Patent Application
20110120202
The present invention relates to a method and an apparatus for suppression of oscillations in a rolling installation.
Specifically, the invention relates to a method for suppression of oscillations, in particular 3rd-octave oscillations, in a rolling installation having at least one rolling stand with roller engagement and having at least one roller set, wherein at least one permanently measured variable of the rolling installation is supplied to a regulator, a manipulated variable which varies over time is determined in real time with the aid of this regulator, and the controlled variables are kept substantially at defined nominal values by at least one actuator acting on the roller engagement.
In the case of rolling installations, in particular cold rolling lines, it is known for undesirable oscillations to occur in certain operating states, for example strip tension, strip tension difference, coefficients of friction, thickness decrease, material strength and strip velocity, and these oscillations can lead to considerable damage to the installation, as well as to defects in the rolled material. 3rd-octave oscillations, also referred to as 3rd-octave chatter, are known by a person skilled in the art from the multiplicity of oscillations which occur in rolling processes. 3rd-octave oscillations typically occur in a frequency range from about 80 to 170 Hz, and are characterized by a high energy content and unstable oscillating states, as a result of which considerable mechanical damage can also occur to the rolling stand of a rolling installation. Since, however, these oscillations also lead to movements of the roller set and therefore to discrepancies from the nominal rolling gap, this leads to defects in the rolled material, which may be in the form of surface defects, geometric defects or else combinations thereof. Typically, when oscillations such as these occur, the personnel operating the rolling installation will immediately reduce the rolling speed, which involves a reduction in throughput (that is to say reduced productivity), and leads to the oscillations decaying. The stated frequency range for 3rd-octave oscillations depends substantially on the respective installation configuration and the rolling parameters, and may therefore also differ therefrom. In a method for suppression of oscillations (so-called “active oscillation compensation”), at least one permanently measured variable of the rolling installation is supplied to a regulator, which calculates a manipulated variable which varies over time. By acting on at least one actuator for roller engagement, it is possible to maintain the controlled variables substantially at defined nominal values, that is to say except, for example, for overshoot processes.
EP 1457274 A2 discloses a method and an apparatus for preventing 3rd and 5th-octave oscillations in a rolling stand. In this case, at least one roller in a roller set is acted on by means of a controller and an actuator, by which means the controlled variables are kept at defined nominal values. Specific embodiments and selection criteria for the actuator cannot, however, be found in the disclosure.
The object of the invention is to provide a method and an apparatus having hydraulic roller engagement, for suppression of oscillations in a rolling installation, by means of which, in particular, 3rd-octave oscillations are effectively suppressed, thus making it possible to improve the quality of the rolled material and/or the productivity of the rolling installation.
This object is achieved by a method of the type mentioned initially, in which the manipulated variable is supplied to an electrohydraulic actuating element and this actuating element acts on at least one hydraulic actuator for the roller engagement, wherein the electrohydraulic actuating element has a rated flow rate of ≧50 l/min, and at least a portion of the frequency response at frequencies f≧80 Hz is characterized by a magnitude drop of ≦3 dB, and the phase lag φ in this frequency range satisfies the conditions f≧19·{square root over (φ)}+3.1·10−6·φ4 and φ≦90°.
In this case, an electrohydraulic actuating element means a hydraulic valve which can be operated electrically, for example by means of a 4 to 20 mA current signal, for example a continuous, single-stage or multiple-stage control valve, proportional valve or servovalve. Although hydraulic valves have a nonlinear response, for example in the flow characteristic, the dynamic response of valves can be characterized well by means of the frequency response. The frequency response is therefore suitable for specifying the suitability of a valve for specific purposes, in the sense of the dynamic response. The determination of the frequency response, that is to say the phase response and the magnitude response, of continuous valves is known to a person skilled in the art from, for example:
For the purposes of the disclosure, a decrease in magnitude of ≦3 dB means that the magnitude response has a value ≧−3 dB; a positive value of the magnitude drop therefore leads to a reduction in the amplitude of the output signal. Analogously, a phase lag of, for example, ≦45° can be understood to mean that the phase response has a value ≧−45°, that is to say that the output signal lags the input signal by ≦45° (LAG response). Since the frequency response depends on various operating parameters, the stated values for the phase lag and the magnitude drop can be determined at a drive level of ±50%, preferably 85% (0% corresponds to a valve which has not been operated, that is to say on that is closed; 100% corresponds to a completely operated valve, that is to say a completely open valve) and a system pressure of 70% of the rated pressure of the valve. In many cases, the frequency response can but need not necessarily be determined experimentally, since the frequency response for many valves is already stated in the data sheets. The data sheets state the magnitude response, that is to say the amplification factor between the input signal and output signal, typically using the logarithmic scale of decibels (dB for short), and the phase response, that is to say the phase difference between the input signal and the output signal, in degrees°. This notation is likewise known, for example from Backé, although statements using other units are, of course, also possible. The definition of the rated flow rate, or the rated volume flow, is known from Chapter 3.6.3, ‘Rated volume flow’ from Backé. The rated flow rate is determined with a pressure difference of 70 bar, with the valve slide completely operated. The values for the phase lag φ in ° can be determined from a numerical-value inequality, in which the frequency f can be inserted using Hz.
The method according to the invention can be carried out in a particularly advantageous manner if at least one portion of the frequency response of the electrohydraulic actuating element is characterized at frequencies 200≧f≧80 Hz by a magnitude drop of ≦3 dB and, in this frequency range, the phase lag φ satisfies the conditions f≧19·{square root over (φ)}+3.1·10−6·φ4, preferably f≧23·{square root over (φ)}+3.1·10−6·φ4, particularly preferably f≧27·{square root over (φ)}+3.1·10−6·φ4, and φ<90°. These advantageous embodiments make it possible to achieve further improvements in the results for the suppression of oscillations, since the phase lag of the electrohydraulic actuating element was reduced further, and/or the frequency response, that is to say the phase lag and magnitude drop, are in a frequency band which is particularly advantageous for solving the problem according to the invention.
The method according to the invention can be carried out advantageously if the acceleration in the engagement direction, a hydraulic pressure or the engagement force of a hydraulic actuator for the roller engagement is used as a permanently measured variable. This fact is immediately evident because the acceleration is linked to the hydraulic pressure and piston area of the actuator via Newton's fundamental law F=m·{umlaut over (x)} where m is the mass and F is the force acting, to be precise the force F where F=p·A, thus allowing a very sensitive and accurate measurement.
Oscillations which occur are advantageously identified particularly quickly and, as a consequence of this, are suppressed particularly rapidly, if a permanently measured variable is supplied to a regulator with a sampling time of <1 ms, preferably <0.2 ms.
A further advantageous embodiment of the method consists in that the difference in the accelerations between the value at the piston rod and the value at the cylinder housing of a hydraulic actuator for the roller engagement is used as a permanently measured variable. This embodiment makes it possible to detect particularly accurately the forces and/or accelerations which effectively occur.
In two further advantageous embodiments of the method, a permanently measured variable is filtered by means of one or more bandpass filters, preferably by more than second-order bandpass filters. These embodiments make it possible to filter frequency components which are relevant for chatter oscillations out of a measured variable, and to supply them to a regulator.
It is also advantageous that the regulator determines the manipulated variable taking account of a mathematical control rule and a model element, which characterizes the installation state and/or the installation response, and preferably contains a hydraulic and/or mechanical and/or rolling force model. This regulator according to the invention ensures that the rolling installation exhibits the desired response, which is predetermined by the manipulated variable, largely independently of the respective operating point. Since the frequency response of any actual actuating element is subject to a phase lag—particularly strongly, of course, at higher frequencies—it is advantageous for the manipulated variable to be supplied to a lead/lag element, and for the phase angle of the manipulated variable to be changed in this case. A lead/lag element makes it possible to change the phase angle of a signal, in this specific case the manipulated variable signal, and therefore to at least partially, or even completely, compensate for the phase shift caused by the actuating element.
It is also advantageous to supply the manipulated variable to a non-linear compensation element, and in this case to reduce or to compensate for non-linearities in the hydraulic roller engagement. A person skilled in the art knows, for example, that the flow characteristic of a hydraulic valve and the dynamic response of a hydraulic cylinder have significant non-linearities. Once these non-linearities are known, it is possible to overcome them completely or at least partially by means of non-linear compensation.
In a further advantageous version of the method according to the invention, the manipulated variable of the regulator is superimposed additively on a further manipulated variable, for example rolling gap regulation, in order to suppress oscillations and is supplied to an electrohydraulic actuating element, if necessary after a phase change and/or non-linear compensation. It is therefore possible to optimize the two control loops i) for suppression of oscillations and ii) for rolling gap regulation largely independently of one another, thus making it possible to improve the performance of the overall system.
The efficiency of the method according to the invention can be further improved if the supply pressure and/or the control pressure and/or the tank pressure at the electrohydraulic actuating element are/is stabilized by means of hydraulic accumulators. This measure shortens the response time of the actuating element and results in the actuating element responding uniformly, largely independently of transient pressure fluctuations.
In the case of rolling stands with high rolling forces, it is advantageous for the electrohydraulic actuating element to have a rated flow rate of ≧100 l/min, preferably ≧200 l/min. This makes it possible to use one actuating element to also produce high volume flows for operating one or more actuators for roller engagement. As noted above, the rated flow rate is determined for a pressure drop of 70 bar.
Advantageously, the size of the electrohydraulic actuating element is selected using the inequality Qrated≧1592·Vcyl while the cylinder volume can be entered in this numerical inequality in m3, resulting in the rated volume flow Qrated in l/min. The cylinder volume is obtained from the formula Vcyl=Acyl·stroke, in which the piston area is Acyl and the maximum stroke of the hydraulic cylinder is “stroke”. In order to achieve a particularly large dynamic range for oscillation suppression, it is advantageous to associate one and only one hydraulic actuator for roller engagement with each actuating element.
In order to allow the method according to the invention, which solves the problem on which the invention is based, to be implemented as directly as possible, it is advantageous that an electrically operated hydraulic valve, to which the manipulated variable can be supplied, and at least one hydraulic cylinder for the roller engagement, via which at least one roller in the roller set can be acted on, are provided, wherein the hydraulic valve has a rated flow rate of ≧50 l/min, at least a portion of the frequency response has a magnitude drop of ≦3 dB at frequencies f≧80 Hz and, in this frequency range, the phase lag φ satisfies the conditions f≧19·{square root over (φ)}+3.1·10−6·φ4 and φ<90°.
In a particularly advantageous manner, the apparatus for suppression of oscillations is designed such that at least a portion of the frequency response of the hydraulic valve at frequencies ≧80 Hz, preferably 200≧f≧80 Hz has a magnitude drop of ≦3 dB, and in this frequency range the phase lag 0 satisfies the conditions f≧19·{square root over (φ)}+3.1·10−6·φ4, preferably f≧23·{square root over (φ)}+3.1·10−6·φ4, particularly preferably f≧27·{square root over (φ)}+3.1·10−6·φ4, and φ<90°.
In a further advantageous embodiment of the apparatus according to the invention, a measurement device is in the form of an acceleration, pressure or force sensor. The measurement devices are connected to the digital regulator for example via cable or fieldbus.
An advantageous measurement device can be achieved if a measurement device has two acceleration sensors, wherein one sensor is connected to the piston rod and one sensor is connected to the cylinder housing of a hydraulic cylinder for roller engagement. In this case, it is advantageous for the measurement axis of an acceleration sensor to be arranged parallel to the engagement direction of a hydraulic cylinder for roller engagement.
A further improvement in the dynamic characteristics of the apparatus according to the invention can be achieved if a supply line and/or a control line and/or a tank line to the hydraulic valve has a hydraulic accumulator for pressure stabilization.
When the rolling forces are high, it is advantageous to design the apparatus such that the hydraulic valve has a rated flow rate of ≧100 l/min, preferably ≧200 l/min.
Advantageously, the electrohydraulic actuating element has a rated flow rate of Qrated≧1592·Vcyl, in which case, once again, the cylinder volume Vcyl can be inserted in m3, resulting in the rated flow rate Qrated in l/min.
One advantageous form of the apparatus, because it is particularly compact, can be achieved if the regulator together with the hydraulic valve forms an assembly, or the regulator is located in the immediate physical vicinity of the hydraulic valve. By way of example, the hydraulic valve is connected to the digital regulator by cable or fieldbus.
Particularly advantageous dynamic characteristics of the apparatus can be achieved if a hydraulic valve together with a hydraulic cylinder for roller engagement forms an assembly, or the hydraulic valve is located in the immediate physical vicinity of the hydraulic cylinder.
Further advantages and features of the present invention will become evident from the following description of exemplary embodiments, which are not restrictive, with reference being made to the following figures, in which:
| Number | Date | Country | Kind |
|---|---|---|---|
| A979/2008 | Jun 2008 | AT | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP2009/055526 | 5/7/2009 | WO | 00 | 2/9/2011 |
