Cold Rolling Mill Emulsion Control for Vibration Suppression
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Solution Overview
Problem
Current methods for controlling emulsion concentration in cold continuous rolling mills rely on constant concentration control, which fails to optimize lubrication status in each stand, leading to vibration issues, affecting production efficiency and product quality.
Innovation Solution
A method that optimizes emulsion concentration in each stand by calculating and adjusting the emulsion concentration based on specific parameters such as bite angle, vibration determination index, and oil film thickness to maintain a reasonable lubrication status, using a comprehensive optimization target function to determine the optimal concentration value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant concentration control of emulsion is used in each stand, then the control system is simple and easy to operate, but the lubrication status cannot be optimized leading to vibration issues
Solution Approach 1:
The patent transforms the static constant concentration control into a dynamic optimization system where emulsion concentration is continuously adjusted based on real-time parameters. The control system dynamically calculates optimal concentration for each stand using vibration determination index, bite angle, and oil film thickness, then adjusts concentration accordingly to suppress vibrations while adapting to changing rolling conditions.
Solution Approach 2:
The patent changes the emulsion concentration parameter from a fixed constant to a variable that is optimized for each stand based on specific rolling parameters. By calculating the optimal concentration that satisfies vibration suppression requirements and adjusting the concentration parameter dynamically, the system resolves the contradiction between simple control and effective vibration suppression.
2Reliability
If emulsion concentration is increased to improve lubrication, then oil film thickness increases, but friction coefficient becomes too small causing slip and self-excited vibration
Solution Approach 1:
The patent introduces a feedback mechanism where the control system continuously monitors rolling parameters, calculates the vibration determination index and oil film thickness, and adjusts emulsion concentration based on this feedback. The system detects when oil film thickness approaches optimal values and reduces concentration to prevent excessive lubrication, thereby avoiding slip and self-excited vibration while maintaining oil film stability.
Solution Approach 2:
The patent applies partial action by precisely controlling emulsion concentration to achieve just the right amount of lubrication needed. Instead of uniformly high concentration, the system calculates and applies the minimal necessary concentration to maintain stable oil film thickness, preventing over-lubrication conditions that cause vibration while ensuring adequate lubrication.
3Object-generated harmful factors
If emulsion concentration is decreased to reduce friction, then slip is reduced, but oil film thickness becomes insufficient causing film cracking and friction increase
Solution Approach 1:
The control system continuously monitors oil film thickness and provides feedback to adjust emulsion concentration. When oil film thickness approaches minimum safe values, the system increases concentration to prevent film cracking. This feedback loop ensures oil film integrity is maintained while friction is kept at optimal levels, preventing the harmful cycle of film cracking and friction increase.
Solution Approach 2:
The patent applies preliminary action by proactively adjusting emulsion concentration before oil film thickness becomes insufficient. The system calculates predicted oil film thickness based on current parameters and pre-adjusts concentration to prevent film cracking before it occurs, maintaining both friction stability and oil film integrity.
4Reliability
If rolling speed is reduced to suppress vibration, then vibration defects are minimized, but production efficiency deteriorates
Solution Approach 1:
The patent changes the control parameter from rolling speed to emulsion concentration. Instead of reducing speed to suppress vibration, the system optimizes concentration for each stand based on vibration determination index and rolling parameters. This parameter substitution allows maintaining high rolling speeds for production efficiency while achieving vibration suppression through precise concentration control.
Solution Approach 2:
The patent replaces the mechanical approach of speed reduction with a chemical/lubrication approach. Instead of mechanically slowing down the rolling process to suppress vibration, the system uses emulsion concentration optimization to achieve vibration suppression, thereby substituting a mechanical control method with a lubrication-based method that preserves production efficiency.
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
This approach effectively suppresses vibrations in the rolling mill, improves product quality, and enhances production efficiency, providing economic benefits by optimizing the lubrication status in each stand.
Implementation Method 1
the lubrication status of the roll gap directly affects the occurrence of vibration defects of the rolling mill
Implementation Method 2
If the roll gap is in an over-lubricated status, the friction coefficient is too small, which is likely to cause slip in the rolling process
Data Source
AI summary
Disclosed is a method of emulsion concentration optimization for a cold continuous rolling mill set for achieving vibration suppression, the method comprising: defining the process parameters involved in the process of emulsion concentration optimization; setting an initial set value of an emulsion concentration comprehensive optimization target function for a cold continuous rolling mill set for achieving vibration suppression; calculating a bite angle of each stand; calculating a vibration determination index reference value of each stand; setting the emulsion concentration of each stand; calculating the outlet temperature of a strip steel of each stand; calculating the dynamic viscosity of an emulsion in a roll gap of each stand; calculating the oil film thickness in the roll gap of each stand; calculating the emulsion concentration comprehensive optimization target function; determining whether the inequation F(X)<F0 is established; determining whether the concentration of the emulsion exceeds a feasible region range, and outputting the optimal emulsion concentration set value.