Rolling Device Backlog Detection and Flatness Control
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Solution Overview
Problem
Existing rolling devices struggle to reliably detect material backlogs in front of the roll gap, leading to irregularities in rolled material flatness and quality issues due to delayed or insufficient correction of flatness deviations.
Innovation Solution
A rolling device equipped with a measuring device to detect material backlogs in front of the roll gap, coupled with a control unit that adjusts actuators for work and backup rolls to maintain flatness, utilizing optically or mechanically sensing devices and feedback from post-gap flatness measuring devices to enable real-time correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are arranged far away from the roll gap to measure thickness profile and flatness, then measurement can be performed, but material backlog in front of the roll gap cannot be reliably detected and flatness deviations cannot be corrected in time
Solution Approach 1:
The patent places a measuring device immediately in front of the roll gap to detect material backlog before it causes flatness deviations. This preliminary detection allows the control system to take corrective action before the material passes through the roll gap, preventing quality defects rather than detecting them after the fact.
Solution Approach 2:
The patent implements a feedback control system where measuring devices detect material backlog and flatness conditions, and the control unit automatically adjusts actuators (such as work roll bending or backup roll positioning) to correct flatness deviations in real-time, creating a closed-loop control system that continuously monitors and adjusts rolling conditions.
2Ease of operation
If flatness measurements are performed after the nip, then flatness control can be implemented, but corrections are too late as deviations have already occurred
Solution Approach 1:
The patent positions measuring devices both before and after the roll gap. The device before the roll gap detects material backlog preliminarily, enabling preventive control. The device after the roll gap provides verification and additional control opportunities, ensuring flatness quality is maintained throughout the rolling process.
Solution Approach 2:
The patent uses feedback from measuring devices positioned at multiple locations to control flatness actuators. The control unit processes signals from these devices and adjusts work roll bending, backup roll positioning, or other actuators to correct flatness deviations, creating a responsive closed-loop control system that maintains manufacturing precision.
3Reliability
If measuring devices are placed close to the roll gap to detect material backlog, then timely detection is achieved, but device complexity increases
Solution Approach 1:
The patent introduces a control unit as an intermediary that receives signals from measuring devices positioned close to the roll gap and automatically actuates control elements. This intermediary component simplifies the overall system by automating the control process, reducing the need for complex manual intervention while maintaining reliable detection and correction capabilities.
Solution Approach 2:
The patent implements a self-regulating system where measuring devices detect material backlog conditions and the control unit automatically adjusts actuators to correct flatness deviations without external intervention. The system serves itself by using its own measurement data to make real-time adjustments, reducing operational complexity while maintaining high reliability.
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 reliable detection and timely correction of material backlogs, preventing flatness deficits and ensuring stable rolling conditions by allowing prompt intervention in real-time, thereby maintaining the quality of the rolled material.
Implementation Method 1
the at least one measuring device for measuring a backlog of the rolling material of the rolling stock in front of the roll gap is an optically or mechanically measuring measuring device
Data Source
Figure 1
AI summary
The invention relates to a method and a rolling device (1) comprising at least two working rolls (2, 3) and a roll gap (4) between the working rolls (2, 3) for leading through and rolling rolled stock (5), such as for example a strip (6), preferably of metal, and possibly comprising an arrangement of supporting rolls (7, 8), wherein at least one measuring device (11) is also provided, for measuring a backward slip of the rolled material of the rolled stock before the roll gap (4), and wherein an open-loop or closed-loop control unit (13) is also provided, activating final control elements for setting the flatness of the rolled stock on the basis of the signals from the measuring device (11).