Rolling Mill Edge Crack Control Through Adaptive Rolling Conditions
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Solution Overview
Problem
Existing techniques for detecting edge cracks in metal plates during rolling mill processes can only detect cracks but fail to prevent their growth, leading to potential breakage.
Innovation Solution
A control device for a rolling mill apparatus that includes an edge crack sensor and a control system to adjust rolling conditions from a first condition to a second condition capable of suppressing edge crack growth upon detection, using a detection signal acquisition part and a rolling condition decision part to manage tension and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an edge profile meter is disposed on the output side of the rolling mill process line to detect edge cracks, then edge crack detection is achieved, but the metal plate may break during mill rolling due to undetected crack growth
Solution Approach 1:
The patent applies preliminary action by detecting edge cracks at the upstream end of the metal plate before the crack can grow to a critical size that would cause breakage during rolling. The edge crack sensor is positioned to detect cracks early in the rolling process, allowing preventive measures to be taken before the crack propagates further.
Solution Approach 2:
The patent implements feedback by using the detection signal from the edge crack sensor to automatically adjust rolling conditions in real-time. When a crack is detected, the control device modifies rolling parameters such as speed or tension to suppress crack growth, creating a closed-loop control system that responds to actual crack conditions.
2Productivity
If rolling conditions are maintained at high speed to improve productivity, then production efficiency increases, but edge crack growth is accelerated leading to potential breakage
Solution Approach 1:
The patent applies dynamics by making the rolling conditions adjustable and responsive rather than fixed. The control device can dynamically change rolling parameters based on real-time crack detection signals, allowing the system to optimize between productivity and crack suppression by adjusting speed or tension according to actual crack conditions.
Solution Approach 2:
The patent implements parameter changes by modifying rolling conditions such as rolling speed or applied tension when edge cracks are detected. The control device adjusts these physical parameters to suppress crack growth, demonstrating how changing operational parameters can mitigate harmful effects while maintaining overall process efficiency.
Data Source
AI summary
A control device for a rolling mill apparatus including at least one rolling mill stand for rolling a metal plate includes: a detection signal acquisition part for receiving, from an edge crack sensor, a detection signal of an edge crack at an end portion of the metal plate in a plate width direction; and a rolling condition decision part for deciding a rolling condition for the rolling mill apparatus. The rolling condition decision part is configured to change, if the detection signal acquisition part receives the detection signal of the edge crack, the rolling condition for the rolling mill apparatus from a first rolling condition immediately before detection of the edge crack to a second rolling condition which is more capable of suppressing growth of the edge crack than the first rolling condition.