Modular rolling mill health monitoring system

Abstract

This invention relates to a modular rolling mill health status monitoring system, belonging to the field of metallurgical machinery equipment monitoring. It includes a rolling mill body, a weighing module, and a monitoring module. The rolling mill body consists of a work base, rolls, and bearings. The weighing module is located below the work base, and the monitoring module is located at the rolls. The weighing module includes a base plate, which is connected to a collection trough via a pressure sensor. A connecting rod is connected to the side wall of the base plate and is connected to the bottom of the work base. The pressure sensor signal is connected to a controller, and the controller signal is connected to a display module. The monitoring module includes a resolver sensor and a vibration sensor, both connected inside the rolls and connected to the controller signal. This invention acquires digital signals by monitoring the condition of the rolls and bearings, enabling the detection of the rolling mill's health status and simultaneous monitoring of multiple parameters. This provides a basis for predicting the remaining service life of the rolling mill, saving resources and time costs.

Description

Technical Field

[0001] This invention belongs to the field of metallurgical machinery and equipment monitoring technology, and relates to a modular rolling mill health status monitoring system. Background Technology

[0002] A rolling mill is a machine used to manufacture and process metal materials. It is typically used to flatten, heat, fold, or cut large pieces of metal into desired shapes and sizes. Different types of rolling mills have different designs and operating principles, and they can be used to produce various metal products such as steel plates, steel pipes, steel strips, and aluminum profiles. Rolling mills usually operate continuously for extended periods under heavy loads, strong impacts, variable speeds, and high temperatures, bearing significant loads, which makes the roll bearings highly susceptible to damage. Currently, most methods rely on periodic maintenance to check for faults. If the intervals are too short, it not only wastes manpower and resources and affects production capacity, but also reduces the lifespan of the equipment due to excessive maintenance. If the intervals are too long, untimely maintenance can easily lead to equipment performance deterioration and even safety accidents. Therefore, monitoring the health status of rolling mills is essential.

[0003] Rolling mill health monitoring refers to the real-time monitoring and analysis of various performance parameters of the rolling mill to assess its operational status. By using various sensors and data acquisition systems, data collected from various components of the rolling mill can be aggregated and analyzed to identify potential faults and deterioration processes, and to issue early warning signals. Rolling mill health monitoring can effectively improve equipment reliability and production efficiency, reduce maintenance costs and downtime, and extend equipment lifespan.

[0004] Existing rolling mill condition monitoring technologies use sensors and corresponding parameters that can only detect whether a fault has occurred in the rolling mill at present, but cannot detect signs of faults in advance, and cannot perform timely maintenance to address faults, resulting in production interruptions and emergency repairs, generating unnecessary downtime and maintenance costs, and failing to maximize production efficiency. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide a modular rolling mill health status monitoring system, which proposes a status parameter that can characterize rolling mill faults, and monitors the health status of roll bearings by collecting this parameter, and can detect signs of rolling mill faults in advance, so as to carry out maintenance in a timely manner and avoid production interruption due to faults, thus avoiding impact on production efficiency.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A modular rolling mill health status monitoring system includes a rolling mill body consisting of a work stand, rolls, and bearings, with the bearings sleeved at both ends of the rolls; it also includes a weighing module and a monitoring module; the weighing module includes a base plate, with a pressure sensor fixedly connected to the top of the base plate, and the pressure sensor is electrically connected to a controller; the monitoring module includes a resolver sensor, a vibration sensor, and an ultrasonic imager, all electrically connected to the controller; the controller is electrically connected to a display module;

[0008] A collection trough is fixedly connected to the end of the pressure sensor away from the base plate, and a connecting rod is fixedly connected to the side wall of the base plate. The connecting rod is detachably connected to the bottom of the machine base. The pressure sensor is used to detect the gravity of the debris collected in the collection trough.

[0009] Both the resolver sensor and the vibration sensor are fixedly connected inside the roll. The resolver sensor is used to detect the rotation trajectory of the roll, and the vibration sensor is used to detect the vibration of the bearing.

[0010] The ultrasonic imager is electrically connected to a conductive ring and a brush. The inner wall of the conductive ring has multiple metal contact points. The conductive ring is sleeved on the outer walls of both ends of the roll and is slidably connected to the roll. The brush is fixed to the inner wall of the bearing. The ultrasonic imager is used to detect images on the surface of the roll.

[0011] Furthermore, the controller's control logic includes:

[0012] The rotation trajectory of the rolls is monitored by a resolver sensor, while the vibration signal of the bearings is monitored by a vibration sensor.

[0013] If the resolver sensor detects that the rotation trajectory does not conform to the initial preset value, the pressure sensor monitors the weight of the debris in the collection tank, and the ultrasonic imager acquires an image of the roll surface. When the weight of the debris is greater than the preset weight value, or when the roll surface image shows cracks after image comparison, the display module will display the information.

[0014] If the vibration sensor detects vibration signals with different frequencies, the remaining service life is predicted using vibration analysis, and the result is displayed on the display module.

[0015] Furthermore, the roll includes a work roll and a support roll with a clearance fit, and the monitoring module also includes strain gauges connected to the controller signal. The strain gauges are fixedly connected to the outer side wall of the work roll and the outer side wall of the support roll, respectively.

[0016] This solution can detect the cyclic contact stress during the use of rolls, and then, in conjunction with existing fatigue damage accumulation models, analyze and calculate the fatigue damage degree of the rolls. For example, the pressure between the work roll and the support roll can be calculated and verified using the Stone rolling pressure formula.

[0017] Furthermore, it also includes an alarm module, which includes a buzzer and an indicator light. Both the buzzer and the indicator light are connected to the controller signal and are embedded in the bottom of the machine base.

[0018] When the controller detects certain abnormalities or needs to perform tests, it sends signals to the buzzer and indicator lights, thereby controlling the buzzer to emit sound and the indicator lights to display corresponding colors. Through the dual reminder effect of color and sound, it effectively assists operators in distinguishing and identifying different alarm states. It can also ensure the reliability of the warning effect in noisy working environments, promptly attracting the attention of technical engineers or maintenance personnel, and avoiding damage to the rolling mill or operational safety accidents.

[0019] Furthermore, a temperature sensor is fixedly connected to the outer wall of the machine base. The temperature sensor is connected to the controller signal and is used to provide early warning of abnormal temperature or abnormal temperature change rate.

[0020] This solution involves installing a temperature sensor on the machine base and monitoring the temperature of the machine base in real time through a controller. By monitoring the temperature changes of the machine base in real time, it is possible to determine whether the temperature is normal and whether the rate of temperature change is normal, reflecting the stability and health of the machine's operating status, thereby enabling timely maintenance and adjustment and effectively protecting the safety of equipment and personnel.

[0021] Furthermore, heat dissipation and dust removal modules are provided on both sides of the machine base. The heat dissipation and dust removal modules include a mounting bracket, on which a motor is fixedly connected. A fan blade is coaxially fixedly connected to the output shaft of the motor. The motor is electrically connected to the controller. When the temperature sensor detects that the temperature of the machine base has risen to a preset temperature, the motor is controlled to drive the fan blade to rotate. When the temperature sensor detects that the temperature of the machine base has risen to an abnormal temperature threshold, the motor speed is increased.

[0022] This solution controls the motor to drive the fan blades to rotate, dissipating heat from the machine base. When the temperature of the machine base changes abnormally, the motor speed is increased to run at full power or even overload for a short period of time, thereby improving the heat dissipation effect and achieving emergency cooling. This prevents the machine base from overheating and causing safety accidents, and also blows away the dust adhering to the machine base.

[0023] Furthermore, a protective shell is detachably attached to the outside of the motor.

[0024] The detachable protective shell for the motor facilitates inspection and maintenance; it also protects the motor from damage caused by external environmental factors, extending its service life; the protective shell can also prevent unnecessary accidents and ensure the personal safety of operators.

[0025] The beneficial effects of this invention are as follows:

[0026] This solution proposes new characterization parameters to more accurately and comprehensively characterize the fault conditions of the rolling mill. It uses the rotation trajectory of the rolls to characterize whether roll wear has occurred, and uses the pressure of debris generated by roll wear on pressure sensors to characterize the degree of roll wear. Combined with the technology of predicting remaining life through bearing vibration signals, this solution enables comprehensive real-time monitoring of the fault conditions of the rolling mill's rolls and bearings. This improves the comprehensiveness of fault prediction, reduces the probability of misjudgment in early fault prediction, and makes the results of early fault detection more accurate and reliable. This allows for the early detection of fault signs, which is impossible with existing technologies, enabling more timely maintenance and avoiding unnecessary downtime and maintenance costs caused by production interruptions and emergency repairs. This prevents impacts on production efficiency, improves maintenance efficiency, and reduces maintenance costs.

[0027] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0028] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein:

[0029] Figure 1 This is a circuit block diagram of an embodiment of the modular rolling mill health status monitoring system of the present invention. Detailed Implementation

[0030] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0031] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0032] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0033] Please see Figure 1 The modular rolling mill health status monitoring system includes the rolling mill body, weighing module and monitoring module. The rolling mill body consists of a working base, rolls and bearings. The bearings are sleeved at both ends of the rolls. The weighing module is located below the working base and the monitoring module is located at the rolls. The bearings consist of an inner ring, an outer ring, rolling elements and a cage.

[0034] The weighing module includes a base plate, with a pressure sensor fixedly connected to the top of the base plate. In this embodiment, the pressure sensor model is DS18B20. A collection trough is fixedly connected to the end of the pressure sensor away from the base plate. A connecting rod is fixedly connected to the side wall of the base plate. The connecting rod is detachably connected to the bottom of the machine base. The pressure sensor signal is connected to a controller. In this embodiment, the controller model is NX7-48ADR programmable controller. The controller signal is connected to a display module.

[0035] The monitoring module includes a resolver sensor, a vibration sensor, and an ultrasonic imager. In this embodiment, the resolver sensor model is hid-58-k-5000-24h-5-5m, the vibration sensor model is BL-2030, and the ultrasonic imager model is LE7800.

[0036] Both the resolver sensor and the vibration sensor are fixedly connected inside the roll and are connected to the controller signal. Conductive rings are fitted onto the outer walls of both ends of the roll, forming a ball screw structure with the roll. Brushes are fixedly connected to the inner walls of the bearings, forming a conductive slip ring structure with the conductive rings and brushes. Both the conductive rings and brushes are electrically connected to the ultrasonic imager, which is connected to the controller signal. During operation, the collection trough in the weighing module collects debris generated during the mill's operation. The weight of the debris exerts pressure on the collection trough, which is monitored in real-time by a pressure sensor. This pressure data is transmitted to the controller. When the pressure reaches a preset value in the controller, it indicates severe wear on the mill body. The controller then feeds this information back to the display module to alert operators or maintenance personnel.

[0037] The display module includes a remote PC monitor and a system server. The system server, PC monitor, and controller all utilize NB-IoT (Internet of Things) technology for data transmission. Within the display module, the system server can connect to the PC monitor and controller via NB-IoT technology, enabling remote data transmission and sharing. NB-IoT technology boasts wide coverage and high penetration, supporting applications such as data measurement, monitoring, and remote control. It can connect a large number of devices with low bandwidth occupancy. This makes it possible to establish a stable and reliable communication connection between the controller and the monitor. Secondly, display modules built on NB-IoT enable remote monitoring and control without the need for traditional data links or LAN connections, eliminating complex wiring and equipment configuration work, while also optimizing communication efficiency and stability. Finally, display modules using NB-IoT technology are characterized by low power consumption and low cost, saving users energy and reducing costs. They also provide better support for real-time data monitoring and troubleshooting, thereby enhancing the reliability and precision of equipment operation and management.

[0038] As the roll rotates, the conductive ring slides on the roll and continuously rubs against the brush surface. Through the metal contact points in the conductive ring structure, the ultrasonic imager is energized and captures images of the roll. The images generated by the ultrasonic imager are transmitted to the display module via the controller. Operators or maintenance personnel can monitor the health status of the roll through the images on the display module, preventing phenomena such as cracks from occurring. By monitoring the health status of the roll in real time and checking for cracks, peeling, etc., abnormalities can be detected promptly, and early warnings can be issued. This effectively avoids quality accidents and unnecessary costs caused by roll failures, ensuring stable production quality. Timely monitoring and evaluation of the roll can effectively extend its service life while reducing maintenance costs and replacement frequency. With image monitoring, the usage frequency and maintenance cycle of the roll can be flexibly adjusted, allowing for more precise inspections. Thus, while ensuring the efficiency of roll use, the risks of improper use or unsafe conditions of the roll can be effectively avoided.

[0039] Meanwhile, the resolver sensor in the monitoring module monitors the rotation trajectory of the roll in real time and transmits the real-time monitoring data to the controller. When the roll is intact, the data of the rotation trajectory monitored by the resolver sensor is the initial preset value; when the roll is subjected to cyclic stress, it will be worn, so the data of the rotation trajectory monitored by the resolver sensor will change.

[0040] Simultaneously, vibration sensors monitor the bearing vibration in real time and transmit the data to the controller, which then transmits the data to the display module. When the roll bearing starts operating, it is in good health during normal operation, exhibiting good performance and stable vibration signals. However, after a period of operation, due to poor lubrication, corrosion, and other reasons, the bearing suffers damage. With prolonged overload operation and improper maintenance, its performance gradually degrades, and the vibration signals exhibit different frequencies and rich degradation characteristics. Extracting effective information from the raw data and performing feature recognition is the core of condition monitoring. The following analysis examines the forms of vibration data under different fault conditions.

[0041] The controller's control logic includes:

[0042] The rotation trajectory of the rolls is monitored by a resolver sensor, while the vibration signal of the bearings is monitored by a vibration sensor.

[0043] If the resolver sensor detects that the rotation trajectory does not conform to the initial preset value, the pressure sensor monitors the weight of the debris in the collection tank, and the ultrasonic imager acquires an image of the roll surface. When the weight of the debris is greater than the preset weight value, or when the roll surface image shows cracks after image comparison, the display module will display the information.

[0044] If the vibration sensor detects vibration signals with different frequencies, the remaining service life is predicted using vibration analysis, and the result is displayed on the display module.

[0045] The formula for calculating the fault characteristic frequency is as follows:

[0046] Bearing inner ring failure frequency:

[0047]

[0048] Bearing outer ring failure frequency:

[0049]

[0050] Bearing rolling element failure frequency:

[0051]

[0052] Bearing cage failure frequency:

[0053]

[0054] In the formula, D represents the bearing pitch diameter (mm); d represents the rolling element diameter (mm); α represents the contact angle (°); and f represents the bearing pitch diameter (mm). r —Bearing rotation frequency.

[0055] This invention employs vibration analysis as a condition monitoring method for rolling mill bearings, acquiring digital signals to predict remaining service life. Comprehensive analysis of bearing characteristic information at different frequencies contained in the vibration signals helps to grasp the bearing's condition indicators, thus aiding in the prediction of remaining service life.

[0056] In another embodiment, the system further includes an alarm module comprising a buzzer and an indicator light, both of which are signal-connected to the controller and are embedded in the bottom of the workpiece base. When the data received by the controller is outside the preset data range, i.e., when the controller detects certain abnormalities or needs to perform detection, it sends signals to the buzzer and indicator light, causing the buzzer to sound and the indicator light to display a corresponding color, such as yellow for caution and red for danger, to alert operators or maintenance personnel.

[0057] The use of buzzer and indicator light alarm modules can promptly alert technical engineers or maintenance personnel to any malfunctions or abnormalities in the rolling mill, enabling them to take appropriate measures to prevent damage to the rolling mill or operational safety accidents. Both the buzzer and indicator light have dual color and sound alert effects, which can effectively assist operators in distinguishing and identifying different alarm states, and can also ensure the reliability of the warning effect in noisy working environments.

[0058] As another implementation method, the difference from the above embodiment is that: the roll includes a work roll and a support roll, the work roll and the support roll are fitted with a clearance, strain gauges are fixedly connected to the outer walls of the work roll and the support roll, and the strain gauges are connected to the controller signal.

[0059] The specific implementation process is as follows: When the working roll and the support roll are in operation, the strain gauge monitors the pressure applied between the working roll and the support roll, and converts this physical quantity into an electrical signal. The controller then converts this signal into a digital signal for subsequent data processing and analysis.

[0060] The prerequisite for using the driving energy fatigue damage accumulation model to analyze and calculate roll contact fatigue damage is the ability to calculate the fatigue damage degree at any point in the roll contact area. To calculate the fatigue damage at any point in the roll contact area, firstly, the contact stress at any point within the roll cross-section needs to be obtained; secondly, the damage equivalence law and remaining life model for the work roll and support roll of a four-roll mill under multi-stage loading conditions are required as prerequisites; finally, the damage degree under multi-stage loading conditions is calculated using the damage model. Ultimately, the damage degree at any point in the contact area between the support roll and work roll in the mill body can be obtained.

[0061] In this invention, the Stone model is used to calculate and verify the pressure between the work roll and the support roll. The specific formula is as follows:

[0062]

[0063] In the formula: τ is the average unit pressure; J For the initial tension; τ b For post-tension.

[0064] In another embodiment, a temperature sensor is fixedly connected to the outer wall of the work stand. In this embodiment, the temperature sensor model is JTW-ZCD-G3N, and the temperature sensor is connected to the controller for signal transmission. When the rolling mill body is working, the temperature sensor monitors the real-time temperature of the work stand and transmits the real-time monitoring data to the controller. The controller alerts the operators or maintenance personnel through an alarm module to prevent excessively high temperatures or abnormally rapid temperature changes, which could lead to machine malfunctions or damage, or even pose safety hazards to the operators.

[0065] In addition, heat dissipation modules are located on both sides of the machine base. Each module includes a mounting bracket on which a motor is fixedly connected. Fan blades are coaxially connected to the motor's output shaft. The rotation of the fan blades, driven by the motor, increases airflow around the machine base, reducing the external temperature rise and thus effectively dissipating heat. It also blows away dust accumulated on the machine base. A detachable protective shell is attached to the motor, facilitating inspection and maintenance. This shell also protects the motor from external environmental damage, extending its lifespan. Furthermore, the protective shell prevents accidents and ensures operator safety.

[0066] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A modular rolling mill health status monitoring system, comprising a rolling mill body consisting of a work stand, rolls, and bearings, wherein the bearings are sleeved at both ends of the rolls; characterized in that: It also includes a weighing module and a monitoring module; the weighing module includes a base plate, with a pressure sensor fixedly connected to the top of the base plate, and the pressure sensor is electrically connected to a controller; the monitoring module includes a resolver sensor, a vibration sensor, and an ultrasonic imager, all electrically connected to the controller; the controller is electrically connected to a display module; A collection trough is fixedly connected to the end of the pressure sensor away from the base plate, and a connecting rod is fixedly connected to the side wall of the base plate. The connecting rod is detachably connected to the bottom of the machine base. The pressure sensor is used to detect the gravity of the debris collected in the collection trough. Both the resolver sensor and the vibration sensor are fixedly connected inside the roll. The resolver sensor is used to detect the rotation trajectory of the roll, and the vibration sensor is used to detect the vibration of the bearing. The ultrasonic imager is electrically connected to a conductive ring and a brush. The inner wall of the conductive ring has multiple metal contact points. The conductive ring is sleeved on the outer walls of both ends of the roll and is slidably connected to the roll. The brush is fixed to the inner wall of the bearing. The ultrasonic imager is used to detect images on the surface of the roll. The controller's control logic includes: The rotation trajectory of the rolls is monitored by a resolver sensor, while the vibration signal of the bearings is monitored by a vibration sensor. If the resolver sensor detects that the rotation trajectory does not conform to the initial preset value, the pressure sensor monitors the weight of the debris in the collection tank, and the ultrasonic imager acquires an image of the roll surface. When the weight of the debris is greater than the preset weight value, or when the roll surface image shows cracks after image comparison, the display module will display the information. If the vibration sensor detects vibration signals with different frequencies, the remaining service life is predicted using vibration analysis, and the result is displayed on the display module.

2. The modular rolling mill health status monitoring system according to claim 1, characterized in that: The rolls include a work roll and a support roll with a clearance fit. The monitoring module also includes strain gauges connected to the controller signal. The strain gauges are fixedly connected to the outer walls of the work roll and the support roll, respectively.

3. The modular rolling mill health status monitoring system according to claim 1, characterized in that: It also includes an alarm module, which includes a buzzer and an indicator light, both of which are embedded in the bottom of the machine base. Both the buzzer and the indicator light are connected to the controller signal, and the controller controls the buzzer and indicator light to adjust the sound, color, and flashing frequency according to different fault types.

4. The modular rolling mill health status monitoring system according to claim 3, characterized in that: A temperature sensor is fixedly connected to the outer wall of the machine base. The temperature sensor is connected to the controller signal and is used to provide early warning of abnormal temperature or abnormal temperature change rate.

5. The modular rolling mill health status monitoring system according to claim 4, characterized in that: The machine base is equipped with heat dissipation and dust removal modules on both sides. Each heat dissipation and dust removal module includes a mounting bracket, on which a motor is fixedly connected. A fan blade is coaxially fixedly connected to the output shaft of the motor. The motor is electrically connected to the controller. When the temperature sensor detects that the temperature of the machine base has risen to a preset temperature, the motor is controlled to drive the fan blade to rotate. When the temperature sensor detects that the temperature of the machine base has risen to an abnormal temperature threshold, the motor speed is increased.

6. The modular rolling mill health status monitoring system according to claim 5, characterized in that: The motor is detachably connected to a protective shell.

Images