Rolling Mill Model Parameter Determination via Process Observer
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Solution Overview
Problem
Existing methods for simulating and operating rolling mills struggle with accurately determining and adjusting parameters for mathematical models, leading to deviations between calculated and actual values, especially in the presence of disruptions like roll slipping, which are not accounted for in real-time control and regulation.
Innovation Solution
A method for determining and adjusting parameters of a rolling mill model by comparing measured and calculated actual values, using a process observer to generate an error signal that indicates deviations, allowing for immediate real-time intervention and parameter refinement through iterative comparison and adjustment using a digital computing device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real-time simulation and control of rolling mill operations is implemented, then operational stability and control accuracy are improved, but parameter determination accuracy deteriorates due to disruptions like roll slipping that are not accounted for in real-time control
Solution Approach 1:
The patent applies preliminary action by using historical process data from previous rolling operations to pre-determine and adjust model parameters before real-time control begins. This allows the system to account for disruptions like roll slipping that cannot be detected in real-time, thereby improving parameter determination accuracy while maintaining operational stability during actual rolling operations.
2Measurement precision
If model parameters are adjusted to account for disruptions like roll slipping, then parameter determination accuracy is improved, but device complexity increases due to the need for additional data processing and iterative adjustment mechanisms
Solution Approach 1:
The patent implements feedback by using measured actual values from rolling operations to compare against calculated values from the simulation model. The differences (deviations) are fed back to iteratively adjust the model parameters, creating a closed-loop system that continuously improves parameter accuracy without requiring complex real-time intervention mechanisms.
Solution Approach 2:
The patent uses copying by creating a mathematical replica (simulation model) of the rolling mill that can be adjusted independently of the actual physical system. This allows parameter determination and adjustment to be performed on the digital copy using historical data, avoiding the need for complex real-time modifications to the physical rolling mill system.
3Manufacturing precision
If iterative parameter refinement is performed using historical data, then manufacturing precision of rolled products is improved, but loss of time increases due to the iterative comparison and adjustment process
Solution Approach 1:
The patent applies preliminary action by performing iterative parameter refinement using historical process data before actual production begins. This pre-adjustment phase allows the system to achieve high manufacturing precision for subsequent productions without incurring time losses during actual rolling operations, as the parameters are already optimized based on past performance data.
Data Source
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AI summary
The method involves providing initial values to a parameter to be determined to a model (13), and feeding the initial values to the model by measuring input parameters that are determined within the roller system. A model-initial parameter is computed by the model based on the input parameters and the initial values of the parameter. The model-initial parameter is compared with an associated initial parameter that is determined by measurement within the roller system. Additional values for the parameter of the model are determined based on the comparison. Independent claims are also included for the following: (1) a method for operating a roller system (2) a computing device i.e. notebook, for performing a method for determining parameters of models.