Automating Hot-Rolling: Designing an Integrated Mechatronics System for Enhanced Efficiency in Sheet Metal Production
Mostafa A. Mostafa, Mohamed Khaled, Abdelrahman Ali, Amr Mostafa, Mariam Mohamed, Omar Ahmed, Osama Khalil
TL;DR
The paper tackles the inefficiency and imprecision of manual parameter adjustments in hot-rolling by proposing an integrated mechatronics system that automates roll-speed and sheet-thickness control. It combines a power-screw gap mechanism, a high-power AC induction motor with a 40:1 gear head, and a VFD, supported by dynamic modeling, open-loop and gap-control transfer functions, and fault-detection strategies. Key contributions include analytical force/torque/power calculations ($F \approx 6\times10^5\ \text{N}$, $T \approx 7.5\times10^4\ \text{N·m}$, $P \approx 3\times10^5\ \text{W}$), a 40:1 gear-head integration, PID-based electronics design, and a multi-body dynamics framework with tuned gains ($K_p = 0.00941$, $K_i = 6.53\times10^{-5}$, $K_d = 0.339$). The work demonstrates feasibility through modeling and lays out practical implementation steps to improve productivity and product quality in heavy steel sheet production, with potential reductions in manual labor and process variability. In sum, the integrated mechatronics solution modernizes hot-rolling by enabling precise, automated gap and speed control with robust fault detection.
Abstract
The hot-rolling process is a critical stage in sheet metal production within the heavy steel industry. Traditionally, parameter adjustments such as sheet metal velocity and roll gap are performed manually, leading to inefficiencies and limited precision. This project introduces an integrated mechatronics system designed to automate the control of rolling speed and sheet metal thickness, enhancing efficiency, consistency, and quality. The proposed system consists of a pair of rolls applying compression loads, with a mechanism for gap control, suitable motors and sensors, and dynamic modeling to optimize performance. Through simulation and practical implementation strategies, we demonstrate the feasibility of automating the hot-rolling process. By integrating mechatronics, this solution aims to modernize sheet metal production, improve productivity, and enhance product quality in the steel industry.