Rolling Mill Cooling Unit Diagnosis Using Strip Flatness Response
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Solution Overview
Problem
Current methods for detecting faulty cooling units in rolling mills are time-consuming and require manual labor, as they rely on offline visual inspections of spray patterns, which are inefficient for real-time monitoring and quality control.
Innovation Solution
A method that varies the coolant flow rate across cooling units and measures the resulting flatness variation of the work item, comparing these values to a reference to detect faulty units, allowing for on-line diagnostics and improved automation without extensive prior reference measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If offline visual inspection of spray patterns is performed, then cooling unit faults can be detected, but the process is time-consuming and requires manual labor
Solution Approach 1:
The patent replaces manual visual inspection with an automated measurement system that uses sensors to detect flatness variations in the work item. This substitution of mechanical/manual inspection with automated sensing technology eliminates the need for manual labor and significantly reduces inspection time while maintaining or improving detection accuracy.
Solution Approach 2:
The system enables self-diagnosis of cooling unit faults by automatically measuring flatness variations and comparing them against reference values. The process does not require external manual intervention - the system performs its own diagnostics continuously during operation, transforming a manual inspection task into an automated self-monitoring function.
2Reliability
If offline inspection methods are used, then cooling system faults can be identified, but real-time monitoring and quality control are inefficient
Solution Approach 1:
The patent implements continuous online measurement of work item flatness during the rolling process, rather than periodic offline inspections. This continuous monitoring allows real-time detection of cooling unit faults, enabling immediate quality control actions and significantly improving productivity by eliminating downtime associated with offline inspection cycles.
Solution Approach 2:
The system establishes a feedback loop where flatness measurements are continuously taken, compared against reference values, and used to automatically identify cooling unit faults. This closed-loop feedback mechanism enables real-time quality control and rapid response to deviations, transforming offline batch inspection into continuous online quality management.
3Reliability
If manual visual inspection is performed, then cooling unit performance can be evaluated, but automation is limited
Solution Approach 1:
The patent replaces manual visual evaluation with automated sensor-based measurement systems that objectively quantify flatness variations. This substitution eliminates subjectivity in manual assessment and enables full automation of the diagnostics process, allowing computers to automatically detect, measure, and report cooling unit faults without human intervention.
Solution Approach 2:
The system performs self-diagnosis by automatically comparing measured flatness values against reference values and identifying faulty cooling units. The process is fully automated and does not require manual evaluation or interpretation, transforming a semi-manual assessment process into a completely automated diagnostic system.
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
Enables real-time detection of faulty cooling units, enhancing the quality control of metal rolling products by automatically identifying deviations in flatness variation, thus improving the efficiency and accuracy of thermal control in rolling mills.
Implementation Method 1
Cooling system often include nozzles arranged to spray a cooling fluid onto the work rolls
Implementation Method 2
Cooling system often include nozzles arranged to spray a cooling fluid onto the work rolls
Implementation Method 3
The flatness value may be derived from a transversal strain profile of the work item calculated from a measured work item tension profile
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present invention is related to a method for detecting a faulty cooling unit in a set of cooling units (106a) configured to provide a coolant to work rolls (100a) arranged to process a work item (102) therebetween, the method comprising: varying the flow rates of the coolant ejected from a sub-set of the cooling units; in response to varying the flow rates, determining a flatness variation value of the work item for at least each of the cooling units in the sub-set of cooling units, the flatness variation value being indicative of the work item flatness variation downstream of the work rolls; and detecting a faulty cooling unit based on comparing the flatness variation values to a reference flatness variation value.