Reversing Mill Cooling Beam Control for Strip Overheating
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Solution Overview
Problem
Reversing rolling mills experience undesirably high strip temperatures due to insufficient heat dissipation, leading to issues like strip quality degradation, equipment wear, and reduced throughput, which existing control methods fail to address effectively.
Innovation Solution
Implement a feedforward or online control method for cooling beams in a reversing rolling mill, using a sensitivity factor to adjust coolant flow rates based on strip speed and thickness to maintain a specified maximum temperature, primarily targeting outlet-side cooling beams to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling beams are added to control strip temperature, then strip temperature is reduced and quality is improved, but device complexity increases
Solution Approach 1:
The cooling system is segmented into inlet-side cooling beams and outlet-side cooling beams, allowing independent control of cooling at different locations. This segmentation enables targeted temperature management without requiring a complete system redesign, thus improving temperature control while limiting the increase in overall device complexity.
Solution Approach 2:
The control method calculates and sets cooling beam parameters (flow rates, pressures) in advance before the rolling pass begins. This preliminary action allows the system to prepare appropriate cooling settings based on predicted temperature conditions, enabling effective temperature control without requiring complex real-time adjustment mechanisms during operation.
2Temperature
If outlet-side cooling beams are activated, then strip temperature is reduced, but control complexity increases
Solution Approach 1:
The control system dynamically adjusts outlet-side cooling beam parameters based on real-time temperature measurements and process conditions. The control complexity is managed by implementing adaptive algorithms that automatically optimize cooling settings, transforming a potentially complex manual control problem into a streamlined automated process.
Solution Approach 2:
The system incorporates temperature measurement and feedback control, where actual strip temperature is measured and used to adjust cooling beam parameters. This feedback mechanism simplifies control by using actual process data to automatically optimize cooling, reducing the need for complex predictive models while maintaining effective temperature control.
3Temperature
If coolant flow rate is increased, then cooling effect is enhanced, but energy consumption increases
Solution Approach 1:
The system applies different cooling intensities to different locations and times based on actual temperature needs. Inlet-side cooling beams operate at baseline settings while outlet-side cooling beams are activated only when and where temperature exceeds thresholds. This localized, demand-based approach maximizes cooling effectiveness while minimizing overall energy consumption compared to uniform high-intensity cooling.
Solution Approach 2:
The control method dynamically changes coolant flow rate parameters based on strip temperature conditions, rolling speed, and pass characteristics. By adjusting flow rates to match actual cooling requirements rather than maintaining constant high flow, the system achieves effective temperature control while optimizing energy consumption.
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
Effectively controls strip temperature within desired limits, enhancing strip quality and reducing equipment wear while maintaining mill throughput with minimal computational and structural changes.
Implementation Method 1
The cooling beam(s) are(are) for applying coolant to an underside of the strip, which coolant is(are) supplied by the cooling beam(s)... The application of the cooling beam to the underside of the strip serves to achieve a temperature change ΔT in the strip
Implementation Method 2
dissipate the resulting forming heat
Implementation Method 3
by means of which lubrication and cooling of the work rolls or the roll gap takes place... dissipate the resulting forming heat
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method for cold rolling a strip 2 in a reversing rolling mill 1 is carried out according to the invention by means of a feedforward control or by means of an online control for at least one cooling beam 20, 21 of the reversing rolling mill 1, such that a predetermined maximum temperature Tmax is not exceeded by the strip 2. The cooling beam 20, 21 is configured to apply coolant 22 to an underside of the strip 2 during cold rolling as it exits a group of rolling stands 10, 11. The feedforward control or the online control of the cooling beam is carried out with the aid of a sensitivity σ, which depends on a flow rate Φ of coolant through the cooling beam 20, 21, a strip speed vB and a strip thickness dB and is known in advance. Further second setup values Σi determined for the rolling process of the strip 2 are not influenced by the feedforward control or the online control according to the invention.