Rolling Mill Automation Prioritization for Flexible Optimization Goals
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Solution Overview
Problem
Existing automation solutions for metallurgical plants, particularly rolling mills, lack flexibility in adjusting optimization goals to accommodate varying utilization needs, such as energy efficiency, productivity, and product quality, especially during planned or unplanned downtimes.
Innovation Solution
A multi-stage control system with Level 1, Level 2, and optionally Level 3 automation, incorporating a prioritization system that allows users to select and prioritize different optimization strategies, including manual, rule-based, or AI-driven methods, to adjust operating parameters and goals like CO2 efficiency, energy efficiency, and product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing automation solutions are designed for full plant capacity, then productivity is optimized, but adaptability to varying utilization needs deteriorates
Solution Approach 1:
The automation system dynamically adjusts optimization goals based on current plant utilization. The control system transitions between different optimization modes (productivity-oriented at full capacity, efficiency-oriented at partial capacity) rather than being fixed for full capacity operation. This dynamic adaptation resolves the contradiction by making the system flexible while maintaining high productivity when needed.
Solution Approach 2:
The system changes operational parameters and optimization criteria based on plant utilization level. At full capacity, the system optimizes for productivity with aggressive process parameters. At partial capacity, it shifts to optimizing for energy efficiency and resource consumption with modified parameters. This parameter adaptation enables both high productivity when required and flexibility across different utilization scenarios.
2Loss of energy
If automation is optimized for energy efficiency during downtime, then energy consumption is reduced, but productivity deteriorates
Solution Approach 1:
The automation system dynamically switches between energy-saving mode during shutdowns and productivity-maximization mode during operation. The same automated control system adapts its optimization criteria based on operational state, enabling energy efficiency during downtime without permanent loss of productivity capability when the plant resumes full operation.
Solution Approach 2:
The system applies different optimization strategies periodically based on operational requirements. During shutdown periods, energy efficiency is prioritized. During operational periods, productivity is prioritized. This periodic switching of optimization goals allows the system to minimize energy loss during necessary downtime while maintaining high productivity during production periods.
3Manufacturing precision
If a comprehensive hierarchical control structure is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies a universal automated control architecture that handles multiple functions across different plant utilization scenarios. The same control system performs both productivity optimization and energy efficiency optimization, and manages transitions between different operational modes. This multi-functionality reduces the need for separate specialized control systems for each scenario, thereby reducing overall device complexity while maintaining manufacturing precision through consistent automated control.
Data Source
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AI summary
The invention relates to a method for automating a metallurgical installation, in particular an installation for rolling metal strips, comprising at least one rolling mill line having at least one mill stand, wherein: the method is carried out using a multi-stage control system comprising at least a level-1 automation, a level-2 automation and, optionally, a level-3 automation; in the level-2 automation, a preliminary calculation of the operating variables of the installation in the form of set-point values for the level-1 automation is carried out, and the method is also carried out using a prioritisation system (1) that is higher-level than the control system; and the prioritisation system makes and/or allows the selection of predefined automation goals for operating the installation using different, higher-level optimisation strategies, and the prioritisation system produces optimisation targets corresponding to the selected automation goal and transfers these targets to the level-1 and/or level-2 automation.