Rolling Mill Plate End Detection for Tension-Free Winding
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Solution Overview
Problem
In rolling mill operations, when no tension is applied to the tip end of a metal plate, existing systems struggle to accurately detect the plate's position, leading to improper winding and potential separation from the conveyance line, as the inclination of the plate's outgoing direction cannot be properly grasped by position sensors.
Innovation Solution
A control device is implemented, featuring first and second plate end detection parts on the entry and exit sides of the mill rolls, respectively, to determine if tip end tension-free rolling can commence, ensuring the plate's position is correctly aligned before starting the rolling process, thereby preventing separation and ensuring proper winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single position sensor is used to detect plate position on the exit side, then the device complexity is reduced, but the measurement precision of plate inclination is insufficient
Solution Approach 1:
The plate end position detection is segmented into two separate detection parts: one on the entry side and one on the exit side of the mill rolls. Each detection part independently measures plate position at its location, and the control device calculates inclination by comparing these segmented measurements, thereby achieving accurate inclination detection without requiring a single complex sensor.
Solution Approach 2:
The solution transitions from single-point detection to two-point detection in space. By adding the entry side detection part and utilizing the spatial dimension between entry and exit sides, the system can calculate plate inclination through coordinate geometry, converting a one-dimensional position measurement problem into a two-dimensional spatial measurement solution.
2Productivity
If tip end tension-free rolling is performed without proper alignment detection, then productivity is improved, but the reliability of winding operation deteriorates
Solution Approach 1:
The control device performs preliminary detection of plate end positions at both entry and exit sides before initiating tip end tension-free rolling. By calculating plate inclination in advance and determining whether the plate is properly aligned with the conveyance line, the system ensures reliable winding conditions are met before high-speed rolling begins, preventing separation issues during winding.
Solution Approach 2:
The control device continuously monitors plate end positions through the two detection parts and provides feedback on plate inclination. This feedback mechanism allows the system to maintain awareness of plate alignment status during tension-free rolling, enabling timely adjustments to ensure the plate remains properly positioned for accurate winding operation.
Data Source
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AI summary
A control device for controlling a rolling mill device including a pair of mill rolls disposed on opposite sides of a metal plate includes: a first plate end detection part disposed on an entry side of the pair of mill rolls in a conveying direction of the metal plate and configured to detect a plate end position in a plate width direction of the metal plate at a first position in the conveying direction; a second plate end detection part disposed on an exit side of the pair of mill rolls in the conveying direction and configured to detect a plate end position in the plate width direction of the metal plate at a second position in the conveying direction; and a determination part configured to determine whether tip end tension-free rolling, which is rolling of the metal plate by the pair of mill rolls in a state where an exit-side tension applied to the metal plate is zero, can be started, on the basis of a first plate end position of the metal plate detected by the first plate end detection part and a second plate end position of the metal plate detected by the second plate end detection part.