Rolling Process Lubrication Control for Forward Slip Stability
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Solution Overview
Problem
The existing rolling processes face instability due to the close proximity of the neutral point to the exit position, leading to potential slippage and increased friction losses, which are not effectively managed by traditional methods.
Innovation Solution
A method and device that regulate the rolling process by adjusting the lubricant rate based on the actual and target forward slip values to optimize the position of the neutral point, using the forward slip as a controlled variable to prevent slipping and minimize friction losses, without relying on fixed mathematical models or altering existing rolling models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the neutral point is positioned closer to the exit position, then friction losses are reduced, but the rolling process becomes unstable and slippage occurs
Solution Approach 1:
The patent applies dynamics by making the lubricant application rate variable rather than constant. The lubricant rate is dynamically adjusted based on real-time measurement of the neutral point position, allowing the system to adapt to changing rolling conditions and maintain optimal friction levels without causing instability or slippage.
Solution Approach 2:
The patent implements feedback control by measuring the actual neutral point position during the rolling process and using this information to regulate the lubricant application rate. This closed-loop feedback mechanism ensures that the neutral point position is maintained within an optimal range, preventing both excessive friction losses and rolling instability.
2Reliability
If the neutral point is positioned farther from the exit position, then rolling stability is improved, but friction losses increase
Solution Approach 1:
The system dynamically adjusts the lubricant application rate based on the measured neutral point position. When the neutral point moves too far from the exit, the lubricant rate is increased to reduce friction losses, while when it moves too close, the rate is decreased to maintain stability, optimizing the trade-off in real-time.
Solution Approach 2:
The patent changes the lubricant application rate parameter in response to variations in neutral point position. By adjusting this parameter dynamically, the system optimizes the balance between friction reduction and rolling stability, preventing both excessive energy loss and process instability.
3Measurement precision
If traditional mathematical models are used to control the rolling process, then process parameters can be estimated, but the models are complex and require modifications to existing rolling models
Solution Approach 1:
The patent extracts the essential control function from complex mathematical models by directly measuring the neutral point position and using this measurement to control lubricant application. This eliminates the need for complex model calculations while achieving precise control of the rolling process parameters.
Solution Approach 2:
The patent replaces complex mathematical modeling with direct physical measurement of the neutral point position. Instead of using computational models to estimate parameters, the system directly measures the actual neutral point location and uses this information for control, simplifying the overall system architecture.
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 allows for reliable detection and prevention of slippage, optimized lubricant usage, and reduced friction losses by dynamically adjusting the lubricant rate according to real-time measurements, making it suitable for existing roll trains and improving product quality without modifying the traditional rolling model.
Implementation Method 1
a lubricant rate of a lubricant is applied to the rolling material and/or to at least one working roll based on the actual forward slip value and the target forward slip value
Data Source
AI summary
A method and a regulating device for regulating a rolling process, wherein a rolling material is rolled in a rolling gap between two working rollers of a rolling stand. A target forward slip value (fs) for a forward slip (f) of the rolling material is specified, and an actual forward slip value (fM) of the forward slip (f) of the rolling material is ascertained. The forward slip (f) of the rolling material is regulated to the target forward slip value (fs) in that a lubricant rate (uR) of a lubricant is applied to the rolling material and/or at least one working roller depending on the actual forward slip value (fM) and the target forward slip value (fs).