The present disclosure relates to systems and methods for improving the flatness of a metal strip.
Hot and cold rolling are metal forming processes in which stock sheets or strips are passed through a pair of rolls to reduce the thickness of the stock sheet or strip. In some cases, the rolled strips are processed or otherwise treated after rolling. For example, rolled strips may pass through a coating line to apply a coating of polymeric materials or other suitable coating to the rolled strips. After the coating is applied, the coated strip may be cured in an oven. In many cases, rolled strips emerge from the oven with center waves or other distortion along the strip that reduce the overall flatness of the strip. It is thus desirable to improve the flatness of the metal strip.
The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings and each claim.
The present disclosure recites methods and systems for improving the flatness of a metal strip, including applying differential cooling across the width of a hot strip to improve the flatness of the strip. In some embodiments, a feedback control loop can be implemented including a flatness measurement device and a control system that controls the differential cooling. If used, the control system can make automatic, dynamic adjustments based on the flatness measurement of the differentially cooled strip.
The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.
Disclosed herein are systems and processes for improving the flatness of a piece of rolled metal, hereinafter referred to as a “rolled strip” or a “strip.” In some embodiments, a flatness measurement device is used to measure the flatness of a rolled strip. A control system can receive the flatness measurements and control a cooling unit that differentially cools the metal strip to create a desired non-homogenous temperature gradient across the width of the metal strip. The temperature gradient generates differential tensions in the strip, which are imparted while the metal strip is sufficiently hot and can improve the flatness of the metal strip.
As mentioned above, cooling unit 108 can distribute a cooling agent 112 to the strip 102. The cooling agent 112 can be distributed from above, below, or to the sides of the strip 102, or any combination thereof. In some embodiments, the cooling agent 112 is air, gas, water, oil, or any other cooling agent capable of sufficiently removing heat from the strip 102 to generate the desired differential cooling. The amount and application of cooling to particular locations along the width of the strip 102 can be adjusted based on the desired flatness.
Differential cooling can be achieved by cooling selected portions 204 of strip 102 along the width 202 of strip 102. In some embodiments, the selected portions 204 are portions where the strip tension is highest. Strip tension can be highest at the edges 208 of the strip 102. The more localized the stress, the less differential cooling may be required to achieve the desired improved flatness. In some cases, a relatively small amount of cooling (for example, but not limited to, cooling at or around 250° Celsius) can be applied to the edges 208 of the strip 102, which can remove or reduce significant center buckles and/or distortion from the strip 102. Portions along the width 202 of the strip 102 that receive less cooling than the selected portions 204 are referred to as unselected portions 206. Unselected portions 206 can be portions where the strip tension is lower. Differential cooling includes any difference in temperature applied across the width 202 of the strip 102. In some embodiments, a selected portion 204 (e.g., an edge 208) along the width 202 of the strip 102 can be subjected to cooling while an unselected portion 206 (e.g., the middle of the strip 102) along the width 202 of the strip 102 is not subjected to any cooling. In other embodiments, a selected portion 204 (e.g., an edge 208) along the width 202 of the strip 102 can be subjected to greater cooling than the cooling provided to the unselected portion 206 (e.g., the middle of the strip 102) along the width 202 of the strip 102.
Application of differential (also referred to as non-uniform, preferential, or selective) cooling to selected portion 204 of the width 202 of a strip 102 can cause the selected portions 204 to thermally contract, increasing the tension along the selected portions 204. Differential cooling can cause a temporary temperature gradient along the strip 102 where the selected portions 204 of the width 202 of the strip 102 (e.g., the edges 208) are cooler than the unselected portion(s) 206 (e.g., the middle).
In an embodiment where cooling is applied to the edges 208 of the strip 102 to generate the temperature gradient, the tension at the edges 208 of the strip 102 can be temporarily increased, compared to the warmer, unselected portion 206 (e.g., middle) of the strip 102. Because the temperature along the width 202 of the strip 102 is not uniform, differential tension exists along the width 202 of the strip 102. If this imposed tension distribution is not equalized soon after being applied (e.g., by intervening support rolls, or otherwise), and the strip 102 is sufficiently hot to yield slightly under the differential tension, the differential temperature imparted by the differential cooling can cause the strip 102 to lengthen slightly along the colder portion of the width 202 (e.g., the selected portions 204) of the strip 102. Yield, as used herein, can be considered a permanent strain or elongation of the strip 102, which partially relieves the applied stress (e.g., from the imposed tension distribution). The stress required to cause permanent strain decreases as the strip 102 temperature increases. As used herein with reference to strip 102, yield includes permanent strain at conventionally accepted yield stress levels, as well as at stress levels below the conventionally accepted yield stress levels, such as the permanent strain that can occur from rapid creep. Therefore, for a strip 102 to yield, as the term is used herein, it is not necessary to induce differential tension that provides stress levels at or above the conventionally accepted yield stress of the strip 102.
Regardless of whether or not the actual temperature gradient imposed on the strip 102 is known, the temperature gradient is based on the differential cooling, which can be based on various factors, such as models, flatness measurements, or other, as disclosed herein.
Differential cooling of the edges 208 of a strip 102 causes a local concentration of tensile stress sufficient to put the strip 102 into yield and stretch the edges 208, correcting any center waves or distortion present in the strip 102. In this way, the flatness of the strip 102 can be adjusted and/or improved using differential cooling. When active differential cooling of the strip 102 is discontinued, the temperature profile of the strip 102 across its width 202 will eventually equalize, but any changes due to yield will remain, and therefore the improved flatness will be maintained.
Cooling agent 112 can be delivered by cooling unit 108 in any suitable way. In one embodiment, as shown in
In some embodiments, the sleeve 306 can be movable and/or adjustable to adjust the size and/or position of the occlusion portion 404 with respect to the continuous slot 304. The sleeve 306 can incorporate two overlapping sleeves 306 that slidably move with respect to one another, wherein each of their occlusion portions 404 can overlap to varying extents in order to adjust the size of the actual occlusion portion 404 with respect to the continuous slot 304. The sleeve 306 can be manually adjustable or automatically adjustable. In some embodiments, the sleeve 306 may be dynamically adjusted by a control system 118. The sleeve 306 can be adjusted depending on the desired distribution path of the cooling agent 112 and the desired flatness of the strip 102. In some embodiments, each sleeve 306 may be adjusted differently along the strip 102 (e.g., over each edge 208 of the strip 102) to provide independent control so that the strip 102 can be asymmetrically cooled relative to a midpoint of the width 202 of the strip 102.
In some embodiments, the differential cooling described above can be applied and adjusted using information obtained from a feedback control loop.
As described above, the system 100 shown in
The flatness measuring device 114 of
In some embodiments, the flatness measuring device 114 is positioned so it is higher than the strip 102. In other embodiments, the flatness measuring device 114 is positioned at any suitable height and in any suitable location. In some embodiments, the actual flatness of the strip 102 is measured downstream of the cooling unit 108 or at another location where the strip 102 temperature is approximately uniform (e.g., the temperature profile of the strip has substantially equalized so the temperature gradient is substantially no longer present) to obtain an accurate reading of flatness.
The control system 118 can use the flatness signal 116 to determine any necessary adjustments that are to be made to the cooling unit 108 in order to achieve the desired flatness. The control system 118 can compare the measured flatness from the flatness measuring device 114 with a desired flatness that has been previously selected and/or stored in the memory of the control system 118. The control system 118 can then send a cooling signal 120 to the cooling unit 108. The cooling signal 120 can direct the cooling unit 108 to adjust the dispersion of cooling agent 112 as described herein. Adjustments can be made to the volume and/or temperature of the cooling agent 112 and/or the locations to which the cooling agent 112 will be applied relative to the strip 102 (e.g., the size and position of the selected portions 204).
In one embodiment, delivery of the cooling agent 112 is adjusted by adjusting the one or more moveable sleeves 306, as described herein. In other embodiments, the delivery of cooling agent 112 is adjusted by adjusting valves 210 in the supply lines 214 to discrete cooling nozzles 110. In this way, the flatness measurement of a strip 102 can be used to automatically and dynamically adjust and control the differential cooling to improve the flatness of the strip 102. The feedback control system enables the differential cooling of the strip 102 to serve as an adjustable actuator to adjust and correct any buckling and/or curvature of the strip 102, so its flatness reaches a desired level. The flatness then can be optimized by automatic feed-forward or feedback control, depending on the actual flatness measurement.
In some embodiments, the control system 118 can use information from a model-based approach (e.g., a coil stress model) instead of flatness measurements to determine the necessary differential cooling to be applied to the strip 102. A flatness measuring device 114 can be omitted in some embodiments. In some embodiments, using a model-based approach eliminates or reduces the need for actual measurements of the flatness of the strip 102, such that the determination of what differential cooling is to be applied could be made based on the model.
It can be desirable to differentially cool strips 102, as described herein, after rolling, at least because distortions can appear in the strip 102 after rolling, although the differential cooling described herein is not so limited. It can be desirable to differentially cool strips 102, as described herein, after the strip 102 has been coated and passed through an oven 106, at least because the coating and heating stages can induce distortions in the strip 102. However, differential cooling is not limited to use in cooling sections after the strip 102 passes through a coating line. Instead, differential cooling can be applied in any other suitable process line or at any other stage in the process. For example, differential cooling can be applied at the cooling section of a continuous annealing line, or at any other suitable line or stage of the process. In addition, the differential cooling described above can also be used to control the camber (sometimes referred to as the lateral bow) of the strip by applying differential cooling resulting in an asymmetric temperature gradient. Various embodiments can apply differential cooling, as described above, in various desired fashions along any suitable thermal line, including cold rolling mills.
It can be desirable to differentially cool strips 102, as described herein, rather than use other flattening devices in an effort to improve the flatness of the strip 102, at least because other flattening devices can add in some degree of unflatness, harm coatings and/or finishes of the strip 102, and/or can have negative effects (e.g., reduced formability of the strip 102 due to leveling) on certain mechanical properties of the strip 102. It can be desirable to differentially cool strips 102, as described herein, rather than use other methods, at least because the differential cooling described herein can produce strips 102 with increased uniformity across the width 202 of the strip 102. It can be desirable to differentially cool strips 102, as described herein, over other methods, as it can reduce the amount of leveling that may be necessary downstream.
All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. Various embodiments have been described. It should be recognized that these embodiments are merely illustrative of the principles of the present disclosure. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present disclosure as defined in the following claims.
The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/776,241 filed Mar. 11, 2013, which is hereby incorporated by reference in its entirety.
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