Ironing roller thermal imaging monitoring and control

Abstract

A metal working system includes a roller and a control system. The roller includes a non-metallic surface for contacting the metal substrate, and the control system includes a sensor for detecting a temperature of the non-metallic surface of the roller. The control system also includes a controller that receives the detected temperature from the sensor and controls the roller based on the detected temperature. A method of controlling a roller having a non-metallic contact surface includes receiving a detected temperature of at least a portion of the non-metallic contact surface of the roller from a sensor and controlling the roller based on the received temperature.

Description

[0001] Citation of Related Applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 364,057, filed on May 3, 2022, and entitled “IRONING ROLL THERMAL IMAGE MONITORING AND CONTROL,” the contents of which are hereby incorporated by reference in their entirety. Technical Field

[0003] The present application relates generally to metal manufacturing and, more particularly, to systems and methods for controlling an ironing roll of a metal processing system. Background Art

[0004] During the rolling operation, the metal product may be rolled into a metal strip, which in turn may be wound into a coil. During the winding of the metal strip, an ironing roller may be used to press the metal strip against the coil to help ensure that the coil is tightly wound and minimize or prevent damage to the surface of the metal strip. Any situation in which incorrect force is used (e.g., due to misalignment of the ironing roller, imbalance of the ironing roller, etc.) can cause scratches or scars on the surface of the metal strip. In addition, failure of the ironing roller itself is another important cause of scratches and gouging on the surface of the metal strip. Specifically, the rubber coating of the ironing roller often cracks and fails in other ways during metal processing, which is sometimes unexpected, and such failures usually form scratches or dents on the surface of the metal strip. Such damage to the metal strip requires the damaged portion of the coil or even the entire coil to be scrapped. Summary of the invention

[0005] The embodiments covered by this patent are defined by the following claims rather than by this summary. This summary is a high-level summary of various embodiments and introduces some concepts that will be further described in the following detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. This subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0006] According to certain embodiments, a metal processing system includes a roller and a control system. The roller is rotatable about an axis and includes a first end, a second end, and a non-metallic surface between the first end and the second end for contacting a metal substrate. The control system includes a sensor for detecting a temperature of the non-metallic surface of the roller. The control system also includes a controller that is communicatively coupled to the sensor. The controller can receive a detected temperature from the sensor and control the roller based on the detected temperature.

[0007] According to some embodiments, a control system for a metalworking system having a roller with a non-metallic contact surface includes a sensor for detecting a temperature of the non-metallic contact surface of the roller, and a controller communicatively coupled to the sensor. The controller can receive the detected temperature from the sensor and generate an output signal for controlling the roller based on the received temperature.

[0008] According to various embodiments, a method of controlling a roller having a non-metallic contact surface for contacting a metal substrate includes receiving a sensed temperature of at least a portion of the non-metallic contact surface of the roller from a sensor and controlling the roller based on the received temperature.

[0009] The various implementations described herein may include additional systems, methods, features, and advantages that may not necessarily be explicitly disclosed herein but will be apparent to one of ordinary skill in the art after reviewing the following detailed description and the accompanying drawings. It is intended that all such systems, methods, features, and advantages should be included in this disclosure and protected by the following claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] This description refers to the following drawings, in which the use of the same reference numerals in different drawings is intended to illustrate the same or similar components.

[0011] Figure 1 A metal processing system having an ironing roller and a control system according to an embodiment is illustrated, and wherein the ironing roller is in a first position relative to a sensor of the control system.

[0012] Figure 2 Illustrated Figure 1 Ironing roller.

[0013] Figure 3 Illustrated Figure 1 A metal processing system wherein the ironing roller is in a second position relative to the sensor.

[0014] Figure 4 The invention illustrates a method according to an embodiment of the present invention having a detection zone. Figure 1 Control system for the ironing roller.

[0015] Figure 5 yes Figure 1 Top view of a sensor of a control system and an ironing roller, wherein the ironing roller is in a first position and in a second position.

[0016] Figure 6 Illustrated Figure 1 The ironing roller is in a first position and a second position relative to a sensor of the control system.

[0017] Figure 7A metal processing system having an ironing roller and a control system according to an embodiment is illustrated.

[0018] Figure 8 A temperature profile of another ironing roller according to an embodiment is illustrated.

[0019] Fig. 9 The temperature profiles of the ironing roller before and after the ironing roller is controlled by the control system according to the embodiment are illustrated. DETAILED DESCRIPTION

[0020] Described herein are systems and methods for controlling a roller having a non-metallic surface for a metalworking system. The roller can be used to contact the surface of a metal substrate, including but not limited to an ironing roller for contacting the surface of a metal substrate in a roll. In certain embodiments, the systems and methods provided herein include a control system that measures and detects the temperature of the non-metallic surface of the roller and controls the operating parameters of the roller based on the detected temperature. In certain embodiments, the control system measures the temperature of multiple zones across the width of the roller, which can allow detection of temperature differences in the roller (the temperature may be different on one side than on the other side), and allows corrections to be made as needed.

[0021] In some embodiments, the control system can amplify and / or otherwise control the size of the zone based on the distance between the sensor and the roller of the control system, which can improve the measurement and / or control based on such temperature measurement by maintaining the ratio of the roller measured for a specific zone (i.e., regardless of the distance between the sensor and the roller, the measured range is kept at a certain ratio relative to the size of the overall roller). In certain embodiments, the systems and methods provided herein can prevent and / or minimize the failure of the ironing roller during metal processing, thereby minimizing and / or preventing defects or damage (e.g., scratches) in the metal substrate caused by the failure of the ironing roller. In some embodiments, the systems and methods provided herein can be used to predict the failure or service life of the ironing roller, so that the ironing roller can be replaced as needed before the ironing roller fails. In various embodiments, the systems and methods provided herein can provide improved flatness control by using an ironing roller. Various other benefits and advantages can be achieved using the systems and methods provided herein, and the above advantages should not be considered limiting.

[0022] Figure 1-Figure 6 A metalworking system 100 is illustrated having a workstation 102 that includes at least one roller 104. Figure 1-Figure 6In the embodiment of the present invention, the workstation 102 is a winding station, which includes a coiler 106 for selectively forming a coil 108 of a metal substrate 110 or unwinding the coil 108. The roller 104 in this embodiment is an ironing roller for contacting the coil 108 to promote good winding and stacking of the coil 108 and / or to promote unwinding of the metal substrate 110 from the coil 108. Although the workstation 102 is illustrated as a winding station and the roller 104 is shown as an ironing roller, in other embodiments, the workstation 102 need not be a winding station and / or the roller 104 need not be an ironing roller, and the roller 104 can be provided at various other locations within the metal processing system as desired. As some non-limiting examples, the workstation 102 having the roller 104 can be a cold rolling mill, a foil rolling mill, a slitting line, a continuous annealing solution heat treatment line, a coating line, and / or various other types of stations and / or metal processing systems as desired.

[0023] refer to Figure 2 In various embodiments, the roller 104 includes a first end 112, a second end 114, and a contact surface 116 between the first end 112 and the second end 114. In certain embodiments, the contact surface 116 is a non-metallic surface suitable for contacting the metal substrate 110 during processing (e.g., Figure 1-Figure 6 The contact surface 116 is provided on the roller 104 to contact the metal substrate 110. In one non-limiting example, the contact surface 116 is a rubber coating disposed on the roller 104 between the ends 112, 114. Alternatively, the non-metallic surface may be deformable during metal processing. The contact surface 116 may be provided on the roller 104 using a variety of techniques or processes as desired. Figure 1-Figure 6 The particular roller 104 illustrated with the contact surface 116 should not be considered limiting.

[0024] refer to Figure 1 and Figure 3 During metal processing, the roller 104 can be supported on a support 121 so that at least the contact surface 116 contacts the roll 108. The specific support 121 illustrated should not be considered limiting, and various devices or structures can be used as the support 121 as desired. In some embodiments, at least one of the ends 112, 114 of the roller 104 is driven by various suitable actuators or drive mechanisms so that the roller 104 moves around its axis 118 (see Figure 2 ) maintains contact with roll 108 during rotation.

[0025] By Figure 1 and Figure 3 As shown in the example for comparison, when volume 108 is increased from a smaller (or initial) size ( Figure 1 ) resizes to final (or larger) size ( Figure 3), the roller 104 may move in a radial direction. The contact between the contact surface 116 and the roll 108 may subject the contact surface 116 to thermal oscillations and variations, which in turn may ultimately lead to failure of the contact surface 116 and potential damage to the metal substrate 110. In addition, during metal processing, the actuator of the roller 104 may cause flatness issues with the metal substrate 110 due to the oscillating movement, and such flatness issues may render the metal substrate 110 unsuitable for its intended use and / or require correction prior to further processing. Figure 1 and Figure 3 As illustrated, for example, to minimize and / or prevent problems with the roller 104, the metalworking system 100 includes a control system 122 that measures a temperature of at least the contact surface 116 and generates an output response based on the measured temperature.

[0026] In certain embodiments, the control system 122 includes a sensor 124 and a controller 126. Although a single sensor 124 and a single controller 126 are illustrated, in other embodiments, the control system 122 can have any number of sensors 124 and / or controllers 126 as desired.

[0027] The sensor 124 of the control system 122 can be various suitable devices or mechanisms for detecting the temperature of at least the contact surface 116 of the roller 104. In some embodiments, the sensor 124 is a thermal imager with a field of view 127. In various embodiments, the thermal imager can be a high frame rate thermal imager that acquires images at a rate greater than the operating frequency of the roller 104 to avoid or minimize aliasing effects. As some non-limiting examples, the sensor 124 can acquire images at a frame rate greater than 20 Hz, such as greater than 30 Hz, such as greater than 40 Hz, such as greater than 50 Hz, such as greater than 60 Hz. In some non-limiting examples, a thermal imager as the sensor 120 can have an acquisition rate greater than 60 Hz, such as about 70 Hz. In other embodiments, cameras with other acquisition rates can be used as desired.

[0028] In various embodiments, and as Figure 4 As illustrated, the sensor 124 may detect the temperature of at least the contact surface 116 of the roller 104 using one or more detection zones 132 located on the roller 104 between the ends 112, 114. Figure 4In the illustrated embodiment, the sensor 124 detects the temperature in six detection zones 132A-F; however, the number of detection zones 132 should not be considered as limiting. In some non-limiting examples, the sensor 124 can use at least two detection zones, at least three detection zones, at least four detection zones, or at least five detection zones. In a non-limiting example, the sensor 124 can include at least ten detection zones, such as at least fifteen detection zones, such as at least twenty detection zones. In various embodiments, the sensor 124 detects the temperature of each detection zone independently. As an example, the sensor 124 detects the temperature within the detection zone 132A of the contact surface 116, independently of the temperature within the detection zone 132B of the contact surface 116. In certain embodiments, and as discussed in detail below, multiple detection zones 132 can use the control system 122 to improve the temperature measurement and control of the roller 104. Figure 4 The particular size or area of ​​each detection zone 132 illustrated in relation to the roller 104 should not be considered limiting, and in other embodiments, the detection zone 132 need not cover the entire width of the roller 104. Figure 6 A non-limiting example is illustrated in which the detection range 134 (ie, all of the detection areas 132 ) is less than the width of the roller 104 .

[0029] In various embodiments, multiple detection zones 132 may together form a detection area 136. The number of detection zones 132 within a particular detection area 136 need not be the same along the roller 104. Figure 4 In the illustrated embodiment, roller 104 includes three detection areas 136 - a first detection area 136A formed by detection areas 132A-B; a second detection area 136B formed by detection areas 132C-D; and a third detection area 136C formed by detection areas 132E-F. The number of detection areas 136 should not be considered limiting. When included, the number of detection areas 136 can be less than or equal to the number of detection areas 132.

[0030] In certain embodiments, and if Figure 5 As illustrated, the sensor 124 is disposed at an initial position (eg, Figure 1 The position of the middle roller 104, and Figure 5 At such a predetermined distance, at least the contact surface 116 can be at an initial position and a final position (represented by the roller 104 with a dashed line in FIG. Figure 5 Both are located within the field of view 127 (indicated by the solid line roller 104 in FIG. 1 ).

[0031] refer to Figure 6 , the detection range 134 as the combined detection area 132 can be controlled to maintain its size or area relative to the roller 104. Figure 6, the various detection areas 132 are omitted for clarity of the drawings. In these embodiments, the sensor 124 can automatically adjust its focus so that the detection range 134 is adjusted based on the position of the roller 104 relative to the sensor 124. This automatic adjustment of the focus and detection range 134 can provide improved temperature measurement and control of the roller 104 using the control system 122. As a non-limiting example, in Figure 6 , the detection range 134 on the roller 104 in the initial position (represented by the dotted line) is smaller than the detection range 134 of the roller in the final position (represented by the solid line and closer to the sensor 124), but the size of the detection range 134 relative to the roller 104 is the same in the initial position and the final position.

[0032] Reference again Figure 1 , the sensor 124 may optionally be provided at an angle 130 relative to the roller 104. In such an embodiment, the sensor 124 may be provided below the roller 104, and the angle 130 may optionally be such as Figure 1 In such embodiments, angle 130 can further facilitate at least contact surface 116 being within field of view 127 when roller 104 moves in a radial direction. In other embodiments, angle 130 of sensor 124 can be any other angle as desired, and sensor 124 need not be positioned below roller 104 and / or at an oblique angle 130.

[0033] The controller 126 of the control system 122 may include one or more processing units and / or one or more memory devices. The processing unit of the controller may be various suitable processing devices or combinations of devices, including but not limited to one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, other electronic units, and / or combinations thereof. The one or more memory devices of the controller 126 may be any machine-readable medium accessible by the processor, including but not limited to any type of long-term, short-term, volatile, non-volatile or other storage media, and are not limited to any particular type of memory or amount of memory, or the type of medium storing the memory. In addition, as disclosed herein, the term "storage medium", "storage device" or "memory" may represent one or more memories for storing data, including read-only memory (ROM), random access memory (RAM), magnetic RAM, magnetic core memory, magnetic disk storage media, optical storage media, flash memory devices, and / or other machine-readable media for storing information. The term "machine-readable medium" includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or various other storage media capable of storing or carrying instruction(s) and / or data.

[0034] In certain embodiments, the controller 126 optionally includes an associated user interface, including but not limited to a graphical user interface, so that the controller 126 can obtain information from a user and / or provide information to a user. In such embodiments, the user interface can be located on the controller 126 itself, or can be located at a location remote from the controller 126, such as but not limited to another location within the metalworking system 100. Additionally or alternatively, the controller 126 can optionally include various communication modules so that the controller 126 can receive and / or send information as desired. Non-limiting examples of communication modules can include implementing wired communication and / or wireless communication (e.g., industrial Ethernet, Near field, cellular, Wi-Fi, Bluetooth Low Energy (BLE), etc.) systems and mechanisms.

[0035] The controller 126 of the control system 122 is communicatively coupled to the sensor 124 such that the controller 126 receives thermal data for one or more detection zones 132 and / or one or more detection areas 136 from the sensor 124. In various embodiments, the controller 126 and / or the sensor 124 may determine the temperature of a particular detection zone 132 and / or detection area 136 using various techniques as desired, including based on a maximum temperature detected within a particular detection zone 132 and / or detection area 136, an average of the temperatures detected within a particular detection zone 132 and / or detection area 136, a temperature at the center of a detection zone 132 and / or detection area 136, and / or others as desired.

[0036] The controller 126 may generate various output responses based on the temperature data from the sensor 124. The output responses may include, but are not limited to, generating an alarm or notification (e.g., audio or visual) on a user interface of the controller 126, sending an alarm or notification to an operator, controlling an operating parameter of the roll 104 (e.g., by sending a control signal to an actuator or control device of the roll 104), and / or controlling an operating parameter of the metalworking system 100 (e.g., by sending a control signal to an actuator or control device of the metalworking system 100). The operating parameters of the roll 104 may include, but are not limited to, roll pressure, the inclination of the roll 104, the pressure applied by an actuator on the roll 104, combinations thereof, and / or various other operating parameters as desired, and the control of these operating parameters may include controlling the drive mechanism of the roll 104, the actuator of the roll 104 causing the roll 104 to apply the roll pressure, combinations thereof, and / or other as desired. The operating parameters of the metal processing system may include, but are not limited to, line speed, winding rate, unwinding rate, combinations thereof and / or various other operating parameters as desired, and control of these operating parameters may include controlling a worktable upstream of the winder 106, a drive mechanism controlling the rotation rate of the winder 106, combinations thereof and / or others as desired.

[0037] The output response from controller 126 may be based on various analyses of the measured temperature from sensor 124 as desired.

[0038] As a non-limiting example, the output response from the controller 126 can be based on a comparison of the measured temperature of a particular detection zone 132 and / or detection area 136 with a threshold temperature of the particular detection zone 132 and / or detection area 136. In such an embodiment, the threshold temperature can correspond to the temperature at which the contact surface 116 fails and can be predetermined, calculated, or otherwise generated or provided as desired. In other embodiments, the threshold temperature can be other temperatures as desired and need not be the failure temperature of the contact surface 116. In an embodiment with such a comparison, the controller 126 can generate an output response based on the measured temperature of one of the detection zones 132 being within a predetermined range and / or exceeding the threshold temperature. As a non-limiting example, the controller 126 can generate an output response of the actuator controlling the roller 104 based on the measured temperature of the detection area 136A exceeding its threshold temperature to reduce the rolling force of the portion in the detection area 136A of the roller 104 and reduce the temperature in the detection area 136A of the roller 104. Additionally or alternatively, the output response may include an alert or alarm provided to an operator based on the measured temperature exceeding a threshold temperature or being within a threshold temperature range.

[0039] As another non-limiting example, the output response from the controller 126 may be based on a comparison of the measured temperatures of adjacent detection zones 132 and / or detection areas 136. In such an embodiment, an output response may be generated if the temperature variation between adjacent detection zones 132 and / or detection areas 136 is within a predetermined range or exceeds a threshold. As a non-limiting example, the controller may generate an output response based on the difference between the measured temperatures of detection area 132C and detection area 132D exceeding a threshold. Additionally or alternatively, the output response may include an alarm or warning provided to an operator based on the temperature difference exceeding a threshold or being within a threshold range.

[0040] As yet another non-limiting example, the output response from the controller 126 may be based on the measured temperature of each detection zone 136. In such an embodiment, the measured temperature from each detection zone 132 may be used to derive a temperature value for each detection zone 136. Alternatively, the difference between the detection zone 136A and the detection zone 136C may be used to adjust the difference in rolling force applied to the first end 112 and the second end 114, e.g., if the temperature in the detection zone 136A is higher, the force may be adjusted to reduce the force on the first end 112 and increase the force on the second end 114. As another non-limiting example, the difference between the detection zone 136B (e.g., at the center of the roller 104) and the average temperature (or edge control temperature) of the detection zones 136A, 136C may be used to increase or decrease the total ironing roller force, e.g., if the temperature gradient from the center to the edge control temperature exceeds a certain limit, the total ironing roller force may be increased.

[0041] As a further non-limiting example, the output response from the controller 126 can be based on the curvature or curve of the temperature signal along the roller 104, which can correspond to the pressure distribution from one or more actuators of the roller 104. In such an embodiment, the temperature signal can be a combined measured temperature along the roller 104, and the controller 126 can compare the temperature signal to a target signal and / or identify oscillations in the temperature signal above a threshold. As a non-limiting example, the controller 126 can control the pressure applied by the actuator (e.g., a cylinder) on the roller 104 to improve the flatness of the metal substrate 110 based on the identification of multiple oscillations in the temperature signal and / or the temperature signal having a "wavy" curve.

[0042] As another non-limiting example, the controller 126 may predict the future performance of the roller 104 based on the detected temperature, and the controller 126 may generate an alarm based on the predicted performance meeting a predetermined condition. As a non-limiting example, the controller 126 may predict the remaining useful life of the roller 104 based on the historical temperature of the roller 104 and / or the current measured temperature of the roller 104, and the controller 126 may generate an alarm or warning to an operator based on the remaining useful life of the roller 104 being less than a predetermined minimum remaining useful life of the roller 104.

[0043] The controller 126 may perform various other analyses as desired, and the foregoing examples should not be considered limiting.

[0044] Based on the measured temperature of the contact surface 116 , the output response from the controller 126 may provide improved control of the roller 104 , which may provide benefits including, but not limited to, minimizing or preventing failure of the contact surface 116 during metal processing and / or providing improved planarity for the metal substrate 110 .

[0045] refer to Figure 1 , a method of controlling a roller 104 having a contact surface 116 may include receiving, by a controller 126, a detected temperature of at least a portion of the contact surface 116 of the roller 104 from a sensor 124. The method includes generating, by the controller 126, an output response based on the received temperature. In some embodiments, generating the output response includes one or more of controlling an operating parameter of the roller 104, controlling an operating parameter of the metalworking system, or generating an alarm or warning to an operator.

[0046] In some embodiments, controlling the roll includes adjusting an operating parameter of the roll based on the received temperature exceeding a threshold temperature.Alternatively, controlling the roll may include controlling at least one actuator of the roll to control a rolling force from the roll.

[0047] In various embodiments, receiving the detected temperature from the sensor 124 includes independently receiving the detected temperature of each detection zone 132 in the plurality of detection zones 132 along the roller 104. Optionally, controlling the roller 104 is based on at least one of: the detected temperature of a particular detection zone 132 exceeds a threshold temperature for the particular detection zone 132, or the difference between the detected temperature of a first detection zone (e.g., detection zone 132A) in the plurality of detection zones 132 and the detected temperature of a second detection zone (e.g., detection zone 132B or 132F) in the plurality of detection zones 132 exceeds a threshold limit.

[0048] In some embodiments, the method includes determining a pressure profile of at least one actuator on the roller based on a temperature signal formed from the detected temperature. In some embodiments, generating an output response may include controlling at least one actuator of the roller 104 based on the determined pressure profile.

[0049] Optionally, the method may include predicting a performance of the roller based on the detected temperature, and generating an alarm based on the predicted performance satisfying a predetermined condition. Optionally, generating an alarm includes generating a visual alarm or an audible alarm to an operator.

[0050] Various other processes may be performed using the control system 122 , and the aforementioned control processes should not be considered limiting.

[0051] Figure 7 An example of a thermal image 701 from a volume 704 of a control system similar to the control system 122 is illustrated. Figure 4 In comparison, thermal image 701 includes twenty detection zones 132 and three detection areas 136 .

[0052] Figure 8 104 using a control system similar to control system 122. Fig. 9 As illustrated, each temperature signal has a "wavy" portion (see, for example, region 803 of the temperature signal) that is caused by the oscillating movement of the roller caused by the roller actuator. The controller 126 can adjust the roller actuator and / or generate various other outputs to minimize such oscillations.

[0053] Fig. 9 Measured temperature signals of rollers similar to roller 104 and temperature signals of the same rollers after the control system 122 controls the rollers based on the measured temperatures are illustrated. As illustrated, the temperature of certain portions of certain rollers exceeds a threshold temperature 905 before the control system 122 takes control. In these embodiments, in response to such detected temperatures, the control system 122 controls the rollers (e.g., by adjusting an actuator, controlling a line speed of the metal substrate, etc.) such that the temperature of the rollers is below the threshold temperature 905.

[0054] A collection of exemplary embodiments is provided below, including at least some embodiments that are expressly listed as "illustrative" to provide additional descriptions of various exemplary embodiments according to the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or limiting; and the present disclosure is not limited to these exemplary illustrations, but covers all possible modifications and variations within the scope of the claims set forth and their equivalents.

[0055] Example 1. A metal processing system, comprising: a roller configured to rotate about an axis, the roller comprising a first end, a second end, and a non-metallic surface located between the first end and the second end for contacting a metal substrate; and a control system, comprising: a sensor configured to detect a temperature of the non-metallic surface of the roller; and a controller communicatively coupled to the sensor, wherein the controller is configured to receive the detected temperature from the sensor and control the roller based on the detected temperature.

[0056] Example 2. The metal processing system of any preceding or subsequent example or combination of examples, wherein the roller is an ironing roller for contacting a coil of a metal substrate, and the non-metallic surface comprises a deformable material.

[0057] Example 3. A metal processing system as in any preceding or subsequent example or combination of examples, wherein the deformable material comprises a rubber material.

[0058] Example 4. A metal processing system as in any preceding or subsequent example or combination of examples, wherein the sensor comprises a thermal imager, and wherein the thermal imager is configured to detect the temperature at a frame rate of at least 60 Hz.

[0059] Example 5. A metal processing system as in any preceding or subsequent example or combination of examples, wherein the frame rate is at least 70 Hz.

[0060] Example 6. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the sensor is configured to detect the temperature of the non-metallic surface of the roller by: generating a plurality of independent detection zones along the roller between a first end and a second end; and independently detecting the temperature of the non-metallic surface in each of the plurality of detection zones.

[0061] Example 7. A metal processing system as in any preceding or subsequent example or combination of examples, wherein the plurality of independent detection zones includes at least three detection zones.

[0062] Example 8. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the controller is configured to: receive a detection temperature of each detection zone among a plurality of detection zones; for each detection zone, compare the detection temperature with a threshold temperature of the particular detection zone; and control the roller based on the detection temperature of at least one detection zone among the plurality of detection zones exceeding the threshold temperature of the particular detection zone.

[0063] Example 9. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the controller is configured to: receive a detection temperature of each of a plurality of detection zones; compare the detection temperature of a first detection zone of the plurality of detection zones with the detection temperature of a second detection zone of the plurality of detection zones; and control the roller based on the difference between the detection temperature of the first detection zone and the detection temperature of the second detection zone.

[0064] Example 10. A metal processing system as in any preceding or subsequent example or combination of examples, wherein a first detection zone of the plurality of detection zones is located at the first end or the second end of the roller, and wherein a second detection zone of the plurality of detection zones is located between the first end and the second end of the roller.

[0065] Example 11. The metalworking system of any preceding or subsequent example or combination of examples, wherein the controller is configured to control the roller based on a difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone exceeding a threshold limit.

[0066] Example 12. A metalworking system as in any preceding or subsequent example or example combination 6, wherein the sensor is configured to change the size of each detection zone based on a change in the distance between the roller and the sensor.

[0067] Example 13. A metal processing system as in any preceding or subsequent example or combination of examples, wherein the sensor is configured to detect a maximum temperature of each detection zone or an average temperature of each detection zone.

[0068] Example 14. A metalworking system as in any preceding or subsequent example or combination of examples, wherein the controller is configured to control the roller by controlling a rolling force applied by the roller, and wherein controlling the rolling force comprises controlling at least one actuator for the roller.

[0069] Example 15. The metalworking system of any preceding or subsequent example or combination of examples, wherein the controller is further configured to generate an alarm based on the detected temperature exceeding a threshold temperature.

[0070] Example 16. A metal processing system as in any preceding or subsequent example or combination of examples, wherein the controller is further configured to determine a pressure distribution of the at least one actuator on the roller based on the detected temperature, and control the at least one actuator based on the determined pressure distribution.

[0071] Example 17. The metal processing system of any preceding or subsequent example or combination of examples, wherein the controller is further configured to predict performance of the roller based on the detected temperature, and to generate an alarm based on the predicted performance satisfying a predetermined condition.

[0072] Example 18. The metalworking system of any preceding or subsequent example or combination of examples, wherein the predetermined condition comprises failure of a non-metallic surface of the roller.

[0073] Example 19. A control system for a metal processing system including a roller, wherein the roller includes a non-metallic contact surface, the control system comprising: a sensor for detecting the temperature of the non-metallic contact surface of the roller; and a controller communicatively coupled to the sensor, the controller being configured to receive the detected temperature from the sensor and to generate an output signal for controlling the roller based on the received temperature.

[0074] Example 20. A control system as in any preceding or subsequent example or combination of examples, wherein the sensor comprises a thermal imager, and wherein the thermal imager is configured to detect temperature at a frame rate of at least 60 Hz.

[0075] Example 21. A control system as in any preceding or subsequent example or combination of examples, wherein the frame rate is at least 70 Hz.

[0076] Example 22. A control system as in any preceding or subsequent example or combination of examples, wherein the sensor is configured to detect the temperature of the non-metallic surface of the roller by: generating a plurality of independent detection zones along the roller; and independently detecting the temperature of the non-metallic surface in each of the plurality of detection zones.

[0077] Example 23. A control system as in any preceding or subsequent example or combination of examples, wherein the plurality of independent detection zones comprises at least three detection zones.

[0078] Example 24. A control system as in any preceding or subsequent example or combination of examples, wherein the controller is configured to: receive a detected temperature of each of a plurality of detection zones; for each detection zone, compare the detected temperature with a threshold temperature of the particular detection zone; and generate an output signal based on the detected temperature of at least one of the plurality of detection zones exceeding the threshold temperature of the particular detection zone.

[0079] Example 25. A control system as in any preceding or subsequent example or combination of examples, wherein the controller is configured to: receive a detection temperature of each of a plurality of detection zones; compare the detection temperature of a first detection zone of the plurality of detection zones with the detection temperature of a second detection zone of the plurality of detection zones; and generate an output signal based on a difference between the detection temperature of the first detection zone and the detection temperature of the second detection zone.

[0080] Example 26. The control system of any preceding or subsequent example or combination of examples, wherein the controller is configured to generate an output signal based on a difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone exceeding a threshold limit.

[0081] Example 27. A control system as in any preceding or subsequent example or combination of examples, wherein the sensor is configured to detect a maximum temperature of each detection zone or an average temperature of each detection zone.

[0082] Example 28. The control system of any preceding or subsequent example or combination of examples, wherein the controller is further configured to generate an alarm based on detecting a temperature exceeding a threshold temperature.

[0083] Example 29. A control system as in any preceding or subsequent example or combination of examples, wherein the controller is further configured to determine a pressure distribution of the at least one actuator on the roller based on the detected temperature, and to control the at least one actuator based on the determined pressure distribution.

[0084] Example 30. The control system of any preceding or subsequent example or combination of examples, wherein the controller is further configured to predict performance of the roller based on the detected temperature, and to generate an alarm based on the predicted performance satisfying a predetermined condition.

[0085] Example 31. A method for controlling a roller including a non-metallic contact surface for contacting a metal substrate, the method comprising: receiving a detected temperature of at least a portion of the non-metallic contact surface of the roller from a sensor; and controlling the roller based on the received temperature of at least the portion of the non-metallic contact surface.

[0086] Example 32. The method as in any preceding or subsequent example or combination of examples, wherein controlling the roller comprises adjusting an operating parameter of the roller based on the received temperature exceeding a threshold temperature.

[0087] Example 33. A method as described in any preceding or subsequent example or combination of examples, wherein receiving a detected temperature includes independently receiving a detected temperature of each detection zone in a plurality of detection zones along a roller, and wherein controlling the roller is based on at least one of: the detected temperature of a particular detection zone exceeds a threshold temperature of the particular detection zone; or the difference between the detected temperature of a first detection zone of a plurality of detection zones and the detected temperature of a second detection zone of the plurality of detection zones exceeds a threshold limit.

[0088] Example 34. The method of any preceding or subsequent example or combination of examples, wherein controlling the roller comprises controlling at least one actuator of the roller to control a rolling force from the roller.

[0089] Example 35. The method of any preceding or subsequent example or combination of examples, further comprising determining a pressure distribution of at least one actuator on the roller based on the detected temperature, and controlling the at least one actuator based on the determined pressure distribution.

[0090] Example 36. The method of any preceding or subsequent example or combination of examples, further comprising predicting a performance of the roller based on the detected temperature, and generating an alert based on the predicted performance satisfying a predetermined condition.

[0091] Example 37. The method of any preceding or subsequent example or combination of examples, wherein generating an alarm comprises generating a visual alarm or an audible alarm.

[0092] The subject matter of the embodiment is specifically described herein to meet the statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter can be embodied in other ways, can include different elements or steps, and can be used in combination with other existing or future technologies. This description should not be interpreted as implying any specific order or arrangement among or between various steps or elements, except when the order of the arrangement of each step or element is clearly described. Directional references such as "upward", "downward", "top", "bottom", "left side", "right side", "front" and "rear" are intended to refer to the orientation shown and described in one (or more) figures of the reference parts and directions. Throughout this disclosure, the reference numerals with letters refer to specific instances of elements, and the reference numerals without letters refer to elements generally or collectively. Therefore, as an example (not shown in the figure), device "12A" refers to an instance of a device class, which can be collectively referred to as device "12", and any of which can be collectively referred to as device "12". In the drawings and specifications, the same reference numerals are intended to represent the same elements. As used herein, the meanings of "a", "an" and "the" include both singular and plural references unless the context clearly indicates otherwise.

[0093] The above-mentioned various aspects are only possible examples of implementation modes, which are merely set forth for a clear understanding of the principles of the present disclosure. Without departing substantially from the spirit and principles of the present disclosure, many changes and modifications may be made to the above-mentioned one or more embodiments. All such modifications and changes are intended to be included in the scope of the present disclosure herein, and all possible claims for various aspects or combinations of elements or steps are intended to be supported by the present disclosure. In addition, although specific terms are used herein and in the appended claims, these specific terms are used only in a general and descriptive sense and are not intended to limit the described embodiments or the purpose of limiting the appended claims.

Claims

1. A metal processing system, comprising: a roller configured to rotate about an axis, the roller comprising a first end, a second end, and a non-metallic surface between the first end and the second end for contacting a metal substrate; as well as A control system comprising: a sensor configured to detect a temperature of the non-metallic surface of the roller; as well as A controller is communicatively coupled to the sensor, wherein the controller is configured to receive the detected temperature from the sensor and control the roller based on the detected temperature.

2. The metalworking system of claim 1, wherein the roller is an ironing roller for contacting a coil of the metal substrate, and the non-metallic surface comprises a deformable material.

3. The metal processing system of claim 1, wherein the sensor comprises a thermal imager, and wherein the thermal imager is configured to detect the temperature at a frame rate of at least 60 Hz.

4. The metalworking system of claim 1 , wherein the sensor is configured to detect the temperature of the non-metallic surface of the roller by: creating a plurality of independent detection zones along the roller between the first end and the second end; and The temperature of the non-metallic surface in each of the plurality of detection zones is independently detected.

5. The metal processing system of claim 4, wherein the controller is configured to: receiving a detected temperature of each detection zone in the plurality of detection zones; For each detection zone, comparing the detected temperature to a threshold temperature for that particular detection zone; and The roller is controlled based on the detected temperature of at least one detection zone of the plurality of detection zones exceeding the threshold temperature of the particular detection zone.

6. The metal processing system of claim 4, wherein the controller is configured to: receiving a detected temperature of each detection zone in the plurality of detection zones; comparing a detected temperature of a first detection zone among the plurality of detection zones with a detected temperature of a second detection zone among the plurality of detection zones; and The roller is controlled based on a difference between the detected temperature of the first detection area and the detected temperature of the second detection area.

7. The metalworking system of claim 4, wherein the sensor is configured to change the size of each detection zone based on a change in the distance between the roller and the sensor.

8. A control system for a metalworking system including a roller, the roller including a non-metallic contact surface, the control system comprising: a sensor for detecting a temperature of the non-metallic contact surface of the roller; as well as A controller is communicatively coupled to the sensor, the controller being configured to receive the detected temperature from the sensor and generate an output signal for controlling the roller based on the received temperature.

9. The control system of claim 8, wherein the sensor comprises a thermal imager, and wherein the thermal imager is configured to detect the temperature at a frame rate of at least 60 Hz.

10. The control system of claim 9, wherein the sensor is configured to detect the temperature of the non-metallic surface of the roller by: creating a plurality of independent detection zones along the roller; and The temperature of the non-metallic surface in each of the plurality of detection zones is independently detected.

11. The control system of claim 10, wherein the controller is configured to: receiving a detected temperature of each detection zone in the plurality of detection zones; For each detection zone, comparing the detected temperature to a threshold temperature for that particular detection zone; and The output signal is generated based on the detected temperature of at least one detection zone of the plurality of detection zones exceeding the threshold temperature of the particular detection zone.

12. The control system of claim 10, wherein the controller is configured to: receiving a detected temperature of each detection zone in the plurality of detection zones; comparing a detected temperature of a first detection zone among the plurality of detection zones with a detected temperature of a second detection zone among the plurality of detection zones; and The output signal is generated based on a difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone. 13 . The control system of claim 12 , wherein the controller is configured to generate the output signal based on the difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone exceeding a threshold limit.

14. The control system of claim 9, wherein the controller is further configured to determine a pressure distribution of at least one actuator on the roller based on the detected temperature, and control the at least one actuator based on the determined pressure distribution.

15. The control system of claim 9, wherein the controller is further configured to predict a performance of the roller based on the detected temperature, and to generate an alarm based on the predicted performance satisfying a predetermined condition.

16. A method of controlling a roller comprising a non-metallic contact surface for contacting a metal substrate, the method comprising: receiving from a sensor a sensed temperature of at least a portion of the non-metallic contact surface of the roller; as well as The rollers are controlled based on the received temperature.

17. The method of claim 16, wherein receiving the detected temperature comprises independently receiving the detected temperature of each of a plurality of detection zones along the roller, and wherein controlling the roller is based on at least one of: The detected temperature of a specific detection zone exceeds a threshold temperature of the specific detection zone; or A difference between the detected temperature of a first detection zone among the plurality of detection zones and the detected temperature of a second detection zone among the plurality of detection zones exceeds a threshold limit.

18. The method of claim 16, wherein controlling the roller comprises controlling at least one actuator of the roller to control a rolling force from the roller.

19. The method of claim 16, further comprising determining a pressure distribution of at least one actuator on the roller based on the detected temperature, and controlling the at least one actuator based on the determined pressure distribution.

20. The method of claim 16, further comprising predicting a performance of the roller based on the detected temperature, and generating an alert based on the predicted performance satisfying a predetermined condition.

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