Development of Thermal Protection for Rolling Mill Motors
DOI:
https://doi.org/10.24160/0013-5380-2025-10-64-75Keywords:
rolling mill, synchronous motor, temperature, monitoring, four-mass thermal model, protection, system, testing, implementationAbstract
Monitoring of rolling mill motors thermal state and protecting them against overheating are of key importance for ensuring reliable rolling mill operation. The majority of thermal protection systems disconnect the motors when their temperature limits are exceeded. The article considers studies of the synchronous motors driving the stands and winders of a reversible two-stand cold rolling mill. A two-stage protection system is developed, which produces a warning alarm when the motor thermal state becomes worsened and a command for trouble-free shutdown of the mill upon finishing the rolling cycle if the temperature continues to increase. A digital four-mass model is proposed, using which the temperatures of motor winding and rotor and stator iron are monitored. The structure of the model based on the Simscape Thermal Models library modules is considered. The protection system functional diagram and the structure of the algorithm explaining its operation are presented. Hardware-in-loop (HIL) modeling was used for setting up and implementing the thermal protection system on the mill. The system operability has been confirmed by the passive experiment method. The proposed adaptive two-stage protection algorithm ensures trouble-free shutdown of the mill and prevents the temperature from exceeding the limit value. The system has undergone industrial testing and has been implemented in electric drives of a cold rolling mill and a thick-sheet rolling mill.
References
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20. Фираго Б.И., Павлячик Л.Б. Теория электропривода. Минск: Техноперспектива, 2007, 586 с.
21. Radionov A.A., Lyubimov I.V., Khramshin R.R. Furnace Transformer Protection Device Mitigating Open-Phase Mode During Switching of Vacuum Circuit Breaker. – ICIEAM, 2024, pp. 1221–1225, DOI: 10.1109/ICIEAM60818.2024.10554007.
#
1. Khramshin V.R. et al. Development and Industrial Introduction of Systems for Monitoring Technical State of the Rolling Mills’ Electrical Equipment. – IEEE EIConRusNW, 2015, pp. 208–213, DOI: 10.1109/EIConRusNW.2015.7102264.
2. Karandaev A.S. et al. Trudy VII kongressa prokatchikov – in Russ. (Proceedings of the VII Congress of Rollers), 2007, vol. 1, pp. 71–75.
3. Karandaev A.S. Mashinostroenie – in Russ. (Mechanical Engi-neering), 2014, No. 1, pp. 3–15.
4. Luk’yanov S.I. et al. Vestnik MGTU im. G.I. Nosova – in Russ. (Bulletin of Nosov Magnitogorsk State Technical University), 2014, No. 1, pp. 129–136.
5. Selivanov I.A. et al. Izvestiya vuzov. Elektromekhanika – in Russ. (News of Higher Educational Institutions. Electromechanics), 2009, No. 1, pp. 5–11.
6. Radionov A.A. et al. Method for Forecasting the Remaining Useful Life of a Furnace Transformer Based on Online Monitoring Data. – Energies, 2023, vol. 16, DOI: 10.3390/en16124630.
7. Karandaev A.S. et al. Metodology of Calculation of the Reliability Indexes and Life Time of the Electric and Mechanical Systems. – International Conference on MEACS, 2014, DOI: 10.1109/MEACS.2014.6986866.
8. Jing T. et al. Formulations, Solving Algorithms, Existing Problems and Future Challenges of Pre-Programmed PWM Techni-ques for High-Power AFE Converters: A Comprehensive Review. – Energies, 2022, vol. 15, DOI: 10.3390/en15051696.
9. Maklakov A.S., Radionov A.A. EMC Evaluation of Three Level NPC Converter Based on Space Vector PWM. – IEEE EIConRusNW, 2015, pp. 236–240, DOI: 10.1109/EIConRusNW.2015.7102269.
10. Ejiofor O.S. et al. Development and thermal modeling of an induction machine. – International Journal of Engineering & Techno-logy, 2019, vol. 8(4), pp. 500–508, DOI: 10.14419/ijet.v8i4.29727.
11. Radionov A.A. et al. Construction Principle for Object-Oriented Digital Twins of Mechatronic Complexes of Rolling Mills. – International Russian Smart Industry Conference, 2023, pp. 516–522, DOI: 10.1109/SmartIndustryCon57312.2023.10110770.
12. Radionov A.A., Loginov B.M., Loginov A.B. Digital Temperature Observer for Rolling Mill Motors. – ICIEAM, 2024, pp. 1232–1237, DOI: 10.1109/ICIEAM60818.2024.10553666.
13. Liao G., Xi J. Intelligent Monitoring and Overheating Protection System for Motor. – International Conference on Compu-ting, Control and Industrial Engineering, 2010, DOI: 10.1109/CCIE.2010.85.
14. Toliyat H.A., Kliman G.B. Handbook of Electric Motors. Boca Raton: CRC Press, 2004, 850 p.
15. Voronin S.S. et al. Justifying and Implementing Concept of Object-Oriented Observers of Thermal State of Rolling Mill Motors. – Energies, 2024, vol. 17, DOI: 10.3390/en17163878.
16. Gasiyarov V.R. et al. Substantiating and Implementing Concept of Digital Twins for Virtual Commissioning of Industrial Mechatronic Complexes Exemplified by Rolling Mill Coilers. – Machines, 2023, vol. 11, DOI: 10.3390/machines11020276.
17. Basics of Hardware-in-the-Loop Simulation [Electron. resource], URL: https://www.mathworks.com/help/simscape/ug/what-is-hardware-in-the-loop-simulation.html (Access on 03.05.25).
18. Production Data Collection (PDA): Definition, Characteristics, Goals [Electron. resource], URL: https://forcam.com/en/operational-da-ta-acquisition-de-definition-characteristics-goals/#pda (Access on 03.05.25).
19. Karandaev A.S. et al. Vestnik YuUrGU. Seriya: Energeti-ka – in Russ. (Bulletin of South Ural State University. Series: Power Engineering), 2022, vol. 22, No. 4, pp. 23–33.
20. Firago B.I., Pavlyachik L.B. Teoriya elektroprivoda. Minsk: Tekhnoperspektiva, 2007, 586 p.
21. Radionov A.A., Lyubimov I.V., Khramshin R.R. Furnace Transformer Protection Device Mitigating Open-Phase Mode Du-ring Switching of Vacuum Circuit Breaker. – ICIEAM, 2024, pp. 1221–1225, DOI: 10.1109/ICIEAM60818.2024.10554007
2. Карандаев А.С. и др. Технологические схемы управления электроприводами чистовой группы широкополосного стана горячей прокатки. – Труды VII конгресса прокатчиков, 2007, т. 1, с. 71–75.
3. Карандаев А.С. Совершенствование автоматизированных электроприводов агрегатов прокатного производства. – Машиностроение, 2014, № 1, с. 3–15.
4. Лукьянов С.И. и др. Разработка и внедрение интеллектуальных систем диагностирования технического состояния электрического оборудования. – Вестник МГТУ им. Г.И. Носова, 2014, № 1, с. 129–136.
5. Селиванов И.А. и др. Совершенствование автоматизированных электроприводов и диагностика силового электрооборудования. – Известия вузов. Электромеханика, 2009, № 1, с. 5–11.
6. Radionov A.A. et al. Method for Forecasting the Remaining Useful Life of a Furnace Transformer Based on Online Monitoring Data. – Energies, 2023, vol. 16, DOI: 10.3390/en16124630.
7. Karandaev A.S. et al. Metodology of Calculation of the Reliability Indexes and Life Time of the Electric and Mechanical Systems. – International Conference on MEACS, 2014, DOI: 10.1109/MEACS.2014.6986866.
8. Jing T. et al. Formulations, Solving Algorithms, Existing Problems and Future Challenges of Pre-Programmed PWM Techniques for High-Power AFE Converters: A Comprehensive Review. – Energies, 2022, vol. 15, DOI: 10.3390/en15051696.
9. Maklakov A.S., Radionov A.A. EMC Evaluation of Three Level NPC Converter Based on Space Vector PWM. – IEEE EIConRusNW, 2015, pp. 236–240, DOI: 10.1109/EIConRusNW.2015.7102269.
10. Ejiofor O.S. et al. Development and thermal modeling of an induction machine. – International Journal of Engineering & Technolo-gy, 2019, vol. 8(4), pp. 500–508, DOI: 10.14419/ijet.v8i4.29727.
11. Radionov A.A. et al. Construction Principle for Object-Oriented Digital Twins of Mechatronic Complexes of Rolling Mills. – International Russian Smart Industry Conference, 2023, pp. 516–522, DOI: 10.1109/SmartIndustryCon57312.2023.10110770.
12. Radionov A.A., Loginov B.M., Loginov A.B. Digital Temperature Observer for Rolling Mill Motors. – ICIEAM, 2024, pp. 1232–1237, DOI: 10.1109/ICIEAM60818.2024.10553666.
13. Liao G., Xi J. Intelligent Monitoring and Overheating Protection System for Motor. – International Conference on Computing, Control and Industrial Engineering, 2010, DOI: 10.1109/CCIE.2010.85.
14. Toliyat H.A., Kliman G.B. Handbook of Electric Motors. Boca Raton: CRC Press, 2004, 850 p.
15. Voronin S.S. et al. Justifying and Implementing Concept of Object-Oriented Observers of Thermal State of Rolling Mill Motors. – Energies, 2024, vol. 17, DOI: 10.3390/en17163878.
16. Gasiyarov V.R. et al. Substantiating and Implementing Concept of Digital Twins for Virtual Commissioning of Industrial Mechatronic Complexes Exemplified by Rolling Mill Coilers. – Machines, 2023, vol. 11, DOI: 10.3390/machines11020276.
17. Basics of Hardware-in-the-Loop Simulation [Электрон. ресурс], URL: https://www.mathworks.com/help/simscape/ug/what-is-hardware-in-the-loop-simulation.html (дата обращения 03.05.25).
18. Production Data Collection (PDA): Definition, Characteristics, Goals [Электрон. ресурс], URL: https://forcam.com/en/operational-data-acquisition-de-definition-characteristics-goals/#pda (дата обращения 03.05.25).
19. Карандаев А.С. и др. Наблюдатель упругого момента двухмассовой электромеханической системы. – Вестник ЮУрГУ. Серия: Энергетика, 2022, т. 22, № 4, с. 23–33.
20. Фираго Б.И., Павлячик Л.Б. Теория электропривода. Минск: Техноперспектива, 2007, 586 с.
21. Radionov A.A., Lyubimov I.V., Khramshin R.R. Furnace Transformer Protection Device Mitigating Open-Phase Mode During Switching of Vacuum Circuit Breaker. – ICIEAM, 2024, pp. 1221–1225, DOI: 10.1109/ICIEAM60818.2024.10554007.
#
1. Khramshin V.R. et al. Development and Industrial Introduction of Systems for Monitoring Technical State of the Rolling Mills’ Electrical Equipment. – IEEE EIConRusNW, 2015, pp. 208–213, DOI: 10.1109/EIConRusNW.2015.7102264.
2. Karandaev A.S. et al. Trudy VII kongressa prokatchikov – in Russ. (Proceedings of the VII Congress of Rollers), 2007, vol. 1, pp. 71–75.
3. Karandaev A.S. Mashinostroenie – in Russ. (Mechanical Engi-neering), 2014, No. 1, pp. 3–15.
4. Luk’yanov S.I. et al. Vestnik MGTU im. G.I. Nosova – in Russ. (Bulletin of Nosov Magnitogorsk State Technical University), 2014, No. 1, pp. 129–136.
5. Selivanov I.A. et al. Izvestiya vuzov. Elektromekhanika – in Russ. (News of Higher Educational Institutions. Electromechanics), 2009, No. 1, pp. 5–11.
6. Radionov A.A. et al. Method for Forecasting the Remaining Useful Life of a Furnace Transformer Based on Online Monitoring Data. – Energies, 2023, vol. 16, DOI: 10.3390/en16124630.
7. Karandaev A.S. et al. Metodology of Calculation of the Reliability Indexes and Life Time of the Electric and Mechanical Systems. – International Conference on MEACS, 2014, DOI: 10.1109/MEACS.2014.6986866.
8. Jing T. et al. Formulations, Solving Algorithms, Existing Problems and Future Challenges of Pre-Programmed PWM Techni-ques for High-Power AFE Converters: A Comprehensive Review. – Energies, 2022, vol. 15, DOI: 10.3390/en15051696.
9. Maklakov A.S., Radionov A.A. EMC Evaluation of Three Level NPC Converter Based on Space Vector PWM. – IEEE EIConRusNW, 2015, pp. 236–240, DOI: 10.1109/EIConRusNW.2015.7102269.
10. Ejiofor O.S. et al. Development and thermal modeling of an induction machine. – International Journal of Engineering & Techno-logy, 2019, vol. 8(4), pp. 500–508, DOI: 10.14419/ijet.v8i4.29727.
11. Radionov A.A. et al. Construction Principle for Object-Oriented Digital Twins of Mechatronic Complexes of Rolling Mills. – International Russian Smart Industry Conference, 2023, pp. 516–522, DOI: 10.1109/SmartIndustryCon57312.2023.10110770.
12. Radionov A.A., Loginov B.M., Loginov A.B. Digital Temperature Observer for Rolling Mill Motors. – ICIEAM, 2024, pp. 1232–1237, DOI: 10.1109/ICIEAM60818.2024.10553666.
13. Liao G., Xi J. Intelligent Monitoring and Overheating Protection System for Motor. – International Conference on Compu-ting, Control and Industrial Engineering, 2010, DOI: 10.1109/CCIE.2010.85.
14. Toliyat H.A., Kliman G.B. Handbook of Electric Motors. Boca Raton: CRC Press, 2004, 850 p.
15. Voronin S.S. et al. Justifying and Implementing Concept of Object-Oriented Observers of Thermal State of Rolling Mill Motors. – Energies, 2024, vol. 17, DOI: 10.3390/en17163878.
16. Gasiyarov V.R. et al. Substantiating and Implementing Concept of Digital Twins for Virtual Commissioning of Industrial Mechatronic Complexes Exemplified by Rolling Mill Coilers. – Machines, 2023, vol. 11, DOI: 10.3390/machines11020276.
17. Basics of Hardware-in-the-Loop Simulation [Electron. resource], URL: https://www.mathworks.com/help/simscape/ug/what-is-hardware-in-the-loop-simulation.html (Access on 03.05.25).
18. Production Data Collection (PDA): Definition, Characteristics, Goals [Electron. resource], URL: https://forcam.com/en/operational-da-ta-acquisition-de-definition-characteristics-goals/#pda (Access on 03.05.25).
19. Karandaev A.S. et al. Vestnik YuUrGU. Seriya: Energeti-ka – in Russ. (Bulletin of South Ural State University. Series: Power Engineering), 2022, vol. 22, No. 4, pp. 23–33.
20. Firago B.I., Pavlyachik L.B. Teoriya elektroprivoda. Minsk: Tekhnoperspektiva, 2007, 586 p.
21. Radionov A.A., Lyubimov I.V., Khramshin R.R. Furnace Transformer Protection Device Mitigating Open-Phase Mode Du-ring Switching of Vacuum Circuit Breaker. – ICIEAM, 2024, pp. 1221–1225, DOI: 10.1109/ICIEAM60818.2024.10554007
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2025-08-28
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