Remote Rolling Mill Control Using Real-Time Model-Based Automation

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Solution Overview

Problem

Existing systems for producing and treating metal rolled products require on-site control due to the need for fast response times, limiting remote operation and exposing control personnel to harsh conditions.

Innovation Solution

Implementing an automation system that uses sensors to detect status signals, including dimensional signals, and models the system behavior in real-time to determine control signals, transmitting these via an open data network to a human-machine interface for operator input, ensuring high reliability and low latency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If on-site control is implemented to ensure fast response times, then response speed is improved, but operator safety deteriorates due to exposure to harsh conditions

Engineering Contradiction:

Improveresponse timeVSAvoidoperator safety

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a remote control station as an intermediary between the operator and the rolling mill system. The control station communicates with the automation system via a data network, allowing operators to control the system from a safe distance while maintaining fast response times through automated model-based control that processes sensor data and generates control signals without human delay

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical presence of operators on-site with an automated control system that uses sensors, a model-based automation system, and data transmission networks. This substitution eliminates the need for operators to physically be in harsh environments while maintaining control capabilities through digital communication and automated decision-making algorithms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If remote control is implemented to improve operator safety, then operator safety is improved, but response time deteriorates due to distance from the system

Engineering Contradiction:

Improveoperator safetyVSAvoidresponse time

Core Design Contradiction:

Object-affected harmful factorsVSSpeed

Solution Approach 1:

The patent replaces the mechanical limitation of physical distance with an automated control system that uses sensors, a model-based automation system, and data transmission networks. This substitution eliminates the need for operators to physically be near the system while maintaining fast response times through automated processing of sensor data and generation of control signals

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automation system performs self-service by automatically processing sensor data, updating its internal model of the system state, and generating control signals without human intervention. This self-service capability eliminates delays associated with human reaction times while allowing operators to safely monitor and intervene when necessary through the remote control station

Inventive Principle:

Principle #25Self-service

3Speed

If on-site control is implemented to ensure fast response times, then response speed is improved, but system flexibility deteriorates due to fixed control station location

Engineering Contradiction:

Improveresponse timeVSAvoidcontrol location flexibility

Core Design Contradiction:

SpeedVSAdaptability or versatility

Solution Approach 1:

The patent introduces a data network as an intermediary that decouples the control station from the physical location of the rolling mill. The control station can be positioned anywhere within communication range of the automation system, allowing operators to control the system from remote or safe locations while maintaining fast response times through automated control processing

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The automation system serves multiple functions: it processes sensor data, maintains an internal model of the system state, generates control signals, and communicates with the control station via data network. This multi-functionality allows the system to operate autonomously while also accepting remote control inputs, providing both fast automated response and flexible operator control from various locations

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12370589B2Remote control of a plant for producing and/or treating a rolled product made of metal

Publication Date: 2025.07.29 PRIMETALS TECH GERMANY GMBH

AI summary

Sensors detect states of units of a plant for producing and/or treating a rolled product made of metal and transmit them to an automation system. The state signals (Z) are, in part, dimensional signals. The automation system determines, by taking into account the state signals (Z), control signal signals (S) for actuators associated with the units and actuates the actuators accordingly. The automation system includes at least one model-based system which models the behavior of the system and/or of the rolled product in real time. The automation system transmits the state signals (Z), the control signals (S) and/or signals derived therefrom at least in part via an open data network to a human-machine interface arranged at an operating location. The transmitted signals comprise at least one of the dimensional signals. The automation system takes specifications (V) from the human-machine interface in determining the control signals (S).