MODULAR ROLLING TRAIN, PARTICULARLY HOT ROLLING TRAIN, PREFERABLY IN CONJUNCTION WITH AN UPSTREAM CASTING FACILITY

Abstract

A modular rolling train, particularly a hot rolling train, preferably in conjunction with an upstream casting facility, and a method for operating a modular rolling train are described. The rolling train is standardized and modularized by dividing the rolling train into discrete units n and by modularization of the discrete units. The rolling train can be flexibly adapted to new requirements by exchanging a module.

Claims

1.-21. (canceled)

22. A modular rolling train, comprising: at least one heat treatment unit, a roughing rolling unit, a finishing rolling unit, and a transport unit for forming a metallic starting product into a finished product along a throughput section of the starting product through the rolling train, wherein the rolling train is subdivided into discrete units along the throughput section, wherein at least one of the discrete units is a subdivided discrete unit comprising at least two modules, and wherein at least one of the at least two modules of the subdivided discrete unit can be exchanged with another module by a transport device assigned to the subdivided discrete unit.

23. The modular rolling train according to claim 22, wherein the subdivided discrete unit is a roughing rolling unit, a finishing rolling unit, a transport unit, or a heat treatment unit, and wherein a module of the at least two modules is a set of rolls of a roughing stand, a set of rolls of a finishing stand, a roll table, an enclosed roll table, a furnace module, a cooling section, a separating unit, a surface treatment unit, or a measuring equipment.

24. The modular rolling train according to claim 22, wherein the at least two modules of the subdivided discrete unit can be exchanged with one another.

25. The modular rolling train according to claim 22, wherein a further of the discrete units is a further subdivided discrete unit with a further transport device being assigned to the further subdivided discrete unit, and wherein the modules can be exchanged between one another by a transport operation between the transport device and the further transport device.

26. The modular rolling train according to claim 25, wherein a base length of 0.25 m to 1 m is provided for dividing the rolling train into a length grid, and wherein dimensions of the discrete units and/or the modules of the rolling train are integer multiples of the base length.

27. The modular rolling train according to claim 22, wherein the subdivided discrete unit is a heat treatment unit, and wherein at least one of the at least two modules of the heat treatment unit is a furnace module, a roll table module, an enclosed roll table module, a cooling section module, a surface treatment module, or a measuring section module.

28. The modular rolling train according to claim 27, wherein the at least one of the at least two modules is a roller hearth furnace module.

29. The modular rolling train according to claim 27, wherein the at least one of the at least two modules is an induction heating module.

30. The modular rolling train according to claim 22, wherein the subdivided discrete unit is a roughing rolling unit, and wherein at least one of the at least two modules of the roughing rolling unit is a roughing stand with two driven work rolls and/or two support rolls.

31. The modular rolling train according to claim 22, wherein the subdivided discrete unit is a finishing rolling unit, and wherein at least one of the at least two modules of the finishing rolling unit is a finishing roll stand with two driven work rolls and/or two support rolls.

32. The modular rolling train according to claim 22, wherein the rolling train is a hot rolling train, and wherein different cast products comprising different materials and/or having different dimensions can be produced by an upstream casting facility, and wherein the different cast products can be fed to the hot rolling train directly after the casting and solidification process.

33. The modular rolling train according to claim 32, wherein the casting facility is a continuous casting line, and wherein an ingot mold can be exchanged to change the dimensions.

34. The modular rolling train according to claim 22, wherein a continuous casting line with an exchangeable ingot mold, a first heat treatment unit before a roughing rolling unit, a second heat treatment unit between the roughing rolling unit and a finishing rolling unit, and a third heat treatment unit after the finishing rolling unit are provided, and wherein the second heat treatment unit is the subdivided discrete unit.

35. The modular rolling train according to claim 34, wherein by exchanging the modules of the second heat treatment unit the modular rolling train can be adjusted to different materials and dimensions.

36. The modular rolling train according to claim 22, further comprising a higher-level control or regulation system for the rolling train and associated control or regulation system for the discrete units and/or the modules, wherein the higher-level control or regulation system can initiate and execute an automatic exchanging of the at least two modules.

37. A method for operating the modular rolling train according to claim 22, wherein, in the event of a desired change in format and/or material of the finished product, a process control in the rolling train is adjusted based on predetermined production parameters by performing the following steps: checking of the modules present in the throughput section as to whether the production parameters can be achieved by a roll gap adjustment and/or adjustment of cooling parameters; and automatically exchanging unsuitable ones of the of the at least two modules with modules suitable for compliance with the production parameters.

38. The method according to claim 37, wherein the modules are exchanged within 10 min.

39. The method according to claim 37, wherein a higher-level control system (C) suggests alternative formats and/or materials if no modules (m) suitable for maintaining the production parameters can be exchanged with one another.

40. The method according to claim 39, wherein the higher-level control system uses process models for discrete units and/or modules.

41. The method according to claim 39, wherein the higher-level control system (C) exchanges data with a production planning system.

42. The method according to claim 39, wherein the higher-level control system (C), in conjunction with a production planning system, optimizes production sequences in terms of material, dimensions, throughput and/or deadlines.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1: System diagram of rolling train.

[0029] FIG. 2: System diagram of hot rolling train with continuous casting line.

[0030] FIG. 3a: Side view illustrating a module exchange with a transport device using the example of a furnace module.

[0031] FIG. 3b: Top view illustrating a module exchange with a transport device using the example of a furnace module.

[0032] FIG. 4: Mode of operation of the higher-level control device.

DETAILED DESCRIPTION

[0033] The invention is described in detail below with reference to the specified figures in the form of exemplary embodiments. In all figures, the same technical elements are designated with the same reference signs.

[0034] FIG. 1 shows a diagram of a rolling train 1 divided into discrete units n with n.sub.1 to n.sub.x. Some of the discrete units n have at least one subdivision into modules m with m.sub.1 to m.sub.y. In this example, the rolling train 1 is divided into the discrete units of heat treatment unit n.sub.2, roughing rolling unit n.sub.3, finishing rolling unit n.sub.4 and transport unit n.sub.5. The discrete units nz and n.sub.3 have exchangeable modules m in this example. The modules are exchanged by means of a transport device T assigned to the discrete unit.

[0035] FIG. 2 shows a schematic illustration of a hot rolling train 1 for a metallic flat product with an upstream continuous casting line 6. The continuous casting line 6 comprises at least one discrete unit n.sub.6, the hot rolling train 1 has as discrete units n a pre-heating unit n.sub.21, a roughing rolling unit n.sub.3, an intermediate heating unit n.sub.22, a finishing rolling unit n.sub.4, a transport unit n.sub.5 and a recoiling unit n.sub.8, along with various separating units n.sub.7. The rolling train 1 can have other units, such as scale washers, possible induction heaters, etc., in addition to the modules or units shown in the figure.

[0036] In this exemplary embodiment, the discrete unit n.sub.6 of the continuous casting line 6 has an exchangeable module m in the form of the ingot mold. The ingot mold m.sub.6.1 as module m of the continuous casting line 6 can be designed to be funnel-shaped. Alternatively, a parallel ingot mold m.sub.6.2 is available as an exchange module. With a funnel-shaped ingot mold, a thickness tapering can already be carried out during the solidification process. It is particularly suitable for casting thicknesses in the range of 100 mm to 130 mm. With a parallel ingot mold m.sub.6.2, particularly rapid solidification and a large casting thickness can be achieved. It can be used for larger casting thicknesses of 150 mm, for example, and preferably for the manufacturing of peritectic materials and tubular steels.

[0037] In the present exemplary embodiment, in accordance with FIG. 2, the pre-heating unit n.sub.21 is designed as a non-modular discrete unit n. However, this could be replaced by a discrete unit with at least one exchangeable module. Thus, comparable modules m could be exchangeable with the intermediate heating unit m.sub.22 described later.

[0038] In this exemplary embodiment, the roughing rolling unit n.sub.3 is designed as a two-stand roughing rolling train in 4-roll design with driven work rolls. The number of stands can usually vary between 1 and 3. In this example, the exchangeable modules m are the sets of work rolls m.sub.3.1 and m.sub.3.2, which have different diameter ranges. The work roll diameter ranges between the two sets of rolls differ beyond the usual grinding range of a work roll of about 10% and allow modified forming conditions to be adjusted. For example, a work roll module m.sub.3.1 can have a diameter range of 1050 mm to 950 mm and is used for the rough rolling of large casting thicknesses up to 150 mm. The exchangeable work roll module m.sub.3.2 can have a diameter range of 950 mm to 850 mm, for example. The module exchange in the form of a set of work rolls for another set of work rolls with a different work roll diameter range produces a roll gap adjustment. The module exchange of the sets of work rolls m.sub.3.1, m.sub.3.2 is carried out by a transport device T in the form of a work roll changing device, which removes the work rolls to be changed from the stand and brings in the exchange rolls.

[0039] The example of the work roll diameter ranges of the sets of work rolls m.sub.3.1 and m.sub.3.2 shows that it is possible to match the dimensional ranges. These are quite intentional, as it provides complete and comprehensive coverage of technologically sensible production options, helping to improve production flexibility.

[0040] In this exemplary embodiment, the intermediate heating unit n.sub.22 is in the form of a discrete unit with a fixed section and four modules m.sub.22.1, m.sub.22.2, m.sub.22.4 and m.sub.22.5. The two modules m.sub.22.1 and m.sub.22.2 are designed as individual roller hearth furnace modules and are arranged one after the other along the throughput section D. In addition, the modules m.sub.22.4 and m.sub.22.5 are available in the form of open roll tables as exchange modules. Through the exchange of module m.sub.22.1 for exchange module m.sub.22.4 and/or through the exchange of module m.sub.22.2 for exchange module m.sub.22.5, a partial length of intermediate heating unit n.sub.22 is created from an open roll table where the roughing strip is subjected to corresponding cooling.

[0041] As a result, other module compositions are also conceivable. Thus, the number of modules along the throughput section D from m.sub.22.1 to m.sub.22.x can be selected to be as large as desired, and the same applies to the number and/or type of exchange modules. Thus, in a variant not shown, a single roller hearth furnace module m.sub.22.1 installed in the throughput section (D) can be exchanged for a single open roll table module m.sub.22.4 or alternatively for an enclosed roll table module m.sub.22.6 or alternatively a cooling section m.sub.22.7, etc. An overhead crane can be used as the transport device T, but automated embodiments such as those described in more detail in FIG. 3 are preferred.

[0042] The finishing rolling unit n.sub.4 of the present exemplary embodiment is designed as a non-modular discrete unit. In the exemplary embodiment, the finishing rolling unit n.sub.4 is designed as a 6-stand finishing rolling train in 4-roll design with driven work rolls. In an alternative not shown, the finishing rolling mill n.sub.4 can also be designed as a modular discrete unit. Then, following the principle of the roughing rolling unit n.sub.3, exchange modules with different work roll diameters or cooling devices are suitable, but other exchange modules can also be provided in the form of intermediate stand devices, such as straightening units, additional cooling devices and/or intermediate stand heating devices.

[0043] The rolling train 1 further comprises a transport unit n.sub.5, in the exemplary embodiment with an integrated cooling section module m.sub.5.4, along with a recoiling unit n.sub.8. The various possible embodiments of the cooling section module m.sub.5.4 and the recoiling unit n.sub.8 are known to the skilled person from the prior art.

[0044] The control device C shown here is connected in terms of signal technology to those discrete units n which have modules m. In the rolling train 1 shown, these are the continuous casting line 6 with modules m.sub.6.1 and m.sub.6.2, the roughing rolling unit n.sub.3 with modules m.sub.3.1 and m.sub.3.2, along with the intermediate heating unit n.sub.22 with modules m.sub.22.1, m.sub.22.2, m.sub.22.4 and m.sub.22.5.

[0045] FIG. 3a and FIG. 3b schematically show the exchange of a module m with a transport device T using the example of an intermediate heating unit n.sub.22, along with a transport unit n.sub.5 in side view (FIG. 3a) and top view (FIG. 3b). In FIGS. 3a and 3b, various transport devices T and embodiments are shown combined with one another for example purposes.

[0046] The intermediate heating unit n.sub.22 consists of three modules m.sub.22.1, m.sub.22.2 and m.sub.22.3 arranged one behind the other in the throughput section D, which are designed as roller hearth furnace modules. Each of the modules m is mounted on a rail system S1 associated with the transport devices T, which extends transversely to the throughput section in the direction of the double arrow P1 and on which the module m that can be moved into or out of the throughput section can be transported. In the top view, such rail system is shown with dashed dots. Two exchange modules are mounted in a position adjacent to the throughput direction; in the present case, an open roll table m.sub.22.4 and an enclosed roll table m.sub.22.6 are positioned parallel to the throughput section D.

[0047] In one embodiment, the roller hearth furnace module m.sub.22.3 can be exchanged simultaneously, through a connected operation, in a simple partially or fully automated manner with the open roll table module m.sub.22.4. For this purpose, the cylinder T.sub.1, as a further component of the transport device T, couples to the roll table module m.sub.22.4, and the two modules are jointly displaced perpendicular to the throughput section D, such that the roll table module m.sub.22.4 is now positioned in the throughput section.

[0048] In a further embodiment, illustrated using the example of the middle roller hearth furnace module m.sub.22.2, either the module m.sub.22.4 or the module m.sub.22.6 can be used as an exchange module. For this embodiment, a second rail system S2 belonging to the transport device T must be provided parallel to the throughput section D, which extends through a double line with whole and dashed line in the direction of arrow P2. For exchanging the roller hearth furnace module m.sub.22.2, the position on the second rail system S2 transverse to the throughput section D must initially be unoccupied. A drive device T.sub.2 belonging to the transport unit T, in this variant as a motor with pinion and rack, transports the roller hearth furnace module m.sub.22.2 out of the throughput section D onto the axis of the transport section in the direction of the arrow P2 and then moves it on the rail set S2. If the enclosed roll table module m.sub.22.6 is to be introduced into the throughput section D, the modules m located on the rail set S2 are moved in such a manner that the module m.sub.22.6 is located in front of the rail system of the transport device of the middle module and can then be transported into the throughput section D. The roller hearth furnace module m.sub.22.1 can be exchanged in the same manner.

[0049] The exchange of modules m between two discrete units n is shown with respect to the transport unit n.sub.5. The transport unit n.sub.5 has two roll table modules m.sub.5.1 and m.sub.5.2, which can be moved along the rails S3 by means of assigned transport devices T. The transport options correspond to those described for the intermediate heating unit n.sub.22. An additional inductive heating module m.sub.5.3 is assigned to the n.sub.5 transport unit. According to the method described above, the roll table module m.sub.5.2 can be exchanged, for example for repair reasons, by the roll table module m.sub.22.4 assigned to the intermediate heating unit n.sub.22. The positioning and the displacement in the direction of the arrows P1 and P2 takes place as already described. Similarly, the inductive heating module m.sub.5.3 assigned to the transport unit m.sub.5 can replace the roll table module m.sub.5.1 within the transport unit n.sub.5 and thus increase the overall heating power, or alternatively it can be inserted at any position within the intermediate heating unit n.sub.22 if required. The exchange of modules m between two different discrete units n can thus additionally extend the flexibility of the entire system.

[0050] FIG. 4 shows an exemplary embodiment of the mode of operation of a higher-level control unit C. The control unit C receives data regarding the target product to be manufactured with regard to the alloy, the dimensions and the metallurgical properties. In addition, the current composition of all discrete units n.sub.1 to n.sub.x with their modules m.sub.1 to m.sub.y in the throughput section D and the exchange modules must be known to control unit C. Such composition gives rise to a current system configuration. The next step is to determine whether the production of the target product is possible with the current composition of all discrete units n with their modules m in the throughput section D. For this purpose, the control unit makes extensive calculations. It is useful if the control device for the calculations is linked to further calculation systems or can exchange data. A link with a casting model or a pass schedule calculator can support and simplify the calculation necessary for the decision. Further links to a cooling model, a profile and flatness model, an energy consumption calculation, for example based on a model, along with other models can be provided.

[0051] If the result of the calculation affirms that the manufacturing of the target product is possible with the current system configuration, manufacturing is initiated. If the ability to manufacture is answered in the negative, the control unit asks whether an alternative target product is to be produced.

[0052] If this is affirmed, a modified target product is set. Through the setting of a new target product, even a short shutdown for a necessary module exchange can be avoided in favor of increased productivity, and products that can be manufactured on a uniform line assembly of all discrete units can be produced as a sequence. For this reason, it is helpful to link the setting of the new target product with a production planning system or production control planning. The link to maintenance planning, which for example provides for regular intervals for roll changes or ingot mold changes, can have an additional effect on such decision.

[0053] If the manufacturing of an alternative target product is rejected, the control unit determines the necessary composition of the modules m, in conjunction with the composition of all discrete units n in the throughput section. In the following step, the necessary exchange of those modules m whose exchange is necessary to achieve the required composition is initiated. Thus, a new updated composition of all discrete units n with modules m in the throughput section D is ready for the manufacturing of the target product. A modified system configuration is available and manufacturing can be initiated.

[0054] Optionally, the control can additionally integrate a change of an operating mode for the manufacturing of a target product. This is shown in FIG. 4 with the dashed additional queries and defaults. The operation of a hot rolling mill 1 in different modes increases its flexibility and its production range. Operating modes ranging from continuous production to batch operation, along with various intermediate forms, are known to the skilled person from the state of the art and will not be described in detail here. In conjunction with the modular structure of the hot rolling train 1, even greater flexibility and an even wider production range can be achieved with the availability of a plurality of operating modes.

[0055] The current manner of operation must be known for the operating mode of the controller. If the question of manufacturing an alternative target product is answered in the negative, the next step is to determine whether the intended target product can be manufactured by a different operating mode. For this purpose, the controller makes various calculations that can be supported by the models etc. already specified. If the question is answered in the affirmative, the operating mode is changed and the manufacturing of the target product is thereby enabled. If the question is answered in the negative, the usual subsequent step to determine the necessary composition of the modules m is initiated.

[0056] The control device C can be connected in terms of signal technology online to the hot rolling train 1 and/or continuous casting line 6. Yet, it can also work offline. Offline operation can simulate production sequences and thus pre-optimize advance planning of production.

[0057] With the overall consideration of the hot rolling mill, its subdivision into discrete units n, at least one of which has a plurality of modules m, a step is taken away from a selective consideration of individual units towards an overall system consisting of connected units n with modules m. The composition of the modules m in conjunction with the sum of the discrete units n within the throughput section D, but also as available exchange modules, allow the entire hot rolling mill to be expanded in terms of its flexibility and its possible production spectrum.

REFERENCE SIGNS

[0058] 1 Rolling mill [0059] 6 Continuous casting line [0060] C Higher-level control system [0061] D Throughput section [0062] m Module [0063] m.sub.22.1 Roller hearth furnace module [0064] m.sub.22.2 Roller hearth furnace module [0065] m.sub.22.3 Roller hearth furnace module [0066] m.sub.22.4 Open roll table module [0067] m.sub.22.5 Open roll table module [0068] m.sub.22.6 Enclosed roll table module [0069] m.sub.22.7 Cooling section module [0070] m.sub.3.1 First set of work rolls as the module of the roughing rolling unit [0071] m.sub.3.2 Second set of work rolls as the module of the roughing rolling unit [0072] m.sub.5.1 Roll table module [0073] m.sub.5.2 Roll table module [0074] m.sub.5.3 Inductive heating module [0075] m.sub.5.4 Cooling section module [0076] m.sub.6.1 Funnel-shaped ingot mold as the first module of the continuous casting line [0077] m.sub.6.2 Parallel ingot mold as the second module of continuous casting line [0078] m.sub.y Module y [0079] N Discrete unit [0080] n.sub.1 First discrete unit as the transport unit [0081] n.sub.2 Heat treatment unit [0082] n.sub.2 Second discrete unit as the [0083] n.sub.21Pre-heating unit [0084] n.sub.22 Intermediate heating unit [0085] n.sub.23 Drive device [0086] n.sub.24 Drive device [0087] n.sub.3 Roughing rolling unit [0088] n.sub.3 Roughing rolling unit [0089] n.sub.4 Finishing rolling unit [0090] n.sub.4 Finishing rolling unit [0091] n.sub.5 Transport unit [0092] n.sub.7 Separating unit [0093] n.sub.x Discrete unit x [0094] P1 Directional arrow [0095] P2 Directional arrow [0096] S1 Rails [0097] S2 Rails [0098] S3 Rails [0099] T Transport device [0100] T.sub.1 Cylinder [0101] T.sub.2 Drive unit