Stepped Metal Strip Rolling With Constant Force Tension Control
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Solution Overview
Problem
Stepped rolling processes face challenges in maintaining constant rolling force, leading to levelness defects and geometrical limitations due to rapid changes in strip thickness and high strip speeds, which are exacerbated by the response time and regulation time of existing correction methods.
Innovation Solution
Implementing a method to control strip tension applied to the metal strip, ensuring a constant or approximately constant rolling force by adjusting forward and reverse strip tensions, along with the speed of rotation and setting speed of working rolls, to compensate for elastic deformations and maintain stable rolling conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the roll gap is changed to produce different strip thicknesses in stepped rolling, then the versatility of the rolling process is improved, but the rolling force changes significantly causing levelness defects
Solution Approach 1:
The bending lines of the working rolls are pre-corrected before the rolling process to compensate for the elastic deformations that will occur during stepped rolling. This preliminary correction ensures that when the roll gap changes and rolling force varies, the rolls maintain the correct geometry to produce uniform strip levelness throughout the thickness variation process.
2Productivity
If strip rolling is performed at high strip speeds to increase productivity, then the productivity is improved, but the response time of regulation circuits becomes insufficient leading to levelness defects
Solution Approach 1:
The working rolls are pre-set with corrected bending lines that account for the specific rolling conditions and speed requirements. This preliminary configuration eliminates the need for real-time regulation during high-speed rolling, as the rolls are already optimized to compensate for elastic deformations at the intended operating speed, thus avoiding levelness defects that would otherwise require time-consuming regulation.
3Manufacturing precision
If correction of bending lines is applied to reduce elastic deformations, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The bending line correction of the working rolls is performed as a preliminary setup operation rather than requiring complex real-time correction mechanisms during production. This approach achieves improved strip profile uniformity through pre-configured roll geometry while avoiding the need for complicated active correction systems that would increase device complexity during the rolling process.
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
This approach effectively prevents levelness defects and extends the geometrical capabilities of stepped rolling by maintaining a consistent rolling force, reducing the impact of elastic deformations and ensuring a stable rolling process, even during rapid thickness changes.
Implementation Method 1
the rolling force applied by the working rolls is kept constant or approximately constant during the rolling process
Implementation Method 2
changes in the rolling force during the rolling process lead to elastic deformations of all the rolls, such as roll flattening, roll bending, and embedding into the rolls
Implementation Method 3
strip tensions applied by way of the reel support the rolling process and improve the levelness or straightness of the metal strip that is produced
Data Source
AI summary
A method for the stepped rolling of a metal strip unwinds the metal strip by a feed reel device and winds-up the metal strip by a winding reel device. The metal strip is guided through a roller gap formed between two working rollers during the rolling process, and the roller gap is changed in a controlled manner during the rolling process, whereby a thickness of the metal strip is changed in steps in the longitudinal direction during the rolling process. Tension applied to the metal strip is controlled such that the rolling force applied to the metal strip by the working rollers is constant during the rolling process.