Induction Furnace Control for Rolling Mill Temperature Accuracy
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Solution Overview
Problem
Existing methods for controlling induction furnaces in rolling mills face high procedural uncertainty due to deviations in temperature control, leading to inefficiencies in the heating process and subsequent processing steps.
Innovation Solution
A method that calculates the energetic state of the rolling stock section using a model predictive controller, allowing for precise control and regulation of the induction coils based on deviations between actual and target temperatures, with the ability to dynamically adjust target profiles for each section of rolling stock, minimizing energy consumption while maintaining high-quality products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heuristic estimation and iterative processes are used to control induction coil power, then the heating process can be implemented, but large deviations from desired setpoint temperature occur leading to high procedural uncertainty
Solution Approach 1:
The patent implements a closed-loop feedback control system where the actual temperature of the rolling stock is continuously measured and compared with the desired setpoint temperature. The control device adjusts the induction coil power based on the temperature deviation, ensuring accurate temperature control and eliminating the large deviations characteristic of open-loop heuristic methods.
Solution Approach 2:
The patent replaces the mechanical/heuristic iterative estimation process with an automated electronic control system. Instead of relying on operator experience and iterative guessing, the system uses sensors, controllers, and actuators to automatically regulate temperature, significantly improving precision and reducing procedural uncertainty.
2Manufacturing precision
If intermediate heating steps are performed to compensate for temperature loss during processing, then the desired rolling stock end product can be achieved, but energy consumption increases
Solution Approach 1:
The control system performs preliminary calculations to predict the temperature loss that will occur during subsequent processing steps. Based on these predictions, the system proactively adjusts the heating parameters before the temperature loss occurs, rather than requiring intermediate heating corrections. This reduces the total energy consumption while maintaining end product quality.
Solution Approach 2:
The patent dynamically changes heating parameters (power, duration, distribution) based on real-time temperature measurements and predicted processing requirements. Instead of using fixed or excessive heating margins, the system optimizes parameters to achieve the minimum necessary heating, reducing energy consumption while ensuring the rolling stock reaches the required temperature for the desired end product.
3Manufacturing precision
If multiple reference points and model predictive control are used to calculate future energetic state, then temperature control accuracy is significantly enhanced, but system complexity increases
Solution Approach 1:
The patent divides the heating zone into multiple reference points along the rolling stock path, with each point having its own temperature measurement and control parameters. This segmentation allows the system to account for temperature variations at different locations and predict future states more accurately. The complexity is managed by using a modular control architecture where each reference point is handled independently but coordinated through the overall predictive model.
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 significantly enhances the accuracy of the induction heating process, reduces energy expenditure, and ensures consistent product quality by accurately controlling temperature and enthalpy profiles, thereby improving the efficiency and precision of the rolling mill operations.
Implementation Method 1
In an induction furnace, an eddy current is induced in the rolling stock by means of induction coils comprised by the induction furnace. This induced eddy current leads to heating of the rolling stock.
Implementation Method 2
an eddy current is induced in the rolling stock by means of induction coils comprised by the induction furnace. This induced eddy current leads to heating of the rolling stock.
Data Source
AI summary
The invention relates to a rolling mill (20) for producing rolling stock (G), to a control and/or regulating device (9) for a rolling mill (20), and to a method for controlling and/or regulating an induction furnace (1) for a rolling mill (20), in particular a composite casting and rolling mill, rolling stock (G) running through the induction furnace (1), the induction furnace (1) having a plurality of induction coils (2) for heating the rolling stock (G), and a state of a section (X) of the rolling stock (G) being determined before the rolling stock (G) runs into the induction furnace (1). The accuracy of a rolling stock state variable existing after the rolling stock has been heated by means of the induction furnace can be increased in that, for the rolling stock section (X), a future actual variable which is present at at least one second reference point (R, R1, R2, R3, Ri, RN), and which describes the energetic state of the rolling stock section (X) or an energy supply, is calculated by means of a model (5) which describes the energetic characteristics of the rolling stock section (X) or the energy supply characteristics, wherein for the at least one second reference point (R, R1, R2, R3, Ri, RN), a desired associated nominal variable is determined, and the plurality of induction coils (2) are controlled and/or regulated on the basis of the deviations of the future actual variable from the nominal variable, in such a way that the effective actual variable is approximated to the nominal variable at the second reference point (R, R1, R2, R3, Ri, RN).