Wedge-Type Roll-Gap Adjustment for Roughing Stands
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Solution Overview
Problem
Existing rolling mill processes struggle to consistently avoid or reduce thickness wedges in finish-rolled flat metal stock, which can lead to undesirable asymmetrical thickness distributions, and often require complex modeling or additional equipment to prevent saber formations during the roughing process.
Innovation Solution
The implementation of an operating method that uses lateral guides or edgers to exert transverse forces on the rolling stock during roughing, adjusting the wedge setting based on deviations from target thickness to prevent saber formations and minimize thickness wedges, without the need for elaborate modeling, by ensuring reproducibility of thickness measurements post-finish rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex modeling or additional equipment is used to prevent saber formations and reduce thickness wedges, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system uses the existing finish-rolled product itself as the measurement source. The thickness measuring device measures the actual thickness wedge in the finish-rolled flat item, and this measurement is fed back to automatically adjust the roughing pass wedge setting for the next item, making the system self-regulating without external intervention or complex modeling
Solution Approach 2:
A feedback loop is established where the thickness measurement from the finish-rolled product is used to determine the wedge setting for the next roughing pass. The control device compares the measured thickness wedge with target values and automatically adjusts the wedge setting proportionally to the deviation, creating a closed-loop control system that eliminates the need for complex forward modeling
2Manufacturing precision
If elaborate modeling is implemented to predict and control thickness wedges, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent replaces complex mechanical modeling and prediction systems with a direct measurement and feedback system. Instead of using elaborate models to predict thickness wedges, the system directly measures the actual thickness in the finish-rolled product and uses this real data to control the roughing pass settings, substituting measurement-based control for model-based control
Solution Approach 2:
The system changes the control parameter from predicted thickness wedge (based on complex models) to actual measured thickness wedge. By measuring the real thickness distribution in the finish-rolled product and using this actual parameter for feedback control, the system achieves accurate wedge setting without requiring elaborate modeling
3Reliability
If additional equipment is added to prevent saber formations, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent makes the existing thickness measuring device serve a dual function: it measures thickness for quality control and simultaneously measures the thickness wedge for feedback control of the roughing pass wedge setting. This multi-functionality eliminates the need for separate equipment for saber formation prevention while maintaining reliability
Solution Approach 2:
The system merges the thickness measurement function with the wedge control function. The same thickness measuring device and control device are used both for measuring thickness and for determining wedge settings, combining multiple functions into existing equipment rather than adding separate systems
Data Source
AI summary
A plurality of flat metal items to be rolled (3) are fed to a plurality of rolling stands (1, 2) of a rolling installation, one after the other over a feed path (4). The items (3) are rolled by the rolling stands (1, 2) past which they are fed. In the rolling stands (1, 2), the flat item to be rolled (3) is first rough-rolled in at least one roughing pass with a wedge-type roll gap adjustment (ds) and then finish-rolled in finishing passes. After the finish-rolling of the flat item, a thickness taper (dd) that is present in the respective finish-rolled flat item is recorded by measuring instruments. The thickness taper (dd) is compared with a target taper (dZ). On the basis of a deviation of the thickness taper (dd) from the target taper (dZ) and the wedge-type roll gap adjustment (ds), a new wedge-type roll gap adjustment (ds) is determined for the at least one roughing pass. The wedge-type roll gap adjustment (ds) for the at least one roughing pass for the next flat item to be rolled (3) is set to correspond to the newly determined value of the wedge-type roll gap adjustment (ds), so that the next flat item to be rolled (3) is rough-rolled in the at least one roughing pass with the newly determined value of the wedge-type roll gap adjustment (ds).