Cold Rolling Mill Emulsion Concentration for Vibration Suppression
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Solution Overview
Problem
Current cold continuous rolling mills face vibration issues due to inconsistent emulsion concentration across stands, leading to inefficiencies and economic losses, as they rely on constant concentration control rather than optimizing emulsion concentration to manage lubrication status effectively.
Innovation Solution
A method for optimizing emulsion concentration in each stand of a cold continuous rolling mill by calculating and adjusting the emulsion concentration based on specific parameters and conditions to achieve optimal lubrication status, using a comprehensive optimization target function and control system to minimize vibration and improve production efficiency.
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, but vibration suppression is ineffective and production efficiency is limited
Solution Approach 1:
The patent divides the cold continuous rolling mill set into multiple stands (typically 4-6 stands) and optimizes the emulsion concentration for each stand independently based on its specific rolling conditions, rather than using a uniform concentration across all stands. This segmentation allows each stand to have tailored lubrication parameters that effectively suppress vibrations specific to that stand's operating conditions.
Solution Approach 2:
The patent transitions from static constant concentration control to dynamic optimization by calculating and adjusting emulsion concentration based on varying rolling parameters such as rolling force, strip speed, thickness reduction, and temperature. The emulsion concentration becomes a dynamic variable that adapts to changing rolling conditions to maintain optimal lubrication and suppress vibrations.
2Reliability
If emulsion concentration is increased to improve lubrication, then friction coefficient decreases, but slip occurs leading to self-excited vibration
Solution Approach 1:
The patent changes the emulsion concentration parameter within an optimal range (typically 5-15%) rather than simply increasing it. By precisely controlling the concentration parameter and its distribution across different stands, the system achieves the right balance between reducing friction coefficient and preventing slip-induced vibrations.
Solution Approach 2:
The patent establishes a feedback mechanism where rolling parameters (force, speed, temperature, vibration levels) are continuously monitored and used to adjust emulsion concentration in real-time. This closed-loop control ensures that lubrication remains optimal without causing slip or vibrations, as the system responds to actual operating conditions.
3Object-generated harmful factors
If emulsion concentration is decreased to prevent slip, then friction coefficient increases, but oil film cracks causing periodic fluctuation of system stiffness and vibration
Solution Approach 1:
The patent maintains emulsion concentration within an optimal range (5-15%) rather than decreasing it excessively. By optimizing the concentration parameter and its distribution across stands, the system ensures sufficient oil film thickness to prevent cracking while avoiding the harmful effects of excessive concentration.
Solution Approach 2:
The patent applies different emulsion concentrations to different stands based on their specific rolling conditions, friction requirements, and vibration characteristics. Each stand receives a locally optimized concentration that ensures adequate lubrication and oil film integrity without causing slip or vibrations.
4Reliability
If rolling speed is reduced to suppress vibration, then vibration defects are suppressed, but production efficiency and economic benefits deteriorate
Solution Approach 1:
The patent changes the emulsion concentration parameter to optimize lubrication and suppress vibrations, allowing the rolling speed to be maintained at efficient levels. By adjusting the chemical/lubrication parameters rather than mechanical speed parameters, the system achieves vibration suppression without sacrificing productivity.
Solution Approach 2:
The patent replaces mechanical vibration suppression (reducing rolling speed) with a chemical/lubrication-based approach (optimizing emulsion concentration). This substitution allows the system to maintain high rolling speeds for production efficiency while using optimized lubrication to suppress vibrations through improved friction control and oil film stability.
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 optimizes the lubrication status of roll gaps, effectively suppresses vibrations, enhances product quality, and increases production efficiency, thereby providing economic benefits to enterprises.
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
Implementation Method 3
calculating the dynamic viscosity η0i of an emulsion in a roll gap of each stand
Data Source
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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.