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Procedia Engineering 00 (2017)000–000
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Procedia Engineering 206 (2017) 1753–1760
International Conference on Industrial Engineering, ICIE 2017
International Conference on Industrial Engineering, ICIE 2017
Setting Automated Roll Axial Shifting Control System of Plate Mill
Setting Automated Roll Axial Shifting Control System of Plate Mill
A.S. Karandaeva,*, B.M. Loginovb, A.A. Radionova, V.R. Gasiyarova
a,
A.S. Karandaev
*, B.M. Loginovb, A.A. Radionova, V.R. Gasiyarova
South Ural State University, 76, Lenin Avenue, Chelyabinsk 454080, The Russian Federation
a
b
a
Magnitogorsk
Steel Works,
Kirova
St., 70,Chelyabinsk
Magnitogorsk,
455000,
Russian
Federation
South Ural Iron
Stateand
University,
76, Lenin
Avenue,
454080,
TheThe
Russian
Federation
b
Magnitogorsk Iron and Steel Works, Kirova St., 70, Magnitogorsk, 455000, The Russian Federation
Abstract
Abstract
The paper provides the CVCplus system designed for control of cross-section and sheet flatness of the 5,000 mm plate mill stand
at
Iron plus
andsystem
Steel Works.
considers
of rolland
axial
shifting
andofspindle
horizontal
balancing.
It
designedItfor
control principles
of cross-section
sheet
flatness
the 5,000
mm plate
mill stand
TheOJSC
paperMagnitogorsk
provides the CVC
describes
designs of correlated
of automated
roll and
spindle of
position
control.
Theand
authors
offer
oscyllograph
records
at OJSC Magnitogorsk
Iron andsystems
Steel Works.
It considers
principles
roll axial
shifting
spindle
horizontal
balancing.
It
reflecting
system settings.
Theirsystems
coordinated
functioning
proven
to provide
gap between
the roll
and spindlerecords
under
describes designs
of correlated
of automated
rollis and
spindle
positiona constant
control. The
authors offer
oscyllograph
conditions
of rolling
and setting
between passes.
The oscyllograph
confirm
efficiency
theand
spindle
position
reflecting system
settings.
Their coordinated
functioning
is proven torecords
provideprovided
a constant
gap between
theof
roll
spindle
under
control system
with automated
switching
force control
in the hydraulic
cylinder.
conditions
of rolling
and setting
betweentopasses.
The oscyllograph
records
provided confirm efficiency of the spindle position
© 2017 system
The Authors.
Published by Elsevier
B.V. control in the hydraulic cylinder.
control
with automated
to force
© 2017 The Authors.
Publishedswitching
by
Ltd. committee
Peer-review
under responsibility
of Elsevier
the scientific
of the International Conference on Industrial Engineering.
©
2017
The
Authors.
Published
by
Elsevier
B.V.
Peer-review under
responsibility
of the scientific
committee
of the
International
Conference
on Industrial
Engineering
Keywords: Plate
mill;responsibility
mill stand; horizontal
axial committee
shifting system;
spindle
horizontal Conference
balancing; servo-system;
design;
setting; experimental
Peer-review
under
of the rolls;
scientific
of the
International
on Industrial
Engineering.
studies.
Keywords: Plate mill; mill stand; horizontal rolls; axial shifting system; spindle horizontal balancing; servo-system; design; setting; experimental
studies.
1. Introduction
1. Introduction
Today, rolling mills are equipped with systems enabling roll horizontal shifting relative to each other [1,2]. Thus,
theToday,
mill stand
of the
5,000
mm platewith
mill systems
at OJSCenabling
Magnitogorsk
Iron andshifting
Steel Works
(hereafter
referred
to as
the
rolling
mills
are equipped
roll horizontal
relative
to each other
[1,2].
Thus,
plus
5,000
mill)
is 5,000
equipped
WRS
(Work RollIron
Shifting)
system
being
a partreferred
of the toCVC
the millmm
stand
of the
mm with
plate the
millaxial
at OJSC
Magnitogorsk
and Steel
Works
(hereafter
as the
(Continuously
Variable
Crown) with
unit for
flatness
control
[3,4]. system being a part of the CVCplus
5,000
mm mill)
is equipped
thesheet
axialshape
WRSand(Work
Roll
Shifting)
The CVC principle
been developed
by Schloemann-Siemag
in cooperation
with Krupp [5]. It is based on rolls
(Continuously
Variablehas
Crown)
unit for sheet
shape and flatness control
[3,4].
with
anCVC
unsymmetrical
crown.
shifting
these rolls enables continuous
variation
the required
roll crowning
The
principle has
been Axial
developed
by Schloemann-Siemag
in cooperation
with of
Krupp
[5]. It is based
on rolls
directly
mill operation.
the same
direction variation
results in of
thethe
same
variation
the roll
with an during
unsymmetrical
crown. Axial
Axial shifting
shiftingboth
theserolls
rollsinenables
continuous
required
roll of
crowning
gap
profile
at both
andAxial
positive
roll crown
(dependent
on the
shiftingresults
direction).
directly
during
millnegative
operation.
shifting
both rolls
in the same
direction
in the same variation of the roll
gap profile at both negative and positive roll crown (dependent on the shifting direction).
* Corresponding author. Tel.: +7-351-943-12-56.
E-mail
address: askaran@mail.ru
* Corresponding
author. Tel.: +7-351-943-12-56.
E-mail address: askaran@mail.ru
1877-7058 © 2017 The Authors. Published by Elsevier B.V.
Peer-review
the scientific
committee
1877-7058 ©under
2017responsibility
The Authors. of
Published
by Elsevier
B.V.of the International Conference on Industrial Engineering .
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering .
1877-7058 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering.
10.1016/j.proeng.2017.10.709
A.S. Karandaev et al. / Procedia Engineering 206 (2017) 1753–1760
A.S. Karandaev et al. / Procedia Engineering 00 (2017) 000–000
1754
2
The improved CVCplus system differs from the known CVC one mainly in the following [6]:
 CVCplus-shape – work roll crown with a control range significantly increased;
 CVCplus-shape – crown of a support roll reducing load imposed on it;
 form-optimized shifting approaches for reduced shape deviations and increased sheet lots.
The WRS system is used for pre-setting the roll bite shape between passes without metal in the stand. It
automatically provides correction of work roll wear and, thus, increases their durability. The control range of
transverse gage interference and strip flatness is increased. The system functions also include elimination of edge
thinning, monitoring and control of strip cross-section shape.
The mill is also furnished with the spindle horizontal balancing system along with the axial shifting one. It is
designed for spindle shifting in the same direction as for the roll CVC-displacement. Thus, the specified gap between
the roll and spindle head is controlled. The system also limits axial forces between them in dynamic modes.
Many authors studied the system of axial shifting theoretically and experimentally with the outcome published, in
particular, in [7–11]. This paper considers issues of practical setting controllers of these systems and outcome of
study of their coordinated operation.
2. Problem statement
2.1. CVCplus work roll shifting control
The design of the CVCplus system of the 5,000 mm mill is shown in Fig. 1,a. Its main function is axial shifting
work rolls in the horizontal direction along the rolling axis. Corresponding grinding work rolls enables crown
variation and consequent roll bite outline by shifting the top and bottom rolls oppositely. A special roll design with
a gap up to 320 mm has been implemented for a rolling stand of the plate mill.
A definite shape of a finishing sheet is achievable due to the roll crown corresponding to the rolling force and
sheet width. The CVC versions of the top and bottom work rolls have a S-cross-section shown in Fig. 1,b [12, 13].
The diameter difference across the crown of a roll is 0.2–0.4 mm [14-17]. The crowns of both rolls are identical but
turned by 180° relative to each other. As a result, rolls complement each other and form a parallel outline of the
opening between them. With a mutually antithetical axial shifting, the roll bite changes towards a negative or
positive crowing dependent on the shifting direction. The shifting value can infinitely vary, thus providing a
constantly variable roll crowing. The term "crowing" means the difference of the values of roll bite from the sheet
center to its edge [15]. If roll convex areas approach each other at axial shifting, strip draft will be greater in the
middle portion than at edges. If convex crown portions move apart at axial shifting work rolls, draft is reduced in the
middle portion and increased at edges.
Axial shifting range, mm
-150
150
Roll crown range (μm)
-200 ...+ 400
a
b
5350 mm
Fig. 1. (a) Typical design of plate mill's CVCplus system; (b) Example of axial shifting CVC work rolls.
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As the shifting value is set smoothly within available control range (±150 mm), a sufficiently high compliance of
the roll bite form with the incoming section shape can be ensured. It helps minimizing non-uniformity of edgewise
drawing distribution and enabling a high flatness of the rolled sheet. CVC position setting is formed with a model of
rolling of level 2 of the automated rolling control system.
Support rolls of a standard quarto-CVC system have a cylindrical forming with beveled edges resulting in a
essential irregularity in pressure distribution along the length of work and support roll contact. Consequently, it
leads to reduced durability of support rolls in the area of contact with convex sections of work rolls. Support rolls of
modern CVCplus systems also have a S-shaping significantly enhancing uniformity of inter-roll pressure and
durability of support rolls [18].
2.2. Spindle hydraulic balancing
One hydraulic cylinder in a horizontal plane and another in a vertical one are used for position control of every
spindle. Arrangement of hydraulic cylinders of the bottom roll spindle is shown in Fig. 2. Hydraulic cylinders of the
upper rolls are arranged similarly.
Obviously, coordinated operation of roll and spindle axial shifting systems must be synchronized. No gap
between the spindle head and roll results in forces, heating and increased wear and, ultimately, in accident evolution.
This situation may be prevented by coordinated functioning shift control systems. Here, the CVC ACS (roll position
automated control) system should be a (main system) master. The spindle position control system shall be used as a
servo ACS and have a switching design to prevent appearing forces at a non-allowable gap reduction.
This paper is aimed at design specifications and setting analysis of correlated CVC ACS and that of spindle
horizontal balancing implemented at the 5,000 mm mill. It is connected with a number of system improvements
introduced at mill operation that have increased performance and control accuracy. It is rationally to consider design
solutions of the systems under study preliminary.
3. Main part
3.1. Specification of roll axial shifting system
The roll axial shifting system is designed as an automated position control system with proportional controllers. It
also includes integrators with a high integration constant compensating valve "zeros". A simplified ACS design is
shown in Fig. 3. CVC shifting rate depends on the roll rotation speed and rolling force and is calculated with a
special unit. An output of this unit is used as a rate for the position power-up sensor. A positive setting signal
supplied to the servo-valve corresponds to roll shift in the drive direction. Subsequently, with a positive CVC
position setting, the top roll is shifted in the drive direction, while the bottom one is displaced to the stand.
Fig. 2. Arrangement of spindle hydraulic equipment.
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CvcCalcSpd
rolling force
speed v c
WRB
TFFC
S
CvcPosCtrl
Setup data
from PCFC
CvcShftSync
TP
TP
TP
TP
CvcCalcAct
WRB = Work-roll bending
PCFC = Profile, contour and flatness computer
CvcCalcRef = Setpoint generation
CvcCalcAct = Act.-value generation
CvcPosCtrl = Position controller
CvcShftSync = Shifting synchronisation
CvcCalcSpd = Shifting speed calculation
CvcCalcAktFs = Shifting forces calculation (optional)
S
act. forces
+
S
S
CvcCalcAktFs
pressure transducer
Fig. 3. Design of CVC roll position automated control system.
When shifting, roll position shall be constantly monitored. Absolute probes with SSI interface built in hydraulic
cylinders are used as position sensors. A zero position corresponds to the roll middle one without shifting. Forces at
shifting used for diagnostic purposes are also calculated for CVC.
An indicative oscyllograph record displaying a final adjustment of roll shifting is shown in Fig. 4. The Figure
shows (up down) the following:
 window 1: position of CVC bottom hydraulic cylinder rods at stand entry and exit, mm;
 window 2: the same signals for top hydraulic cylinders and setting supplied to the position controllers for top
cylinders (setting at output of the power-up sensor– position PS), mm;
 window 3: setting signals supplied to servo-valves of top hydraulic cylinders at stand entry and exit, %;
 window 4: similar setting signals supplied to servo-valves of bottom cylinders, %;
 window 5: forces of hydraulic cylinders, kN;
 window 6: rate of roll horizontal shifting (to be calculated with a special unit; rate of position power-up sensor),
as well as discrete signal requesting for speed of the main electric drive, mm/s;
 window 7: linear speed of the main drive, m/s.
When setting for every new pass, the second level system supplies a signal setting position of horizontal rolls to
the stand controller. As rolls' CVC-shifting is possible at their rotation only, monitoring current speed of the main
drive is required. For this purpose, a request needed for CVC re-adjustment (CvcLogicOut.CvcSpdRed signal) is
supplied to the (SPC) speed control system. Dependent on speed of the main drive, a signal of allowable rate of
CVC-shifting (CvcPpmsLoopOut.ShiftingSpeed) is generated. The following condition provides the above: the
lower speed of the electric drive, the lower is the shifting rate. Thus, CvcPpmsLoopOut.ShiftingSpeed shifting rate
depends on speed of the main electric drive (MdcRtData.MdcActLin SpdWrTop signal). It prevents mechanical
damage of work rolls at their contact with support ones. A signal of allowable speed of CVC shifting is supplied to
the CVC position power-up sensor. A pattern of roll motion from a current position to the specified one is formed at
its output with provisions for allowable shifting speed. Prior operations performed result in setting for roll position
change (CvcLoopOut.ReflntTwr signal).
CVC cylinder position controllers adjust position setting by affecting servo-valves. As a result, a mutually
antithetical shifting bottom and top rolls takes place. Signals of current position shown in the first and second
window vary correspondingly. Motion friction result in forces in hydraulic cylinders shown in window 5.
Karandaev
et /al.
/ Procedia
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206 (2017)
1753–1760
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et al.
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Fig. 4. CVC shifting adjustment: act – actual value; P – pressure; os – operator side; ds – drive side; Bwr – bottom work roll; Twr – top work
roll; Es – entering side (at stand entrance); Xs – exit side (at stand exit); ref – reference; svo – servo-valve setting.
Based on analysis of oscyllograph records, we may conclude that an optimal controller setting enables smooth
processes according to the specified pattern without any shocks or impacts.
3.2. Spindle position control system
A flowchart of the spindle horizontal balancing is shown in Fig. 5. This system can be operated with a position
controller (main mode) or force controller.
Fig. 5. Flowchart of the spindle horizontal balancing.
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The horizontal balancing ACS is operated in a normal mode as a position loop and maintains the set gap between
the spindle head and roll. The spindle position control system monitors roll horizontal CVC-motion. For this
purpose, a CVC-position signal is supplied to the input of the cylinder position computer. A setting for rod position
of the spindle's hydraulic cylinder needed for maintaining the specified gap is formed at the unit output. Thus, the
spindle position control system is a servo one relative to the CVC system.
Emergencies (wedging up) are accompanied by increased force at motion of the hydraulic cylinder. If its value
exceeds the set point, the system switches automatically to the force control mode and pushes the spindle in the roll
direction. However, the force is controlled rather than the position, limiting it at allowable level. Then, after the
force has been stabilized, the system returns to the position control mode. Furthermore, it provides for a constant
gap control. With the gap exceeding the upper tolerance, rotation of the main electric drive is blocked and
emergency shutdown follows. It limits the maximum runs of the roll and spindle and prevents their uncoupling.
The system operation considered above is illustrated with oscyllograph records shown in Fig. 6. They have been
obtained at spindle motion together with rolls' CVC-shifting. Oscillograph records correspond to the system normal
operation. The spindle-roll gap for a bottom roll (window 2) is calculated as a difference between
HssLoopOut.ActBotSpPos and CvcLoopOut.ActPosBwrXs signals shown in window 1. As we can see, the set gap
of 20 mm is maintained by the spindle position control servo-system in all modes. The force of the spindle
horizontal cylinder is within the limit (set point of 345 kN).
3.3. Coordinated operation of CVC and spindle horizontal balancing systems
Fig. 7 shows oscyllograph records explaining operation of the spindle position ACS. System operation with
mechanical problems is shown as switching to the force controller does not usually occur at normal operation.
Fig. 6. Oscillograph records illustrating CVC and spindle horizontal balancing operation. Window layout (up-down): 1 – position of CVC
cylinder and spindle head relative to roll, mm; 2 – gap between spindle and roll, mm; 3 – set and actual positions of bottom spindle; 4 – force in
spindle hydraulic cylinder, kN; 5 – setting to servo-valve of spindle hydraulic cylinder, %; 6 – rolling force, kN.
A.S. Karandaev et al. / Procedia Engineering 206 (2017) 1753–1760
A.S. Karandaev et al. / Procedia Engineering 00 (2017) 000–000
t1
t2
t3
t4
1759
7
t5
Fig. 7. Oscillograph records of axial shifting and spindle horizontal balancing systems at rolling. Window layout: 1 – rolling force, kN; 2 – actual
and set positions of bottom spindle and discrete signal of switching to force control; 3 – gap between spindle and roll, mm; 4 – force of the
bottom spindle, kN; 5 – setting to servo-valve of horizontal balancing bottom spindle, %.
Metal is gripped at t1, and a rolling force signal in window 1 rises. This process is accompanied by significant
dynamic surges of the drive torques of the bottom and top rolls (not shown in Fig. 7). In the case at hand, it results in
varying position of the bottom spindle (window 2) by about 5 mm relative to the set position (-77 mm). The gap
between the spindle and roll varies by the same value (from -20 to -25 mm, window 3). At that, force in the bottom
hydraulic cylinder of the spindle horizontal balancing is increased (window 4). With the force value achieving the
threshold of 345 kN, the horizontal balancing ACS (Fig. 5) switches to force control. It takes place at t2
(FPM.CVC.ClobVar.HssLoopOut.ForceCtrlBotActive discrete signal appears in window 2). Through this operation,
force is stabilized at about 250 kN (window 4), and the spindle is moved in the drive direction (from -24 to -17 mm,
window 3) in the t2– t3 range. At t3, the system tries to re-switch to position control. At that, the discrete signal
disappears and returns after a small time period. This is due to the fact that the force in the bottom hydraulic cylinder
(window 4) has been risen again at the attempt of switching to the position controller. Further, the system is
operated in the mode of force limiting and switches to position control at t4. t5 moment corresponds to rolling finish,
whereupon the system is set for the next pass (not shown in the Figure).
As we can seen in oscyllograph records, loop switching of the horizontal balancing system prevents force rise in
the roll and spindle connections, thus, accident evolution.
The example provided clearly demonstrates efficiency of the introduced algorithm for control of roll and spindle
horizontal shifting at the specified ACS designs and controller settings. Switching the spindle horizontal balancing
ACS to force control is a justified solution.
4. Conclusion
The considered CVCplus system is operated at the 5,000 mm mill. With gained experience, we may draw an
inference that it is relevant and enables rolling 8 to 50 mm thick, 1,600 to 4,800 mm wide and 6 to 52 m long sheets
with high quality indexes and minimized side and butt end crops.
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A.S. Karandaev et al. / Procedia Engineering 00 (2017) 000–000
Experimental results have confirmed a great accuracy of roll position control at CVC-shifting. It validates
selection of control algorithms and the best controller setting. The CVCplus solution with its roll shifting between
passes provides automated correction of work roll wear. As a result, their durability is improved, while unit roll
consumption and replacement number are reduced.
The spindle horizontal balancing system that automatically monitors roll shifting at setting for every new pass
maintains a constant gap between the roll and spindle during the rolling cycle with accuracy of ±1 mm and higher.
Automatic switching the system loops provides force at non-allowable gap reduction and, thus, prevents
emergencies. These conclusions have been confirmed by experiment results and long-tern operation of the systems
under study at the 5,000 mm mill. Roll process shifting increases their operation by up to 10%. The number and
duration of outages due to mechanical damages of the spindles and stand is also mitigated by (10–15)%.
Generally, we may state that the CVCplus solution implemented at the 5,000 mm mill provides significant
advantages in respect of sheet quality, helps performance enhancing and reducing products cost, as well as improves
reliability of process equipment.
Acknowledgements
South Ural State University acknowledges financial support from Ministry of Education and Science of the
Russian Federation (grant No 13.9656.2017/8.9)
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