The present application relates to, and claims the priority of, the German patent application 10 2018 101 501.1, filed on Jan. 23, 2018, and of the German patent application 10 2018 111 627.6, filed on 15 May 2018, the disclosure of which is hereby expressly incorporated by reference into the subject matter of the present application.
The invention relates to a stretching-bending-straightening system according to the preamble of claim 1 and to a method for the actuation thereof according to the preamble of claim 10.
Stretching-bending-straightening systems as illustrated schematically in
For the finishing process, a brake S-block 16 and a tension S-block 18 are used to produce a high-tension region in the stretching-bending-straightening system shown in
In order to produce alternating bending in the bending-straightening apparatus 26, according to
In addition, according to the prior art, an unflatness measuring system (UMS) according to
From document DE 35 24 382 A1 there is known a stretching-bending-straightening system for a strip material, the system having a low-tension region and a high-tension region. Areas of unflatness are measured in both regions, and on that basis setpoint values for the slipping of the rollers are calculated by processors so as to thereby achieve the most uniform tension possible and thus a uniform quality of the strip. Specifically, the stress is measured on both sides equally, and the setpoint values are determined on that basis; there is no selection means for choosing selectively between low-tension region or high-tension region.
In document DE 22 03 911 A1 there is disclosed a method and a device for controlling the flatness of a metal strip. Areas of unflatness are detected by spacing sensors and there is then an appropriate adjustment of the penetration depth of the straightening rollers. This is achieved by use of a control system, not by a selection of high-pressure region or low-tension region.
From document DE 10 2004 043 150 A1 there is known a measurement system in
Proceeding from this prior art, the object of the present invention is to arrange a stretching-bending-straightening system and a method for the actuation thereof such that the quality of the strips processed by the system is increased.
This is achieved with a stretching-bending-straightening system having the features of claim 1 and by a method for the actuation thereof having the features of claim 10. Advantageous developments are the subject of the dependent claims. The features described individually in the claims are combinable with one another in a technically feasible manner and can be supplemented by explanatory information from the description and by details from the drawings, thus providing further variants of the invention.
The stretching-bending-straightening system has a feed means for feeding a material in strip form into a high-tension region and a low-tension region, wherein the low-tension region is arranged downstream of the high-tension region in the movement direction of the material in strip form. A bending-straightening apparatus is situated in the high-tension region. In addition, a measuring system for determining first measured values is provided in the high-tension region, and a measuring system for determining second measured values is provided in the low-tension region. A controller is provided for determining the deviation of the first measured values from a predefined or predefinable desired value of the bending-straightening result, as well as a controller for determining the deviation of the second measured values from said desired value. Manipulated variables are determined by the one or more controllers so as to minimize the deviations within closed control loops. In other words, at least two measuring systems are thus provided: one in a high-tension region and one in a low-tension region, so as to optimize the quality of the material to be processed, as necessary. Selection means may be used to decide whether the first or the second closed control loop is used for optimization. A selection of this kind may be made depending on certain criteria, which are based either on empirical values or material characteristic values, but also can be created for the first time during the course of the process itself, since, in each closed control loop, measurements are taken in the high-tension region and in the low-tension region at the same time, so that an optimization can be selected on the basis of the characteristic values thus determined. A strip of higher quality can thus be produced easily and conveniently.
It must be considered that a measuring device for the high-tension region was used previously generally only in rolling mills, whereas the solutions known in the prior art excluding rolling mills detect measured values and in particular detect areas of unflatness of the material in the low-tension region, the material having been straightened already coming from the coil by the bending-straightening apparatus situated in the high-tension region. Only the combination of both measuring devices, however, allows an optimal influence depending on the conditions of the strip, the requirements of the material to be manufactured and/or the material properties.
A single controller is preferably provided in order to simultaneously determine the deviation of the first and the second measured values from the desired value, so that the selection means choose the first or the second control loop alternatively. An optimization may thus be implemented in the controller even in the case of slight deviations, such that a switch is made from one control loop to the other, without further synchronization between different control assemblies.
An analysis unit for analyzing the first and/or the second measured values is expediently provided, that is to say more than one analysis unit may also be provided. The selection means are thus enabled to select the first or the second closed control loop depending on the analysis. Both a manual and a semi-automatic or automatic selection constitute potential selection means, depending on what specifications are given to the controller and the analysis unit.
It is furthermore advantageous if display means for displaying the first and second measured values are provided and/or the selection means are provided for manual selection performed by an operator. An operator, on the basis of the display, is thus able to identify at a glance the direction in which the measured values of the two measuring devices are heading and is thus able to decide whether preference should be given to the first or the second control loop.
The measuring system in the high-tension region is preferably formed by a measuring roller arranged after the bending-straightening apparatus. It is advantageous in particular if, to this end, a roller of a tension S-block, which is usually situated after the bending-straightening apparatus, is replaced by a measuring roller having sensors deployed on its circumference, the running surface of the measuring roller being covered by a resilient coating. It is thus possible to determine, practically immediately after the bending-straightening apparatus, whether there is a result of good quality in the high-tension region, so that the dead space between bending-straightening apparatus and measuring system is reduced. If the measuring roller in a preferred embodiment is formed as part of the tension S-block, there is no need for a separate mount for such a roller, and instead the roller provided anyway in the tension S-block may be replaced by the measuring device, which further reduces the costs of the overall structure.
The measuring system for determining the second measured values in the low-tension region should advantageously be arranged after the tension S-block, wherein it is arranged as close as possible to this block. An arrangement of this kind contributes to reducing the dead space, and thus the amount of waste, for this measuring system as well.
It is particularly preferred if the measuring roller used for this purpose has adjacently arranged measuring segments having at least one sensor, preferably having two force sensors, since it is important particularly in the low-tension region to detect the differences over the strip width as exactly as possible over the entire area. Whereas some deformations are not perceptible in the high-tension region on account of the forces occurring there, these deformations are intensified under lower tensile forces in the low-tension region after elastic recovery and may be clearly identifiable there. To this end, a higher resolution is advantageous and may be achieved by the arrangement of the measuring segments.
It is advantageous if storage means for storing operating parameters are additionally provided so as to use previously determined operating parameters for future processes. These operating parameters, for this purpose, are stored in a database, in which the operating parameters are stored together with data regarding the processed material. In this way a data bank and, possibly also supplemented by expert knowledge, a data record may be stored which may be used from the start for comparable materials so as to work on the system from the outset with the best possible approximation. The result may thus be optimized more quickly, and in general the amount of waste may be reduced.
In accordance with the method, the material in strip form is fed to the high-tension region and low-tension region. First and second measured values are determined in the high-tension region and also in the low-tension region, and a deviation from a desired value is determined. On the basis of this deviation, a manipulated variable for the bending-straightening apparatus is calculated for both measuring systems which are able to contribute to an optimization of the result. On the basis of predefined or predefinable criteria, such as a deviation from the desired value, but also empirical values or material characteristic values, a selection is then made between the first and the second closed control loop in order to attain the desired result. Both the advantages of a measurement in the high-tension region and the advantages of a measurement in the low-tension region may thus be considered simultaneously, such that it is possible to decide at all times in which of the control loops an improved result should be attained. Depending on the provided information and the features of the device, the system may then be switched over manually, semi-automatically, or automatically to the relevant control loop so as to attain an optimal result.
The deviation of the first and second measured values is preferably determined by means of a single controller simultaneously for both measuring systems, such that the first or second closed control loop is selected alternatively. In accordance with the method, all information is thus provided at the same time so as to be able to make an informed decision.
The first and second measured values are expediently analyzed on the basis of predetermined criteria in view of achieving a good result, wherein the appropriate control loop is then selected depending on the analysis. Such criteria may be constituted by determined requirements on the sought quality of the strip to be processed, but also may be constituted by material characteristic values or empirical values, which are predefined by the operator or are deducible from expert knowledge, which potentially is stored in a data bank.
For manual selection, the first and second measured values are advantageously displayed to an operator simultaneously, such that the operator may use selection means 48 to choose the control loop optimal for the result that is to be attained. The operator may thus decide, at a glance, which is currently the optimal solution. Since this may change over the course of time, even within the same coil, this process may also be automated and monitored, such that an indication of a suitable switchover time may be output to the operator as necessary.
Since the material to be processed firstly passes through the high-tension region and then through the low-tension region, it is particularly advantageous if the method is operated initially on the basis of the first measured values from the high-tension region in a first closed control loop, until the straightened material in strip form reaches the measuring roller in the low-tension region, such that it is then possible to switch to the second closed control loop in the low-tension region. Whether or not it is actually necessary to switch over at that moment, may be determined on the basis of the determined measured values. The dead space may be further reduced by such a configuration.
It is particularly advantageous if operating parameters already determined on the stretching-bending-straightening system are stored in a data bank jointly with data regarding the material to be processed and may be used again at a later time for the processing of comparable materials. This reduces the tooling and set-up time and optimizes the process such that a good result may be achieved quickly. The knowledge provided in the data bank may optionally be supplemented by expert knowledge, which contains information regarding certain material properties, and thus detailed operating parameters for the stretching-bending-straightening system.
Both the stretching-bending-straightening system and the method may be operated with a program, which is configured and/or programmed with a program code, in order to achieve the desired results and advantages if the program code is executed on a computer, a processor or a programmable hardware component.
Further advantages will become clear from the dependent claims and from the following description of a preferred exemplary embodiment.
The invention will be explained in greater detail hereinafter with reference to an exemplary embodiment of the invention illustrated in the drawings, in which:
The invention will now be explained in greater detail with reference to the accompanying drawings. The exemplary embodiments, however, are merely examples not intended to limit the inventive concept to a certain arrangement. Before the invention is described in detail, it is noted that the invention is not limited to the various components of the device or the various method steps, since these components and methods may vary. The terms used here are merely intended to describe particular embodiments and are not used in a limiting sense. In addition, if the singular or an indefinite article are used in the description or in the claims, this also refers to the plurality of these elements, provided the overall context does not clearly indicate otherwise.
In accordance with the invention, both measuring systems for the high-tension and low-tension regions are combined for the first time. This system is characterized preferably by the use of a single controller C, however a plurality of controllers may be used in principle. This, preferably one, controller C is able to analyze the flatness measured values of the measuring roller 40 in the high-tension region 50 and of the measuring roller 36 in the low-tension region 52. The supports of the straightening movement are adjusted on the basis of these values.
The analysis units 34 of the two measuring units are connected to the controller. This receives the flatness values of the two units and, using the measured values of the active measuring unit, calculates the optimal parameters for the straightening process. The system operator preferably determines which of the two measuring units should be used as a basis for controlling the straightening process. The operator is therefore able to use the measuring unit that is better suited according to the requirements and material and may also change the measuring unit during a process. So as to be able to compare the two units with one another for the process currently underway, it is possible to visualize the flatness measured values. To this end, the measured values of the measuring roller 36 in the low-tension region and of the measuring roller 40 in the high-tension region 50 are displayed in graphic form and/or as numerical values, preferably at the same time on a display unit 46.
A more precise adaptation of the supports to the areas of unflatness of the strip is thus achieved by the system according to the invention. In addition it is now possible to use the system that is better suited according to material requirements, material alloy and/or material thickness, and thus to attain optimal straightening results.
In the case of very thin and soft materials, such as aluminum, it could be that areas of unflatness may not be clearly detected due to the high tension. This may be caused by the resilient properties of the strips. If the strip is stretched with the high tension to such an extent that it appears to be flat, areas of unflatness at this moment might not be measurable and might reappear after reduction of the tension as a result of the elastic recovery. In this case it would be possible to change the measuring system during the process and thus improve the process.
A further advantage is that the waste of materials with which better straightening results are attained with the measuring roller 36 in the low-tension region 52 may be permanently reduced. To this end the measuring roller 40 in the high-tension region 50 is firstly activated and is switched over to the measuring roller 36 in the low-tension region 52 after the dead space.
The measuring roller 40 in the high-tension region, by contrast, is suitable for example for high-strength materials. Since the strip is much stronger, the areas of unflatness are not falsified by the high tension. Thus, the measuring roller 40 in the high-tension region 50 may be used for this situation, and the advantage of the much shorter dead space also utilized.
Once the material 10 in strip form has been threaded in, the system may be started. The controller C initially operates with the values of the high-tension measuring roller 40, since the dead space thereof is much smaller. The dead space is understood here to mean the material length that is necessary, due to the control system from an adjustment means, i.e. the bending-straightening apparatus 26, to the measuring point, before a detected unflatness leads to an influencing of the detected unflatness as a result of a control intervention at the bending-straightening apparatus 26. The controller C adjusts the bending-straightening apparatus 26 in accordance with the calculated parameters so as to attain the optimal straightening result. Once the straightened strip has reached the low-tension measuring roller 36, the controller C automatically switches over from the high-tension measuring roller 40 to the low-tension roller 36 and controls the support rollers 32 of the bending-straightening apparatus with the measured values of the low-tension measuring roller 36, provided no other adjustment is specified by the operator by way of the input means 49 or by the stretching bending-straightening system, for example on the basis of results already made known to the movement earlier.
The system operator may at any time intervene manually by way of input means 49 and may adjust the controller C as needed. The operator may also use the input means 49 to input and specify process data. Furthermore, the system operator may create a data bank 44, in which parameters for the process may be stored, for example for specified materials or materials already straightened before on the system. The controller C may thus select the optimal measuring roller 36 or measuring roller 40 automatically in the case of repeated jobs.
Besides the data regarding processes already performed on the system, further data may also be stored in the data bank 44, for example an allocation of certain operating parameters to certain materials or also expert knowledge. Expert knowledge constitutes information relating to how an experienced operator would operate the stretching-bending-straightening system and with which parameters the operator would work in order to attain a good result. Further physical properties may also be specified here, such as the operating speed or temperature-dependent properties.
Since both the measuring roller 40 in the high-tension region 50 and the measuring roller 36 in the low-tension region 52 are engaged and display their measured values, it is possible to interpolate the measured values of the two measuring devices and to compare them with one another by the software. This is made possible for example by forming a mean value for each measuring device and determining this mean value with defined limits with an interval of 50 control cycles, for example. Depending on the result and analysis of the software, the controller C may then decide independently which measuring system is the more suitable one. This switchover may be implemented automatically, or a recommendation may be expressed to the system operator.
In step 103 the flatness deviations are compared with a desired value for the flatness deviations. If the flatness deviation is less than or equal to the desired value, the stretching bending-straightening system is operated with these operating parameters. If the desired value is not observed, a choice is made in step 104, preferably on the basis of predefined criteria, whether the result, and thus the flatness deviation, should be influenced with the control system in the high-tension region or in the low-tension region. Depending on which system is selected, the manipulated variable for the high-tension region 50 or the low-tension 52 is calculated either in step 105 or in step 106. The manipulated variable is then applied in step 107 to the bending-straightening apparatus 26, and the method then jumps back to step 101 and 102, so as to measure the flatness deviations in the high-tension region 50 or in the low-tension region 52. The method then starts again.
Information originating from a data bank 44, into which operating parameters from earlier processes, material characteristic values or also expert knowledge have been input, may also be applied for the selection of the control system in step 104 and the determination of the manipulated variable in steps 105 and 106.
It is self-evident that this description may be subject to a very wide range of modifications, alterations and adaptations which lie within the scope of equivalents to the accompanying claims.
Number | Date | Country | Kind |
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10 2018 101 501.1 | Jan 2018 | DE | national |
10 2018 111 627.6 | May 2018 | DE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2019/051584 | 1/23/2019 | WO | 00 |