Leveling Machine Drive Control for Balanced Sheet Stress
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Solution Overview
Problem
Current leveling machines for sheet material often face inefficiencies in stress distribution and energy consumption due to the independent operation of drives, leading to uneven deformation and curvature correction processes.
Innovation Solution
A control method and machine configuration where the first and second drives are independently controlled using torque setpoint signals based on error signals and an additional torque gain, ensuring equitable stress distribution and optimized energy use by adjusting the torque applied to each drive according to the difference between setpoint and actual speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the first and second drives are operated independently with basic speed control, then each drive can be controlled separately, but the stress distribution becomes uneven and energy consumption increases
Solution Approach 1:
The control method employs feedback mechanisms where the actual speeds of the first and second drives are continuously measured and compared against the setpoint speed. Error signals are generated from these comparisons and fed back to adjust the torque setpoint signals, creating a closed-loop control system that optimizes energy consumption while maintaining independent drive control capability
Solution Approach 2:
The invention dynamically changes the torque parameter by applying different torque setpoint signals to the first and second drives based on their respective error signals. The second drive receives an additional torque gain to enhance its pulling capability, while the first drive's torque is adjusted based on its speed error, allowing optimized stress distribution and energy efficiency
2Ease of operation
If the first and second drives are operated independently with basic speed control, then each drive can be controlled separately, but the stress distribution becomes uneven
Solution Approach 1:
The control method applies different torque control strategies to different parts of the system - the first drive receives a torque setpoint signal based on its speed error, while the second drive receives an additional torque gain beyond its speed error-based signal. This local differentiation of control quality ensures equitable stress distribution across the sheet material while preserving independent drive control
Solution Approach 2:
Feedback loops continuously monitor the speeds of both drives and adjust their respective torque setpoint signals accordingly. This feedback mechanism ensures that stress is distributed equitably between the two drives during operation, preventing uneven stress concentration while maintaining operational independence
3Manufacturing precision
If the second drive operates at setpoint speed to measure first torsion torque value, then the torsion torque relationship can be established, but the system requires complex torque measurement and coordination
Solution Approach 1:
The control system uses feedback from measured speeds to continuously adjust torque setpoint signals, replacing complex direct torque measurement and coordination with a more manageable speed-based feedback control approach that achieves precise torsion torque control
Solution Approach 2:
The invention introduces speed measurements and error signals as intermediary variables that mediate between the control inputs and the actual torque application. This intermediary layer simplifies the control architecture by using easily measurable speed parameters rather than requiring direct torque sensing and coordination
Data Source
AI summary
A method that includes moving a sheet material between first and second groups of rolls following a winding path according to a setpoint speed, driving the first group of rolls by a first drive, driving the second group by a second drive independent of the first drive, measuring the speed of the first drive, measuring the speed of the second drive controlling the speed of the first drive by means of a first torque setpoint signal which is a function of a first error signal obtained from the difference between the setpoint speed and the speed of the first drive, and controlling the speed of the second drive by means of a second torque setpoint signal which is a function of a second error signal obtained from the difference between the setpoint speed and the speed of the second drive, and is also a function of an additional torque gain.