Straightening Roller Feedback Control for Wire and Strip Straightness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for straightening wire or strip material lack reliability in achieving desired straightness, especially when dealing with unknown or variable curvature, as they do not provide clear measurements or adjustments based on real-time data during the process.
Innovation Solution
A closed control loop system is implemented, where the forces on straightening rollers, material temperature, and position deviations are measured and fed into a model to adjust the rollers automatically, ensuring precise straightening. This includes using strain gauges for force measurement, temperature sensors for forming energy correction, and optical or non-contact methods for position measurement, with adjustable rollers in a dressage device setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional straightening methods are used without real-time measurement and adjustment, then the device complexity is low, but the manufacturing precision of straightness is insufficient
Solution Approach 1:
The patent implements a closed-loop feedback control system where measured values from strain gauges, temperature sensors, and position measurement devices are continuously fed back to the control unit. The control unit processes these values and automatically adjusts the straightening roller positions to maintain desired straightness, resolving the contradiction between precision and complexity through intelligent automation.
Solution Approach 2:
The patent replaces manual mechanical adjustment with automated electronic control. Strain gauges, temperature sensors, and optical/magnetic position measurement devices substitute for human operators, enabling precise measurement and automatic adjustment of roller positions based on real-time material conditions.
2Reliability
If no real-time measurement is performed during straightening, then the measurement system is simple, but the reliability of achieving desired straightness is low
Solution Approach 1:
The control unit continuously receives measured values from multiple sensors during the straightening process and dynamically adjusts roller positions based on this feedback. This closed-loop approach ensures reliable achievement of desired straightness by constantly monitoring and correcting material behavior in real-time.
Solution Approach 2:
The measurement system is designed to be integrated into the straightening process itself, where the material's own response (forces on rollers, temperature changes, position deviations) during straightening provides the measurement data needed for control, eliminating the need for separate complex measurement systems.
3Manufacturing precision
If multiple measurement parameters are monitored in real-time, then the straightness control is more accurate, but the device complexity and measurement system cost increase
Solution Approach 1:
The control unit serves multiple functions: it processes data from strain gauges, temperature sensors, and position measurement devices, performs stochastic model calculations, and controls roller adjustments. This multi-functional approach consolidates complexity into a single control system rather than requiring separate systems for each measurement type.
Solution Approach 2:
The patent introduces a stochastic model as an intermediary between raw measurement data and control decisions. The model processes multiple measurement parameters (forces, temperature, position) and translates them into optimal roller adjustment commands, simplifying the control logic while maintaining high precision.
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
The system ensures greater reliability in achieving desired straightness by continuously adapting to real-time data, improving the accuracy and consistency of the straightening process, even with materials of unknown or variable curvature.
Implementation Method 1
the measurement (i) of the forces acting on the straightening rollers is expediently carried out by means of strain gauges arranged on the bearing bolts of the straightening rollers, which measure the bending moments in the axial, vertical and/or horizontal direction
Implementation Method 2
the temperature of the material before and after passing through the arrangement of straightening rollers is measured
Implementation Method 3
the position of the material following each of the straightening rollers is measured in the form of the deviation of the material from the axis of passage in or parallel to the direction of application of the straightening rollers. Known optical or non-contact (e.g., magnetic) measuring methods are suitable for this purpose
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for straightening wire or strip material by means of a straightening device comprising straightening rollers (3, 4, 6, 10) engaging on opposite sides of the passing-through material in an offset manner, of which, some are automatically activated according to a model which has been stochastically determined on the basis of input data of the material and data relating to the wire and the straightening device that is determined during the passing of the material through the straightening device, such that requirements of the straightening unit are met, wherein the position of at least one straightening roller is continuously adapted on the basis of said data detected during the passage through the straightening device, which data is representative of the target straightness, wherein (i), the size and direction of the forces acting on the straightening rollers and/or (ii) the temperature of the material before and after passing through the assembly of straightening rollers and/or (iii) the position of the material in relation to each of the straightening rollers are measured and the obtained measurement values are input into the model controlling the activation of the activatable straightening rollers.