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Gap Compensations detail
Gap Compensations are open loop corrections to the Gap Position Regulator for known effects which change the effective roll gap opening but are not measured by the gap position transducers. Some of these effects are predictable and so an open loop estimate of the effect is calculated. Gap Compensations include:(辊缝补偿是对辊缝位置调节器（GAP POSITION REGULATOR）的开环修正，主要指那些已为人们所知但辊缝位置传感器无法测量的影响因素。其中有些因素可预先估算出来。辊缝补偿包括：)
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Backup Roll Bearing Speed and Force Effect detail（支撑辊轴承转速和轧制力的影响） Roll Thermal and Roll Wear detail （辊子温升及磨损）
Work Roll Bending Force Compensation detail（工作辊弯辊力补偿） Tension Loss detail （失张（抛钢时））
Gagemeter detail （厚度计方式）
Gagemeter calculates strip thickness by the Gagemeter principle as the feedback to regulate exit thickness from each stand. Gagemeter has become the most critical AGC function. It provides almost instantaneous feedback to regulate strip thickness. Gagemeter depends on Gap Compensations and Eccentricity Compensation to prevent mis-operation.（根据厚度计原理计算出各机架带钢厚度作为本机架出口厚度调节的反馈值。厚度计方式已变为最关键的AGC功能。它几乎可以瞬间提供反馈值用于带钢厚度调节。厚度计方式依赖于辊缝补偿和偏心度补偿来避免控制过程中的误差。）
Eccentricity Compensation detail（偏心度补偿）
Eccentricity Compensation detects out of round backup rolls and changes Gap position to compensate for the eccentricity or to filter it out. Eccentricity is critical to obtaining optimum performance from Gagemeter since Gagemeter will amplify roll eccentricities.（偏心度补偿即检测支撑辊的不圆部分（偏心）并改变辊缝位置对偏心度作补偿，或将其过滤掉。厚度计方式要获得最佳性能偏心度是关键，因为厚度计方式会放大辊子的偏心度。）
Xray Monitor Regulator detail（（X射线）监控调节器）
The Xray Monitor function uses mill exit strip thickness as measured by a Xray Gage as the feedback to
regulate mill exit thickness by adjusting roll gaps.（（X射线）监控功能是利用X射线厚度计的测
量值作为反馈信号，通过调节辊缝来达到控制精轧出口厚度的目的。） Feedforward detail(前馈)
Feedforward measures the hardness pattern ( furnace skid marks) at the entry stand and adjusts the gap of downstream stands to correct for hardness changes not removed by Gagemeter. Feedforward may not be used at all if Gagemeter can be tuned to near optimum.（前馈控制是在入口机架测量带钢硬度曲线（加热炉水印）并用来调节下游机架辊缝从而校正厚度计AGC不能解决的硬度变化的影响。注意：在厚度计AGC未达到最优化之前不能使用前馈控制。）
Mass Flow Compensation detail（质量流量（即秒流量）补偿）
Mass Flow Compensation measures changes in Mass Flow at each stand and adjusts upstream stand speed to help the Loop Position Regulator maintain mass flow which should allow higher performance gage regulation.
（质量流量（即秒流量）补偿是通过测量轧制过程中各机架秒流量的变化来调节其上游机架的速度的方式来协助活套位置调节器（Loop Position Regulator）维持秒流量相等，从而使系统的厚度调节性能更好。）
File Name: 12488574.doc RequisitionName: Req.No. Hot Mill Automatic Gage Control
User's Guide
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Finish Adaptive Thread detail（精轧自适应穿带）
Finish Adaptive Thread uses the Gagemeter principle to measure thickness and hardness setup model errors at the head of the bar and adjust downstream stand setup references to deliver the desired stand exit thicknesses.（精轧自适应穿带即使用厚度计原理测量带钢头部实际厚度和硬度，从而获知设定模
型误差，对下游机架设定基准进行调整，以便得到预定的各机架带钢出口厚度。） Load Distribution detail（负荷分配）
Load Distribution detects significant changes in stand to stand load distribution and changes roll gaps to restore the load pattern to that present at the head of the bar or after manual intervention.（负荷分配功能检测各机架的负荷变化情况，并及时改变辊缝来将负荷曲线恢复到轧制头部时或人工干预后的状态。）
Gap Compensations（辊缝补偿）
Gap Compensations are open loop corrections to the Gap Position Regulator for known effects which change the effective roll gap opening but are not directly measured by the gap position transducers. Gap position transducers measure the amount of cylinder extension. Although the measurements are very accurate, between position
measurements and the actual gap opening are the backup roll chock and bearings, the backup roll diameter and the work roll diameter. When force is applied, the mill housing stretches, the backup roll neck bends, the roll surfaces flatten at the points of contact, the oil in the cylinder compresses and the backup roll moves off center in its bearing. As the mill stand speed increases the backup roll will become more centered in its bearing. As the rolls heat up they expand and their diameters increase. As the rolls wear their diameters decrease. The bending of rolls change as roll bending force changes. The centerline gap changes as the side shift or pair cross position changes. Force measurements (load cells) drift. In addition, the strip thickness changes when strip tension changes.（辊缝补偿是对辊缝位置调节器的开环修正，它对辊缝开度的改变不直接由辊缝位置变送器测量。辊缝位置变送器测量的是液压缸的位移量。虽然测量设备非常精确，但在测量设备和实际辊缝之间存在支撑辊轴承和轴承座，支撑辊和工作辊辊径等影响因素。当承受压力时，牌坊会弹跳，支撑辊轴颈会弯曲，辊面接触部分会变平，液压缸中的油会压缩，同时油膜轴承中的支撑辊会偏离中心线。当轧机速度增加时，支撑辊向油膜轴承中心线移动。当辊子变热时会膨胀且辊径会增加。当辊子磨损时辊径会减小。弯辊力改变会引起辊子扰度改变。（辊子）侧移（即窜辊）或交叉时中心线辊缝会改变。轧制力测量设备（压头）存在漂移。另外，带钢张力变化也会引起带钢厚度变化。）
Some of these effects are predictable and so an open loop estimate of the effect on the actual roll gap opening is
calculated and used to establish the roll gap position. The mill zeroing procedure accounts for all the factors under the specific zeroing conditions of speed and force. The open loop calculations attempt to take care of the changes from the zeroing conditions. In general, factors that change slowly like roll wear and roll heating can be calculated by the setup models. Factors that change quickly are calculated by AGC functions. （某些影响因素是可以预知的，它们对辊缝开度的影响可以计算出来，然后作为开环量参于辊缝摆放。轧机清零就是为了消除在一定速度和压力条件下影响因素的影响。开环计算试图克服影响因素变化（与清零时的条件相比）的影响。一般，象轧辊磨损和轧辊温升等慢速变化的影响因素可由设定模型计算。而快速变化的影响因素则由AGC功能计算。）
The stretch of the mill housing and the stack deflection (roll chock dimension changes with force and roll flattening) are corrected by the Gagemeter AGC function. The Backup Roll Eccentricity function compensates for Backup roll diameter variations during a revolution. Compensation for oil compression in the gap cylinders and manual load cell zeroing is provided by the Gap Control function. All other effects which can be predicted by open loop calculations are grouped into the Gap Compensations AGC function. （牌坊弹跳变形以及由于轧制力变化导致轴承座外形尺寸变化和轧辊接触面变平从而引起轧辊组倾斜的影响由厚度计AGC修正。支撑辊旋转过程中辊径变化由支撑辊偏心度补偿功能进行补偿。辊缝液压缸液压油压缩的补偿及压头手动清零功能由辊缝控制功能提供。其它能够通过开环计算预知的影响因素全部由辊缝补偿AGC功能完成。）
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Oil Film Compensation（油膜补偿）
The Backup rolls settle to the outer side of their bearings at low speeds, but as the rotation of the Backup Roll increases, the bearing oil is pulled evenly around the roll, causing the roll to center itself. The speed effect on roll gap is to decrease roll opening as mill speed increases. The magnitude of this effect decreases as roll force increases as shown in Figure 2. The gap position sensors do not detect the change in roll gap opening. This change can be significant in oil type bearings and can cause large errors in gage control if not properly
compensated. Roller bearings may not require compensation.（低速时支撑辊偏离轴承中心，但当转速加快时，轴承油受牵引力的影响围绕辊子均匀分布，使辊子自动回到中心。速度对辊缝的影响表现为速度增加辊缝开度变小。但其影响能力又与轧制力有关，轧制力增加则影响力下降，见图2。类似上述因素引起的辊缝开度变化辊缝位置传感器检测不到。对于油膜轴承这些变化不能忽视，如果不正确进行补偿会给厚度控制带来较大误差。而对于滚柱轴承则不需要补偿。）
This compensation provides an offset to the Gap Position regulator to maintain a constant effective gap as mill speed changes. The amount of compensation is determined by an Oil Film Test included in the Gap Control function. The effect on the roll gap is separated into a Speed Effect and a Force Effect. The speed effect determines the correction to roll gap position with the roll separating force equal to zeroing force. The speed effect is zero at zeroing speed as shown in Figure 2. As speed increases the gap will be opened. The force effect determines a per unit modifier which relates the correction at other forces to the correction required for zeroing force. The per unit effect is 1.0 at zeroing force. As force increases the amount of correction must be reduced. （当轧制速度变化时上述补偿会给辊缝位置调节器提供一个偏置量以保证辊缝恒定不变。补偿量的大小由辊缝控制功能中的油膜测试功能（Oil Film Test）决定。对辊缝的影响分为“速度影响”和“轧制力影响”两个独立部分。当轧制力等于清零轧制力时，辊缝位置修正取决于“速度影响”。当速度在清零速度时，“速度影响”为零。见图2。当速度增加时(辊缝变小)要打开辊缝。轧制力影响定义为一个所谓的单位修正量，任何轧制力时的修正量均与轧制力等于清零轧制力时的修正量有关。轧制力等于清零轧制力时影响定义为1个单位。随着轧制力的增加，修正量将减小。）
Curves of the speed effect and force effect are stored as arrays. Linear interpolation between data points is used to determine the speed effect and force effect for operating speed and force. The final correction is calculated by multiplying the interpolated speed effect value times the interpolated per unit force effect.（“速度影响”和“轧制力影响”曲线以数组的形式存储。使用线性插值法。最终的修正量计算如下：“速度影响”*“单位轧制力影响”。）
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OUTER BEARINGSURFACEOIL FILMLOWRPMHIGHRPM
When Speed IncreasesEffective Gap ClosesROLLNECKWhen Force IncreasesEffective Gap OpensLOWFORCESPEEDEFFECT(INCH)FORCEEFFECT(PU)HIGHFORCE1.0RPMZeroing Figure 2 Backup Roll Bearing Oil Film Effect Speed FORCERoll Thermal and Wear（轧辊温升和磨损）
ZeroingForceThe work and backup rolls heat up when metal is in the stand and cool down when the stand is empty. As roll
OIL FILM CORRECTION =SPEED EFFECT * FORCE EFFECTtemperature increases the diameter expands causing the actual roll gap to decrease. The surface of the roll also
wears away while rolling causing a decrease in roll diameter. Neither of these effects can be measured by the gap position sensors so they are modeled using the roll material characteristics, metal temperatures, rolling time and length, cooling spray flows, etc. The calculations are performed by the setup model because of the large number of inputs. The calculation includes both short and long term roll heating effects. （轧件在机架中时工作辊和支撑辊会发热，机架中无轧件时工作辊和支撑辊会变冷。辊子温度升高时辊径会变大，使得实际辊缝减小。另外轧制过程中辊面的磨损又会使辊径变小。所有上述这些影响因素辊缝位置传感器都无法测量，因此只能用轧辊材料特性、轧件温度、轧制时间和长度、冷却水流量等进行模型化计算。由于输入量太大，计算工作由设定模型完成。计算过程中短期和长期轧辊发热的影响均予以考虑。） Approximately every 5 seconds the setup model provides a predicted accumulated change in roll gap due to thermal and wear. When the roll gap is zeroed the current value is captured. Changes from the captured value are used as a gap position offset. A ramp is provided to smooth the transition between each 5 second update.
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Hot Mill Automatic Gage Control
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Figure 3 provides a simplified block diagram.（对于温升和磨损引起的辊缝变化，设定模型约5秒钟预报一次。辊缝清零时对最新的相关参数进行采集。这些值的变化用于辊缝位置偏置。系统提供一个斜坡模块用于5秒钟刷新周期期间的平滑过渡。图3为一简单框图。）
Model PredictedThermal + Wear(updated every 5 sec)-ClampRampThermal + WearCorrectionMoveMill Zeroing
Figure 3 Roll Thermal and Wear Compensation
Roll Bending Compensation（弯辊补偿）
Roll Bending is used to help control strip profile and flatness. Depending on the mechanical configuration, the force produced by positive (crown in) roll bending cylinders can be measured by the stand force sensors even though the positive bending forces do not help to reduce the strip. Therefore the Strip Force is calculated by subtracting the positive roll bending force from the load cell force. Note that the load cells are calibrated to produce zero tons with Backup Roll balance on, Roll Bending and balance off, and the stand roll gap open which determines a Tare Force which must also be subtracted from load cell force. （弯辊功能用于改善带钢板型和平直度。由于机械结构的原因，正弯液压缸所产生的弯辊力即使未能起明显作用也可由轧机压力传感器检测出来。因此带钢轧制力等于load cell实测力减去正弯力。需要注意的在支撑辊平衡ON，工作辊弯辊和平衡OFF，同时轧机辊缝打开（即从实测力中减去辊子自重）的情况下才能对load cell清零。）
Roll Bending force changes also cause the effective roll gap to change. The predominant effect on the roll gap is that an increase in positive bending will stretch the mill housing causing the effective gap to open. Gagemeter AGC will not correct for this stretch because the positive bending force is not included in strip force. The amount of gap correction required for this stretch is equal to the Bending Force (above balance) divided by the mill Housing Modulus and must close the gap. （弯辊力变化会引起辊缝变化。主要表现在正弯力增大使轧机牌坊伸长从而使辊缝变大。厚度计AGC不对这一弹跳进行补偿，因为轧制力不包括正弯力。这一弹跳所需修正总量应等于弯辊力（大于平衡力部分）除以牌坊弹性模量，它必然会使辊缝变小。） Bending force changes will also change the shape of the roll gap. Increasing positive bending force will deflect the work roll centerline to close gap but some of this change is offset by bending of the backup roll neck and roll flattening. These effects have been investigated using an off line stack deflection model. This study
determined that a linear coefficient applied to positive bending force can model this effect.(弯辊力的变化还会引起辊缝形状的改变。随着正弯力的增加工作辊中间部分的辊缝会变小（当然支撑辊的轴颈弯曲以及两辊接触部分变平坦会抵消掉一部分这种变化）。对于这些影响已经用离线轧辊挠度模型进行充分研究，并使模型得到了一个正弯力的线性系数用于补偿这一影响因素。) Figure 4 summarizes these concepts.（上述概念总结）
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