Justifying and Implementing Concept of Object-Oriented Observers of Thermal State of Rolling Mill Motors

Stanislav S. Voronin, Andrey A. Radionov, Alexander S. Karandaev, Ivan N. Erdakov (), Boris M. Loginov and Vadim R. Khramshin
Additional contact information
Stanislav S. Voronin: Department of Automation and Control, Moscow Polytechnic University, 107023 Moscow, Russia
Andrey A. Radionov: Department of Automation and Control, Moscow Polytechnic University, 107023 Moscow, Russia
Alexander S. Karandaev: Department of Automation and Control, Moscow Polytechnic University, 107023 Moscow, Russia
Ivan N. Erdakov: Department of Metal Forming, South Ural State University, 454080 Chelyabinsk, Russia
Boris M. Loginov: Power Engineering and Automated Systems Institute, Nosov Magnitogorsk State Technical University, 455000 Magnitogorsk, Russia
Vadim R. Khramshin: Power Engineering and Automated Systems Institute, Nosov Magnitogorsk State Technical University, 455000 Magnitogorsk, Russia

Energies, 2024, vol. 17, issue 16, 1-30

Abstract: Implementing the IIoT concept in industry involves the development and implementation of online systems monitoring the technical state of electromechanical equipment. This is achieved through the use of digital twins and digital shadows (object state observers). The tasks of mastering new rolling profiles and optimizing plate mill rolling programs require improved methods for calculating equivalent motor currents and torques. Known methods are generally based on calculations using smoothed load diagrams, which are assumed to be identical for the upper and lower main drive (UMD and LMD) rolls. These methods do not consider the differences in actual loads (currents or torques) in steady rolling states. Experiments performed on the 5000 plate mill have shown that due to speed mismatches, the UMD and LMD torques differ three times or more. This causes overheating of the more heavily loaded motor, insulation life reduction, and premature failure. Therefore, the problem of developing and implementing techniques for monitoring the load and thermal regimes of motors using digital observers is relevant. The paper’s contribution is the first justification of the concept of object-oriented digital shadows. They are developed for specific classes of industrial units using open-source software. This research justifies a methodology for assessing motor load and temperature by processing arrays of motor currents or torques generated during rolling. An equivalent load observer and a temperature observer were proposed and implemented using Matlab-Simulink resources. The algorithm was implemented on the mill 5000 and tuned using an earlier-developed virtual commissioning methodology with digital twins. Thermal regimes were studied, proving that torque alignment ensures equal motor temperatures. The proposed considerations contribute to the development of the theory and practice for creating digital systems to monitor the technical condition of electromechanical and mechatronic systems and implementing the Industry 4.0 concept at industrial enterprises.

Keywords: Industry 4.0; digital shadow; concept; plate rolling mill; individual electric drive; motor; load regimes; temperature; calculation; methodology; implementation (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2024
References: View complete reference list from CitEc
Citations:

Downloads: (external link)
https://www.mdpi.com/1996-1073/17/16/3878/pdf (application/pdf)
https://www.mdpi.com/1996-1073/17/16/3878/ (text/html)

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:gam:jeners:v:17:y:2024:i:16:p:3878-:d:1451003

Access Statistics for this article

Energies is currently edited by Ms. Agatha Cao

More articles in Energies from MDPI
Bibliographic data for series maintained by MDPI Indexing Manager ().