Visualization system and method for harsh production environment during metal processing

Abstract

A metalworking system for a metal substrate includes a vision system for providing visual data regarding the metal substrate in a harsh environment. The harsh environment may at least partially conceal the metal substrate in the visible spectrum due to smoke, mist, etc. generated during metal working.

Description

[0001] Citation of Related Applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 371,795, filed on Aug. 18, 2022, and entitled "VISUALIZATION SYSTEMS AND METHODS FOR HARSH PRODUCTION ENVIRONMENTS DURING METAL PROCESSING", the content of which is hereby incorporated by reference in its entirety. Technical Field

[0003] This application relates to the metal processing of metals such as, but not limited to, aluminum and aluminum alloys. More specifically, this application relates to systems and methods for visualizing metal strips in harsh production environments during metal processing. Background Art

[0004] Metal processing systems for metal substrates can include multiple locations that create harsh environments due to the ongoing processes. Such harsh environments limit the operator's observation of the metal substrate and / or the processes being performed on the metal substrate, and the limited observation can lead to problems in the metal substrate and / or the processes because they cannot be seen. As an example, a rolling mill provides a harsh environment where thick smoke is generated, which greatly limits (or even makes impossible) the visualization of the rolling process. Such limited visibility can lead to problems such as, but not limited to, flatness problems and / or surface quality problems during threading. Summary of the Invention

[0005] The embodiments covered by this patent are defined by the following claims rather than by this summary of the invention. This summary of the invention is a high-level overview of various embodiments and introduces some concepts that will be further described in the following detailed description section. This summary of the invention is not intended to identify the 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. The subject matter should be understood by reference to the 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 vision system for a harsh environment that obscures at least a portion of a metal substrate in the visible spectrum. The vision system includes at least one camera for detecting the metal substrate in the harsh environment and providing visual data of the metal substrate in the harsh environment.

[0007] According to some embodiments, a metalworking system includes a workstation for machining a metal substrate and creating a harsh environment during the metalworking. The harsh environment can include smoke or mist that at least partially obscures the metal substrate at the workstation. The metalworking system also includes a vision system having at least one camera for detecting the metal substrate in the harsh environment at the workstation and providing visual data of the metal substrate in the harsh environment at the workstation.

[0008] According to various embodiments, a method of machining a metal substrate with a metalworking system includes moving the metal substrate in a harsh environment that obscures at least a portion of the metal substrate in the visible spectrum. The method also includes detecting the metal substrate in the harsh environment using at least one camera of the vision system and providing visual data of the metal substrate in the harsh environment using the at least one camera.

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

[0010] This specification refers to the following drawings, where like reference numerals in different drawings are intended to illustrate the same or similar components.

[0011] Figure 1 is a side view of a metalworking system with a visualization system according to an embodiment.

[0012] Figure 2 is an end view of another metalworking system with a visualization system according to an embodiment.

[0013] Figure 3A is a photograph of a location of a portion of a metalworking system using a visible spectrum camera.

[0014] Figure 3B is of a location of a Figure 3A using a visualization system according to an embodiment.

[0015] Figure 3C is of a location of a Figure 3A using another visualization system according to an embodiment.

[0016] Figure 4 is a photograph of a portion of a metalworking system using a visualization system according to an embodiment.

[0017] Figure 5A photograph of a part of a metalworking system using a visualization system according to an embodiment.

[0018] Figure 6 A photograph of a part of a metalworking system using a visualization system according to an embodiment. Detailed Description

[0019] Visualization systems and methods for harsh environments during metalworking are described herein. In certain embodiments, the visualization systems and methods described herein can be used for metalworking of aluminum and aluminum alloys, although in other embodiments any type of metal substrate can be processed. The visualization systems and methods described herein allow visualization of areas in a metalworking system that would otherwise be obscured or hidden in the visible spectrum (e.g., due to smoke, mist, etc.). In certain embodiments, the visualization system includes one or more infrared cameras. The infrared cameras can be configured to detect different spectral ranges from near-infrared (NIR) to long-wave infrared (LWIR), and in certain embodiments, at least one camera is optionally an LWIR camera or a short-wave infrared (SWIR) camera. Visual data from one or more infrared cameras can be provided to an operator of the metalworking system to provide improved visualization of the process being performed compared to conventional techniques. The systems and methods described herein can also facilitate detection of problems / issues with the metal substrate and / or equipment that would otherwise be hidden in the visible spectrum during metalworking. In some embodiments, a control system can use the visual data from the visualization system to generate one or more control responses, such as but not limited to generating an alert, performing an analysis, and / or controlling equipment. Various other benefits and advantages can be achieved using the systems and methods provided herein, and the above advantages should not be considered limiting.

[0020] Figure 1 A metalworking system 100 is shown, where a workstation 102 creates a harsh environment 104 during machining of a metal substrate 106 (the machining movement is indicated by arrow 101). As used herein, a harsh environment refers to an environment where portions of the workstation 102 and / or the metal substrate 106 are obscured and / or otherwise unobservable in the visible spectrum due to thick smoke 108, mist, water on the metal, oil on the metal, and / or other environmental conditions caused by using the workstation 102 to machine metal and / or the surrounding environment.

[0021] In Figure 1In the illustrated embodiment, the workstation 102 is a rolling mill 110 having worktables 112A-B for rolling a metallic substrate 106. Each worktable 112A-B includes work rolls 113A-B and backup rolls 115A-B. In other embodiments, the workstation 102 can be a rolling mill having other configurations as desired, and / or the workstation 102 can be other equipment and / or locations of the metalworking system 100, such as but not limited to a casting pit for ingots, an ingot preparation area within a preheating furnace, a scrap bin, and / or other processing stations and / or combinations of processing stations as desired.

[0022] According to various embodiments, the metalworking system 100 includes a visualization system 114 for generating visual data of the workstation 102 and / or the metallic substrate 106 in the harsh environment 104. The visualization system 114 includes at least one camera 116, and in certain embodiments, the visualization system 114 can include multiple cameras. In various embodiments, one or more of the cameras 116 are infrared (or thermal) cameras that create images or visual data using infrared radiation. A visualization system 114 having an infrared camera as one or more of the cameras 116 allows visualization of the metallic substrate 106 and / or the equipment of the workstation 102 through thick smoke 108 and / or other environmental conditions of the harsh environment 104 (e.g., water on the metal, oil on the metal, etc.). The infrared camera can detect different ranges of infrared radiation, such as but not limited to NIR, SWIR, mid-wave infrared (MWIR), and / or LWIR. In one non-limiting example, the camera 116 is an LWIR camera. When multiple cameras 116 are included, the cameras 116 can be of the same type of infrared camera or different types of infrared cameras as desired. Optionally, one or more thermal cameras 116 can include various filters to further modify the visual data using infrared radiation.

[0023] One or more cameras 116 can be provided at various positions relative to the equipment of the workstation 102 and / or relative to the metallic substrate 106. As a non-limiting example, in Figure 1 the camera 116 is provided at an inter-stand position 118 and above the metallic substrate 106. Figure 2 An example of another metalworking system 100 is shown, and compared with Figure 1 in Figure 2 a visualization system 114 having two cameras 116 is shown. In Figure 2 the cameras 116 are provided offset from the edges 120, 122 of the metallic substrate 106. In other embodiments, other numbers and / or positions of cameras 116 can be utilized as desired.

[0024] Optionally, the visualization system 114 includes one or more controllers 124 (processing units and / or memory devices) communicatively coupled to one or more cameras 116 according to a desired use using various communication technologies. The processing unit of the controller can 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. One or more memory devices of the controller 124 can 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 medium, and not limited to any particular type of memory or number of memories, or the type of medium storing the memories. Additionally, as disclosed herein, the terms "storage medium", "storage device", or "memory" can refer to one or more memories for storing data, including read-only memory (ROM), random access memory (RAM), magnetic RAM, core memory, disk storage media, optical storage media, flash 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 instructions and / or data.

[0025] In certain embodiments, the controller 124 optionally includes an associated user interface 126, including but not limited to a human-machine user interface, such that the controller 124 can obtain information from and / or provide information to a user via the user interface 126. When included, the user interface 126 can be located on the controller 124 itself or at a location remote from the controller 124, such as but not limited to another location within the metalworking system 100. Additionally or alternatively, the controller 124 optionally can include various communication modules such that the controller 124 can receive and / or send information to user devices and / or other locations according to a desired use. Non-limiting examples of communication modules can include systems and mechanisms for implementing wired communication and / or wireless communication (e.g., industrial Ethernet, near field, cellular, Wi-Fi, Bluetooth Low Energy (BLE), GigE interface, enhanced small form-factor pluggable (SFP+), CoaXPress (CXP), Camera Link (CL), USB3 Vision (Universal Serial Bus 3), embedded vision applications, etc.).

[0026] The controller 124 of the visualization system 114 is communicatively coupled to one or more cameras 116 such that the controller 124 receives visual data from the cameras 116. The controller 124 can generate various control or output responses based on the visual data from the cameras 116. In some embodiments, the output response can include providing (e.g., via the user interface 126, via another interface, via a user device, etc.) a visual image of the workstation 102 and / or the metal substrate 106 in the harsh environment 104 to the operator, thereby allowing the operator to view the equipment and / or the metal substrate 106. Additionally or alternatively, the control response can include generating an alert or notification on the user interface 126 and / or other interfaces based on the visual data, and / or the control response can include controlling the equipment of the workstation 102 and / or the metalworking system 100.

[0027] In some embodiments, the control response generated by the controller 124 can be based on various analyses of the visual data from one or more cameras 116. As a non-limiting example, the controller 124 can generate a control response based on the detection of flatness issues in the visual data, based on the detection of the edges of the metal substrate in the visual data, based on the strip centering measurement in the visual data, based on the detection of defects in the metal substrate using the visual data, based on the substrate temperature gradient using the visual data, based on the roll thermal camber detected using the visual data, their combination, and / or according to other analyses desired. The controller 124 can perform various other analyses as desired, and the foregoing examples should not be considered limiting.

[0028] The output response from the controller 124 can provide an improved visualization of the harsh environment 104 to the operator of the metalworking system 100, which in turn can allow for improved control of the metal substrate 106 and / or the workstation 102 during metalworking. This improved visualization and control can improve the quality of the metal substrate 106. In certain embodiments, the output response from the controller 124 can be used to automatically control various devices associated with the workstation 102 to further improve the control of the processing and quality of the metal substrate 106.

[0029] Refer back to Figure 1, A method of processing a metal substrate 106 using a metalworking system 100 may include moving the metal substrate 106 along a processing direction 101 and through a harsh environment 104. The method includes using one or more cameras 116 to detect the metal substrate 106 in the harsh environment 104 and providing visual data using the detected infrared radiation. In certain embodiments, the method includes using a workstation 102 to process the metal substrate 106, and in one non-limiting example, the method includes using a rolling mill 110 as the workstation 102 to roll the metal substrate 106. In some embodiments, detecting the metal substrate 106 in the harsh environment 104 includes using a LWIR camera as the camera 116. Optionally, the method includes generating a control response based on the visual data from the camera 116. In some embodiments, generating the control response includes one or more of the following: providing visual data to an operator using a user interface 126 and / or other interfaces, generating an alert to the operator, and / or controlling devices of the workstation 102 and / or the metalworking system 100 based on the visual data. Various other processes may be performed using a controller 124, and the foregoing control processes should not be considered limiting.

[0030] As mentioned, Figure 2 Another example of the metalworking system 100 is shown, where the visualization system 114 includes two cameras 116 instead of a single camera 116, and the cameras 116 are offset from the edges 120, 122 of the metal substrate 106.

[0031] Figures 3A - 3C is a photograph of the in-between stand position 318 of the rolling mill 310. Figure 3A is an image 301A using a visible spectrum camera, Figure 3B is an image 301B using a first thermal camera according to an embodiment of the present disclosure, and Figure 3C is an image 301C using a second thermal camera according to an embodiment of the present disclosure. As shown by comparing Figure 3B and Figure 3C with Figure 3A it can be seen that the images 301B and 301C are capable of providing visualization of the metal substrate 306, but in the image 301A, the metal substrate is not visible due to thick smoke 308.

[0032] Figure 4 is an image 401 of a metal substrate 406 from a visualization system according to an embodiment. As Figure 4 shown, defects such as but not limited to delamination 409 can be detected and visualized, allowing an operator to control the processing of the metalworking system as needed or desired.

[0033] Figure 5 is an image 501 of a backup roll 515 from a visualization system according to an embodiment. AsFigure 5 As shown, the characteristics of the backup roll 515, such as roll thermal camber and cold spots, can be detected and visualized, thereby allowing an operator to control the processing of the metalworking system as needed or desired.

[0034] Figure 6 is an image 601 from the workstation 602 of the visualization system according to an embodiment, and shows a non-limiting example of an operator's output response, which includes a strip gradient measurement 617 of the metal substrate 606.

[0035] A collection of exemplary embodiments is provided below, including at least some embodiments explicitly listed as "Illustrations" that provide additional description of various exemplary embodiments in accordance with 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 example illustrations, but encompasses all possible modifications and variations within the scope of the claimed subject matter and its equivalents.

[0036] Illustration 1. A metalworking system comprising a vision system for concealing at least a portion of a metal substrate in a harsh environment in the visible spectrum, the vision system including at least one camera configured to detect the metal substrate in the harsh environment and provide visual data of the metal substrate in the harsh environment.

[0037] Illustration 2. The metalworking system according to any preceding or subsequent illustration or combination of illustrations, wherein the at least one camera is a thermal camera configured to detect the metal substrate based on infrared radiation of the metal substrate in the harsh environment.

[0038] Illustration 3. The metalworking system according to any preceding or subsequent illustration or combination of illustrations, wherein at least one camera is a long-wave infrared camera.

[0039] Illustration 4. The metalworking system according to any preceding or subsequent illustration or combination of illustrations, wherein at least one camera is a short-wave infrared camera.

[0040] Illustration 5. The metalworking system according to any preceding or subsequent illustration or combination of illustrations, further comprising a rolling mill for processing the metal substrate, wherein the rolling mill creates the harsh environment during rolling of the metal substrate.

[0041] Illustration 6. The metalworking system according to any preceding or subsequent illustration or combination of illustrations, wherein at least one camera is a long-wave infrared camera.

[0042] Example 7. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the vision system further includes a controller communicatively coupled to the at least one camera, the controller being configured to receive the vision data from the at least one camera and generate a control response based on the vision data.

[0043] Example 8. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the controller is configured to control a piece of metalworking equipment of the metalworking system as the control response based on the vision data.

[0044] Example 9. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the controller is configured to generate an alert on a user interface as the control response.

[0045] Example 10. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the controller is configured to detect at least one characteristic of the metal substrate in the harsh environment and generate the control response based on the detected at least one characteristic.

[0046] Example 11. A metalworking system comprising: a workstation for processing a metal substrate, the workstation creating a harsh environment during metalworking, the harsh environment including smoke that at least partially obscures the metal substrate at the workstation; and a vision system including at least one camera configured to detect the metal substrate in the harsh environment at the workstation and provide vision data of the metal substrate in the harsh environment at the workstation.

[0047] Example 12. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the workstation is a rolling mill.

[0048] Example 13. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the at least one camera is configured to detect the metal substrate based on infrared radiation of the metal substrate.

[0049] Example 14. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the at least one camera is a long-wave infrared camera.

[0050] Example 15. A metalworking system as described in any of the foregoing or subsequent examples or combinations of examples, wherein the at least one camera is a short-wave infrared camera.

[0051] Exemplification 16. A method of processing a metal substrate using a metal processing system, the method comprising: moving the metal substrate in a harsh environment that conceals at least a portion of the metal substrate in the visible spectrum; detecting the metal substrate in the harsh environment using at least one camera of a vision system; and using the at least one camera to provide visual data of the metal substrate in the harsh environment.

[0052] Exemplification 17. The method according to any preceding or subsequent exemplification or combination of exemplifications, wherein moving the metal substrate comprises rolling the metal substrate with a rolling mill of the metal processing system.

[0053] Exemplification 18. The method according to any preceding or subsequent exemplification or combination of exemplifications, wherein detecting the metal substrate comprises detecting the metal substrate in the infrared spectrum.

[0054] Exemplification 19. The method according to any preceding or subsequent exemplification or combination of exemplifications, wherein the at least one camera is a long-wave infrared camera, and wherein detecting the metal substrate comprises detecting the metal substrate in the long-wave infrared spectrum.

[0055] Exemplification 20. The method according to any preceding or subsequent exemplification or combination of exemplifications, further comprising generating a control response based on the visual data by controlling a piece of equipment or generating an alert on a user interface.

[0056] The subject matter of the embodiments is specifically described herein to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. Such description should not be construed as implying any particular order or arrangement among or between the various steps or elements, except when the order of individual steps or element arrangements is explicitly described. Directional references such as "upward", "downward", "top", "bottom", "left", "right", "front", and "rear" are intended to refer to the orientation shown and described in one (or more) of the figures in which the components and directions are mentioned. Throughout this disclosure, reference numerals with letters refer to specific instances of elements, and reference numerals without letters generally or collectively refer to elements. Thus, by way of example (not shown in the figures), device "12A" refers to an instance of a class of devices that may be collectively referred to as device "12", and any one of them may be collectively referred to as device "12". In the figures and the specification, the same reference numerals are intended to indicate the same elements. As used herein, unless the context clearly indicates otherwise, the meanings of "a", "an", and "the" include singular and plural referents.

[0057] The above aspects are merely possible examples of implementation manners, which are set forth only for the purpose of clearly understanding the principles of the present disclosure. Many variations and modifications can be made to the above one or more embodiments without materially departing from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included within the scope of the present disclosure herein, and all possible claims regarding aspects or combinations of elements or steps are intended to be supported by the present disclosure. In addition, although specific terms are employed herein and in the appended claims, these specific terms are used only in a general and descriptive sense and are not used for the purpose of limiting the described embodiments nor the appended claims.

Claims

1. A metal processing system comprising a vision system for a harsh environment that conceals at least a portion of a metal substrate in a visible light spectrum, the vision system comprising at least one camera configured to detect the metal substrate in the harsh environment and provide visual data of the metal substrate in the harsh environment.

2. The metal processing system of claim 1, wherein the at least one camera is a thermal camera configured to detect the metal substrate based on infrared radiation of the metal substrate in the harsh environment.

3. The metal processing system of claim 1, wherein the at least one camera is a long wave infrared camera.

4. The metal processing system of claim 1, wherein the at least one camera is a short wave infrared camera.

5. The metal processing system of claim 1, further comprising a rolling mill for processing the metal substrate, wherein the rolling mill generates the harsh environment during rolling of the metal substrate.

6. The metal processing system of claim 5, wherein the at least one camera is a long wave or short wave infrared camera.

7. The metalworking system of claim 1, wherein the vision system further comprises a controller communicatively coupled to the at least one camera, the controller being configured to receive the vision data from the at least one camera and to generate a control response based on the vision data.

8. The metalworking system of claim 7, wherein the controller is configured to control a piece of metalworking equipment of the metalworking system based on the visual data as the control response.

9. The metal processing system of claim 7, wherein the controller is configured to generate an alert on a user interface as the control response.

10. The metal processing system of claim 7, wherein the controller is configured to detect at least one characteristic of the metal substrate in the harsh environment and generate the control response based on the detected at least one characteristic.

11. A metal processing system, wherein include: a workstation for processing a metal substrate, the workstation generating a harsh environment during metal processing, the harsh environment including fumes that at least partially conceal the metal substrate at the workstation; as well as A vision system includes at least one camera configured to detect the metal substrate in the harsh environment at the workstation and provide visual data of the metal substrate in the harsh environment at the workstation.

12. The metal processing system of claim 11, wherein the workstation is a rolling mill.

13. The metal processing system of claim 11, wherein the at least one camera is configured to detect the metal substrate based on infrared radiation of the metal substrate.

14. The metal processing system of claim 13, wherein the at least one camera is a long wave infrared camera.

15. The metal processing system of claim 13, wherein the at least one camera is a short wave infrared camera.

16. A method for processing a metal substrate using a metal processing system, the method include: moving the metal substrate in a harsh environment that conceals at least a portion of the metal substrate in the visible light spectrum; inspecting the metal substrate in the harsh environment using at least one camera of a vision system; as well as Using the at least one camera provides visual data of the metal substrate in the harsh environment.

17. The method of claim 16, wherein moving the metal substrate comprises rolling the metal substrate with a rolling mill of the metal processing system.

18. The method of claim 16, wherein detecting the metal substrate comprises detecting the metal substrate in an infrared spectrum.

19. The method of claim 18, wherein the at least one camera is a long wave infrared camera, and wherein detecting the metal substrate comprises detecting the metal substrate in a long wave infrared spectrum.

20. The method of claim 16, further comprising generating a control response based on the visual data by controlling a piece of equipment or generating an alert on a user interface.

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