Roll Wear Calculation Using Sliding Zone Analysis
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Solution Overview
Problem
Existing methods inadequately determine the relative movement-dependent wear of rolls in rolling mills, which affects the quality of rolled materials and require frequent roller changes, as they cannot accurately measure wear in real-time during the rolling process.
Innovation Solution
A method that calculates the relative movement-dependent wear component by determining the sliding zone and using process variables, roll stand variables, and rolling stock variables to assess the wear, allowing for real-time monitoring and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement of roll wear is performed, then measurement precision is improved, but the rolling process must be interrupted and the roll removed from the stand
Solution Approach 1:
The patent replaces direct mechanical measurement of roll wear with an indirect calculation method using a wear model. The model computes wear based on process variables (rolling force, speed, temperature) and operating parameters (pass number, rolled section length), substituting physical measurement with computational analysis to maintain continuous production.
Solution Approach 2:
The patent introduces a wear model as an intermediary between the rolling process and wear assessment. Instead of directly measuring wear, the model acts as a mediator that calculates wear based on measurable process variables and operating conditions, enabling indirect real-time monitoring without interrupting the rolling process.
2Device complexity
If a simple wear model is used, then device complexity is reduced, but measurement precision of relative movement-dependent wear deteriorates
Solution Approach 1:
The patent segments the wear model into two distinct components: thermal wear and relative movement-dependent wear. This segmentation allows the model to address different wear mechanisms separately, improving precision for the relative movement component by specifically incorporating sliding zone length and pressure distribution while keeping the overall model structure manageable.
Solution Approach 2:
The patent enhances the wear model by introducing specific parameters for relative movement-dependent wear, including sliding zone length, pressure distribution in the roll gap, and coefficients of friction. These parameter changes enable more precise calculation of the relative movement wear component without requiring complete model redesign.
3Measurement precision
If wear is determined offline, then calculation accuracy is improved, but real-time monitoring capability is lost
Solution Approach 1:
The patent implements preliminary calculation of the wear model structure and relationships during the planning phase, with pre-defined formulas for thermal and relative movement wear components. During online operation, only the specific process variables and operating parameters need to be input, enabling real-time calculation with accuracy comparable to offline methods.
Solution Approach 2:
The patent transforms the static offline wear calculation into a dynamic online system by continuously updating the wear model with real-time process variables (rolling force, speed, temperature) and operating parameters. This dynamic approach maintains calculation accuracy while enabling real-time monitoring and control.
Data Source
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AI summary
The method involves determining roll goods variable (S2) and determining a sliding zone for each of roll goods section based on a set of process variables. The process variables are arranged in connection with roller structure variables of a roller structure. A respective relative movement dependent wear component is determined by taking length of respective sliding zone into account. A relationship is determined for the respective relative movement dependent wear component. Independent claims are also included for the following: (1) a computer program having a set of instructions for performing a method for investigating wear of a roller (2) a rolling mill.