Patent Application
20200230677
The invention relates to a method for operating a roll straightening machine, wherein the roll straightening machine has a number of forming tools, wherein the forming tools comprise at least one set of upper and lower straightening rollers, wherein a metallic flat material to be straightened is conveyed in a conveying direction between the upper and the lower straightening rollers. The invention furthermore relates to a roll straightening machine.
A roll straightening machine of the generic type is known from EP 0 551 658 B1. In the case of this solution it is provided that individual straightening rollers are actuated in a targeted manner so as to implement the required position of the rollers for the straightening procedure.
Furthermore, straightening machines having dissimilar roll diameters are known from, for example, DE 10 2013 207 307 A1 and from WO 2017/32652 A1. Individually actuatable straightening rolls are known from WO 2017/013099 A1, DE 1 930 349 A1 discloses an individual drive for the rolls of a straightening machine.
JP-A-405111716 discloses a conventional straightening machine in which the entire straightening rolls set is adjusted for wear. Similar solutions are described in JP-A-2015123460 and JP-A-359097719.
In practice, straightening machines which in most instances do not have any individually actuatable straightening rollers, or only one individually actuatable entry or exit straightening roller, respectively, are mainly used. The actuation of the straightening rollers is performed conjointly by actuating the frame in which the straightening rollers are installed. In order for the machine to be actuated in a targeted manner, the installed straightening and support rollers, as tools installed in the machine, all have to possess the same diameter, even in the case of the previously known solution mentioned.
Said previously known straightening machines that are commonplace in practice in most instances specifically provide a group drive for the straightening rollers, The straightening rollers of one group thus all have to have the same barrel diameter in order for uniform speeds to be attained and no torsion stresses that cannot be controlled to build up in the drivetrain.
This can disadvantageously lead to tools having only slight wear, or even new tools, first having to be post-machined in order for said tools to be able to be installed together with the most heavily worn-out tool in one roller set.
The different state of wear of straightening rollers, support rolls, and moreover also of actuating elements of the technological closed-loop control systems also has a disadvantageous effect in the case of individually driven and/or individually actuatable straightening rollers. Variations in term of the speed, the plunging depth, and/or the bending of the straightening rollers are created on account of wear such that the straightening task, that is the elimination of planarity errors, is achieved only by way of quality compromises in the metal sheet or strip. Wear on the straightening rollers and support rollers is created by the production operation per se and can falsify the original cylindrical contour of the rollers.
However, wear has also be paid attention to when using refurbished rollers since the latter indeed have a cylindrical contour, however at a smaller diameter.
Moreover, signs of wear in terms of the roller deflections in relation to plunging depth and bending are also observed, said signs of wear compromising the accuracy and thus the effectiveness of said actuating members.
The invention is therefore based on the object of refining a method of the type mentioned at the outset such that a high straightening quality can be achieved even in the case of wear of the tools taking place, without compromising the performance of the straightening machine.
The achievement of said object by the invention is characterized in that the method comprises the following steps:
wherein the straightening rollers are individually driven and individually actuatable and wherein the adapting of an operating parameter according to step c) includes adapting the rotating speed of a straightening roller and/or the actuated position of the straightening roller and/or the modification of an applied bending moment for a bending compensation.
The at least one forming tool herein can preferably be a straightening roller, a support roll, and/or an actuating system for the straightening roller.
The determining of the state of wear of at least one of the forming tools according to above step a) can be or comprise manual measuring of wear of the forming tool with subsequent inputting of the measured value into a machine controller.
Alternatively, it is also possible that the determining of the state of wear of at least one of the forming tools according to above step a) is or comprises an automatically carried out measuring procedure and an automated comparison with a nominal value.
A further alternative solution thereto provides that the determining of the state of wear of at least one of the forming tools according to above step a) is or comprises determining the wear by virtue of a predefined empirical wear behavior of the forming tool.
Finally, it can furthermore alternatively be provided that the determining of the state of wear of at least one of the forming tools according to above step a) is performed by a calibrating procedure of the roll straightening machine, wherein data determined during the calibrating are compared with data of a calibrating procedure carried out earlier and a conclusion pertaining to intervening wear is drawn on account thereof.
The determining of a correction value and/or an equalization value for the operating of the forming tool according to above step b) can be performed virtue of a simulation calculation which is based on a simulation mode, of the roll straightening machine.
Alternatively thereto, it can be provided that the determining of a correction value and/or an equalization value for the operating of the forming tool according to above step b) is performed by virtue of a predefined characteristic line which predefines in particular the state of wear over time.
The proposed roll straightening machine having a number of forming tools, wherein the forming tools comprise at least one set of upper and lower straightening rollers, wherein a metallic flat material to be straightened can be conveyed in a conveying direction between the upper and the lower straightening rollers, provides according to the invention that the roll straightening machine has means for identifying wear of at least one of the forming tools as well as means for compensating the determined wear on the forming tools, wherein roll straightening machine furthermore has means for individually driving and individually actuating the straightening rollers as well as for adapting the rotating speed of a straightening roller and/or the actuated position of the straightening roller and/or for modifying an applied bending moment for a bending compensation.
A machine controller is preferably present for controlling the means for compensating the determined wear on the forming tools.
The means for identifying wear can be or comprise measuring means for detecting force, pressure, drive torque, and/or travel.
The means for compensating the determined wear can be or comprise a bending system for the straightening rollers and/or an actuating system for the straightening rollers.
The means for compensating the determined wear can comprise a technological model of the roll straightening machine.
It is possible for the determined type of wear to be assigned to a preferred tool function. Furthermore, checking for potential collisions with a view to operating the machine functionality within permissible operating positions can be performed. The invention permits the simultaneous use of tools which are worn out and tools which are not worn out to be provided in the straightening machine without suffering losses in terms of the quality of the straightening procedure.
The means for compensating wear can be individual drives of the straightening rollers in order for the rotating speed or the torque, respectively, to be corrected, optionally having a closed-loop load equalization system.
The forming tools are be understood in the present case in general terms as driven straightening rollers which perform the actual forming work; support rolls or support rollers, respectively, for the straightening rollers, said support rolls or support rollers having a corresponding mounting; bending systems in the form of individual actuating systems for adjusting the straightening gap contour across the straightening roller barrel in the stressed and the unstressed state; as well as actuating systems for setting plunging depths of individual rolls in the stressed and the unstressed state.
Various types of wear can be considered herein: first, local or planar, respectively, modifications on the roller barrel or roll barrel, respectively, are possible, that is to say a modification across the longitudinal extent of the roller or roll, respectively. Furthermore, planar wear on slip surfaces is possible. Apart from abraded straightening rollers or support rolls having local signs of wear, completely worn-out barrels can also arise; the roller or roll, respectively, in this instance has been overall modified in terms of the diameter of said roller or roll, respectively.
In the case of setting the roll straightening machine, this refers to the setting of operating parameters of the straightening machine for carrying out a straightening procedure. Each straightening roller herein receives individual actuation parameters for the adjustable tools.
It can be provided that adapting the rotating speed of the straightening roller over time is performed according to a predefined correlation that is stored in the machine controller. It is in particular provided herein that the correlation that is stored in the machine controller is determined in that the state of wear of the straightening roller over time is observed, recorded, and is defined as numerical values or as a correlation in terms of a formula. The correlation stored in the machine controller herein can alternatively or additionally also be determined by virtue of a theoretical calculation, wherein the parameters influencing the wear of the straightening roller are considered in a simulation model, said parameters being in particular the number of straightening passes, the drive torque of the straightening roller, the straightening force, the coefficient of static friction, and/or the incidence of scales.
The proposed solution accordingly makes available a method for compensating wear in the case of straightening machines, said method being able to be used in particular when straightening metallic flat material such as metal sheets, sheet-metal material, plates and parts thereof, and strips. Said method is particularly suitable for straightening steel sheets or strips.
A straightening machine having individually driven straightening rollers as well as individually adjustable straightening rollers is in particular used.
The wear of the straightening tools, that is to say of the straightening rollers and of the support rollers, of a straightening machine can be compensated by way of the method so as to maintain a consistent straightening quality across the use cycle of said tools.
It thus becomes possible for new as well as worn-out straightening rollers and support rollers, or else straightening rollers and support rollers that by virtue of wear or damage have been refurbished or post-machined (abraded), respectively, to be used in one roller set while maintaining the performance of the machine by compensating the wear and tear.
On account of the proposed solution, complex planarity faults in the goods to be straightened can be straightened to the best possible extent by means of the straightening machine, independently of the influence of the wear on the tools.
The simultaneous use of post-machined, worn-out and new tools in one roller set is thus enabled.
By means of the individual drives and the individual actuation of the straightening rollers, straightening rollers and support rollers having dissimilar states of wear and abrasion can be operated simultaneously in a straightening machine in one roller set since the height and the rotating speed of each individual straightening roller can be actuated and set as a function of the state. The same applies for the deflection of the straightening roller as well as for the bending of the straightening roller.
Determining the state of wear of components based on a machine calibration that deviates from the respective preceding machine calibration is possible.
Automatic learning of the temporal state of wear of components of the machine can also be provided by virtue of the determination by way of comparing one machine calibration to another machine calibration as mentioned.
The determining of the state of wear of components is possible based on a theoretical calculation (for example, number of straightening passes, drive torque, straightening force, coefficient of static friction, incidence of scales).
Furthermore, the determining of the state of wear of components based on the deviation of the calculated nominal parameters (SETUP) with a view to the straightening force, the torque, and the resilience from measured actual values is also possible.
As has been mentioned, a technological model can be used herein for calculating and closed-loop controlling of the functional units of the machine (primary actuation including tilting and pivoting for influencing various planarity faults; compensation of bending, elongation, and compression; individual straightening roller actuation; drive torques), in particular while considering the state of wear of the tools.
Furthermore, the wear of the tools of the straightening machine (wastage of the straightening rollers and of the supporting apparatus of the support rollers) can be compensated based on a wear model.
Predefining the state of wear of components by the operator is possible for the technological automation.
The drive torques can advantageously be distributed in a targeted manner by way of the individual drives for the optimized utilization of the service life and the is distribution of the wear behavior of components.
The threading of the material to be straightened can be optimized by way of a closed-loop control of the drive torque. Consequently, the risk of marking when the material head impacts the straightening roller, and thus also the risk of a defective location (defect) on the straightening roller barrel being embossed in the material surface and the surface quality of the product being negatively influenced on account thereof, is reduced.
Advantageously, not all or at least some of the straightening rollers to be installed in a set of straightening rollers have to be abraded in a complex manner to a uniform straightening roller diameter.
Furthermore advantageously, not all or at least some of the support rollers to be installed in a set of straightening rollers have to be abraded in a complex manner to a to a uniform support roller diameter.
Finally, it is advantageous that not all of the support rollers to be installed in a set of straightening rollers have to be shimmed so as to lift all straightening rollers of uniform diameter to a respective straightening roller height level.
Exemplary embodiments of the invention are illustrated in the drawing, in which:
A straightening roller (this can be an upper straightening roller 2 or a lower straightening roller 3) of a roll straightening machine 1 is drawn in a schematic manner in
As can be seen from
It can be seen in
Viewing
To this end, a machine controller 7 which comprises a correction value determination 13 is provided (cf.
The roll straightening machine 1 can be schematically seen in the lateral view in
The following is therefore to be noted in this context:
Should a straightening roller 2, 3 display regions with local signs of wear 9, in which regions the diameter has been reduced to the smaller value d, the forming task cannot be correctly carried out in these regions since the contact forces deviate in a localized manner. The stretching of the strip segment is incomplete.
To this end,
On account of the suitable actuation, in this case of the bending cylinders of the bending system 8, it becomes evident that the effect of the local signs of wear 9 is compensated in such a manner that the contact between the straightening roller 2 and the material 6 to be straightened is uniform. The bending cylinders of the bending system 8 thus act as means for compensating wear. The corresponding signals are transmitted to this end from the machine controller 7 to the bending cylinders of the bending system 8, wherein the local wear of the straightening rover 2 is considered.
The schematic illustration shows that the machine controller 7 positions the actuation in the case of worn-out straightening rollers in such a manner that a plunging depth required for the straightening procedure is achieved even when there is wear. This is achieved by increasing the actuation stroke by the wear value, in this case the difference in terms of the diameter.
Accordingly, the drive parameters in terms of torque and/or rotating speed for the worn-out straightening rollers are corrected by the machine controller 7 such that the smaller straightening roller diameter is compensated. The straightening task can be carried out in an optimal manner. The actuation and the individual drive act as means for compensating wear, the actuation values/setting values of said actuation and said individual drive having been corrected.
The proposed concept first serves for setting the system prior to carrying out a straightening procedure.
The state of wear of the tools first has to be determined by way of suitable methods. Subsequently, the required correction value or an equalization parameter is calculated by way of, said correction value or equalization parameter resulting in a new actuation parameter/setting value that is modified in relation to the tool that is not worn out. The machine controller 7 transfers the corrected actuation parameters to the individual tools such that the operating parameters of said individual tools, the so-called tool functions, are set. The computer unit for determining correction values and the machine controller can be separate units (cf.
The tools that are not worn out receive a correction value of “zero”, that is to say that the originally provided setting is not corrected. The fundamental procedure of setting the roll straightening machine is not discussed in more detail here since this is well known in the prior art.
The central objective here is rather to solve the problem of wear and the integration of said solution in the setting of the system.
On account of the setting of tools that are worn out as compared to toots that are not worn out, tools that are worn out and tools that are not worn out can be used simultaneously in a straightening machine without suffering any losses in terms of the quality of the straightening procedure.
Various possibilities for identifying wear are available. The identification of wear can be performed by a manual input by the operator personnel after manual measuring. A potential automated method step of determining wear lies in the determining of the wear by way of a nominal/actual comparison of process nominal values with measured process actual values and in drawing conclusions pertaining to the wear. In this case, deviating values pertaining to straightening force, torque, resilience, etc., can be resorted to. The measurement can be carried out in the form of travel measurement systems, force measurement systems, and/or pressure measurement systems having a corresponding sensor mechanism installed in the straightening machine. Conclusions pertaining to the state of wear of a straightening roller can thus be drawn in the context of torque measurements during a straightening procedure, said conclusions being considered in the context of the setting for the following straightening procedure.
A further potential automated method step for determining wear can be performed in the form of an empirical determination of wear values. Moreover, the determining of wear can also be performed by way of a system calibration in that the results of a system calibration carried out are compared with the results of one or a plurality of previous system calibrations.
The determination/calculation of the correction values is performed in a separate computer unit or directly by the machine controller 7. This depends on the detailed design embodiment of the system automation and system management. The calculation of the correction values is preferably performed by a technological straightening machine model which calculates the setting values (also the actuation) and the wear-related correction values for the setting. A long-term and/or short-term adaptation of the straightening machine model while considering the wear parameters represents a further improvement. This can be performed independently of the straightening machine model, in the form of a separate wear model, or the straightening machine model has an implemented wear model.
The machine controller 7 performs the setting of the system, thus the targeted transmission of the operating positions and operating values to the respective tools.
For example, when a straightening roller 2, 3 having a continuously smaller diameter is installed in the straightening machine (to this end cf.
The machine controller 7 transfers the corresponding actuation parameters/setting values to the tool functions. In the example of the worn-out straightening roller (to this end cf.
A preferred correction of a tool function is assigned to the forms of wear. Wear across the entire straightening roller barrel is preferably corrected by the actuation of the straightening roller and the rotating speed of the latter, local wear of straightening rollers is corrected by the bending cylinders and the straightening roller rotating speed, wear of support rolls is corrected by the actuation and/or the bending cylinders. Further combinations are possible.
In order for the tool parameters to be equalized in a targeted manner in terms of the wear within the roll straightening machine 1, the roll straightening machine has means for identifying wear, for example in the form of the sensor mechanism already mentioned above. Said roll straightening machine 1 additionally has the means for compensating the wear. Said means for compensation are preferably composed of a combination of individual roller actuations, thus the possibility for each straightening roll to be individually set in terms of the plunging depth thereof, in conjunction with an individual roller drive (thus an individual drivetrain having a rotating speed and torque that are capable of being set).
Furthermore, a bending system by way of which the contour of the straightening roller can be influenced is provided for each straightening roll, so as to correct local wear in a targeted manner (to this end cf. reference sign 9 in
A further feature for improving the straightening result while considering wear parameters is the closed-loop load equalization control of the individual adjacent straightening roller drives. Undesirable distortions in terms of torque or rotating speed, respectively, are thus equalized.
These respective features (individual actuation, bending, individual drive) are known per se but the use thereof is extended in the present case to the task of correcting wear.
| Number | Date | Country | Kind |
|---|---|---|---|
| A 2017 02314 | Mar 2017 | UA | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2018/055992 | 3/12/2018 | WO | 00 |
