Roll Stand Integration During Continuous Rolling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Continuous rolling trains face operational inefficiencies and quality defects due to the need for frequent roll stand replacements, which require stopping the train and result in dimensional and surface defects in the rolling stock, leading to scrap material and reduced operational efficiency.
Innovation Solution
A method for jolt-free removal and integration of roll stands during ongoing operation, where a control device coordinates load relief and application profiles across roll stands to maintain the final properties of the rolling stock, allowing for seamless transition and minimizing disruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If roll stands are replaced by stopping the continuous rolling train, then roll wear is addressed and rolls can be exchanged, but rolling defects occur and operational efficiency is reduced
Solution Approach 1:
The patent applies dynamics by making the roll stand movable rather than fixed. The roll stand can be dynamically removed from and integrated into the continuous rolling train during operation. This is achieved through a control device that coordinates the removal or integration of the roll stand with the rolling process, allowing the roll stand to be in engagement or out of engagement with the rolling stock based on operational needs without stopping the train
Solution Approach 2:
The patent applies preliminary action by performing load relief before physical removal of the roll stand. The control device controls the roll stand to be removed such that it is completely relieved of load according to a defined temporal load relief profile before removal. This ensures that the rolling stock is not affected during the exchange process
2Ease of manufacture
If roll stands are replaced by stopping the continuous rolling train, then roll wear is addressed, but dimensional defects and surface defects occur in the rolling stock
Solution Approach 1:
The continuous operation is maintained through dynamic removal and integration of roll stands. The control device coordinates the timing of roll stand removal or integration with the rolling process, ensuring that the rolling stock is not interrupted. This dynamic approach allows roll maintenance while preserving dimensional accuracy and surface quality of the rolling stock
3Productivity
If roll stands are exchanged during ongoing operation, then operational efficiency is improved, but load transfer between roll stands must be precisely controlled
Solution Approach 1:
The patent applies feedback through a control device that monitors and coordinates the load transfer process. The control device controls the roll stand to be removed according to a defined temporal load relief profile and controls at least one other roll stand according to a defined temporal load application profile. This feedback-controlled coordination ensures smooth load transfer while maintaining continuous operation
Solution Approach 2:
The patent applies parameter changes by controlling the temporal profiles of load relief and load application. The control device manages the transition of load between roll stands through defined temporal profiles, adjusting operational parameters to ensure smooth transfer without affecting the rolling stock quality
Data Source
AI summary
In mill stands of a continuous rolling train, a product passes through the train is rolled such that the product upon leaving the train has predetermined final characteristics. To remove one of the stands, the mill stand to be removed is completely relieved of load according to a defined temporal load relieving sequence. Locally simultaneously with the load relieving, at least one other mill stand is placed under load according to a defined temporal loading sequence. The load-relieving and loading sequence are mutually adjusted to preserve the final product characteristics. A circumferential roll velocity is controlled until the stand has been completely relieved such that a discharge velocity corresponds always to a predetermined desired discharge velocity. After the complete load-relieving, a correspondence of the circumferential roll velocity to the desired discharge velocity is maintained and the working rolls are lifted off. The mill stand is then deactivated.