Rolling Mill Production Sequencing for Temperature-Aware Energy Savings
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Solution Overview
Problem
Existing methods for producing finished products in rolling mills are energy-inefficient due to fixed production sequences that do not account for the availability and temperature of precursor materials, leading to energy losses and increased CO2 emissions.
Innovation Solution
A method that optimizes production planning and control by integrating a higher-level control system to manage inventory levels of cold, warm, and hot precursor materials, using algorithms like MILP and TSP to minimize energy requirements, and includes temperature control devices to adjust material temperature before forming, allowing flexible production sequences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed production sequence is used in the rolling mill, then production planning is simple, but energy consumption increases due to temperature losses and compensatory heating
Solution Approach 1:
The patent implements a dynamic production sequence optimization system that continuously adjusts the production plan based on real-time temperature data of precursor materials. The higher-level control system receives temperature information from measurement devices and temperature models, then dynamically reorders production sequences to minimize energy consumption while adapting to changing material conditions
Solution Approach 2:
The system incorporates feedback loops where temperature measurement devices continuously monitor precursor material temperature, feed this data to the control system, which then adjusts the production sequence accordingly. This closed-loop control enables the system to respond to actual temperature conditions and optimize energy usage in real-time
2Adaptability or versatility
If hot precursor material is transported and stored before processing, then production flexibility increases, but temperature loss occurs requiring additional heating energy
Solution Approach 1:
The system performs preliminary temperature assessment of stored precursor materials before scheduling production. By measuring and recording temperature data in advance, the control system can plan production sequences that utilize materials while they are still at optimal temperatures, reducing the need for compensatory heating and minimizing energy loss
3Use of energy by moving object
If production sequence is optimized for energy efficiency, then energy consumption decreases, but production planning and control complexity increases
Solution Approach 1:
The patent introduces a higher-level control system as an intermediary between the fixed production sequence and the actual production process. This intermediary layer handles the complex optimization calculations, sequence reordering, and coordination of temperature measurement and production scheduling, thereby managing planning complexity while achieving energy efficiency without requiring fundamental changes to the production infrastructure
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
Reduces energy consumption and CO2 emissions by optimizing the production sequence based on real-time material availability and temperature, ensuring compliance with quality parameters and enabling efficient use of precursor materials.
Implementation Method 1
a temperature-influencing device for the pre-material
Implementation Method 2
This can be compensated, for example, by induction heating
Data Source
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AI summary
The invention relates to a method for hot forming starting material, in particular slabs or billets, into finished products by means of a hot forming device (1), comprising the steps of: - determining a target stock level (S) of the finished products; - predetermining an inflow of hot starting material (6) to the forming plant (2); - recording an inflow of cold, warm and/or hot starting material; - optimizing the production orders (P), the sequence of the production orders (Pn) and the material flow between the inflow of hot starting material (6), the storage area (3) and the forming plant (2) by means of the higher-level control or regulation system (7), wherein the optimization preferably minimizes the energy requirement; and - producing the finished products by means of the hot forming device (1) in the optimized production sequence (Pn).