System and method for removing flatness faults from a metal flat product

Abstract

A system and method for removing flatness faults from a metal flat product, in particular a metal sheet or a strip, having multiple straightening rollers arranged on opposite sides of the flat product. In order to simplify and to enable more cost-efficient removal of flatness faults from a metal flat product, at least two cooperating straightening rollers arranged on opposite sides of the flat product each have at least three individually-adjustable partial rollers arranged axially adjacent to one another.

Claims

1. A system for removing flatness faults from a metal flat product, the system comprising: a plurality of straightening rollers disposed on opposite sides of the flat product, wherein at least two interacting rollers of the plurality of straightening rollers that are disposed on opposite sides of the flat product have in each case at least three individually adjustable part-rollers that are disposed so as to be axially neighboring one another; and a plurality of adjustment units, a respective one of the plurality of adjustment units being dedicated to a respective one of the part-rollers of each straightening roller, the adjustment units being configured to actively adjust positions of the respective part-rollers, wherein the plurality of adjustment units includes adjustment units that are assigned to axially external part-rollers of one of the two interacting straightening rollers, wherein at least the adjustment units assigned to the axially external part-rollers each have at least one pivot unit by which the respective part-roller is passively adjustable so as to be inclined to a longitudinal central axis of the one of the two straightening rollers, wherein the at least one pivot unit includes a rocker pivotable about an axle that is parallel to a processing direction of the flat product, and wherein the at least one pivot unit further includes compression springs arranged so as to act on the rocker so that when the rocker pivots from a first position the springs generate a restoring force to urge the rocker back to the first position.

2. The system according to claim 1, wherein at least one of the adjustment units has at least one mechanical, electromechanical, pneumatic, or hydraulic actuator.

3. The system according to claim 1, wherein at least one of the adjustment units has at least one wedge lifting unit.

4. The system according to claim 1, wherein at least one of the part-rollers at least at one axial end portion has an external diameter reduction.

5. The system according to claim 1, wherein the interacting straightening rollers that comprise the part-rollers are disposed so as to be mutually offset or not mutually offset in relation to a processing direction of the flat product through the system.

6. The system according to claim 1, further comprising at least one electronic controlling and/or regulating system that in terms of signaling is connected to the adjustment units and arranged for actuating the adjustment units dependent on a respective quality and position of the flatness faults of the flat product so that straightening, bend-pressing, or combined straightening and bend-pressing is selectively carried out.

7. A method for removing flatness faults from a metal flat product, comprising the steps of carrying out bend-pressing, or combined straightening and bend-pressing using the straightening system according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) FIG. 1 shows a schematic illustration of an exemplary embodiment for a system according to the invention in a first system state;

(2) FIG. 2 shows a schematic illustration of the system shown in FIG. 1 in a further system state;

(3) FIG. 3 shows a schematic illustration of a further exemplary embodiment for a system according to the invention;

(4) FIG. 4 shows a schematic illustration of a further exemplary embodiment for a system according to the invention;

(5) FIG. 5 shows a schematic illustration of a further exemplary embodiment for a system according to the invention;

(6) FIG. 6 shows a schematic illustration of a part-roller of a further exemplary embodiment for a system according to the invention;

(7) FIG. 7 shows a schematic illustration of an exemplary embodiment for a method according to the invention; and

(8) FIG. 8 shows a schematic detailed illustration of an exemplary embodiment for a regulating concept for a system according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

(9) Same components or components with equivalent functions, respectively, are provided with the same reference signs in the figures.

(10) FIGS. 1 and 2 schematically show potential convex or concave straightening gap geometries, respectively, for removing flatness faults of a non-flat metal flat product 2, in particular of a metal sheet or of a strip.

(11) The system 1 comprises a plurality of straightening rollers 3 and 4 that are disposed on opposite sides of the flat product 2, of which only two are shown in FIG. 1. The interacting straightening rollers 3 and 4 shown have in each case three individually adjustable part-rollers 5 or 6, respectively, that are disposed so as to be axially neighboring one another. The part-rollers 5 or 6, respectively, of each straightening roller 3 or 4, respectively, are in each case actively adjustable by way of at least one dedicated adjustment unit 7, in a manner corresponding to the double arrows 8. Only the adjustment units 7 for adjusting the part-rollers 6 are shown in FIG. 1. At least one adjustment unit 7 can have at least one mechanical, electromechanical, pneumatic, or hydraulic actuator (not shown). The part-rollers 6 in solid lines are shown in a state in which the actuators are not active. At least one part-roller 5 or 6, respectively, at least at one axial end portion can be provided with an external diameter reduction (not shown). The interacting straightening rollers 3 or 4, respectively, that comprise the part-rollers 5 or 6, respectively, can be disposed so as to be mutually offset or not mutually offset in relation to a processing direction x of the flat product 2 through the system 1.

(12) The adjustment units 7 that are assigned to the axially external part-rollers 6 of the straightening roller 4 have in each case one pivot unit 9 by way of which the respective part-roller 6 is passively adjustable so as to be inclined to the longitudinal central axis 10 of the straightening roller 4, as is shown in FIG. 1. Each pivot unit 9 comprises a rocker 11 which is mounted so as to be pivotable about an axle 12 that is aligned so as to be parallel with the processing direction x of the flat product 2 through the system 1. Each pivot unit 9 furthermore comprises two compression springs 13 which, when the rocker 11 is pivoted from the position shown, in each case generate a restoring force by way of which the rocker 11 is impinged with a force in the direction of the position shown.

(13) The adjustment units 7 that are assigned to the axially external part-rollers 6 have in each case one wedge lifting unit 14 having two wedges 15 and 16, the respective adjustment of the respective part-roller 6 being defined by the relative position of said wedges 15 and 16. The adjustment units 7 are collectively adjustable by way of a common adjustment unit 17 which has a wedge lifting system that is formed by the wedges 18 and 19.

(14) The system 1 comprises an electronic controlling and/or regulating circuit (not shown) which in terms of signaling is connectable to the adjustment units 7 and is specified for actuating the adjustment units 7 in a manner dependent on the respective quality and position of the flatness faults of the metal flat product 2 such that straightening, bend-pressing, or combined straightening and bend-pressing can be selectively carried out by way of the system 1.

(15) The system 1 can furthermore have at least one detection installation (not shown) for detecting a quality and position of the flatness faults of the flat product 2 that is to be treated by way of the system 1 or is being treated by way of the system 1, said detection installation in terms of signaling being connectable to the electronic controlling and/or regulating circuit.

(16) FIGS. 3 to 5 show potential ways of integrating the split straightening rollers (bend-pressing function) in or on, respectively, a conventional roller straightening machine (straightening function). The system 1 comprises a plurality of straightening rollers 3, 4, and 20 that are disposed on opposite sides of the flat product.

(17) Two interacting straightening rollers 3 and 4 that are disposed on opposite sides of the metal flat product have in each case at least three individually adjustable part-rollers (not shown) that are disposed so as to be axially neighboring one another. The part-rollers of each straightening roller 3 and 4 are in each case actively adjustable by way of at least one dedicated adjustment unit (not shown). At least one adjustment unit comprises at least one mechanical, electromechanical, pneumatic, or hydraulic actuator. At least those adjustment units that are assigned to the axially external part-rollers of one of the two straightening rollers 3 or 4, respectively, can in each case have at least one pivot unit (not shown) by way of which the respective part-roller is passively adjustable so as to be inclined to the longitudinal central axis 10 of this straightening roller 3 or 4, respectively. At least one adjustment unit can have at least one wedge lifting unit (not shown). At least one part-roller at least one axial end portion can be provided with an external diameter reduction (not shown). These components of the system 1 can be configured so as to correspond to FIGS. 1 and 2, for example, for which reason reference is made here to the description above pertaining to FIGS. 1 and 2.

(18) The interacting straightening rollers 3 and 4 that comprise the part-rollers are disposed so as to be mutually offset in relation to a processing direction x of the flat product through the system 1. The remaining straightening rollers 20 are also disposed so as to be correspondingly mutually offset and so as to be offset in relation to the straightening rollers 3 and 4.

(19) The system 1 comprises an electronic controlling and/or regulating circuit (not shown) that in terms of signaling is connectable to the adjustment units and is specified for actuating the adjustment units in a manner dependent on the respective quality and position of the flatness faults of the metal flat product such that straightening, bend-pressing, or combined straightening and bend-pressing can be selectively carried out by way of the system 1.

(20) The system 1 can furthermore have at least one detection installation (not shown) for detecting a quality and position of the flatness faults of the metal flat product that is to be treated by way of the system 1 or is being treated by way of the system 1, said detection installation in terms of signaling being connectable to the electronic controlling and/or regulating circuit.

(21) FIG. 4 shows a schematic illustration of a further exemplary embodiment for a system 1 according to the invention for removing flatness faults from a metal flat product (not shown), in particular a metal sheet or a strip. This system 1 differs from the exemplary embodiment shown in FIG. 3 in that four straightening rollers 3 and 4 which in each case have at least three individually adjustable part-rollers (not shown) that are disposed so as to be axially neighboring one another are present, and in that these straightening rollers 3 and 4 in relation to the processing direction x of the metal flat product through the system 1 are disposed upstream or downstream, respectively, of a conventional roller straightening unit that is formed by the straightening rollers 20. The system 1 otherwise corresponds to the exemplary embodiment shown in FIG. 3, for which reason reference is made here to the above description of FIG. 3 in order to avoid repetitions.

(22) FIG. 5 shows a schematic illustration of a further exemplary embodiment for a system 1 according to the invention for removing flatness faults from a metal flat product (not shown), in particular a metal sheet or a strip. This system 1 differs from the exemplary embodiment shown in FIG. 4 in that only two interacting straightening rollers 3 and 4 which in each case have at least three individually adjustable part-rollers (not shown) that are disposed so as to be axially neighboring one another and in relation to the processing direction x of the metal flat product through the system 1 are disposed upstream or downstream, respectively, of the straightening rollers 20 are present, and in that the straightening rollers 3 and 4 are not disposed so as to be mutually offset in relation to the processing direction x of the metal flat product through the system 1. The system 1 otherwise corresponds to the exemplary embodiment shown in FIG. 3, for which reason reference is made here to the above description of FIG. 3 in order to avoid repetitions.

(23) FIG. 6 shows a schematic illustration of a part-roller 5 or 6, respectively of a further exemplary embodiment for a system according to the invention for removing flatness faults from a metal flat product (not shown), in particular a metal sheet or a strip. The part-roller 5 or 6, respectively, can be used in one of the systems shown in FIGS. 1 to 5. The part-roller 5 or 6, respectively, at both axial end portions is in each case provided with one external diameter reduction 21 in the form of a radius, in order for metal sheet surface faults on account of support by way of the edges to be minimized.

(24) FIG. 7 shows a schematic illustration of an exemplary embodiment for a method according to the invention for removing flatness faults from a metal flat product (not shown), in particular a metal sheet or a strip, while using a straightening system (not shown) by way of which straightening, bend-pressing, or combined straightening and bend-pressing can be selectively carried out. The straightening system can be configured according to one of the exemplary embodiments shown in FIGS. 1 to 6.

(25) Data pertaining to the flatness of the metal flat product that is to be treated by way of the straightening system is acquired in step 100. In step 200 it is determined whether bend-pressing is required in order for flatness faults of the metal flat product to be removed. Items of information 300 in the form of parameters or evaluation criteria of flatness faults, respectively, are considered herein, in particular whether said flatness faults are peripheral undulations, central undulations, hemispheres, or the like. These items of information 300 can be sourced from tables, process models, or by way of visual detection by an operator. If step 200 results in no bend-pressing (−) being required, the operating mode “straightening” in which uni-axial straightening of the metal flat product by means of the straightening system is performed is initiated in step 400. Herein, straightening rollers that comprise part-rollers can be operated as continuous straightening rollers or be excluded from the straightening process. If step 200 results in bend-pressing (+) being required, the required deformation complexity is calculated in step 500. It is subsequently determined in step 600 whether or not the quality of the flatness faults is such that the flatness faults are correctable in a single pass of the metal flat product through the straightening system. If step 600 results in the flatness faults being correctable in a single pass of the metal flat product through the straightening system (+), the operating mode “combined straightening and bend-pressing” is initiated in step 700. Herein, the straightening rollers that comprise the part-rollers are used for correcting multi-axial flatness faults, for example hemispheres, and the continuous straightening rollers without part-rollers are used for correcting undulations. The straightening rollers that comprise the part-rollers can be actuated in a superimposed manner and, on account thereof, can be simultaneously used for correcting undulations. If step 600 results in the flatness faults not being correctable in a single pass of the metal flat product through the straightening system (−), the operating mode “bend-pressing” is initiated in step 800. Herein, multi-axial flatness faults are corrected by means of the straightening rollers that comprise the part-rollers. It is subsequently determined in step 900 whether further treatment of the metal flat product is required for removing flatness faults. Should this be the case, step 100 is chosen.

(26) FIG. 8 shows a schematic detailed illustration of an exemplary embodiment for a regulation concept for a system according to the invention for removing flatness faults from a metal flat product (not shown), in particular a metal sheet or a strip, in the case of a given operating mode of the system.

(27) Detection of flatness faults of the metal flat product at the entry side is performed in step 110. Data 210 from a hot rolling mill, from a visual inspection, or from measuring the flatness of the metal flat product can be supplied to step 110. The flatness data is generated in step 310. The flatness data is subjected to a flatness fault analysis in step 410. The position of the respective flatness fault in the width direction and the length direction of the metal flat product, and the depth of the respective flatness fault are determined herein. The data from step 410, or selectively the data from step 310 in the context of a feed-forward regulation, are supplied to a system controller and/or regulator 510, so as to establish a system setup. The system controller and/or regulator 510 thereupon generates control signals 610 for actuating the adjustment units of the straightening rollers 3, 4, or 20 of the system.

(28) Detection of flatness faults of the metal flat product can be performed at the exit side in step 710. The measured values 810 resulting therefrom are subjected to a flatness fault analysis in step 910. The position of the respective flatness fault in the width direction and the length direction of the metal flat product, and the depth of the respective flatness fault are determined herein. At least one correction value which is supplied to the system controller and/or regulator 510 is determined in step 920.

LIST OF REFERENCE SIGNS

(29) 1 System 2 Flat product 3 Straightening roller 4 Straightening roller 5 Part-roller 6 Part-roller 7 Adjustment unit 8 Adjustment direction 9 Pivot unit 10 Longitudinal central axis 11 Rocker 12 Axle 13 Compression spring 14 Wedge lifting unit 15 Wedge 16 Wedge 17 Common adjustment unit 18 Wedge 19 Wedge 20 Straightening roller 21 External diameter reduction 100 Step 110 Step 200 Step 210 Data 300 Items of information 310 Step 400 Step 410 Step 500 Step 510 System controller and/or regulator 600 Step 610 Control signals 700 Step 710 Step 800 Step 810 Measured value 900 Step 910 Step 920 Step x Processing direction