parameter sets from the learning phase, the system achieves versatile thickness profiling while maintaining simple control logic during production.
3Ease of operation
If traditional rolling control based on roll gap setting is used, then the control process is simple, but the bending of work rolls during flexible rolling is not properly controlled
Solution Approach 1:
The learning phase implements a feedback mechanism where thickness and flatness measurements are continuously monitored and stored. This feedback loop enables the system to identify optimal roll bending characteristics and incorporate them into the parameter sets used during the program-loop phase, achieving precise bending control without complicating the operational process.
Data Source
AI summary
A method for manufacturing flexible rolling of metal strips, in which a metal strip with pre-definable material thickness is guided through a mill stand by at least two operating steps, which includes several rolls, the metallic strip is during the rolling operation set to lead through a roll gap, where a curve bending line is steered to achieve a defined profile.