METHOD AND APPARATUS TO CONTROL AND ADJUST THE DRAWING ACTION IN A ROLLING MILL, AND CORRESPONDING ROLLING MILL

Abstract

Apparatus to control and adjust the drawing action in a rolling mill provided with rolling stands through which a product passes. A video monitoring system acquires frames of the product; a processing system that processes the frames and defines a normal rolling range within which the product being rolled must be positioned; identifies the position of the product and its geometric characteristics; and identifies a possible variation of the position of the product being rolled over time based on the analysis of the sequence of frames acquired. An automation system is associated with the rolling mill, configured to receive data relating to the position of the product to determine the continuation of the rolling if the product is correctly positioned in the range, or a variation of the rolling parameters if the position of the product being rolled is able to generate a cobble which is outside of the range.

Claims

1. An apparatus to control and adjust the drawing action in a rolling mill (11) for long products (13) provided with a plurality of rolling stands (12a, 12b, 12c) located in sequence through which a product (13) being rolled passes in a direction of rolling (A), wherein it comprises: a video monitoring system (14) for acquiring a sequence of frames (15a, 15b, 15c) of the product (13) being rolled positioned, during use, in at least one position along said rolling mill (11); a processing system (16), connected to said video monitoring system (14) and configured to: carry out the processing of said sequence of frames (15a, 15b, 15c) and define in said sequence of frames (15a, 15b, 15c) acquired at least one normal rolling range (17) within which the product (13) being rolled has to be positioned in a situation of normal rolling; identify the position of the product (13) being rolled and its geometric characteristics; identify a possible oscillation of the product (13) being rolled as a function of a variation of the position of the product (13) being rolled over time with respect to said at least one range (17) based on the analysis of said sequence of frames (15a, 15b, 15c) acquired; an automation system (18) associated with the rolling mill (11), connected to said processing system (16) and configured to determine an optimal condition of the drawing action for said product (13) being rolled corresponding to a condition of minimum oscillation of said product (13) being rolled in at least one inter-stand segment and to receive data relating to the position of the product (13) being rolled and of the possible variation of position of the product (13) being rolled, so as to be able to determine the continuation of the rolling if the product (13) is correctly positioned in said normal rolling range (17), or a possible variation of one or more of the rolling parameters if the position of the product (13) being rolled is potentially able to generate a cobble, that is, it is outside of said range (17), in order to maintain or restore said optimal condition of the drawing action in said at least one inter-stand segment.

2. The apparatus as in claim 1, wherein said automation system (18) is configured to apply controlled timed accelerations and decelerations to at least one motorized roll (27, 28) of at least two subsequent rolling stands (12a, 12b, 12c) in order to impose set and controlled vibrations on said product (13) being rolled.

3. The apparatus as in claim 1, wherein said video monitoring system (14) comprises at least one video camera (19) for each inter-stand segment of the rolling mill (11) located, during use, upstream and/or downstream of each rolling stand (12a, 12b, 12c).

4. The apparatus as in claim 1, wherein said video monitoring system (14) comprises, for a same detection position, at least one video camera (19) located according to a direction (B) substantially perpendicular to the direction of rolling (A).

5. The apparatus as in claim 1, wherein said video monitoring system (14) comprises, for a same detection position, a plurality of video cameras (19) disposed according to different inclinations with respect to the direction of rolling (A).

6. The apparatus as in claim 1, wherein said video monitoring system (14) comprises at least one video camera (19) located in a direction (C) inclined by about 45° with respect to said direction of rolling (A).

7. The apparatus as in claim 1, wherein said processing system (16) is connected to at least one display device (20) able to instantly verify the functioning of the rolling mill (11).

8. The apparatus as in claim 1, wherein said processing system (16) is connected to one or more control systems (21) outside the rolling mill (11) and in which other data about the product (13) being rolled can be processed.

9. A rolling mill for long products (13), provided with a plurality of rolling stands (12a, 12b, 12c) located in sequence through which a product (13) being rolled passes in a direction of rolling (A), wherein it comprises an apparatus to control and adjust the drawing action of said product (13) being rolled as in claim 1.

10. A method to control and adjust the drawing action in a rolling mill (11) for long products (13) provided with a plurality of rolling stands (12a, 12b, 12c) located in sequence through which a product (13) being rolled passes in a direction of rolling (A), wherein it comprises: determining an optimal condition of the drawing action for the product (13) being rolled, corresponding to a condition of minimum oscillation of said product (13) being rolled in at least one inter-stand segment; acquiring a sequence of frames (15a, 15b, 15c) of the product (13) being rolled in at least one position along said rolling mill (11); processing said sequence of frames (15a, 15b, 15c), wherein it is provided at least to define, in said sequence of frames (15a, 15b, 15c) acquired, at least one normal rolling range (17) within which the product (13) being rolled has to be positioned in a situation of normal rolling; identifying the position of the product (13) being rolled and its geometric characteristics; identifying a possible oscillation of the product (13) being rolled as a function of a variation of the position of the product (13) being rolled over time based on the analysis of said sequence of frames (15a, 15b, 15c) acquired; sending the data relating to the position of the product (13) being rolled and the possible variation of position of said product (13) being rolled to an automation system (18) associated with the rolling mill (11), so that said automation system (18) can determine the continuation of the rolling if the product (13) is correctly positioned within the range (17) or a possible variation of one or more of the rolling parameters if the position of the product (13) being rolled is potentially able to generate a cobble, that is, it is outside of said range (17), in order to maintain or restore said optimal condition of the drawing action for said product (13) being rolled.

11. The method as in claim 10, wherein in order to determine said optimal condition of the drawing action it provides to induce a set and controlled vibration on said product (13) being rolled by applying controlled and timed accelerations and decelerations to said rolling stands (12a, 12b, 12c).

12. The method as in claim 10, wherein it comprises: an initial step, under conditions of unknown drawing action, in which it is verified whether the product (13) being rolled that passes between two consecutive rolling stands is vibrating or is not vibrating; if the product (13) being rolled is not vibrating, at least one step of inducing a vibration on the product being rolled between two consecutive rolling stands (12a, 12b, 12c), by increasing the speed (Vg1) of the rolling stand located upstream with respect to the speed (Vg2) of the rolling stand located downstream, wherein this increase in speed determines an increase in the flow rate and therefore the creation of a vibration between the two stands; at least one step of detecting the oscillations of the product (13) being rolled with respect to the normal rolling range (17) and possible correction of the rolling parameters in the rolling stand located upstream in order to keep the product in a desired oscillation within the range (17).

13. The method as in claim 10, wherein said acquisition of a sequence of frames (15a, 15b, 15c) occurs before and/or after each rolling stand (12a, 12b, 12c).

14. The method as in claim 1, wherein the processing of said sequence of frames (15a, 15b, 15c) comprises operations such as removal of the background from the frames (15a, 15b, 15c), removal of possible defects and/or disturbances from the frames (15a, 15b, 15c), or other.

15. The method as in claim 10, wherein it comprises the definition on said detected frames (15a, 15b, 15c) of at least a pair of substantially horizontal lines (22, 23) which define said normal rolling range (17), wherein if the product (13) being rolled goes beyond said lines (22, 23) there is a situation of potential blocking.

16. The method as in claim 10, wherein if the automation system (18) changes one or more of the rolling parameters of the rolling mill (11), at least one new control cycle of the drawing action is carried out, so as to verify that the product (13) being rolled is contained within said range (17) after the variation of the drawing action.

17. The method as in claim 10, wherein the variation of the drawing action applied to the product (13) being rolled comprises adjusting the rolling parameters such as adjusting the speed (Vg1, Vg2, Vg3) of one or more rolling stands (12a, 12b, 12c), adjusting the passage gap of the product (13) in one or more rolling stands (12a, 12b, 12c) or other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0063] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of some embodiments, given as a non-restrictive example with reference to the attached drawings wherein:

[0064] FIG. 1 is a schematic view of an apparatus according to the present invention to control and adjust the drawing action in a rolling mill;

[0065] FIG. 2 is a front schematic view of a product being rolled;

[0066] FIGS. 3a, 3b and 3c schematically show three frames of a product being rolled;

[0067] FIGS. 4a, 4b and 4c show some steps of the present method to control and adjust the drawing action in a rolling mill.

[0068] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can conveniently be incorporated into other embodiments without further clarifications.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

[0069] We will now refer in detail to the possible embodiments of the invention, of which one or more examples are shown in the attached drawings. Each example is supplied by way of illustration of the invention and shall not be understood as a limitation thereof. For example, one or more characteristics shown or described insomuch as they are part of one embodiment can be varied or adopted on, or in association with, other embodiments to produce another embodiment. It is understood that the present invention shall include all such modifications and variants.

[0070] With reference to the attached drawings, FIG. 1 schematically shows an apparatus 10 according to the present invention to adjust and control the drawing action in a rolling mill 11 provided with a plurality of rolling stands 12a, 12b, 12c disposed in sequence and through which a product 13 being rolled passes in a direction of rolling A.

[0071] Some embodiments described here also concern a rolling mill 11 comprising such apparatus 10.

[0072] The present apparatus 10 comprises: [0073] a video monitoring system 14 for acquiring a sequence of frames 15a, 15b, 15c (see also FIGS. 3a, 3b, 3c) of the product 13 being rolled in at least one position along the rolling mill 11; [0074] a processing system 16 connected to the video monitoring system 14 and configured to: carry out the processing of the sequence of frames 15a, 15b, 15c and define in this sequence of frames 15a, 15b, 15c acquired at least one normal rolling range 17 within which the product 13 being rolled has to be positioned in situations of normal rolling; identify the position of the product 13 being rolled and its geometric characteristics; identify a possible variation of the position of the product 13 being rolled over time based on the analysis of the sequence of frames 15a, 15b, 15c acquired; [0075] an automation system 18, associated with the rolling mill 11, connected to the processing system 16 and configured to receive the data relating to the position of the product 13 being rolled, and the possible variation of position of the product 13 being rolled, so as to be able to determine the continuation of the rolling if the product is correctly positioned in the normal rolling range 17, or a possible variation of one or more of the rolling parameters if the position of the product 13 being rolled is potentially able to generate a cobble, that is, it is outside of the range 17.

[0076] In particular, the processing system 16, as a function of the variation of the position of the image of the product 13 being rolled in the frames 15a, 15b, 15c with respect to the normal rolling range 17, can identify an oscillation of the product 13 being rolled and possibly quantify the extent thereof.

[0077] According to some embodiments, the automation system 18 can be configured to determine an optimal condition of the drawing action for the product 13 being rolled corresponding to a condition of minimum and defined oscillation of the product 13 being rolled in at least one inter-stand segment, and determine the continuation of the rolling, or the variation of at least one rolling parameter, in order to maintain, or restore, the optimal condition of the drawing action determined.

[0078] According to some embodiments, the automation system 18 can be connected to the rolling stands 12a, 12b, 12c, and be configured to apply controlled timed accelerations and decelerations to at least two subsequent rolling stands 12a, 12b, 12c in order to impose set and controlled vibrations on the product 13 being rolled and control the condition of the drawing action thereof.

[0079] The video monitoring system 14 can comprise at least one video camera 19 for each inter-stand segment of the rolling mill 11 to which it has to be applied.

[0080] In particular, the video monitoring system 14 can comprise at least one video camera 19 located upstream of each rolling stand 12a, 12b, 12c, and at least one video camera 19 located downstream of each rolling stand 12a, 12b, 12c.

[0081] The monitoring system 14, therefore, is able to carry out photo or video detections in one or more determinate positions of the rolling mill 11, in order to have a complete picture of the rolling process.

[0082] The video cameras 19 are in particular configured to acquire a video sequence and/or a sequence of digital images, or frames, for example the frames 15a, 15b, 15c, in several positions of the rolling mill 11, in particular at entry and at exit of each rolling stand 12a, 12b, 12c. Naturally, the number of rolling stands and the distance between them can vary compared to what is schematically shown in FIG. 1.

[0083] The video monitoring system 14 can also comprise infrared devices, such as thermal imaging video cameras or suchlike, as an alternative to or in combination with the video cameras 19.

[0084] The product 13 being rolled has high temperatures, for example about 900-1200° C., therefore it has a high chromatic contrast with respect to the surrounding environment, and is clearly visible and detectable by the video monitoring system 14, provided with video cameras 19 and/or thermal imaging video cameras.

[0085] The video cameras 19 and/or the thermal imaging video cameras can be disposed in various positions with respect to the product 13 being rolled, and therefore with respect to the direction of rolling A.

[0086] For example, the video monitoring system 14 can comprise, for a same detection position, at least one video camera 19 according to a direction B substantially perpendicular to the direction of rolling A, see for example the video camera 19 located upstream of the rolling stand 12b. The positioning according to this direction B allows a better acquisition of the images of the product 13 being rolled.

[0087] The video monitoring system 14 can also comprise, for a same detection position, see FIG. 2, a plurality of video cameras 19 disposed according to different inclinations with respect to the direction of rolling A, and therefore substantially to the direction of longitudinal development of the product 13 being rolled.

[0088] These video cameras 19 can be disposed on the side of the product 13 being rolled, above the product being rolled or inclined with respect to the product being rolled. For example, it is possible to provide that the video monitoring system 14 comprises at least one video camera 19 located according to a direction C inclined by approximately 45° with respect to the direction of rolling A. In this way, it is possible to detect both possible lateral swerves of the product 13 being rolled, that is, swerves in a direction H that is horizontal with respect to the direction of rolling A, and also vertical swerves of the product 13 being rolled, that is, swerves in a direction V that is vertical with respect to the direction of rolling A.

[0089] The provision of several video cameras 19 in the same detection position, as shown schematically in FIG. 2, allows to send to the processing system 16 a series of frames from different angles, and therefore allows to obtain multiple readings of the situation of the product 13 being rolled, allowing in fact to better define the characteristics of the product 13.

[0090] For example, it is possible to use the geometric data of the product 13 detected by the video monitoring system 14 to carry out a measurement of the sizes thereof in the various rolling passes. Therefore, it is possible to determine, in each pass, width, thickness and other possible parameters of the product 13.

[0091] This processing system 16 can be connected to at least one display device 20, for example a pulpit or suchlike, able to allow operators to instantly check the functioning of the rolling mill 11. Furthermore, on this display device 20 there can be projected the data detected and processed by the processing system 16 relating to the status of the product 13 being rolled in the various steps of the rolling process.

[0092] The processing system 16 can be connected to one or more control systems 21 outside the rolling mill 11 and in which other data about the product 13 being rolled can be processed. These other control systems 21 can be, for example, control rooms for use, for example, by technologists.

[0093] The method to control and adjust the drawing action according to the invention substantially comprises the following steps: [0094] acquiring a sequence of frames 15a, 15b, 15c, of the product 13 being rolled in at least one position along the rolling mill 11; [0095] processing the sequence of frames 15a, 15b, 15c, wherein it is provided at least to define, in the sequence of frames 15a, 15b, 15c acquired, at least one normal rolling range 17 within which the product being rolled has to be positioned in a situation of normal rolling; [0096] identifying the position of the product 13 being rolled and its geometric characteristics; [0097] identifying a possible variation of the position of the product 13 being rolled over time based on the analysis of the sequence of frames 15a, 15b, 15c acquired; [0098] sending the data relating to the position of the product 13 being rolled, and the possible variation of the position of the product 13 being rolled, to an automation system 18 associated with the rolling mill 11, so that the automation system 18 can determine the continuation of the rolling if the product 13 is correctly positioned within the normal rolling range 17, or a possible variation of one or more of the rolling parameters if the position of the product 13 being rolled is potentially able to generate a cobble, that is, it is outside of the range 17.

[0099] According to some embodiments, the method provides to determine an optimal condition of the drawing action for the product 13 being rolled, corresponding to a condition of minimum oscillation of the product 13 being rolled in at least one inter-stand segment, and determine the continuation of the rolling, or the variation of one or more rolling parameters, in order to maintain or restore the optimal condition of the drawing action.

[0100] According to some embodiments, in order to determine the optimal condition of the drawing action, the method provides to induce a set and controlled vibration on the product 13 being rolled by applying controlled and timed accelerations and decelerations to the rolling stands 12a, 12b, 12c, as will be better described below.

[0101] In particular, the accelerations and decelerations can be uniformly timed over time in order to pass from a situation of drawing action to a situation of thrust action for a defined time, so as to make the product 13 being rolled pass from a situation of linear progress to a situation in which it is induced to vibrate. The video monitoring system 14 can then record these set and controlled vibrations in order to determine whether or not their amplitude is recurring and the images of the product 13 in the frames 15a, 15b, 15c acquired fall within the normal rolling ranges 17 or whether they take positions outside of them.

[0102] Preferably, the acquisition of a sequence of frames 15a, 15b, 15c takes place before and after each rolling stand 12a, 12b, 12c.

[0103] The step of processing this sequence of frames 15a, 15b, 15c can be carried out by means of suitable algorithms and can comprise operations such as the removal of the background from the frames 15a, 15b, 15c, the removal of possible defects and/or disturbances from the frames 15a, 15b, 15c, for example drops, reflections, or other.

[0104] In particular, on the frames detected, consider for example the frame 15a of FIG. 3a, which substantially represents a frame of a recording carried out by means of one of the video cameras 19, there is defined at least a pair of substantially horizontal lines 22 and 23 which define the normal rolling range 17, for example in a central zone of the frame 15a. If the product 13 being rolled goes beyond these lines 22, 23 there is a situation of potential blocking.

[0105] For example, see FIG. 2b, when the position of the product 13 goes beyond one of the limits of the range 17, that is, one of the lines 22 or 23, the rolling mill 11 goes into emergency. Tolerances can clearly be provided before the emergency actually comes into operation: for example, the percentage of pixels of the product 13 beyond the range 17, compared to the percentage of pixels that have not gone beyond it, or if the product 13 remains beyond the range 17, on one side or the other, for a certain period of time, or if it goes beyond it and re-enters it for a number of times in a certain time. Furthermore, for different rolling passes and products of different shapes, the positioning of the normal rolling range 17 can change, that is, the positions of the lines 22 and 23 can change.

[0106] When the emergency is definite, see frame 15c in FIG. 3c, the emergency procedure is implemented, which normally provides scrapping the product 13 upstream by means of special shears and/or stopping the rolling stands in which the cobble occurred.

[0107] The situation of potential cobble, following for example the detection of a sequence of frames 15b, can generate a state of alarm of the rolling mill 11, which can provide, as a consequence, the adjustment of the drawing action by the automation system 18, see for example the decision node 24 in the diagram of FIG. 1.

[0108] The processing system 16 sends a series of data extrapolated from the images or frames acquired, block 29, which comprise the data relating for example to the frames 15a, 15b, 15c.

[0109] Substantially, if the processing system 16 sends to the automation system 18 the data relating to a sequence of frames 15a in which the product 13 is stably contained within the range 17, the rolling continues with the current parameters, see line 25. On the other hand, if the processing system 16 sends to the automation system 18 the data relating to a sequence of frames 15b, then the rolling mill 11 enters an emergency situation and the automation system 18 varies one or more of the rolling parameters in one or more of the rolling stands 12a, 12b, 12c involved in the potential cobble, see line 26.

[0110] If the automation system 18 modifies the status of the rolling mill 11, at least one new cycle of controlling the drawing action is carried out in order to verify that the product 13 being rolled is contained within the normal rolling range 17, after the variation. This control cycle can be repeated until parameters of the drawing action are identified that are suitable to determine a correct rolling with the product 13 within the range 17.

[0111] The variation of the rolling parameters with the purpose of possibly adjusting the drawing action of the product 13 being rolled can comprise, for example, one or more of either adjusting the speed of one or more rolling stands 12a, 12b, 12c, adjusting the passage gap of the product 13 in one or more rolling stands 12a, 12b, 12c, or other.

[0112] Each rolling stand 12a, 12b, 12c comprises at least one pair of rolls 27, 28 of which at least one roll is motorized and rotates according to a determinate speed of rotation, for example the roll 27. The rolls 27 and 28 can in any case both be advantageously motorized.

[0113] If only the roll 27 is motorized, the other roll 28 can be a support roll, for example an idle roll dragged at the same speed as the roll 27 by the product 13. With the term speed of the rolling stand we therefore mean the speed of rotation of the rolls 27, 28 of the rolling stand 12a, 12b, 12c.

[0114] In the sequence shown in FIGS. 4a, 4b, 4c, the speed of the three rolling stands 12a, 12b, 12c has been indicated respectively with Vg1, Vg2, Vg3.

[0115] The control of the drawing action, according to the sequence of FIGS. 4a, 4b, 4c, comprises: [0116] an initial step in which it is verified whether the product 13 being rolled that passes between two consecutive rolling stands is vibrating or is not vibrating; [0117] if the product being rolled 13 is not vibrating, at least one step of inducing a vibration on the product 13 being rolled between two consecutive rolling stands, for example the rolling stands 12a, 12b, see FIG. 4b, by increasing the speed Vg1 of the rolling stand 12a located upstream with respect to the speed Vg2 of the rolling stand 12b located downstream, so that the flow rate of product that passes in the rolling stand 12a located upstream is increased as a result of the vibration induced; [0118] at least one step of detecting the oscillations of the product 13 being rolled with respect to the normal rolling range 17, delimited for example by the lines 22 and 23, and possible correction of the rolling parameters in the rolling stand 12a located upstream in order to keep the product 13 in a desired oscillation within the range 17.

[0119] The adjustment of the rolling parameters in a rolling stand 12a can provide, for example, an adjustment of the speed Vg1 in such rolling stand and/or a variation of the passage gap of the product 13 between the rolling rolls 27 and 28.

[0120] Substantially, therefore, it is possible that in the rolling mill 11 there is an initial condition of vibration of the product 13, for example due to an insufficient drawing action, which may or may not be contained within the range 17. It can also occur that there is no initial vibration of the product 13, for example in the case of a drawing action in optimal conditions or in the case of an excess of drawing action.

[0121] Therefore, in order to correctly apply the drawing action in the various steps of the rolling process, if the product 13 has an initial vibration, the parameters of the rolling stand 12a located upstream are controlled in order to set the oscillation or vibration to the desired value, therefore maintain the vibration within the range 17. Otherwise, if the product 13 does not have an initial vibration, it is possible to proceed, for example periodically, with inducing a vibration in the product 13 and therefore control the rolling parameters.

[0122] Periodically, therefore, for a defined time and for each pair of rolling stands located in sequence, for example the rolling stands 12a and 12b, the rolling stand 12a located upstream is accelerated slightly: this causes a greater passage of material (same section at higher speed, therefore higher flow rate) toward the subsequent rolling stand 12b. This subsequent rolling stand 12b struggles to accommodate the excess material and hence a vibration is generated. This vibration is detected and processed by the present video monitoring apparatus 10, with the following result: if the product 13 remains within the range 17, the process continues, if it is outside there is the risk of cobble and the rolling process can be stopped.

[0123] Substantially, if there is no wear of the rolling channels in a determinate rolling stand, the excess flow will cause a low vibration, which will not go beyond the range 17. Conversely, if due to wear the gap defined by the rolling channels is excessive, the over-speed induced would be added to the over-section deriving from wear, causing an excessive flow rate which would cause the range 17 to be exceeded. Therefore, the present method and the present apparatus are extremely effective in determining the status of the rolling stands.

[0124] It is clear that modifications and/or additions of parts and steps may be made to the apparatus and method as described heretofore, without departing from the field and scope of the present invention as defined by the claims.

[0125] It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art shall certainly be able to achieve many other equivalent forms of apparatus and method, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby. In the following claims, the sole purpose of the references in brackets is to facilitate reading: they must not be considered as restrictive factors with regard to the field of protection claimed in the specific claims.