Rolling Roll Conformity Detection for Polygonal Wear Control
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Solution Overview
Problem
Conventional methods struggle to detect slight chatter marks on metal strips caused by polygonal wear of rolling rolls, which are not visible through visual inspection or sheet thickness measurement, leading to decreased product yield and productivity issues.
Innovation Solution
A method for determining the conformity of a rolling roll by analyzing rolling load and circumferential speed data to estimate the surface shape of the roll, using a conformity determination device that includes a rolling mill vibration model and frequency analysis to detect polygonal wear and prevent slight chatter marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional visual inspection and sheet thickness measurement are used to detect surface defects, then the inspection method is simple and easy to implement, but slight chatter marks caused by polygonal wear of rolling rolls cannot be detected
Solution Approach 1:
The patent replaces conventional visual inspection and thickness measurement methods with a vibration-based detection system. By measuring vibration characteristics during rolling and analyzing frequency components, the system can detect slight chatter marks that are imperceptible to visual inspection or thickness measurement, thereby substituting mechanical/direct measurement methods with a more sophisticated vibration analysis approach.
Solution Approach 2:
The patent introduces vibration signals as an intermediary parameter to detect surface defects. Instead of directly observing or measuring the chatter marks on the sheet, the system measures vibrations generated during rolling and uses frequency analysis to infer the presence of polygonal wear and resulting chatter marks, making the detection of subtle surface defects feasible.
2Duration of action of moving object
If rolling rolls are used until visible surface defects appear, then roll usage time is maximized, but product yield decreases due to generation of slight chatter marks
Solution Approach 1:
The patent performs preliminary detection of polygonal wear by analyzing vibration characteristics before visible surface defects or chatter marks appear on the rolled product. By detecting the onset of roll degradation through vibration frequency analysis and comparing it against predetermined thresholds, the system enables proactive roll replacement, preventing the generation of slight chatter marks and maintaining consistent product quality.
Solution Approach 2:
The patent implements a feedback mechanism where vibration measurements during rolling are continuously monitored and analyzed. When the vibration frequency components indicate polygonal wear exceeding a predetermined level, the system provides feedback to trigger roll replacement, creating a closed-loop control system that maintains product quality while optimizing roll usage duration.
3Measurement precision
If vibration detectors are installed in each part of the rolling mill to detect chattering, then chattering detection capability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the essential detection function to a single measurement point - the rolling load. By analyzing vibrations through the load measurement system rather than installing multiple detectors throughout the rolling mill, the system achieves effective chattering detection with minimal additional equipment, extracting maximum diagnostic value from a single measurement location.
Solution Approach 2:
The patent makes the rolling load measurement system serve multiple functions - it continues to measure rolling load for process control while simultaneously functioning as a vibration detection system for chatter mark prevention. This multi-functionality eliminates the need for separate vibration detectors, reducing device complexity while maintaining detection capability.
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
Enables on-line estimation of polygonal wear, preventing slight chatter marks and improving product yield and productivity by replacing worn rolls before surface defects occur.
Implementation Method 1
a vibration analysis step of analyzing the vibration behavior of the stand using the rolling load operation data of the stand having the roll to be evaluated acquired in the rolling load data acquisition step
Implementation Method 2
The FFT frequency analysis step performs a frequency analysis of the collected vibration signals by a fast Fourier transform method to obtain frequency components included in the vibration signals and spectrum values thereof
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
There are provided a method for determining the conformity of a rolling roll and the like capable of estimating the state of polygonal wear of a roll to be evaluated occurring during rolling in on-line and preventing slight chatter marks. The method for determining the conformity of a rolling roll includes: a rolling load data acquisition step (Step S3) of acquiring rolling load operation data of a stand (F1 to F5) having a roll to be evaluated; a circumferential speed data acquisition step of acquiring circumferential speed operation data of the roll to be evaluated (Step S4); a vibration analysis step of analyzing the vibration behavior of the stand (F1 to F5) using the rolling load operation data of the stand (F1 to F5) (Step S5); a surface shape estimation step of estimating the surface shape of the roll to be evaluated from the analysis result of the vibration behavior of the stand (F1 to F5) and the circumferential speed operation data of the roll to be evaluated during the rolling of a metal strip (Step S6); and a conformity determination step of determining the conformity of the roll to be evaluated based on the surface shape of the roll to be evaluated (Step S7).