Plating Adhesion Control Using Upstream-Downstream Position Matching

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Solution Overview

Problem

In molten metal plating facilities, the existing techniques face challenges in accurately controlling the plating adhesion amount due to mismatched positions for estimation and measurement, leading to reduced control accuracy, especially when steel strips meander or have different thicknesses, resulting in slow response times for adjusting gas blow pressure.

Innovation Solution

A plating adhesion amount control mechanism that includes upstream and downstream edge sensors and a control system to align the measurement surface portions, using nozzle-strip distance, gas blow pressure, and strip passing speed to calculate and correct the plating adhesion amount estimation, ensuring accurate control by matching the estimation and measurement positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the plating adhesion amount is controlled using a downstream measurement position, then the measurement can be performed after the steel strip has been processed, but the control accuracy deteriorates due to position mismatch between estimation and measurement

Engineering Contradiction:

Improvecontrol accuracyVSAvoidposition matching accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The invention uses upstream edge sensors to detect the position of the steel strip at the upstream position, then calculates the corresponding downstream position based on the measured distance. This creates a virtual copy of the upstream measurement position at the downstream location, allowing the plating adhesion amount meter to measure at the calculated position rather than a fixed downstream position, thereby resolving the position mismatch problem

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The invention introduces an intermediate calculation process that uses the upstream edge sensor detection results and the measured distance between upstream and downstream positions to determine the optimal measurement position. This intermediary calculation acts as a mediator that bridges the gap between the fixed downstream measurement device and the variable steel strip position

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the steel strip meanders or has varying thickness, then the position of the steel strip changes, but the fixed downstream measurement position cannot adapt, resulting in slow response time for control adjustments

Engineering Contradiction:

Improveresponse speedVSAvoidadaptation to strip variation

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The invention transforms the static downstream measurement position into a dynamic position that adapts to steel strip variations. By continuously detecting the upstream edge position and calculating the corresponding downstream position based on real-time distance measurements, the system dynamically adjusts the measurement location to match the actual steel strip position, enabling rapid response to meandering and thickness variations

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention performs preliminary detection of the steel strip position using upstream edge sensors before the steel strip reaches the downstream measurement position. This advance detection allows the system to pre-calculate the optimal measurement position and prepare for accurate measurement, reducing the response time when the steel strip actually passes the measurement point

Inventive Principle:

Principle #10Preliminary action

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 improves the control accuracy of the plating adhesion amount by aligning the estimation and measurement positions, enabling faster and more precise adjustments to match target values, even with varying steel strip conditions.

Implementation Method 1

The nozzle-strip distance is detected by a distance sensor disposed near the gas wiping nozzles

Methodology Applied

Scientific EffectDistance detection:

Implementation Method 2

The plating adhesion amount meter is a fluorescence X-ray adhesion amount meter, for instance, and measures the plating adhesion amount of the front surface and the back surface of the steel strip

Methodology Applied

Scientific EffectFluorescence X-ray: Fluorescence

Implementation Method 3

Gas wiping nozzles blow gas onto the strip surfaces (front surface and back surface) of the steel strip that is transferred upward, and remove molten motel adhering to the front surface and the back surface

Methodology Applied

Scientific EffectGas blowing:

Data Source

PatentUS11248288B2Plating adhesion amount control mechanism and method for controlling an adhesion amount by comparing a plating adhesion amount estimation value at an upstream position and a plating adhesion actual amount at a downstream position

Publication Date: 2022.02.15 PRIMETALS TECHNOLOGIES JAPAN LTD

AI summary

When a portion for measuring the plating adhesion amount reaches an upstream side position, plating adhesion amount estimation values are calculated by using a plating adhesion amount estimation expression at positions away from a position that faces the distance sensors, that is, the upstream side position, by strip-width direction distances, of the surfaces of the steel strip. When the portion for measuring the plating adhesion amount reaches a downstream side position, the strip-width direction distances of the plating adhesion amount meters are matched to the strip-width direction distances, and the plating adhesion amount actual measurement values are obtained. The plating adhesion amount estimation expression is corrected on the basis of the differences between the plating adhesion amount estimation values and the plating adhesion amount actual measurement values. Accordingly, the control accuracy of the plating adhesion amount is improved.