Mathematical modeling, estimation, and control of the contour evolution in heavy-plate rolling

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This work focuses on mathematical modeling, estimation, and control of contour evolution in heavy-plate rolling. Reversing mill stands reduce the thickness of heavy plates, but asymmetric rolling conditions can cause deviations between the actual and desired plate contour, leading to reduced product quality and potential damage to plant components. As these conditions are typically unknown, a feedback approach is necessary when shape defects occur, requiring accurate contour measurements. Precise measurements of the plate's longitudinal boundaries and the shape of the head and tail ends can optimize mill stand adjustments to minimize camber. The estimation of the plate contour is first discussed, utilizing infrared cameras to capture images during rolling passes. Validation through a downstream contour measurement device demonstrates high accuracy in the proposed estimation method. Next, a static model of contour evolution is derived, predicting the plate's contour after a rolling pass based on its prior contour and thickness profiles. This mathematical model informs various control strategies aimed at reducing contour errors. Measurements from an industrial rolling mill indicate that the proposed methods can significantly enhance the contour of rolled plates.