Metal Workpiece Processing with Segment-Specific Physical Data
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Solution Overview
Problem
Existing metal workpiece production methods lack precision in processing, as they do not account for segment-specific physical properties of the material, leading to inefficiencies and potential defects in the final product.
Innovation Solution
A method that involves logically dividing a finished metal material into segments and assigning first physical data to each segment, allowing for segment-specific control of processing parameters such as rolling speed, thickness, and annealing temperature, to produce a desired metal workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional uniform processing is used for the entire finished material, then the processing process is simple and fast, but the processing precision and product quality deteriorate due to ignoring segment-specific physical properties
Solution Approach 1:
The finished material is divided into multiple segments along its length, with each segment assigned specific physical data (thickness, width, temperature, material composition). This segmentation allows the processing system to treat different portions of the material differently, applying segment-specific processing parameters to achieve precise control over the final product quality while maintaining a manageable control structure through modular segment handling.
Solution Approach 2:
The patent implements local quality by assigning unique physical characteristics to each segment of the finished material and applying corresponding localized processing parameters. Instead of uniform processing, the system adjusts rolling speed, pressure, and other parameters based on the specific properties of each segment, ensuring that each portion of the material receives optimal processing tailored to its individual characteristics.
2Manufacturing precision
If segment-specific processing control is implemented, then product quality and processing precision improve, but the complexity of the processing system increases
Solution Approach 1:
The patent uses digital copying by creating a virtual representation (data model) of the finished material's physical properties along its length. This digital twin contains segment-specific information about thickness, width, temperature, and material composition, which can be stored, transmitted, and processed without requiring complex physical measurement systems at every processing station. The digital copy guides the physical processing system, reducing the need for redundant sensors and control hardware.
Solution Approach 2:
The physical data of the finished material is determined and stored before the actual processing begins. This preliminary characterization of the material allows the processing system to be pre-configured with segment-specific parameters, eliminating the need for real-time complex measurements and adjustments during processing. The system prepares the processing plan in advance based on the known material properties.
3Productivity
If physical data of finished material is determined and used for processing control, then processing efficiency and material utilization improve, but measurement and data collection requirements increase
Solution Approach 1:
The patent performs material characterization (determining physical data such as thickness, width, temperature, and composition) before the processing operation begins. This preliminary measurement and data collection allows the processing system to operate with pre-known material properties, reducing the need for complex real-time measurement systems during processing. The data is collected once and reused for multiple processing decisions.
Solution Approach 2:
The patent introduces a data model or digital representation as an intermediary between the physical material and the processing system. Instead of requiring direct complex measurements at every processing stage, the system uses this digital intermediary that contains all necessary physical data about the material segments. This intermediary simplifies the measurement requirements by consolidating data collection into a single preliminary characterization step.
Data Source
AI summary
The invention relates to a method for producing a desired metal workpiece (134), the method comprising:producing an elongate finished material (116; 222) by hot rolling, wherein a first data record (112) is assigned to the finished material (116; 222), wherein the finished material (116; 222) is logically divided in the longitudinal direction thereof into a plurality of first segments (118), wherein the first data record, for each of the first segments (118), includes first physical data (228) characterizing the segment; andworking the finished material (116; 222) using a processing process to obtain the desired metal workpiece (134), wherein the processing process is at least partially controlled based on the first physical data (228) characterizing the first segments (118) that are logically assigned to the finished material (116; 222).