Analysis of Process Control of Roller Leveling by Utilization of a FE Model with Integrated Closed-loop Control Structures

利用集成闭环控制结构的有限元模型分析辊式矫平过程控制

• 批准号: 238040321
• 负责人: Professor Dr.-Ing. Gerhard Hirt
• 金额: --
• 依托单位: Institut für Bildsame Formgebung (IBF)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2013
• 资助国家: 德国
• 起止时间: 2012-12-31 至 2015-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/238040321?language=en
• 关键词: Analysis; Process; Control; Roller; Leveling

Roller leveling is essential to remove flatness defects and residual stresses of e.g. flat products. In contrast to other manufacturing technologies the setting of the leveler is mostly determined by experience. However, stricter tolerances and new materials are showing more and more the limits of this simple approach. Therefore it is vital to gain an improved understanding and to develop a better control of the process.A closed-loop control of the setting of leveling rolls would be a sensible solution. But all existing approaches have three major disadvantages:1) A measurement of the resulting flatness leads to a significant dead time in the control system. As a consequence the beginning of the strip will not be leveled properly.2) Variations in the properties of the work piece (yield stress, strip thickness and initial curvature) will not be detected before they have passed the whole machine.3) No practical measurement techniques are available to measure a residual curvature influenced by gravity in a tension free outlet of the leveler.Especially the last aspect makes experimental research of the influence between target properties (curvature, residual stresses) and real measurement data (e.g. forces and moments at the rolls, deflection of the strip) difficult to conduct. Therefore, a FE model shall be used to create an idealized environment (e.g. without influence of gravity on the curvature) to analyze these influences. Additionally implementing closed-loop control systems in the FE simulation creates a tool to test different control systems virtually. At a later stage of the project the closed-loop control system is tested by practical experiments.Already conducted research has shown that process parameters (e.g. forces and moments) can be utilized before and during the process to identify deviations from the expected work piece properties. Model values created beforehand can then provide the right settings for the machine. Thus, the long term target is to develop a new control concept that utilizes process data starting already during the filling of the machine. This can lead to reduced investments as well as maintenance costs, less wasted material and a higher availability of the subsequent processing line.

辊子矫平对于消除平整度缺陷和残余应力至关重要。扁平产品。与其他制造技术相比，整平机的设置主要由经验决定。然而，更严格的公差和新材料越来越显示出这种简单方法的局限性。因此，加深理解并更好地控制过程至关重要。对矫平辊设置的闭环控制将是一个明智的解决方案。但所有现有方法都具有三个主要缺点：1）对所得平坦度的测量会导致控制系统中出现显着的死区时间。因此，带材的起始端将无法正确矫平。2) 在工件通过整机之前，无法检测到工件性能的变化（屈服应力、带材厚度和初始曲率）。3) 没有实用的测量技术可用于测量矫平机无张力出口中受重力影响的残余曲率。特别是最后一个方面，对目标性能（曲率、残余曲率）之间的影响进行了实验研究。 应力）和实际测量数据（例如辊上的力和力矩、带材的偏转）难以进行。因此，应使用有限元模型创建一个理想化的环境（例如，不受重力对曲率的影响）来分析这些影响。此外，在有限元仿真中实施闭环控制系统创建了一个虚拟测试不同控制系统的工具。在项目的后期阶段，通过实际实验对闭环控制系统进行测试。已经进行的研究表明，可以在过程之前和过程中利用过程参数（例如力和力矩）来识别与预期工件特性的偏差。预先创建的模型值可以为机器提供正确的设置。因此，长期目标是开发一种新的控制概念，该概念利用机器灌装期间已经启动的过程数据。这可以减少投资和维护成本、减少材料浪费并提高后续加工线的可用性。