Cold Rolling Mill Emulsion Flow Control for Vibration Suppression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cold continuous rolling mills face challenges in suppressing vibrations, which affect production efficiency and surface quality, due to inadequate control over lubrication states between roll gaps, leading to either slip or increased friction and periodic fluctuations.
Innovation Solution
An emulsion flow optimization method that calculates optimal emulsion flow rates for each rolling stand based on oil film thickness and friction coefficient models, using device and process parameters to maintain optimal lubrication states, thereby reducing vibrations and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the rolling mill speed is controlled to suppress vibration defects, then the vibration defects can be weakened, but the production efficiency is restricted
Solution Approach 1:
The invention changes the control parameter from rolling mill speed to emulsion flow rate. By adjusting the emulsion flow rate to optimize lubrication conditions (controlling friction coefficient and oil film thickness), the system suppresses vibration defects without restricting production efficiency, as the rolling mill can operate at optimal speeds while emulsion parameters are tuned for vibration suppression.
2Reliability
If the roll gap is in an over-lubrication state with too small friction coefficient, then slip occurs causing self-excited vibration, but if the roll gap is in an under-lubrication state with insufficient oil film thickness, then friction coefficient sharply increases causing periodic fluctuation of system stiffness and self-excited vibration
Solution Approach 1:
The invention implements feedback control by continuously monitoring lubrication parameters (friction coefficient, oil film thickness) and adjusting emulsion flow rate accordingly. The system uses the relationship between emulsion flow rate and lubrication state to maintain optimal conditions, preventing both over-lubrication and under-lubrication states that lead to self-excited vibration.
Solution Approach 2:
The invention dynamically adjusts emulsion flow rate parameters to maintain optimal lubrication conditions. By changing emulsion concentration, temperature, and flow rate, the system optimizes the friction coefficient and oil film thickness to prevent self-excited vibration while ensuring stable lubrication state.
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
The method significantly reduces vibration defects, enhances production efficiency, and improves the stability and quality of finished strips by optimizing emulsion flow rates, leading to greater economic benefits for enterprises.
Implementation Method 1
the rolling mill vibration is directly related to the lubrication state between the roll gaps
Implementation Method 2
it is likely to cause sharp increase of the friction coefficient due to rupture of oil films in the roll gaps
Data Source
AI summary
An emulsion flow optimization method suitable for a cold continuous rolling mill that aims to achieve vibration suppression. The method aims to suppress vibrations by an oil film thickness model and a friction coefficient model. An optimum set value of the emulsion flow rate for each rolling stand that aims to achieve vibration suppression is optimized on the basis of an over-lubrication film thickness critical value and an under-lubrication film thickness critical value that are proposed. The method greatly reduces the incidence of rolling mill vibration defects, improves production efficiency and product quality, treats rolling mill vibration defects, and improves the surface quality and rolling process stability of a finished strip of a cold continuous rolling mill.