Developing Metrics for Roll Pass Design Optimisation - Engineering Assignment Help

Assignment Task :

Background

The metalworking is essential part in manufacturing many products and hot rolling is the most widely used technique in this industry, [1-10]. However, the current socioeconomic and climate trends imply that further rationalisations are needed, i.e. the rolling system sustainability must be improved urgently.

Within the rolling systems, the roll pass design (RPD) is a principal factor that determines process efficiency, product quality and resource consumption. Design of rolling passes is an area in which the current engineering methods applied in designing and controlling the process do not take enough advantage of big data accumulated in repositories of rolling mills. However, the nowadays developments in measuring sensors, information processors and analytical theories have brought in the possibility for uncovering hidden reserves by real-time extracting important knowledge from industrial records and online control of the process. The current strategies for improving the sustainability of rolling plants converge to mobilising systems such as I4 and virtual factory, which in turn employ big data analytics, machine learning and the supporting mathematics ranging from statistics to evolutionary algorithms [9,10]. The comprehensive computerised packages such as Dassault Systemes (DS) are realised and made available as platforms in anticipation of the above trends.

To realise the above advances, there is a need to structure the industrial records using suitable metrics.

The suitable metrics is embodied in the format of high-resolution continuous variables that are measured directly in real manufacturing systems. It enables performing the essential task of translating between knowledge and numbers.

The proposed research

The project aims are as follows

(i)  define algorithms for translating the RPD documentation in digital format,

(ii) define the structured database suitable for extracting useful RPD knowledge,

(iii) program and incorporate the steps (i) and (ii) in the rhino platform as a complementary module, and

(iv) demonstrate by a case study the usefulness of creating (i) to (ii) for improving RPD. 

(i)  The broad spectrum of process record are already available in a digital format suitable for organising into a structured data base projected in (ii). However, the morphometric RPD information needs to be translated in appropriate digital format. Currently, this segment of industrial records is defined in the way that allows for partial and rather superficial analyses and inferences. In the proposed research, the RPD digitizing algorithms will enable complementing the RPD metrics with morphometric variables suitable for structuring and subsequent analyses. The focus in this project is on the RPD for symmetrical log products, ranging from wire rod, bar, merchant products, structural and universal sections and other long products with at least one axis of symmetry.

(ii)  The process variables outlined in the clause (i) will be grouped into the categories such as dependent, independent, random and controllable. Several formats for the  database structure will be defined with having in mind prospective type of analytic methods and the intended application. While the database format will be fully functional for a delimited count of RPD variables and pertinent RPD analyses, the options for including further variables and more comprehensive business, operation and maintenance  system analyses will be anticipated in principle. This extension will made with having in mind that the project-defined data base can be integrated into a wide-ranging matrix, e.g. intended for future design of virtual factory (within a prospective research). A sample (library) of industrial records will be used to create an example of the structured RPD database.

(iii)  The outcome of the stages (i) and (ii) need to be incorporated in the rhino platform. This module must be user-friendly defined within the Rhino and Excel application frames ready for presenting to workers in rolling technology and industrial operations. The input in this module are the industrial RPD documentation and records, while the output is a structured database that can be transferred into other analytic software packages, and also automatically translated back in the RPD documentation format. The meaning for the database structure components will be user-friendly defined, along with the complete module user manual. The manual instructions need to be compatible with the relevant DS applications.  

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