Abstract

Algorithms for monitoring the rolling mill mechatronic system state should be developed on the basis of modern digital technologies. Developing digital shadows (observers) of system state parameters in the periodic measurement mode is promising. This study relevance is defined by frequent emergency breakdowns of rolling stand mechanical transmissions. Most breakdowns are caused by worn end clutches (heads) of countershafts (spindles) transmitting rotation from the motor to the rolls. This is caused by elastic oscillations due to closing angular gaps when the metal enters the stand. The spindle joint angular gap increases over time with the mill operation. Therefore, it is an important diagnostic parameter that allows for an estimation of the transmission serviceability. In this regard, the problem of monitoring the angular gaps in the rolling stand mechatronic systems is relevant. The paper considers developing an observer of angular gaps in the spindle joints of the ‘electric drive-stand’ mechatronic system of the plate Mill 5000 of Magnitogorsk Iron and Steel Works PJSC (MMK PJSC). The monitored signal (angular gap) is calculated with the mathematical processing of the motor’s physical parameters (speed and electromagnetic torque), measured at a given frequency. The gap is determined indirectly by integrating the speed during its closing. To achieve this, the speed is controlled according to the triangular tachogram at no load. The stand’s electromechanical system modes have been studied using mathematical simulation. The observer’s practical use expediency has been reasoned. The structure of the observer-based angular gap monitoring information system is given. The system has been full-scale tested on Mill 5000, which has confirmed the developed algorithm efficiency. The study’s contribution is a justified and implemented concept of a relatively simple technical solution that can be commercially implemented without extra costs. The angular gap calculation algorithm does not involve complex mathematical techniques and can be implemented in industrial rolling mill controllers. Monitoring is automated without human involvement, which eliminates the human factor. The solution has a specific practical focus and is recommended for implementation at operating rolling mills.

Highlights

  • A new digital service—predictive maintenance (PdM)—is gaining momentum in the industry

  • The scientific publication analysis has confirmed the relevance of developing an observer of angular gaps in the spindle joints of the rolling stand mainlines

  • The ultimate research objective is to develop an information-and-measuring system to calculate and visualize the spindle joint wear based on the angular gap monitoring

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Summary

Introduction

A new digital service—predictive maintenance (PdM)—is gaining momentum in the industry. The scientific publication analysis has confirmed the relevance of developing an observer of angular gaps in the spindle joints of the rolling stand mainlines. The ultimate research objective is to develop an information-and-measuring system to calculate and visualize the spindle joint wear based on the angular gap monitoring. The least costly and yet most effective way to solve this problem is to promptly monitor their condition and, primarily, the angular gaps At operating mills, they are manually measured by personnel during scheduled shutdowns. Measuring is performed under uneasy conditions; the human factor affects its reliability

Experimental Justification of Preliminary Acceleration
The Angular Gap Indirect Determination Procedure
Implementation
Conclusions
Findings
A Survey of Predictive Maintenance
Full Text
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