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Spectrum Profile and Shape Model
Spectrum Systems Engineering (SSE) and TelePro, Inc., present a new rolling mill analysis and modeling software suite, the Spectrum Profile and Shape Model (SPS). This new product is an integrated package of proven mathematical models derived from the fundamental physics of the rolling process. These models are applicable to a wide variety of ferrous and non-ferrous, hot and cold flat rolling mills, accommodating both 4-high and 6-high roll stacks with roll bending and side-shifting variable crown work and/or intermediate rolls. Additionally, several commonly accepted mathematical models are included for the estimation of friction and material yield stress.
The software is structured to perform both process prediction and actuator preset calculations:
Prediction Mode:
Inputs: Mill geometry, schedule parameters, and actuator settings.
Outputs: Predicted rolling force, torque, extrusion, roll gap profile, and strip shape.
Preset Mode:
Inputs: Mill geometry, schedule parameters, and target exit strip shape or roll gap profile.
Outputs: Required actuator settings for roll bending, roll side-shifting, and roll gap position.
Sensitivities of roll gap profile and strip shape to changes in work roll bending and roll side-shifting are also calculated by the system. Knowledge of these sensitivities is essential for the design of on-line profile and flatness control systems.
A graphical forms-based user interface simplifies data entry, storage and retrieval of input data files, and viewing of results, including tabular and graphical display of model distributions and vectors.
The Spectrum Profile and Shape Model can be used in a variety of different environments for a variety of different applications:
Process Development and Optimization:
- Develop alternative rolling schedules.
- Investigate the effects of mill stack geometry changes (including roll diameters, crowns, and end relief) on contact force distributions, roll gap profile, and shape.
- Determine profile and shape actuator working ranges for specified rolling conditions.
Control System Development / Optimization:
- Calculate sensitivities of roll gap profile and strip shape to changes in actuator settings for profile and shape control.
- Calculate sensitivities of roll force, torque, and extrusion to changes in entry thickness, exit thickness, entry tension, exit tension, friction, and yield stress. These sensitivities are used in the design of non-interactive gauge and tension controls and for dynamic mill simulations.6
Off-line Mill Setup Calculations:
- Determine initial settings for roll gap position, work roll bending and work roll side shifting actuators for specified rolling conditions.
The graphical user interface for the Spectrum Profile and Shape modeling suite is implemented using HTML web pages. This approach eliminates the need for the end user to purchase dedicated GUI software; instead, all that is required is a PC running a standard web browser. The use of web pages creates a platform independent user interface and assures that the graphics pages can continue to be supported even as new computing hardware and operating system software is introduced.
Input data for a given mill and schedule are entered manually into data entry forms located on a set of web pages. These pages allow the user to modify and configure all parameters applicable to the SPS model. Online help is available simply by clicking on any parameter name.
Model outputs may be viewed as text in tabular format or as graphical objects displayed in the web page. Below is an example of the plot of exit strip stress sensitivity to work roll bending.