A test method for investigating coating defects of grain-oriented silicon steel

Abstract

The application discloses a kind of test methods for researching oriented silicon steel coating defects, the method comprises the following steps: the acrylic plate is horizontally placed and is completely fixed, camera and laser are placed below acrylic plate, coating roll and nozzle engraved with micro groove are placed above acrylic plate;The coating roll is adjusted by controlling lift;Nozzle sprays liquid on the surface of acrylic plate;Laser and camera are turned on;Acrylic plate moves horizontally, drives coating roll to rotate, and uniformly coats liquid on the surface of acrylic plate;Camera observes groove distribution and other results through acrylic plate.The more consistent the liquid distribution of each groove, the smaller the coating defect.The application is beneficial to analyze the coating defect mechanism, design the optimal coating scheme, and improve the production quality and efficiency of oriented silicon steel.

Description

Technical Field

[0001] This invention relates to the field of iron and steel metallurgy technology, and in particular to a test method for studying defects in the coating of grain-oriented silicon steel. Background Technology

[0002] Currently, grain-oriented silicon steel manufacturers all use a grooved two-roll extrusion coating process to apply MgO suspension. The two-roll extrusion coating machine controls the volume of the grooves after extrusion by adjusting the lifting height of the lower roll, thereby controlling the coating thickness. Existing two-roll extrusion coating machines, such as... Figure 1 As shown, during operation, the upper coating roller 2-1 is a fixed-position free roller, while the lower coating roller 2-2 is a liftable free roller. Both the upper and lower coating rollers are rubber rollers with grooves. These grooves are formed by a rubber roller grinding machine carving continuous spiral patterns along the circumference. Figure 2 As shown, nozzle 3 sprays the MgO suspension onto the surface of strip 1, which is sandwiched between the upper and lower rollers and moves horizontally from left to right at a constant speed. Under a certain clamping force, strip 1 drives coating roller 2-1 / 2 to rotate through friction. The rotation of coating roller 2-1 / 2 squeezes and evenly coats the surface of strip 1 with coating liquid.

[0003] Currently, two-roll coating machines commonly suffer from coating defects such as poor axial coating uniformity, double lines in the coating, and missed lines. Studying the formation mechanism of these coating defects requires analyzing the stress conditions on the coating rollers and considering various influencing factors such as rubber material, rubber layer thickness, coating roller clamping amount, and strip width.

[0004] To improve the adaptability, efficiency, and economy of coating research, low-cost experiments are typically employed for study and subsequent application. The results of these low-cost experiments can provide valuable reference for practical engineering problems. Designing effective experimental methods is crucial for analyzing and studying the formation mechanism of coating defects. Considering the influence of different factors on coating defects necessitates experimental research; however, current experiments have not adequately observed the liquid flow patterns and distribution in axial grooves, thus hindering the resolution of coating defects. Developing an experimental method to study defects in grain-oriented silicon steel coatings and reduce coating defects has become an urgent problem to be solved. Summary of the Invention

[0005] The purpose of this invention is to provide an experimental method for studying coating defects in grain-oriented silicon steel. By using machine vision, the distribution of coating defects and the flow patterns of liquid under pressure are observed. The experimental results are used to analyze the mechanism of coating defects, improving the adaptability, efficiency, and economy of coating roller coating research, and ultimately contributing to improved production quality and efficiency of grain-oriented silicon steel.

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

[0007] A test method for studying defects in grain-oriented silicon steel coatings, characterized in that the test system includes a lift, a coating roller connected below the lift, and an acrylic plate, the lower surface of the coating roller contacting the upper surface of the acrylic plate, a camera and a laser emitter disposed below the acrylic plate, and a nozzle disposed above the acrylic plate.

[0008] Furthermore, the coating roller includes a roller, a roller neck, and a rubber layer. The roller neck is composed of a shaft end and a shaft head. The roller is fixed between the two shaft heads. The rubber layer is sleeved on the outside of the roller and the shaft end. The thickness of the rubber layer is 15~25mm. The surface of the rubber layer is engraved with micro-trapezoidal grooves.

[0009] Furthermore, the outer diameter A of the coating roller is 80~120mm, the outer diameter B of the roller is 60~100mm, the outer diameter C of the journal is 15~25mm, the length E of the coating roller is 300~400mm, the length of the rubber layer is 240~300mm, the inner diameter D of the roller is 55~95mm, and the length G of the roller is 230~290mm.

[0010] Furthermore, the rubber hardness of the rubber layer is 53~59 Shore A. The bottom width H of the micro-trapezoidal groove is 0.3~0.6mm, the top width I is 0.25~0.5mm, the groove angle J is 60°, the groove spacing K is 0.97~2.25mm, and the groove depth L is 0.38~1mm.

[0011] Furthermore, the acrylic sheet has a width of 100~300mm, a length of 300~600mm, and a thickness of 4~10mm.

[0012] Furthermore, the nozzle is located on one side of the elevator and sprays liquid onto the surface of the acrylic sheet.

[0013] Furthermore, the camera lens is vertically upward, and the laser emitter is located on one side of the camera to illuminate the camera's shooting area.

[0014] Furthermore, the camera is a line scan camera, and the sensor on the camera has more than 12k pixels.

[0015] A test method for studying defects in grain-oriented silicon steel coatings, the method comprising the following steps:

[0016] S1: Observe the effect of clamping amount on defects in silicon steel coating;

[0017] S2: Observe the effect of strip width on silicon steel coating defects;

[0018] S3: Observe the effect of rubber layer thickness on defects in silicon steel coating;

[0019] S4: Observe the effect of rubber hardness on defects in silicon steel coating;

[0020] S5: Based on the test results of S1-S4, design the optimal coating scheme to reduce coating defects in silicon steel and improve the production quality and efficiency of oriented silicon steel.

[0021] Furthermore, step S1 specifically includes:

[0022] S11: Set the acrylic sheet width to 180mm, the rubber layer thickness to 20mm, and the rubber layer hardness to 56 Shore A. Control the lifting and lowering of the coating roller through the lifting machine to adjust the amount of pressure between the coating roller and the acrylic sheet.

[0023] S12: Start the nozzle to spray liquid onto the surface of the acrylic sheet;

[0024] S13: Move the acrylic sheet horizontally;

[0025] S14: Turn on the laser emitter and camera;

[0026] S15: When the clamping amount is adjusted to 1, 2, 3, and 4 mm, images are captured with a camera and the liquid volume between each groove and the acrylic plate is observed. The more consistent the liquid volume in each groove, the fewer coating defects there will be.

[0027] If the liquid volume consistency of each groove in the image is higher when the clamping amount is adjusted to 3mm than when the clamping amount is set to 1mm, 2mm and 4mm, then setting the clamping amount to 3mm is the optimal clamping amount.

[0028] Furthermore, step S2 specifically includes:

[0029] S21: Set the clamping amount to 3mm, the rubber layer 10 thickness to 20mm, and the rubber layer hardness to 56 Shore A, and adjust the width of the acrylic sheet;

[0030] S22: Start the nozzle to spray liquid onto the surface of the acrylic sheet;

[0031] S23: Move the acrylic sheet horizontally;

[0032] S24: Turn on the laser emitter and camera;

[0033] S25: Using acrylic sheets with widths of 150, 180, and 210 mm, images are captured by a camera, and the liquid volume between each groove and the acrylic sheet is observed. The more consistent the liquid volume in each groove, the fewer coating defects there are.

[0034] If the consistency of liquid volume in each groove in the image is higher when the width of the acrylic sheet is adjusted to 180mm than when the width of the acrylic sheet is 150mm and 210mm, then the optimal coating width is 180mm.

[0035] Furthermore, step S3 specifically includes:

[0036] S31: Set the acrylic sheet width to 180mm, the clamping amount to 3mm, and the rubber layer hardness to 56 Shore A. Adjust the rubber lining thickness of the roller and shaft end surfaces.

[0037] S32: Activate the nozzle to spray liquid onto the surface of the acrylic sheet;

[0038] S33: Move the acrylic sheet horizontally;

[0039] S34: Turn on the laser emitter and camera;

[0040] S35: Coating rollers with rubber layer thicknesses of 15, 20, and 25 mm were produced respectively. Images were captured with a camera, and the liquid volume between each groove and the acrylic plate was observed. The more consistent the liquid volume in each groove, the fewer coating defects there were.

[0041] If the consistency of liquid capacity in each groove in the image is higher when the rubber layer thickness is adjusted to 20mm than when the rubber layer thickness is 15mm and 25mm, then 20mm is the optimal rubber lining thickness.

[0042] Furthermore, step S4 specifically includes:

[0043] S41: Set the acrylic sheet width to 180mm, the rubber layer thickness to 20mm, and the compression amount to 3mm to prepare rubbers of different hardnesses, and then line the roller and shaft end surfaces with rubbers of different hardnesses.

[0044] S42: Activate the nozzle to spray liquid onto the surface of the acrylic sheet;

[0045] S43: Move the acrylic sheet horizontally;

[0046] S44: Turn on the laser emitter and camera;

[0047] S45: Coating rollers with hardnesses of 53, 56, and 59 Shore A were produced respectively. Images were captured with a camera, and the liquid volume between each groove and the acrylic plate was observed. The more consistent the liquid volume in each groove, the fewer coating defects there were.

[0048] If the consistency of liquid volume in each groove in the image is higher when the rubber hardness is adjusted to 56 Shore A than when the rubber hardness is 53 Shore A and 59 Shore A, then 56 Shore A is the optimal rubber lining hardness.

[0049] The present invention has the following effects:

[0050] To address coating defects such as poor axial coating uniformity, double lines, and missed lines produced by two-roll extrusion coating mills, in-depth analysis of the defect formation mechanism can be conducted through experiments to fundamentally solve these defects. This invention facilitates a better analysis of the coating defect formation mechanism and provides significant insights for further optimization of the coating system. In actual operating conditions, the coating roll clamping amount, strip width, rubber layer thickness, and rubber hardness are all important influencing factors on coating defects. The effects on coating performance can be studied by changing the clamping amount at both ends of the coating roll, the acrylic plate width, the rubber layer thickness, and the rubber layer hardness during the experiment. The distribution of each groove can be observed using a camera; the better the consistency of the distribution of each groove, the smaller the coating defects. The observation method used in this experiment is beneficial for analyzing and designing the optimal coating scheme, improving the adaptability, efficiency, and economy of coating research, and enhancing the production quality and efficiency of grain-oriented silicon steel. Attached Figure Description

[0051] Figure 1 Schematic diagram of a two-roll extrusion coating machine;

[0052] Figure 2 Overall 3D view of the coating roller;

[0053] Figure 3 3D model of grooves on the surface of the coating roller

[0054] Figure 4 Schematic diagram of the test method;

[0055] Figure 5 Schematic diagram of the test coating roller;

[0056] Figure 6 Schematic diagram of grooves on the surface of the test coating roller;

[0057] Figure 7 Schematic diagram of the test roller core;

[0058] Figure 8 Schematic diagram of the test roll neck;

[0059] Figure 9 Schematic diagram of test roller Detailed Implementation

[0060] To make the objectives and techniques of this invention clearer, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. In the following description, descriptions of well-known structures and techniques are omitted to avoid confusion with the concepts of this invention.

[0061] A test method for studying defects in the coating of grain-oriented silicon steel is characterized in that the test system includes a lift 4, a coating roller 6 connected below the lift 4, and an acrylic plate 7. The lower surface of the coating roller 6 is in contact with the upper surface of the acrylic plate 7. A camera 8 and a laser emitter 9 are arranged below the acrylic plate 7, and a nozzle 5 is arranged above the acrylic plate 7.

[0062] like Figure 5 , Figure 6 , Figure 7 , Figure 8 and Figure 9 As shown, the coating roller 6 includes a roller 11, a roller neck 12, and a rubber layer 10. The roller neck 12 is composed of a shaft end 14 and a shaft head 13. The roller 11 is fixed between the two shaft heads 13. The rubber layer 10 is sleeved on the outside of the roller 11 and the shaft end 14. The thickness of the rubber layer 10 is 15~25mm. The surface of the rubber layer 10 is engraved with micro-trapezoidal grooves.

[0063] The coating roller 6 has an outer diameter A of 80~120mm, the roller 11 has an outer diameter B of 60~100mm, the journal 12 has an outer diameter C of 15~25mm, the coating roller 6 has a length E of 300~400mm, the rubber layer has a length F of 240~300mm, the roller 11 has an inner diameter D of 55~95mm, and the roller 11 has a length G of 230~290mm.

[0064] The rubber layer 10 has a rubber hardness of 53~59 Shore A. The micro-trapezoidal groove has a bottom width H of 0.3~0.6mm, a top width I of 0.25~0.5mm, a groove angle J of 60°, a groove spacing K of 0.97~2.25mm, and a groove depth L of 0.38~1mm.

[0065] The acrylic sheet 7 has a width of 100~300mm, a length of 300~600mm, and a thickness of 4~10mm.

[0066] The nozzle 5 is located on one side of the elevator 4 and sprays liquid onto the surface of the acrylic plate 7.

[0067] The lens of the camera 8 is vertically upward, and the laser emitter 9 is located on one side of the camera 8 to illuminate the area captured by the camera 8.

[0068] Furthermore, the camera 8 is a line scan camera, and the sensor pixels on the camera 8 are greater than 12k.

[0069] like Figure 4 As shown, this invention proposes an experimental method for studying defects in grain-oriented silicon steel coatings, the method comprising the following steps:

[0070] S1: Observe the effect of clamping amount on defects in silicon steel coating;

[0071] S11: Set the width of acrylic sheet 7 to 180mm, the thickness of rubber layer 10 to 20mm, and the hardness of rubber layer 10 to 56Shore A. Control the lifting of coating roller 6 through lifting machine 4 to adjust the amount of pressure between coating roller 6 and acrylic sheet 7.

[0072] S12: Start nozzle 5 to spray liquid onto the surface of acrylic sheet 7;

[0073] S13: Move the acrylic plate 7 horizontally;

[0074] S14: Turn on laser emitter 9 and camera 8;

[0075] S15: When the clamping amount is adjusted to 1, 2, 3, and 4 mm, the camera 8 is used to collect images and observe the liquid volume between each groove and the acrylic plate 7 in the images. The more consistent the liquid volume in each groove, the fewer coating defects there will be.

[0076] If the liquid volume consistency of each groove in the image is higher when the clamping amount is adjusted to 3mm than when the clamping amount is set to 1mm, 2mm and 4mm, then setting the clamping amount to 3mm is the optimal clamping amount.

[0077] S2: Observe the effect of strip width on silicon steel coating defects;

[0078] S21: Set the clamping amount to 3mm, the thickness of rubber layer 10 to 20mm, the hardness of rubber layer 10 to 56 Shore A, and adjust the width of acrylic sheet 7.

[0079] S22: Start nozzle 5 to spray liquid onto the surface of acrylic sheet 7;

[0080] S23: Move the acrylic plate 7 horizontally;

[0081] S24: Turn on laser emitter 9 and camera 8;

[0082] S25: Using acrylic plates 7 with widths of 150, 180, and 210 mm, images are captured by camera 8. The liquid volume between each groove and the acrylic plate 7 in the images is observed. The more consistent the liquid volume in each groove, the fewer coating defects there are.

[0083] If the consistency of liquid volume in each groove in the image is higher when the width of the acrylic sheet is adjusted to 180mm than when the width of the acrylic sheet is 150mm and 210mm, then the optimal coating width is 180mm.

[0084] S3: Observe the effect of rubber layer thickness on defects in silicon steel coating;

[0085] S31: Set the width of acrylic sheet 7 to 180mm, the pressing amount to 3mm, the hardness of rubber layer 10 to 56 Shore A, and adjust the rubber lining thickness of roller 11 and shaft end 14.

[0086] S32: Start nozzle 5 to spray liquid onto the surface of acrylic sheet 7;

[0087] S33: Move the acrylic plate 7 horizontally;

[0088] S34: Turn on laser emitter 9 and camera 8;

[0089] S35: Coating rollers 6 with rubber layer 10 thicknesses of 15, 20, and 25 mm are produced respectively. Images are captured by camera 8, and the liquid volume between each groove and the acrylic plate 7 in the images is observed. The more consistent the liquid volume in each groove, the fewer coating defects there are.

[0090] If the consistency of liquid capacity in each groove in the image is higher when the rubber layer thickness is adjusted to 20mm than when the rubber layer thickness is 15mm and 25mm, then 20mm is the optimal rubber lining thickness.

[0091] S4: Observe the effect of rubber hardness on defects in silicon steel coating;

[0092] S41: Set the width of acrylic plate 7 to 180mm, the thickness of rubber layer 10 to 20mm, and the compression amount to 3mm to prepare rubbers of different hardnesses, and then line the roller 11 and shaft end 14 with rubbers of different hardnesses.

[0093] S42: Start nozzle 5 to spray liquid onto the surface of acrylic sheet 7;

[0094] S43: Move the acrylic plate 7 horizontally;

[0095] S44: Turn on laser emitter 9 and camera 8;

[0096] S45: Coating rollers 6 with hardnesses of 53, 56, and 59 Shore A are produced respectively. Images are captured by camera 8, and the liquid volume between each groove and the acrylic plate 7 in the images is observed. The more consistent the liquid volume in each groove, the fewer coating defects there are.

[0097] If the consistency of liquid volume in each groove in the image is higher when the rubber hardness is adjusted to 56 Shore A than when the rubber hardness is 53 Shore A and 59 Shore A, then 56 Shore A is the optimal rubber lining hardness.

[0098] S5: Based on the test results of S1-S4, design the optimal coating scheme to reduce coating defects in silicon steel and improve the production quality and efficiency of oriented silicon steel.

[0099] The above are merely embodiments of the present invention, described in a relatively specific and detailed manner, but should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A test system for studying defects in grain-oriented silicon steel coatings, characterized in that, The test system includes a lift (4), a coating roller (6) connected below the lift (4), and an acrylic plate (7). The lower surface of the coating roller (6) contacts the upper surface of the acrylic plate (7). A camera (8) and a laser emitter (9) are arranged below the acrylic plate (7), and a nozzle (5) is arranged above the acrylic plate (7). The coating roller (6) includes a roller (11), a roller neck (12) and a rubber layer (10). The roller neck (12) is composed of a shaft end (14) and a shaft head (13). The roller (11) is fixed between the two shaft heads (13). The rubber layer (10) is sleeved on the outside of the roller (11) and the shaft end (14). The thickness of the rubber layer (10) is 15~25mm. The surface of the rubber layer (10) is engraved with trapezoidal grooves. The camera (8) is used to acquire images to observe the liquid volume between the trapezoidal grooves and the acrylic plate.

2. The testing system as described in claim 1, characterized in that, The coating roller (6) has an outer diameter A of 80~120mm, an outer diameter B of 60~100mm, an outer diameter C of 15~25mm, a length E of 300~400mm, a length F of 240~300mm, an inner diameter D of 55~95mm, and a length G of 230~290mm. The rubber layer (10) has a rubber hardness of 53~59 Shore A, a bottom width H of 0.3~0.6 mm, a top width I of 0.25~0.5 mm, a groove angle J of 60°, a groove spacing K of 0.97~2.25 mm, and a groove depth L of 0.38~1 mm.

3. The testing system as described in claim 2, characterized in that, The acrylic sheet (7) has a width of 100~300mm, a length of 300~600mm, and a thickness of 4~10mm.

4. The testing system as described in claim 3, characterized in that, The nozzle (5) is located on one side of the elevator (4) and sprays liquid onto the surface of the acrylic plate (7).

5. The testing system as described in claim 4, characterized in that, The lens of the camera (8) is vertically upward, and the laser emitter (9) is located on one side of the camera (8) to illuminate the shooting area of ​​the camera (8).

6. The testing system as described in claim 5, characterized in that, The camera (8) is a line scan camera, and the sensor on the camera (8) has more than 12k pixels.

7. A test method for studying defects in grain-oriented silicon steel coatings, said method being based on the test system described in any one of claims 1-6, characterized in that, The method includes the following steps: S1: Observe the effect of the amount of pressure of the coating roller (6) on the acrylic sheet (7) on the coating defects of silicon steel; S2: Observe the effect of strip width on coating defects in silicon steel; S3: Observe the effect of rubber layer thickness on defects in silicon steel coating; S4: Observe the effect of rubber hardness on defects in silicon steel coating; S5: Based on the test results of S1-S4, design a coating scheme.

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