Abstract
The commitment of metallurgical enterprises to digital development dictates the need for industrial implementation of online monitoring systems for rolling mill equipment. The development of Kalman filter (KF)-based monitors for electromechanical rolling stand systems offers significant potential. A literature review highlights the relevance of online monitoring of elastic moments on hot rolling mill spindles. This is due to the fact that the elastic properties of the shaft and the ratio of the rolling stock linear velocities and the rolls affect the amplitude of the elastic moment during roll grip. However, the existing KF-based monitors have not found application in metallurgical production. The main challenge encountered in developing KF-based monitors for rolling mill electric drives is the difficulty in accounting for the filling rate of the deformation zone as the rolling stock enters the stand. Furthermore, electromechanical systems exhibit significant nonlinearity due to the presence of angular clearances in the spindle joints. In this regard, the application of the classical Kalman Filter (KF), developed for linear systems, to the studied two-mass systems with a gap and impact load application causes difficulties. A disadvantage of the modified KFs, including extended Kalman filters (EKF) and their variations (UKF, etc.), is the complexity of the algorithms, which hinders their industrial application. The contribution of the conducted research is that the elastic moment observer and the second mass (roll) moment of a two-mass stand system has been substantiated and developed based on a KF with an augmented state vector, referred to as Augmented Kalman Filter (AKF). A distinctive feature of this filter matrix equations is the addition of the second mass load moment of the two-mass system to the state vector, which allows for the actual filling rate of the deformation zone during gripping. A description of the AKF is presented, and the equation matrices are written down. The procedure for finding matrix elements is automated through the use of the Control System Toolbox™ library. The results of an experimental validation study are presented by comparing the processes obtained in a complex emergency mode. An analysis of transient processes for various angular clearances in the mechanical transmission is performed. In both cases, satisfactory accuracy of elastic moment recovery is confirmed. The developed AKF-based observer has been tested in electromechanical systems of the 5000 plate mill. Recommendations for its industrial implementation are provided.
Keywords
Kalman filter, augmented state vector, rolling mill, electromechanical system, elastic moment, observer, development, adequacy, recommendations
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