Rolling Mill Profile Control via Multi-Point Adaptation
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Solution Overview
Problem
Existing methods for producing metal strips in rolling mills lack precision in setting the profile contour across the width of the metal strip, often resulting in deviations from the desired target values, especially in edge regions where higher accuracy is required.
Innovation Solution
The method calculates adaptation values for the profile contour by determining the difference between measured and forecast values at multiple reference positions, using both short-term and long-term adaptation values to adjust the profile actuators, allowing for more precise setting of the profile contour across the width of the metal strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adaptation values are determined only at a single reference position, then the control system is simpler, but the profile contour precision across the strip width is insufficient
Solution Approach 1:
The strip width is divided into multiple reference positions (at least two) along the transverse direction, with adaptation values determined independently at each position. This segmentation allows precise control of the profile contour at different locations while maintaining a manageable control structure by treating each position as a separate control point.
Solution Approach 2:
The control approach transitions from single-point (one reference position) to multi-point control across the transverse dimension. By determining adaptation values at multiple positions along the strip width, the system achieves two-dimensional profile control (length and width directions) rather than only longitudinal control.
2Measurement precision
If multiple reference positions are used for adaptation value determination, then the profile contour forecasting accuracy improves, but the calculation and control complexity increases
Solution Approach 1:
The profile detection and measurement process is segmented into multiple discrete reference positions across the strip width. Each position is measured and evaluated independently to determine its specific adaptation value, enabling precise local profile control without requiring complex full-width continuous measurement systems.
Solution Approach 2:
Instead of measuring and controlling the entire profile continuously, the system uses partial measurement at strategically selected reference positions (at least two locations along the transverse direction). This partial action approach provides sufficient accuracy for profile control while significantly reducing measurement and calculation complexity compared to full-profile analysis.
3Manufacturing precision
If short-term and long-term adaptation values are both used, then the profile setting accuracy improves, but the processing time increases
Solution Approach 1:
Long-term adaptation values are determined in advance based on historical data and systematic analysis, while short-term adaptation values are calculated quickly for immediate control adjustments. This preliminary preparation of long-term values allows the system to use pre-computed baseline corrections without adding significant processing time to the real-time control loop.
Solution Approach 2:
The system merges short-term and long-term adaptation values into a unified profile control strategy. The long-term values provide baseline corrections for systematic errors, while short-term values address immediate deviations. By combining these two time-scales of adaptation, the system achieves high precision without requiring complete recalculation from scratch for each control cycle.
Data Source
AI summary
A method for producing metal strip in a rolling mill, so that as a result of a more accurate manufacturing of metal strips in the future, a more precise forecasting of the profile contour of the metal strip can be obtained over the width of the metal strip, as well as a more precise setting of the profile actuator of the rolling mill. A forecast value is calculated for the profile contour within the context of the simulation of the rolling process before the rolling of the metal strip. In contrast to that, the calculation in the simulation is not conducted prior to the rolling, but instead it is obtained by a post-calculation after the rolling of the metal strip has been carried out.