Roll steering control systems and methods for tandem mills

Abstract

Systems and associated methods for controlling roll steering during rolling of a metal substrate may include 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. The controller may generate a model for the work stand and determine an adjustment value for the work stand, receive the measured parameter from the sensor, and determine an expected output parameter by adjusting the measured parameter by the adjustment value. The controller may also compare the expected output parameter with a target output parameter and actuate the steering control actuator such that the expected output parameter is within a predefined tolerance of the target parameter.

That which is claimed: 
     
         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 from a sensor at a location upstream from the work stand;   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 to control an inclination of at least one work roll of the work stand relative to a pass line of the metal substrate such that the expected output parameter is within a predetermined tolerance of the target output parameter.   
     
     
         2 . The method of  claim 1 , 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. 
     
     
         3 . The method of  claim 1 , 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. 
     
     
         4 . The method of  claim 1 , 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. 
     
     
         5 . The method of  claim 1 , 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. 
     
     
         6 . The method of  claim 1 , 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. 
     
     
         7 . The method of  claim 1 , wherein actuating the steering control actuator comprises controlling at least one hydraulic cylinder or at least one backup roll. 
     
     
         8 . The method of  claim 1 , 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. 
     
     
         9 . The method of  claim 1 , 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.   
     
     
         10 . The method of  claim 1 , 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 by the sensor during rolling being outside a predetermined tolerance of a target output parameter for the second work stand.   
     
     
         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. 
   
     
     
         12 . The rolling mill of  claim 11 , further comprising the work stand and the work roll, wherein the work roll comprises an upper work roll and/or a lower work roll adapted to contact the metal substrate during rolling. 
     
     
         13 . The rolling mill of  claim 12 , 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. 
     
     
         14 . The rolling mill of  claim 11 , 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. 
     
     
         15 . The rolling mill of  claim 11 , 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. 
     
     
         16 . The rolling mill of  claim 11 , 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. 
     
     
         17 . The rolling mill of  claim 11 , wherein the steering control actuator comprises at least one hydraulic cylinder or at least one backup roll. 
     
     
         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. 
   
     
     
         19 . The steering control system of  claim 18 , 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. 
     
     
         20 . The steering control system of  claim 18 , 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.