Patent Application
20240198402
This application relates to metal processing generally, and, more specifically, to systems and methods for roll steering control in a rolling mill.
Rolling is a metal forming process in which a metal substrate is passed through a pair of work rolls of a work stand. The resulting contact between the metal substrate and the work rolls affects a thickness profile, flatness, and quality of the metal substrate. The inclination of the work rolls relative to a pass line of the metal substrate through the work stand, or roll steering, is one mechanism that may be used to affect a parameter of the metal substrate exiting the work stand. Traditionally, roll steering has required manual control by an operator to set a steering (tilting) value for each work roll and adjust it during production. This control is time consuming, may be inaccurate due to susceptibility to operator error, does not account for actual rolling mill conditions (and thus may be inaccurate), and does not allow for adequate control in real time.
Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments 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 patent, any or all drawings, and each claim.
According to certain embodiments, a method for controlling roll steering during rolling of a metal substrate includes generating a model for a work stand of a rolling mill based on setup data. Generating the model may include determining an adjustment value for the work stand. The method may also include receiving a measured parameter about the metal substrate at a location upstream from the work stand from a sensor and determining an expected output parameter for the work stand by modifying the measured parameter by the adjustment value. In various embodiments, the method includes comparing the expected output parameter with a target output parameter for the work stand and actuating a steering control actuator for the work stand such that the expected output parameter is within a predetermined tolerance of the target output parameter. The steering control actuator is adapted to control an inclination of at least one work roll of the work stand relative to a pass line of the metal substrate.
According to various embodiments, a rolling mill includes a steering control system, and the steering control system includes a steering control actuator, a sensor, and a controller. The steering control actuator controls an inclination of a work roll of a work stand of the rolling mill, and the sensor measures a parameter of a metal substrate upstream from the work stand. The controller is operably connected with the steering control actuator and the sensor and includes a processor and a memory coupled to the processor The memory includes instructions executable by the processor for generating a model for the work stand and determining an adjustment value for the work stand, receiving the measured parameter from the sensor, and determining an expected output parameter by adjusting the measured parameter by the adjustment value. The memory may also include instructions executable by the processor for comparing the expected output parameter with a target output parameter and actuating the steering control actuator such that the expected output parameter is within a predefined tolerance of the target parameter.
According to certain embodiments, a steering control system for a rolling mill includes at least one processor and a memory coupled to the processor. The memory includes a plurality of instructions executable by the processor for generating a model for a work stand and determining an adjustment value for the work stand, receiving a measured parameter about a metal substrate from a sensor upstream from the work stand, and determining an expected output parameter by adjusting the measured parameter by the adjustment value. The memory may also include instructions executable by the processor for comparing the expected output parameter with a target output parameter and generating a control response based on the expected output parameter being outside of a predefined tolerance of the target parameter.
Various implementations described herein may include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.
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.
Described herein are systems and methods for controlling roll steering of one or more work rolls of a work stand of a rolling mill during rolling. While the systems and methods described herein can be used with any metal, they may be especially useful with aluminum or aluminum alloys. In certain embodiments, the systems and methods described herein may automatically control roll steering during rolling. In various embodiments, a model is generated for the work stand based on setup data, and the model includes an adjustment value for the work stand. In embodiments where a rolling mill includes a plurality of work stands, a model may be generated for each work stand based on setup data for each work stand, and each model includes an adjustment value specific to the particular work stand. In various embodiments, the adjustment value is a correction value indicative of the actual efficiency of the work stand or deviation of the actual performance of the work stand compared to expected performance.
In certain embodiments, the setup data may include data measured from a prior rolling operation, although it need not in other embodiments. In various embodiments, the setup data may include a parameter measured by a sensor, an input parameter, or various combinations thereof. As some non-limiting examples, a measured parameter may be measured with one or more sensors including, but not limited to, tension meters, gauge meters, flatness rolls, optical sensors, cameras, temperature sensors, combinations thereof, or other sensors as desired. The measured parameter may include, but is not limited to, a tension in the metal substrate, a chemistry and/or composition of the metal substrate, a temperature of the metal substrate, etc. The input parameter may be other parameters as desired that may not necessarily be measured by a sensor. As some non-limiting examples, the input parameter may include, but is not limited to, a width of the metal substrate or a thickness of the metal substrate. The aforementioned parameters are provided for reference purposes and should not be considered limiting as the model and/or adjustment value for each work stand may be generated using various setup data as desired, including more than one measured parameter.
During rolling, a sensor may measure a parameter of the metal substrate at a location relative to the work stand. A controller may use the measured parameter as an input to the model to determine an expected output parameter by modifying the measured parameter by the adjustment value. The expected output parameter may be compared to a target output parameter for the work stand, and a steering control actuator for the work roll stand may be actuated to adjust the expected output parameter to within a predetermined tolerance of the target output parameter. In certain aspects, by modifying the measured parameter by the adjustment value, which is based on actual rolling conditions, the controller may more accurately predict the output result from the rolling mill. Moreover, comparing the expected output parameter (i.e., the measured parameter modified by the adjustment value) to the target output parameter may allow for the system to achieve target output parameters faster and with improved accuracy.
In various embodiments, each work stand 104A-C optionally includes a steering control actuator 110A-C that may be used to control an inclination or tilt of the work rolls 106 relative to the pass line of the metal substrate 102 and across a width of the metal substrate (i.e., in a direction coming out of the page in
In certain embodiments, the rolling mill 100 includes a steering control system 112. In the embodiment of
Each controller 114A-C includes a processor and a memory and is operably connected to a corresponding sensor 116A-C and a corresponding steering control actuator 110A-C. The memory is coupled to the processor and includes instructions executable by the processor to perform various functions discussed in detail below. The sensors 116A-C may be various devices or mechanisms suitable for measuring at least one parameter of the metal substrate 102 during rolling. As some non-limiting examples, each of the sensors 116A-C may be a tension meter that measures a tension in the metal substrate 102, a temperature sensor that measures a temperature of the metal substrate 102, a gauge or thickness meter that measures a thickness of the metal substrate 102, a position sensor that measures a position of the metal substrate 102 relative to a centerline of one of the work stands (e.g., the halfway point across the width of the work stand, which is transverse to the processing direction 109), a flatness sensor that measures a flatness of the metal substrate 102 across the width of the metal substrate 102, optical sensors, cameras, combinations thereof, or other suitable sensors as desired. In certain embodiments, the sensors 116 may be provided at an interstand location between adjacent work stands, although they need not be in other embodiments. In the example of
Optionally, the steering control system 112 may include an exit sensor 118 after the last work stand (e.g., the work stand 104C). The exit sensor 118 may be various devices or mechanisms that may be similar to or different from the devices used as the sensors 116A-C. In one non-limiting embodiment, the exit sensor 118 is a flatness sensor that measures a flatness profile of the metal substrate 102 across the width of the metal substrate 102. In certain embodiments, the exit sensor 118 may be operably connected to one or more of the controllers 114A-C or to another controller that is operably connected to another piece of processing equipment (e.g., a controller for sprayers of a coolant distribution system).
In some embodiments, and as illustrated in
Referring to
In a block 302, the method 300 includes generating a model for each work stand of the rolling mill. For example, in the embodiment of
In various embodiments where the setup data includes one or more measured parameters, the measured parameters may be obtained using one or more sensors that measure a parameter of the metal substrate during the current rolling operation or during a previous rolling operation. As some non-limiting examples, a measured parameter may be measured with one or more sensors including, but not limited to, tension meters, gauge meters, flatness rolls, optical sensors, cameras, temperature sensors, combinations thereof, or other sensors as desired. The measured parameter(s) may include, but is not limited to, a tension in the metal substrate, a chemistry and/or composition of the metal substrate, a chemistry or composition of the metal substrate, a temperature of the metal substrate, combinations thereof, or other parameters as desired. As one non-limiting example, the setup data used to generate the model for a work stand may include a tension in the metal strip measured by a tension meter during a prior rolling operation, a thickness of the metal substrate measured by a gauge meter during a prior rolling operation, and a temperature of the metal substrate measured by a temperature sensor during a prior rolling operation.
Tn various embodiments where the setup data includes one or more input parameters, the input parameter may be other parameters as desired that may not necessarily be measured by a sensor. As some non-limiting examples, the input parameter may include, but is not limited to, a width of the metal substrate, a chemistry or composition of the metal substrate, and/or a thickness of the metal substrate.
Based on the setup data, the model is generated for each work stand. Generating the model includes generating an adjustment value for the particular work stand based on the setup data. In various embodiments, the adjustment value is a correction value indicative of the actual efficiency of the work stand or deviation of the actual performance of the work stand compared to expected performance.
In a block 304, the method 300 includes receiving a measured parameter from one or more sensors about the metal substrate during rolling. In certain embodiments, block 304 includes receiving the measured parameter from an immediately upstream sensor and/or an immediately downstream sensor. For example, in the embodiment of
In a block 306, the method 300 includes determining an expected output parameter and comparing the expected output parameter to a target output parameter. In certain embodiments, determining the expected output parameter includes modifying the measured parameter by the adjustment value determined in block 302. In certain embodiments, modifying the measured parameter by the adjustment value may more accurately predict an output for the particular work stand because the adjustment value is based on the actual efficiency of the work stand (e.g., based on the setup data).
In a block 308, the method 300 includes generating a control response based on the comparison between the expected output parameter and the target output parameter. In some embodiments, block 308 includes actuating a steering control actuator for the work stand such that the expected output parameter determined in block 306 is within a predetermined tolerance of the target output parameter. In various embodiments, generating the control response and actuating the steering control actuator may include sending a control to the steering control actuator to control an inclination or tilt of one or more work rolls of the particular work stand. In one non-limiting embodiment, block 308 may include actuating a backup roll, a hydraulic cylinder, a bearing, combinations thereof, or other suitable steering control actuators as desired.
Optionally, if a particular work stand is a last work stand of the rolling mill, the method 300 may include receiving a measured parameter from the exit sensor 118 downstream from the last work stand, determining an expected exit parameter based on the measured parameter from the exit sensor 118 and the adjustment value, and actuating the steering control actuator such that the expected exit parameter is within a predetermined tolerance of a target exit parameter. In one non-limiting embodiment, the exit sensor 118 may be a flatness sensor that measures a flatness profile across a width of the metal substrate, and the measured flatness profile may be used to actuate the steering control actuator such that an expected flatness profile is within a predetermined tolerance of a target flatness profile.
As one non-limiting example of controlling roll steering using the method 300, block 302 may include generating a model for a work stand such as the work stand 104A, and block 304 includes receiving a measured thickness of the metal substrate 102 from the sensor 116A (e.g., in this example, the sensor 116A is a gauge or thickness sensor). In this example, block 306 may include comparing an expected output thickness from the work stand 104A to a target output thickness from the work stand 104A. Block 308 may include actuating the steering control actuator 110A and controlling the inclination or tilt of the work roll(s) 106 of the work stand 104A such that the expected output thickness is within a predetermined tolerance of the target output thickness.
As another non-limiting example of controlling roll steering using the method 300, block 302 may include generating a model for a work stand such as the work stand 104A, and block 304 includes receiving a measured flatness profile across the width of the metal substrate 102 from the sensor 116A (e.g., in this example, the sensor 116A is a flatness sensor). In this example, block 306 may include comparing an expected output flatness profile from the work stand 104A to a target output flatness profile from the work stand 104A. Block 308 may include actuating the steering control actuator 110A and controlling the inclination or tilt of the work roll(s) 106 of the work stand 104A such that the expected output flatness profile is within a predetermined tolerance of the target output flatness profile.
As an additional non-limiting example of controlling roll steering using the method 300, block 302 may include generating a model for a work stand such as the work stand 104A, and block 304 includes receiving a measured position of the metal substrate 102 relative to a centerline of the work stand 104A (e.g., a measurement of whether the metal substrate 102 is substantially aligned with the centerline of the work stand 104A, offset to the left, offset to the right, etc.). In this example, the sensor 116A is a position sensor. Block 306 may include comparing an expected output position of the metal substrate 102 upon exiting the work stand 104A to a target output position. Block 308 may include actuating the steering control actuator 110A and controlling the inclination or tilt of the work roll(s) 106 of the work stand 104A such that the expected output position is within a predetermined tolerance of the target output position.
As another non-limiting example of controlling roll steering using the method 300, block 302 may include generating a model for a work stand such as the work stand 104A, and block 304 includes receiving a measured tension in the metal substrate 102 from the sensor 116A (e.g., in this example, the sensor 116A is a tension meter). In this example, block 306 may include comparing an expected output tension from the work stand 104A to a target output tension from the work stand 104A. Block 308 may include actuating the steering control actuator 110A and controlling the inclination or tilt of the work roll(s) 106 of the work stand 104A such that the expected output tension is within a predetermined tolerance of the target output tension.
The aforementioned examples are provided for illustrative purposes and should not be considered limiting on the disclosure. Moreover, as previously discussed, in certain embodiments, more than one parameter may be used for generating the model and/or subsequent control of the work stand using the steering control system 112.
A collection of exemplary embodiments are provided below, including at least some explicitly enumerated as “Illustrations” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.
Illustration 1. A method for controlling roll steering during rolling of a metal substrate, the method comprising: generating a model for a work stand of a rolling mill based on setup data, wherein generating the model comprises determining an adjustment value for the work stand; receiving a measured parameter about the metal substrate at a location upstream from the work stand from a sensor; determining an expected output parameter for the work stand by modifying the measured parameter by the adjustment value; comparing the expected output parameter with a target output parameter for the work stand; and actuating a steering control actuator for the work stand such that the expected output parameter is within a predetermined tolerance of the target output parameter, wherein the steering control actuator is adapted to control an inclination of at least one work roll of the work stand relative to a pass line of the metal substrate.
Illustration 2 The method of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises a measured thickness, wherein the expected output parameter is an expected output thickness, and wherein the target output parameter is a target output thickness.
Illustration 3. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises a measured flatness profile across a width of the metal substrate, wherein the expected output parameter is an expected output flatness profile, and wherein the target output parameter is a target output flatness profile.
Illustration 4. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises a measured position of the metal substrate relative to a centerline of the work stand, wherein the expected output parameter is an expected output position, and wherein the target output parameter is a target output position.
Illustration 5. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the work stand is a first work stand of a plurality of work stands, and wherein the method comprises generating a model for each work stand of the plurality of work stands based on setup data for each work stand.
Illustration 6. The method of any preceding or subsequent illustrations or combination of illustrations, wherein actuating the steering control actuator comprises controlling at least one hydraulic cylinder or at least one backup roll.
Illustration 7. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises a tension in the metal substrate, wherein the expected output parameter is an expected tension, and wherein the target output parameter is a target tension.
Illustration 8 The method of any preceding or subsequent illustrations or combination of illustrations, wherein generating the model for the work stand comprises generating the model prior to rolling of the metal substrate, and wherein the setup data comprises data from a prior rolling operation.
Illustration 9 The method of any preceding or subsequent illustrations or combination of illustrations, further comprising: receiving a measured thickness about the metal substrate at a location after a last work stand of the rolling mill from a sensor; determining an expected thickness for the work stand by modifying the measured thickness by the adjustment value; comparing the expected thickness with a target thickness for the work stand; and actuating the steering control actuator for the work stand such that the expected thickness is within a predetermined tolerance of the target thickness.
Illustration 10. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the work stand is a first work stand and the rolling mill further comprises a second work stand upstream from the first work stand, wherein the sensor is between the first work stand and the second work stand, and wherein the method further comprises: generating a model for the second work stand based on setup data, wherein generating the model for the second work stand comprises determining an adjustment value for the second work stand; and after rolling the metal substrate, updating the model for the second work stand by updating the adjustment value based on the measured parameter of the metal substrate during rolling from the sensor being outside the a predetermined tolerance of a target output parameter for the second work stand.
Illustration 11. A rolling mill comprising a steering control system, the steering control system comprising: 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, wherein the controller comprises a processor and a memory coupled to the processor, wherein the memory comprises instructions executable by the processor for: generating a model for the work stand and determining an adjustment value for the work stand; receiving the measured parameter from the sensor; determining an expected output parameter by adjusting the measured parameter by the adjustment value; comparing the expected output parameter with a target output parameter; and actuating the steering control actuator such that the expected output parameter is within a predefined tolerance of the target parameter.
Illustration 12. The rolling mill of any preceding or subsequent illustrations or combination of illustrations, further comprising the work stand and the work roll, wherein the work roll comprises an upper work roll or a lower work roll adapted to contact the metal substrate during rolling.
Illustration 13. The rolling mill of any preceding or subsequent illustrations or combination of illustrations, wherein the work stand is a first work stand of a plurality of work stands, and wherein the memory comprises instructions executable by the processor for generating a model for each work stand of the plurality of work stands based on setup data for each work stand.
Illustration 14. The rolling mill of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises a measured thickness, wherein the expected output parameter is an expected output thickness, and wherein the target output parameter is a target output thickness.
Illustration 15. The rolling mill of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises a measured flatness profile across a width of the metal substrate, wherein the expected output parameter is an expected output flatness profile, and wherein the target output parameter is a target output flatness profile.
Illustration 16. The rolling mill of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises a measured position of the metal substrate relative to a centerline of the work stand, wherein the expected output parameter is an expected output position, and wherein the target output parameter is a target output position.
Illustration 17 The rolling mill of any preceding or subsequent illustrations or combination of illustrations, wherein the steering control actuator comprises controlling at least one hydraulic cylinder or at least one backup roll.
Illustration 18. A steering control system for a rolling mill, the steering control system comprising: at least one processor; a memory coupled to the processor, wherein the memory comprises a plurality of instructions executable by the processor for: generating a model for a work stand and determining an adjustment value for the work stand; receiving a measured parameter about a metal substrate from a sensor upstream from the work stand, determining an expected output parameter by adjusting the measured parameter by the adjustment value; comparing the expected output parameter with a target output parameter, and generating a control response based on the expected output parameter being outside of a predefined tolerance of the target parameter.
Illustration 19. The steering control system of any preceding or subsequent illustrations or combination of illustrations, wherein the processor is configured to generate the control response by actuating a steering control actuator of the work stand to control an inclination of a work roll of a work stand of the rolling mill.
Illustration 20. The steering control system of any preceding or subsequent illustrations or combination of illustrations, wherein the measured parameter comprises at least one of a thickness of the metal substrate, a flatness of the metal substrate, or a position of the metal substrate relative to a centerline of the rolling mill.
The subject matter of embodiments is described herein with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. Reference to embodiments have element A and/or element B covers embodiments having element A alone, element B alone, or elements A and B taken together.
The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.
This application claims the benefit of and priority to U.S. Provisional Application No. 63/177,129, filed on Apr. 20, 2021, which is hereby incorporated by reference in its entirety for all purposes.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/071372 | 3/28/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63177129 | Apr 2021 | US |
