Process Characteristics of Hot Rolling, Cold Rolling and ESP Steel Coils
Reasonable Setting and Control of Rolling Parameters
Accurate Rolling Force Calculation
Calculate rolling forces using professional formulas before operation
Consider strip material (steel, aluminum, copper alloys), thickness, width, and roller specifications
Set calculated values precisely in mill control systems
Ensure forces remain within roller rated capacity
Use experimental rolling or computer simulation for new materials
Example: Conduct trial rolling for composite strips to determine optimal force settings
Optimized Speed and Tension Control
Select appropriate rolling speeds based on roller capacity and material characteristics
Reduce speeds for harder, thicker materials to minimize friction and heat
Follow manufacturer recommendations while incorporating quality feedback
Example: Start with lower speeds for hard alloy steels, gradually increasing as material thins
Determine tension ranges through theoretical and practical methods
Monitor real-time tension variations using sensors
Maintain stable tension through automated control systems
Example: Calculate optimal tension for cold-rolled aluminum strips based on dimensions
Enhanced Equipment Monitoring and Troubleshooting
Advanced Monitoring Systems
Install high-precision sensors for real-time performance tracking
Utilize pressure, displacement, vibration, and temperature sensors
Implement automatic alarms when parameters approach critical levels
Example: Pressure sensors trigger alerts when forces near rated limits
Analyze data trends using mathematical models
Predict overload risks through vibration and temperature patterns
Example: Identify abnormal conditions through sudden vibration increases
Prompt Incident Response
Activate automatic correction systems for strip deviation
Manual intervention when automated systems fail
Immediate shutdown for foreign object detection
Implement metal detectors and emergency stop protocols
Example: Clear foreign objects and inspect rollers before restarting
Scientific Production Planning
Optimized Rolling Sequences
Schedule production based on roller capacity and material difficulty
Process thinner, softer materials before thicker, harder ones
Example: Roll thin aluminum plates before thick steel plates
Use lighter loads for equipment warm-up and debugging
Balanced Equipment Utilization
Distribute production tasks across multiple roller sets
Match material specifications to appropriate mill units
Consider roller diameter, material, and rated capacity in task allocation
Example: Allocate thick and thin strip rolling to suitable mills in large workshops