Laying Head Speed Control for Consistent Wire Rod Coil Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current wire rod line systems require manual intervention to adjust the speed of the laying head, leading to suboptimal coil formation due to factors like temperature changes and material variations, which affect the accuracy of speed references from level 1 mill control.
Innovation Solution
A system comprising a speed measuring device and a processor that dynamically computes the optimal speed of the laying head based on the material's speed, ring diameter, and gear ratio, eliminating the need for manual adjustments and ensuring consistent coil formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trimming of laying head speed is used to correct coil formation issues, then coil formation quality can be adjusted, but operator intervention time and production efficiency are reduced
Solution Approach 1:
The laying head control system automatically monitors and adjusts its own speed based on real-time material speed feedback, eliminating the need for manual operator intervention. The system self-corrects coil formation issues by dynamically trimming the speed reference, thereby maintaining high production efficiency while ensuring quality coil formation.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the actual material speed is continuously measured and compared with the target speed. The controller automatically adjusts the laying head speed reference based on this feedback, enabling real-time correction of coil formation without manual intervention and maintaining continuous production flow.
2Device complexity
If level 1 mill control speed reference is used without dynamic adjustment, then system simplicity is maintained, but manufacturing precision deteriorates due to unaccounted temperature and material variations
Solution Approach 1:
The system replaces manual mechanical speed adjustment with an automated electronic control system. The controller dynamically computes and adjusts the laying head speed reference based on real-time material speed measurements, automatically compensating for temperature and material variations without requiring complex mechanical modification mechanisms.
Solution Approach 2:
The system dynamically changes the speed parameter of the laying head based on real-time conditions. By continuously adjusting the speed reference in response to measured material speed variations, the system maintains accurate ring formation despite changes in temperature, material properties, or processing conditions.
3Ease of operation
If the laying head speed is not dynamically adjusted to material speed changes, then control system simplicity is maintained, but coil formation precision deteriorates due to speed mismatches
Solution Approach 1:
The control system automatically performs speed matching between the laying head and the material being processed. The controller continuously monitors material speed and self-adjusts the laying head speed reference, eliminating the need for manual operator intervention while maintaining precise ring formation and position accuracy.
Solution Approach 2:
The system implements dynamic speed control where the laying head speed reference is continuously adjusted to match changing material speeds. This dynamic adaptation ensures that the laying head remains synchronized with the material flow under varying processing conditions, maintaining precise coil formation without requiring complex manual control procedures.
Data Source
AI summary
Disclosed is a system for automating and optimizing coil formation in a wire rod cooling conveyor comprising: (a) a speed measuring device (e.g., a laser velocometer) measuring a speed of a material entering a laying head; (b) a processor that: (1) receives, as input, the speed measured in (a), (2) computes an optimal speed of the laying head based on the received speed of the material entering the laying head; and wherein the processor dynamically computes the optimal speed of the laying head as the speed of the material changes. Also disclosed is a camera that monitors actual ring formation on the wire rod cooling conveyor at an exit point of the laying head, wherein the processor receives such monitored information from the camera and outputs a control signal to override the speed measuring device and to adjust a speed of the wire rod cooling conveyor.