Abstract
Development of Digital Twins and Digital Control Systems for Electric Drives at Industrial Units predetermines the virtual models creation that must ensure an optimal combination of result accuracy and high-speed data exchange between the control device and the object. Similar tasks arise during the digitalization of rolling mill units, which has been announced in recent years by all leading metallurgical companies. This requires the verification of models for rolling stand electrical complexes, which would ensure the fulfillment of these conflicting requirements. Such a task arose during the electric drive virtual model development of the 5000 heavy-plate rolling mill stand, which is equipped with high-power synchronous motors with variable frequency speed control. Two digital models have been developed, their difference being the degree of the closed-loop stator current control system detail. The first, the more complex model, is built based on Simscape library modules; it provides for the control of current components along the d and q axes. In the second version, the closed current control loop is represented by the first-order lag element. The characteristic feature of the individual electric drives at rolling mill stands is the nonlinearity caused by the saturation (limitation) of the speed controller output and angular backlashes in the spindle connections. These factors must be considered when creating the models and an analysis of their impact on dynamic performance in transient conditions is also necessary. In the presented paper, the verification of the above models for the 5000 mill stand electric drives is carried out. For this purpose, a comparison of the transient processes that occur during the workpiece bite by the rolls with simultaneous closure of the angular backlash was made. The simulation results are compared with the experiments result obtained at the mill and validation of the processes obtained using the studied models was also carried out. Simulations of modes occurring during the rolling cycle have been performed, namely: impact load application with simultaneous angular backlash closure and no-load reversal of the electric drive. They allow for the assessment of the backlash closure influence on the elastic torque amplitude on the spindle. The integrated implementation of simulation and experimental studies ensures the developed model verification, allows for the evaluation of the their advantages and provides recommendations for their application in the digital control systems development.
Keywords
digital twin, virtual model, verification, mill 5000, rolling stand, electromechanical system, dynamic modes, simulation, experiment, angular backlash, influence, recommendations
1. Radionov A.A., Karandaev A.S., Loginov B.M., Gasiyarova O.A. Conceptual directions for creating digital twins of electrical systems at rolling mill units. Izvestiya vysshikhuchebnykhzavedeniy. Elektromekhanika [Bulletin of Higher Educational Institutions. Electromechanics], 2021, vol. 64, no. 1, pp. 54-68. (In Russian). doi: 10.17213/0136-3360-2021-1-54-68
2. Oztemel E., Gursev S. Literature review of Industry 4.0 and related technologies. Journal of Intelligent Manufacturing. 2020, no. 31, pp. 127-182. doi: 10.1007/s10845-018-1433-8
3. Tsifrovye dvoiniki v promyshlennosti: istoki, kontseptsii, sovremennyy uroven razvitiya i primeryvnedreniya [Digital twins in industry: origins, concepts, current state of development and implementation examples]. Available at: https://digitaltwin.ru/articles/digital-twins-in-industry/ (accessed 26 February 2026)
4. Kunath M., Winkler H. Integrating the Digital Twin of the manufacturing system into a decision support system for improving the order management process. Procedia CIRP. 2018, vol. 72, pp. 225-231. doi: 10.1016/j.procir.2018.03.192
5. Kritzinger W., Karner M., Traar G., Henjes J., Sihn W. Digital Twin in manufacturing: A categorical literature review and classification. IFAC-PapersOnLine. 2018, no. 51(11), pp. 1016-1022. doi: 10.1016/j.ifacol.2018.08.474
6. Zeballos R. J.-P. Digital Twin and Simulation: Replicating Industrial Systems to Enable Improvement. Available at: https://automation.com/article/digital-twin-simulation-industrial-systems-improve (accessed 26 February 2026)
7. Menghal P.M., Laxmi A.J. Real time control of electrical machine drives: A review. International Conference on Power, Control and Embedded Systems. IEEE, 2010. Pp. 1-6. doi: 10.1109/ICPCES.2010.5698697
8. Mihalic F., Truntic M., Hren A. Hardware-in-the-Loop Simulations: A Historical Overview of Engineering Challenges. Electronics. 2022, no. 11(15), 2462. doi: 10.3390/ electronics11152462
9. Math Works Simulink Real-Time Simulation and Testing. Available at: https: //www.windows-soft.ru/catalog/product/kupit-mathworks-simulink-real-time-simulation-and-testing-po-dostupnoy-tsene#det-description (accessed 26 February 2026)
10. Karandaev A.S., Radionov A.A., Loginov B.M., Gasiyarova O.A., Gartlib E.A., Khramshin V.R. Experimental determination of parameters of a two-mass electromechanical system at a rolling mill. Izvestiya vysshikhuchebnykhzavedeniy. Elektromekhanika [Bulletin of Higher Educational Institutions. Electromechanics], 2021, vol. 64, no. 3, pp. 24-35. (In Russian). doi: 10.17213/0136-3360-2021-3-24-35
11. Gasiyarov V.R., Radionov A.A., Loginov B.M., Zinchenko M.A., Gasiyarova O.A., Karandaev A.S., Khramshin V.R. Method for Defining Parameters of Electromechanical System Model as Part of Digital Twin of Rolling Mill. Journal of Manufacturing and Materials Processing. 2023, no. 7(5), 183. doi:10.3390/jmmp7050183
12. Soltani A., Assadian F. A Hardware-in-the-Loop Facility for Integrated Vehicle Dynamics Control System Design and Validation. IFAC-PapersOnLine. 2016, no. 49(21), pp. 32-38. doi: 10.1016/j.ifacol.2016.10.507
13. Gasiyarova O.A. Povyshenie resursa elektroprivodov kleti tolstolistovogo prokatnogo stana za schet ogranicheniya dinamicheskikh nagruzok. Kand. Diss. [Increasing the service life of electric drives of a heavy-plate rolling mill stand by limiting dynamic loads. Kand. Diss.]. Moscow, 2025. 170 p. (In Russian)
14. Karandaev A.S., Loginov B.M., Zinchenko M.A., Khramshin V.R. Electric drive speed control of a heavy-plate rolling mill stand in the "skid" formation mode. Izvestiya vysshikhuchebnykhzavedeniy. Elektromekhanika [Bulletin of Higher Educational Institutions. Electromechanics], 2022, vol. 65, no. 3, pp. 26-41. (In Russian). doi: 10.17213/0136-3360-2022-3-26-41
15. Gasiyarova O.A., Karandaev A.S., Erdakov I.N., Loginov B.M., Khramshin V.R. Developing Digital Observer of Angular Gaps in Rolling Stand Mechatronic System. Machines. 2022, no. 10, 141. doi: 10.3390/machines10020141
16. Zherebtsov A.L., Chuikov V.Yu., Shulpin A.A. Field current control method as a means of ensuring the synchronous motor operation stability. Vestnik Ivanovskogo gosudarstvennogo energeticheskogo universiteta [Vestnik IGEU], 2018, no. 2, pp. 21-31. (In Russian). doi: 10.17588/2072-2672.2018.2.021-031
17. Maximum Torque Per Ampere (MTPA). Available at: https://microchiptech.github.io/mcaf-doc/7.0.2/algorithms/ flux_control/mtpa.html (accessed 26 February 2026)
18. HESM Torque Control. Available at: https://www.mathworks.com/help/physmod/sps/ug/hesm-torque-control.html (accessed 26 February 2026)
19. SM Current Controller. Available at: https:// www.mathworks.com/help/physmod/sps/ref/smcurrentcontroller.html (accessed 26 February 2026)
20. White D.C., Woodson H.H. Elektromekhanicheskoe preobrazovanie energii [Electromechanical Energy Conversion]. Moscow-Leningrad, Energiya Publ., 1964. 528 p. (In Russian)
21. Sadovoi O., Nazarova O., Bondarenko V., Pirozhok A., Hutsol T., Nurek T., Glowacki Sz. Modeling and research of electromechanical systems of cold rolling mills: monograph. Krakow, 2020. 138 p.
22. Klyuchev V.I. Ogranichenie dinamicheskikh nagruzok elektroprivoda [Limitation of electric drive dynamic loads]. Moscow, Energiya Publ., 1971. 320 p. (In Russian)
23. Karandaev A.S., Khramshin V.R., Galkin V.V., Lukin A.A. Mathematical modeling of a thyristor electric drive with a switching structure. Izvestiya vysshikh uchebnykh zavedeniy. Elektromekhanika [Bulletin of Higher Educational Institutions. Electromechanics], 2010, no. 3, pp. 47-53. (In Russian)
24. Gasiyarov V.R., Baskov S.N., Gasiyarova O.A., Loginov B.M., Usatyy D.Yu. Dynamic torque Reduction in the main line of a heavy-plate mill rolling stand. Vestnik Yuzhno-Uralskogo gosudarstvennogo universiteta. Seriya: Mashinostroenie [Bulletin of the South Ural State University. Series "Mechanical engineering industry"], 2019, no. 3, pp. 22-32. (In Russian). doi: 10.14529/engin190303
25. Gasiyarov V.R., Radionov A.A., Loginov B.M., Karandaev A.S., Gasiyarova O.A., Khramshin V.R. Development and Practical Implementation of Digital Observer for Elastic Torque of Rolling Mill Electromechanical System. J. Manuf. Mater. Process. 2023, no. 7(1), 41. doi: 10.3390/ jmmp7010041
26. Karandaev A.S., Loginov B.M., Bodrov E.G., Khramshin V.R., Samodurova M.N. Elastic torque observer of a two-mass electromechanical system. Vestnik Yuzhno-Uralskogo gosudarstvennog ouniversiteta. Seriya "Energetika" [Bulletin of South Ural State University. Series "Power Engineering"], 2022, vol. 22, no. 4, pp. 23-33. (In Russian). doi: 10.14529/power220403.
Karandaev A.S., Litvinov A.V., Gasiyarova O.A., Loginov B.M., Khramshin V.R. Verification of Electromechanical System Models for Rolling Mill Stand. Elektrotekhnicheskie sistemy i kompleksy [Electrotechnical Systems and Complexes], 2026, no. 1(70), pp. 22-34. (In Russian). https://doi.org/10.18503/2311-8318-2026-1(70)-22-34