Ring Rolling Mill Axial Roll Speed Control for Shape Precision
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Solution Overview
Problem
Ring rolling processes face instability in shape control due to variations in the roundness of the ring-shaped material, leading to elongated processing times and precision issues, as existing speed control methods are unsuitable for non-perfect circular shapes.
Innovation Solution
A ring rolling mill equipped with a speed control unit that measures the diameter at predetermined intervals, compares the measurements, and adjusts or maintains the axial roll speed based on the comparison results, avoiding impractical shape changes and stabilizing control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the speed of axial rolls is controlled based on diameter measurements during ring rolling, then the manufacturing precision and shape control are improved, but the device complexity increases due to the need for measuring rolls and speed control units
Solution Approach 1:
The patent implements a feedback control system where the measuring roll continuously monitors the diameter of the ring-shaped material during rolling, and the speed control unit adjusts the rotational speed of axial rolls based on the measured diameter to maintain shape precision. This closed-loop feedback mechanism resolves the contradiction by systematically managing the increased device complexity to achieve superior manufacturing precision.
Solution Approach 2:
The patent replaces traditional mechanical speed control methods with a control system that uses electrical signals from the measuring roll to dynamically adjust axial roll speeds. This substitution of mechanical control with an automated measurement-and-control system resolves the contradiction by managing complexity through automation rather than mechanical adjustment mechanisms.
2Device complexity
If the ring-shaped material is rolled using conventional methods without diameter measurement and speed adjustment, then the device complexity is low, but the manufacturing precision and shape control deteriorate due to variations in roundness
Solution Approach 1:
The patent implements a feedback control system where the measuring roll continuously monitors the diameter of the ring-shaped material during rolling, and the speed control unit adjusts the rotational speed of axial rolls based on the measured diameter to maintain shape precision. This closed-loop feedback mechanism resolves the contradiction by systematically managing the increased device complexity to achieve superior manufacturing precision.
Solution Approach 2:
The patent replaces traditional mechanical speed control methods with a control system that uses electrical signals from the measuring roll to dynamically adjust axial roll speeds. This substitution of mechanical control with an automated measurement-and-control system resolves the contradiction by managing complexity through automation rather than mechanical adjustment mechanisms.
3Manufacturing precision
If the axial rolls speed is frequently adjusted to maintain shape control, then the manufacturing precision is improved, but the productivity decreases due to extended processing times
Solution Approach 1:
The patent implements dynamic speed control where the rotational speed of axial rolls is continuously adjusted based on real-time diameter measurements. This dynamic adjustment allows the system to maintain manufacturing precision while adapting to changing material conditions, resolving the contradiction by making the control system flexible rather than static or overly frequent in adjustments.
Solution Approach 2:
The patent changes the operational parameters of axial rolls (rotational speed) based on measured diameter values to maintain optimal shaping conditions. By dynamically changing this parameter in response to actual material conditions rather than using fixed or frequently adjusted speeds, the system achieves precision without unnecessarily reducing productivity.
4Ease of operation
If the ring rolling process uses a simple speed control method, then the ease of operation is high, but the reliability of shape control deteriorates due to inability to handle non-perfect circular shapes
Solution Approach 1:
The patent implements a feedback control system where the measuring roll continuously monitors the diameter of the ring-shaped material during rolling, and the speed control unit adjusts the rotational speed of axial rolls based on the measured diameter to maintain shape precision. This closed-loop feedback mechanism resolves the contradiction by systematically managing the increased device complexity to achieve superior manufacturing precision.
Solution Approach 2:
The control system automatically adjusts axial roll speeds based on real-time diameter measurements without requiring manual intervention or complex operator judgment. The system serves itself by using its own measurement data to make control decisions, resolving the contradiction by making the system self-regulating rather than relying on simple manual control that cannot handle shape variations.
Data Source
AI summary
A ring rolling mill includes: a rotary drive main roll and a mandrel roll, which are for reducing the thickness of and rolling a ring-shaped material from the radial direction; a pair of rotary drive axial rolls for reducing the thickness of and rolling the ring-shaped material from the axial direction; a measuring roll for measuring the diameter of the ring-shaped material during rolling; and a speed control unit for controlling the speed of the axial rolls. The speed control unit is configured to repeat measuring the diameter at predetermined time intervals Δt and comparing a measurement value Lt of the diameter at time t and a measurement value Lt+Δt of the diameter at time t+Δt, and the speed control unit is further configured to maintain the speed of the axial rolls unchanged upon the result of the comparison being Lt+Δt<Lt.