**Foreword**
The rolling mill is a critical component in the steel production process, and its efficiency and reliability directly impact the overall productivity of the plant. Among its key elements, the drive shaft plays a vital role. Any failure or damage to the drive shaft can disrupt the entire production line, leading to significant financial losses and operational downtime.
As rolling speeds and output levels continue to increase, the challenges posed by the mechanical load on the rolling equipment have become more pronounced. In particular, during the hot rolling process, the reversible nature of the roughing mills (R1 and R2) requires frequent starts and stops, along with sudden engagement and disengagement of the workpiece. These conditions create abrupt changes in the load on the rolling mill, potentially causing long-term damage. Many steel plants have experienced serious accidents involving the main drive system, which not only halt production but also complicate fault diagnosis and prevention efforts. Without proper monitoring systems, it is difficult to assess the condition of the drive system at the time of an incident, making it challenging to identify causes and implement preventive measures.
The root cause of many drive shaft failures often lies in torsional vibrations. While traditional design calculations may not fully capture these dynamic effects, research has shown that torsional vibration and resonance play a major role in equipment damage. Determining whether the main drive system experiences torsional vibration, and if so, whether it reaches dangerous amplification levels, is essential for ensuring safe and efficient operation. To address this issue, real-time monitoring of the drive shaft’s torque and vibration is crucial. This allows operators to make informed decisions and significantly improves equipment availability and safety.
By continuously monitoring the torque and torsional behavior of the rolling mill drive shaft, we can collect detailed data on the maximum, minimum, and average torque values per pass. Combining this data with theoretical models enables us to predict rolling torque accurately, compare it with actual measurements, and optimize rolling parameters. This not only enhances production efficiency and expands capacity but also protects the equipment and improves its overall reliability.
**Development of a Torque Monitoring System for the Roughing Mill**
**2.1 Monitoring Object and Sensor Placement**
This system focuses on monitoring the torque of the main drive shaft. Key parameters include:
- Torque, speed, power, and direction of the R1 and R2 main drive shafts
- Process variables such as rolling force (P), main motor current, coil number, rolling pass, material type, slab dimensions, casting temperature, R1 and R2 exit temperatures, inlet and outlet thicknesses, and temperatures.
Among these, the four main drive shaft parameters (torque, speed, power, and direction) are monitored in real-time and synchronized. The other eight process variables serve as auxiliary signals for additional analysis.
Torque measurement points are installed on the upper and lower universal joints of the drive shaft (see Figure 1). Four strain gauges are attached at 45° angles relative to the axis, forming a full-bridge circuit (as shown in Figure 2). The bridge signal is transmitted via a wireless telemetry device to an embedded data acquisition system, which then sends the data to the server. Table 1 summarizes the torque monitoring points in the roughing mill.
**Figure 1: Schematic diagram of the main drive measuring point arrangement of R1 and R2 rolling mills**
**Figure 2: Schematic diagram of the torque test patch**
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