Tandem Mill Roll Steering Control With Real-Time Work Roll Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional roll steering control in rolling mills is manual, prone to operator error, and does not account for real-time rolling mill conditions, leading to inaccurate and time-consuming adjustments.
Innovation Solution
A system and method for automatically controlling roll steering using a steering control system that generates a model for the work stand based on setup data, adjusts parameters with sensors, and actuates steering control actuators to maintain target output parameters within a predetermined tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual control by operator is used to set steering value, then ease of operation is maintained, but manufacturing precision and productivity deteriorate due to operator error and time consumption
Solution Approach 1:
The system uses sensors to automatically detect substrate parameters (thickness, width, position) and the controller automatically calculates and adjusts steering values without operator intervention. The work roll inclination is self-adjusted based on real-time measurements, eliminating manual control while maintaining ease of operation through automation.
Solution Approach 2:
The patent replaces the manual mechanical adjustment system with an automated control system using sensors, processors, and actuators. The steering control actuator automatically adjusts work roll inclination based on electronic signals from the controller, substituting manual mechanical operations with an integrated electromechanical system.
2Productivity
If manual adjustment during production is used, then adaptability to changing conditions is possible, but productivity and response time deteriorate due to slow adjustment speed
Solution Approach 1:
The system continuously measures substrate parameters using sensors positioned at various locations, feeds this information to the controller, and automatically adjusts steering values in real-time. This closed-loop feedback mechanism enables rapid adaptation to changing rolling conditions while maintaining high productivity through automated real-time control.
Solution Approach 2:
The controller pre-calculates optimal steering adjustments based on measured substrate parameters and rolling conditions, making adjustments before significant deviations occur. This proactive approach maintains substrate quality within specifications while enabling rapid response to changing conditions.
3Measurement precision
If manual control method is used, then device complexity is reduced, but measurement precision and manufacturing precision deteriorate due to inability to account for actual rolling conditions
Solution Approach 1:
The controller serves multiple functions: it receives data from multiple sensors, calculates steering values, controls work roll inclination, and adapts to different substrate types and rolling conditions. This multi-functional integration achieves high measurement and manufacturing precision while managing system complexity through consolidation of control functions.
Solution Approach 2:
The controller acts as an intermediary between sensors and actuators, processing sensor data and translating it into appropriate steering adjustments. This intermediary function coordinates the complex interactions between multiple system components, enabling precise control while managing overall system complexity through centralized intelligence.
Data Source
AI summary
Systems and associated methods for controlling roll steering during rolling of a metal substrate may include a steering control actuator adapted to control an inclination of a work roll of a work stand of the rolling mill, a sensor configured to measure a parameter of a metal substrate upstream from the work stand, and a controller operably connected with the steering control actuator and the sensor. The controller may generate a model for the work stand and determine an adjustment value for the work stand, receive the measured parameter from the sensor, and determine an expected output parameter by adjusting the measured parameter by the adjustment value. The controller may also compare the expected output parameter with a target output parameter and actuate the steering control actuator such that the expected output parameter is within a predefined tolerance of the target parameter.