Straightening roll wear condition detection system and method

Abstract

This application provides a system and method for detecting the wear condition of a straightening roller. The method includes: conveying a target sheet to a preset position in a target straightening machine via a conveying mechanism; the ductility of the target sheet meets a preset ductility requirement; when the target sheet is determined to be at the preset position in the target straightening machine, generating a first control command via a controller to cause the straightening roller of the target straightening machine to apply pressure to the target sheet according to the first control command, and sending a second control command to the conveying mechanism after a preset time; removing the target sheet from the target straightening machine via the conveying mechanism according to the second control command and conveying it to a measuring device; measuring the distance between the maximum deformation point of the target sheet and a reference position of the target sheet via the measuring device; and determining the wear condition of the straightening roller based on the difference between the distance and a standard value via the controller.

Description

Technical Field

[0001] This application relates to the field of instrument testing technology, and in particular to a system and method for detecting the wear condition of straightening rollers. Background Technology

[0002] A straightening machine is a device used to straighten metal profiles, bars, tubes, wires, etc. A straightening machine typically has two rows of straightening rollers, though the number may vary. The straightening rollers compress the bar or other material, changing its straightness. Therefore, the straightening rollers are the core components of the straightening machine, determining its working effect. However, during the operation of the straightening machine, wear occurs on the straightening rollers. In other words, the straightening rollers are core consumable parts. Straightening rollers require high precision, have a special composition, and are expensive. During use, they experience irregular wear depending on the operating conditions. Therefore, periodically measuring and monitoring the wear of the working rollers is an important part of straightening machine maintenance.

[0003] Currently, wear detection of straightening rollers in a straightening machine typically requires disassembling the roller box of the straightening machine to expose the straightening rollers. Then, appropriate measuring tools are used to inspect their dimensions and wear condition. The entire process is labor-intensive and can take several hours. This requires significant downtime and has a substantial impact on the normal operation of the entire production line. Summary of the Invention

[0004] This application provides a system and method for detecting the wear condition of straightening rollers, which can avoid affecting the normal production of the production line when detecting the wear condition of straightening rollers.

[0005] In a first aspect, this application provides a straightening roll wear condition detection system, the straightening roll wear condition detection system comprising: a conveying mechanism, a measuring device, and a controller; the controller is communicatively connected to the conveying mechanism and the measuring device;

[0006] The conveying mechanism is used to transport the target sheet to a preset position in the target straightening machine; the ductility of the target sheet meets the preset ductility requirements;

[0007] The controller is used to generate a first control command when it is determined that the target plate is located at a preset position in the target straightening machine, so that the straightening roller of the target straightening machine applies pressure to the target plate according to the first control command, and sends a second control command to the conveying mechanism after a preset time.

[0008] The conveying mechanism is also used to remove the target sheet from the target straightening machine and transfer it to the measuring device according to the second control command;

[0009] The measuring device is used to measure the distance between the maximum deformation point of the target plate and the reference position of the target plate;

[0010] The controller is also used to determine the wear condition of the straightening roller based on the difference between the spacing and the standard value.

[0011] In some possible implementations, the straightening roll wear condition detection system further includes: a pressure sensor;

[0012] The conveying mechanism is also used to place the pressure sensor on the straightening roller at the edge of the straightening machine;

[0013] The controller is also configured to send a calibration command to the target straightener, so that the target straightener presses down the straightening roller according to the calibration command and applies pressure to the pressure sensor;

[0014] The controller is also used to adjust the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure on the plurality of pressure sensors is within a preset pressure range, and the pressure difference between any two pressure sensors is within a preset error range.

[0015] The controller is also used to send a calibration end command issued by the controller to the target straightener, so that the target straightener raises the straightening roller.

[0016] In some possible implementations, the number of pressure sensors is four, and the four pressure sensors are respectively placed in the following locations:

[0017] The point where the upper straightening roller at the entrance of the straightener intersects with the centerline of the first lower straightening roller;

[0018] The point where the centerline of the upper straightening roller intersects with the centerline of the second lower straightening roller;

[0019] The point where the centerline of the upper straightening roller intersects with the centerline of the first lower straightening roller;

[0020] The point where the centerline of the upper straightening roller intersects with the centerline of the second lower straightening roller;

[0021] Wherein, the first lower straightening roller is the straightening roller at the drive-side inlet below the straightener, and the second lower straightening roller is the straightening roller at the operation-side inlet below the straightener.

[0022] In some possible implementations, the measuring device includes a reference plate and a distance measuring instrument;

[0023] The measuring device is also used to place the reference plate perpendicular to the surface of the target plate at the point of maximum deformation of the target plate.

[0024] The measuring device is also used to measure the distance between the reference straight plate placed at the target position and the position of maximum deformation of the target plate using the ranging instrument;

[0025] The target position is the location perpendicular to the surface of the target plate, at the point of maximum deformation of the target plate.

[0026] In some possible implementations, the controller is also configured to issue a replacement prompt message for the straightener roller box when the wear condition does not meet preset conditions.

[0027] Secondly, this application provides a method for detecting the wear condition of a straightening roll, the method being applied to a straightening roll wear condition detection system, the method comprising:

[0028] The target sheet is conveyed to a preset position in the target straightening machine by a conveying mechanism; the ductility of the target sheet meets the preset ductility requirements;

[0029] When the target plate is determined to be in a preset position in the target straightening machine, a first control command is generated by the controller so that the straightening roller of the target straightening machine applies pressure to the target plate according to the first control command, and after a preset time, a second control command is sent to the conveying mechanism.

[0030] The transport mechanism removes the target sheet from the target straightening machine and transfers it to the measuring device according to the second control command.

[0031] The distance between the maximum deformation point of the target plate and the reference position of the target plate is measured by a measuring device.

[0032] The controller determines the wear condition of the straightening roller based on the difference between the spacing and the standard value.

[0033] In some possible implementations, before the target sheet is conveyed to a predetermined position in the target straightening machine via a transport mechanism, the method further includes:

[0034] Multiple pressure sensors are placed on the straightening rollers at the edge of the straightening machine via a conveying mechanism;

[0035] A calibration command is sent to the target straightener via a communication device, so that the target straightener presses down the straightening roller according to the calibration command and applies pressure to the pressure sensor;

[0036] The controller adjusts the straightening roller based on the pressure values ​​fed back by the pressure sensors, so that the pressures on the multiple pressure sensors are all within a preset pressure range, and the pressure difference between any two pressure sensors is within a preset error range.

[0037] The controller sends a calibration end command to the target straightener, causing the target straightener to raise the straightening roller.

[0038] In some possible implementations, adjusting the straightening rollers by the controller based on the pressure values ​​fed back by the pressure sensors, so that the pressures on the plurality of pressure sensors are all within a preset pressure range and the pressure difference between any two pressure sensors is within a preset error range, includes:

[0039] The controller presses down the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure received by the multiple pressure sensors is within a first preset pressure range;

[0040] The controller adjusts the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure difference between two of the plurality of pressure sensors is within a preset error range.

[0041] In some possible implementations, after adjusting the straightening roller by the controller based on the pressure values ​​fed back by the pressure sensors to ensure that the pressure difference between two of the plurality of pressure sensors is within a preset error range, the method further includes:

[0042] The controller continues to press down the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure received by the multiple pressure sensors is within the second preset pressure range;

[0043] The controller adjusts the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure difference between two of the plurality of pressure sensors is within a preset error range.

[0044] In some possible implementations, after determining the wear condition of the straightening roller by the controller based on the difference between the spacing and a standard value, the method further includes:

[0045] The controller determines the wear status of all straightening rollers in the straightening machine. If the wear status does not meet the preset conditions, a replacement prompt message for the straightening machine roller box is issued.

[0046] The straightening roller wear condition detection system and method provided in this application utilizes a conveying mechanism to place a target sheet material with ductility meeting a preset ductility requirement into a preset position within a target straightening machine. Then, after confirming the target sheet material is in the preset position, a controller generates a first control command to cause the straightening roller of the target straightening machine to apply pressure to the target sheet material according to the first control command. After a preset time, allowing the target sheet material to deform, a second control command is sent to the conveying mechanism to remove the target sheet material from the target straightening machine. The wear condition of the straightening roller is determined by measuring the distance between the maximum deformation point of the target sheet material and a reference position of the target sheet material. This eliminates the need to remove the straightening machine from the production line or disassemble the work roll box, reducing the time and workload required for measurement and avoiding disruption to normal production. Attached Figure Description

[0047] This application can be better understood from the following description of specific embodiments in conjunction with the accompanying drawings, wherein:

[0048] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings, wherein the same or similar reference numerals denote the same or similar features.

[0049] Figure 1 This is a schematic diagram of a straightening roller wear condition detection system provided in one embodiment of this application;

[0050] Figure 2 This is a schematic flowchart of a method for detecting the wear condition of a straightening roller provided in one embodiment of this application;

[0051] Figure 3 This is a schematic diagram of the straightening roller wear condition detection operation process provided in one embodiment of this application. Detailed Implementation

[0052] The features and exemplary embodiments of various aspects of this application will be described in detail below. To make the objectives, technical solutions, and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain this application and not to limit it. For those skilled in the art, this application can be implemented without some of these specific details. The following description of the embodiments is merely to provide a better understanding of this application by illustrating examples.

[0053] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that includes said element.

[0054] To address the problems of the prior art, this application provides a straightening roll wear condition detection system. The straightening roll wear condition detection system provided in this application will be described below.

[0055] Figure 1 A flowchart illustrating a method for detecting the wear condition of a straightening roll according to an embodiment of this application is shown. Figure 1 As shown, the above-mentioned straightening roller wear condition detection system includes: a conveying mechanism 101, a measuring device 103, and a controller 102; the controller 102 is communicatively connected to the conveying mechanism 101 and the measuring device 103.

[0056] The aforementioned conveying mechanism 101 is used to convey the target sheet to a preset position in the target straightening machine; the ductility of the target sheet meets the preset ductility requirements.

[0057] The controller 102 is used to generate a first control command when it is determined that the target plate is located at a preset position in the target straightening machine, so that the straightening roller of the target straightening machine applies pressure to the target plate according to the first control command, and sends a second control command to the conveying mechanism 101 after a preset time.

[0058] The aforementioned conveying mechanism 101 is also used to remove the target plate from the target straightening machine and transfer it to the measuring device 103 according to the aforementioned second control command.

[0059] The measuring device 103 is used to measure the distance between the maximum deformation point of the target plate and the reference position of the target plate.

[0060] The controller 102 is also used to determine the wear condition of the straightening roller based on the difference between the above-mentioned spacing and the standard value.

[0061] The straightening roller wear detection system provided in this application uses a conveying mechanism 101 to place a target sheet material with a preset ductility requirement into a preset position in a target straightening machine. After confirming that the target sheet material is in the preset position, a controller 102 generates a first control command to cause the straightening roller of the target straightening machine to apply pressure to the target sheet material according to the first control command. After a preset time, when the target sheet material deforms, a second control command is sent to the conveying mechanism 101 to remove the target sheet material from the target straightening machine. The wear condition of the straightening roller is determined by measuring the distance between the maximum deformation point of the target sheet material and the reference position of the target sheet material using a measuring device 103. This eliminates the need to remove the straightening machine from the production line or disassemble the work roll box, reducing the time and workload required for measurement and avoiding disruption to normal production.

[0062] Based on the above-mentioned straightening roll wear condition detection system Figure 2 A flowchart illustrating a method for detecting the wear condition of a straightening roll according to an embodiment of this application is shown. Figure 2 As shown, the above method is applied to the above straightening roll wear condition detection system, and the above method includes the following steps: S201 to S205.

[0063] S201: The target sheet is conveyed to a preset position in the target straightening machine by the conveying mechanism 101; the ductility of the target sheet meets the preset ductility requirements.

[0064] In practice, the ductility of the sheet material is tested in advance based on its physical properties, and a target sheet material whose ductility meets the preset ductility requirements is selected. Then, the conveying mechanism 101 accurately conveys the target sheet material to the preset position of the target straightening machine.

[0065] S202: When it is determined that the target plate is located at a preset position in the target straightening machine, the controller 102 generates a first control command so that the straightening roller of the target straightening machine applies pressure to the target plate according to the first control command, and sends a second control command to the conveying mechanism 101 after a preset time.

[0066] In a specific implementation, the controller 102 generates a first control command, which adjusts the position and pressure of the straightening rollers to appropriately change the shape of the sheet metal. The first control command includes a setting for the duration of pressure application. After the preset duration is reached, the controller 102 sends a second control command to the conveying mechanism 101.

[0067] S203: The target plate is taken out from the target straightening machine by the conveying mechanism 101 according to the second control command and transferred to the measuring device 103.

[0068] In a specific implementation, the conveying mechanism 101 takes the plate out of the straightening machine according to the second control command and conveys it to the position of the measuring device 103.

[0069] S204: The distance between the maximum deformation point of the target plate and the reference position of the target plate is measured by the measuring device 103.

[0070] In a specific implementation, the measuring device 103 can be a sensor, a laser rangefinder, or a visual ranging system. The measuring device 103 accurately measures the distance between the plate material at its point of maximum deformation and its reference position. The measured data is then transmitted to the controller 102 for subsequent analysis.

[0071] S205: The wear condition of the straightening roller is determined by the controller 102 based on the difference between the above-mentioned spacing and the standard value.

[0072] In its implementation, the controller 102 receives and analyzes the measurement data, calculating the difference between the actual deformation of the sheet material and its ideal shape. Based on these differences, the controller 102 can infer the degree of wear of the straightening rollers.

[0073] The method for detecting the wear state of straightening rollers provided in this application embodiment utilizes a conveying mechanism 101 to place a target sheet material with ductility meeting a preset ductility requirement into a preset position in a target straightening machine. Then, after confirming that the target sheet material is in the preset position within the target straightening machine, a controller 102 generates a first control command to cause the straightening rollers of the target straightening machine to apply pressure to the target sheet material according to the first control command. After a preset time period, allowing the target sheet material to deform, a second control command is sent to the conveying mechanism 101, causing the conveying mechanism 101 to remove the target sheet material from the target straightening machine. The wear state of the straightening rollers is determined by using a measuring device 103 to measure the distance between the maximum deformation point of the target sheet material and a reference position of the target sheet material. This method eliminates the need to remove the straightening machine from the production line or disassemble the work roll box, reducing the time and workload required for measurement and avoiding disruption to normal production line operations.

[0074] To make the wear condition detection results more accurate, in some embodiments, the above-mentioned straightening roll wear condition detection system further includes a pressure sensor.

[0075] The aforementioned conveying mechanism 101 is also used to place the pressure sensor at the straightening roller at the edge of the straightening machine.

[0076] The controller 102 is also used to send a calibration command to the target straightener so that the target straightener presses down the straightening roller according to the calibration command and applies pressure to the pressure sensor.

[0077] The controller 102 is also used to adjust the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure on the plurality of pressure sensors is within a preset pressure range, and the pressure difference between each pair of pressure sensors is within a preset error range.

[0078] The controller 102 is also used to send a calibration end command issued by the controller 102 to the target straightener so that the target straightener raises the straightening roller.

[0079] The embodiments described above in this application use pressure sensors. A conveying mechanism 101 places the pressure sensors on the straightening rollers at the edge of the straightening machine. Then, a controller 102 sends a calibration command to the target straightening machine, causing the target straightening machine to press down on the straightening rollers, thereby applying pressure to the pressure sensors. The controller 102 adjusts the straightening rollers based on the pressure values ​​fed back from the pressure sensors, ensuring that the pressure on the multiple pressure sensors is within a preset pressure range and the pressure difference between any two pressure sensors is within a preset error range, thus performing calibration. After calibration, the controller 102 sends a calibration end command to the target straightening machine, causing the target straightening machine to raise the straightening rollers. Pre-calibrating the straightening machine using pressure sensors ensures that the positions of the straightening rollers in the straightening machine are all in standard positions, avoiding any impact on subsequent steps and making the wear condition detection results more accurate.

[0080] In order to make the wear condition detection results more accurate, in some embodiments, before S201, the above method may also include the following steps: S2011 to S2014.

[0081] S2011: Multiple pressure sensors are placed at the straightening rollers at the edge of the straightening machine via the conveying mechanism 101.

[0082] In practice, pressure sensors are installed on the straightening rolls, for example, on the edge or contact surface of the rolls. It is also ensured that each sensor is securely fixed in the correct position to accurately detect the pressure applied to the straightening rolls.

[0083] S2012: A calibration command is sent to the target straightener via a communication device, so that the target straightener presses down the straightening roller according to the calibration command and applies pressure to the pressure sensor.

[0084] In a specific implementation, the controller 102 sends a calibration command to the target straightener through its communication module. The calibration command may include the magnitude and speed of the downward pressure to ensure that the straightening roller can apply the corresponding pressure to the pressure sensor according to the predetermined pressure level.

[0085] S2013: The controller 102 adjusts the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure on the multiple pressure sensors is within a preset pressure range, and the pressure difference between each pair of pressure sensors is within a preset error range.

[0086] In practice, the pressure sensor provides real-time feedback on the pressure applied by the straightening roller. The controller 102 receives the feedback data from the sensor and adjusts the force and position of the straightening roller controlled by the hydraulic system or electric actuator according to the set algorithm and logic. This ensures that the pressure on each sensor is within the preset range, while keeping the pressure difference between any two pressure sensors within the allowable error range.

[0087] S2014: The calibration end command issued by the controller 102 is sent to the target straightener via the controller 102, so that the target straightener raises the straightening roller.

[0088] In a specific implementation, the controller 102 generates a calibration completion command and sends it to the target straightener. Upon receiving the command, the target straightener stops the downward pressing operation of the straightening roller and raises the straightening roller.

[0089] The embodiments described above in this application use pressure sensors. A conveying mechanism places the pressure sensors on the straightening rollers at the edge of the straightening machine. Then, the controller 102 sends a calibration command to the target straightening machine, causing the target straightening machine to press down on the straightening rollers, thereby applying pressure to the pressure sensors. The controller 102 adjusts the straightening rollers based on the pressure values ​​fed back from the pressure sensors, ensuring that the pressure on the multiple pressure sensors is within a preset pressure range, and that the pressure difference between any two pressure sensors is within a preset error range, thus performing calibration. After calibration, the controller 102 sends a calibration end command to the target straightening machine, causing the target straightening machine to raise the straightening rollers. Pre-calibrating the straightening machine using pressure sensors ensures that the positions of the straightening rollers in the straightening machine are all in standard positions, avoiding any impact on subsequent steps and making the wear condition detection results more accurate.

[0090] To ensure accurate calibration, in some embodiments, four pressure sensors are used, each positioned at one of the following locations: the intersection of the centerline of the upper straightening roller at the straightener inlet and the centerline of the first lower straightening roller; the intersection of the centerline of the upper straightening roller and the centerline of the second lower straightening roller; the intersection of the centerline of the upper straightening roller and the centerline of the first lower straightening roller; and the intersection of the centerline of the upper straightening roller and the centerline of the second lower straightening roller. The first lower straightening roller is the straightening roller at the drive-side inlet of the straightener, and the second lower straightening roller is the straightening roller at the operation-side inlet of the straightener.

[0091] The above-described embodiments of this application use four pressure sensors, which are respectively placed at the intersection of the upper straightening roller and the center line of the first lower straightening roller at the entrance of the straightening machine, the intersection of the upper straightening roller and the center line of the second lower straightening roller, the intersection of the upper straightening roller and the center line of the first lower straightening roller, and the intersection of the upper straightening roller and the center line of the second lower straightening roller at the entrance of the straightening machine, so as to accurately perform calibration.

[0092] In order to quickly measure the distance between the maximum deformation point of the target material and the reference position of the target material, in some embodiments, the measuring device 103 includes a reference plate and a distance measuring instrument; the measuring device 103 is also used to place the reference plate perpendicular to the surface of the target material at the maximum deformation point of the target material; the measuring device 103 is also used to measure the distance between the reference plate placed at the target position and the maximum deformation point of the target material using the distance measuring instrument; the target position is the position perpendicular to the surface of the target material at the maximum deformation point of the target material.

[0093] In the embodiments of this application, the measuring device 103 includes a reference plate and a distance measuring instrument. The measuring device 103 places the reference plate perpendicular to the surface of the target plate and at the point of maximum deformation of the target plate. Then, the distance measuring instrument measures the distance between the reference plate placed at the target position and the point of maximum deformation of the target plate. This allows for the rapid measurement of the distance between the point of maximum deformation of the target plate and the reference position of the target plate.

[0094] In order to replace the roller box of the straightening machine in a timely manner when the wear condition of the straightening roller is poor, and to avoid the wear of the straightening roller affecting production, in some embodiments, the controller 102 is also used to issue a replacement prompt message for the straightening roller box when the wear condition does not meet the preset conditions.

[0095] Accordingly, following S205 above, the method further includes:

[0096] The controller 102 determines the wear status of all straightening rollers in the straightening machine. If the wear status does not meet the preset conditions, it issues a replacement prompt message for the straightening machine roller box.

[0097] In practical implementation, wear sensors can be installed on each straightening roll of the straightening machine. These sensors can be photoelectric sensors, laser sensors, or contact sensors, monitoring the surface condition and wear degree of the rolls in real time. The controller 102, connected to the sensors, periodically collects wear data for each roll. This data includes parameters such as the roll diameter and surface roughness. Wear standards are preset in the controller. For example, when the roll diameter decreases to a certain threshold or the surface roughness exceeds a specific value, the roll is considered to need replacement. Once it is found that the wear condition of one or more straightening rolls does not meet the preset conditions, the controller generates a replacement prompt message and issues the aforementioned replacement prompt message for the straightening machine roll box.

[0098] The embodiments described above in this application use a controller 102 to issue a replacement prompt for the straightener roller box when the wear condition does not meet preset conditions. This allows for timely replacement of the straightener roller box when the straightener roller wear condition is poor, preventing the wear of the straightener roller from affecting production.

[0099] In order to quickly calibrate the straightening machine, in some embodiments, the above-mentioned S2013 may include the following steps: S20131 to S20132.

[0100] S20131: The controller 102 presses down the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure received by the plurality of pressure sensors is within the first preset pressure range.

[0101] In its implementation, after receiving data from the pressure sensors, the controller 102 analyzes the pressure values ​​returned by each sensor to determine whether the pressure from all sensors is within a preset first range. If some pressure values ​​are found to be below the preset range, the controller calculates the amount of pressure that needs to be applied to ensure that the pressure returned by all pressure sensors reaches the preset range. The controller then uses a drive mechanism to press down the straightening roller until the pressure from all sensors reaches or approaches the preset first pressure range.

[0102] S20132: The controller 102 adjusts the straightening roller based on the pressure value fed back by the pressure sensor to make the pressure difference between two of the plurality of pressure sensors within a preset error range.

[0103] In the specific implementation, after the pressure is applied, the controller 102 reads the data from all pressure sensors again and calculates the pressure difference between each pair of sensors. It checks whether these pressure differences are within a preset error range. If any pressure difference is found to be outside the range, the controller identifies the sensor pair that needs further adjustment. Based on the calculated pressure difference, the controller issues a fine-tuning command to the straightening roller. By finely adjusting the position of the straightening roller or the applied pressure, the pressure difference between the relevant pressure sensors is made to meet the preset requirements and remain within the preset error range.

[0104] The embodiments described above utilize the controller 102 to press down the straightening roller based on the pressure values ​​fed back by the pressure sensors, so that the pressure received by the plurality of pressure sensors is within a first preset pressure range. Then, based on the adjustment of the straightening roller, the pressure difference between two of the plurality of pressure sensors is kept within a preset error range. This allows for rapid calibration of the straightening machine.

[0105] In order to accurately calibrate the straightening machine, in some embodiments, after S20132, the method may further include the following steps: S20133 to S20134.

[0106] S20133: The controller 102 continues to press down the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure received by the multiple pressure sensors is within the second preset pressure range.

[0107] In its implementation, the controller 102 collects the latest pressure data from each pressure sensor. The controller analyzes the pressure value of each sensor, checking if they are all within a first preset pressure range, identifying which sensors have pressure values ​​below this range, and determining the amount of pressure required to further press down on the straightening roller. Then, based on the difference between the current pressure value and a second preset pressure range, the required amount of pressure is calculated. The controller applies additional pressure to the straightening roller via an electric or hydraulic system.

[0108] As another implementation, during the pressing process, the controller continuously monitors pressure changes to ensure real-time adjustments. After pressing is complete, the controller reads the pressure sensor data again to confirm that the pressure values ​​of all sensors have entered the second preset pressure range. If any sensor fails to meet the standard, the system will repeat the above steps until the conditions are met.

[0109] S20134: The controller 102 adjusts the straightening roller based on the pressure value fed back by the pressure sensor to make the pressure difference between two of the plurality of pressure sensors within a preset error range.

[0110] In a specific implementation, the controller 102 reads the latest pressure values of all pressure sensors, calculates the pressure difference between every two sensors, and checks whether the calculated pressure difference is within a preset error range. Any pressure difference situation exceeding this range is identified for adjustment. For a pair of sensors with an out-of-range pressure difference, the controller calculates the required adjustment amount to bring the pressure difference of these sensors back within the preset range.

[0111] As another implementation manner, the controller precisely adjusts the position of the straightening roll or the applied pressure through a driving mechanism. A step-by-step adjustment method can be adopted to ensure the smoothness and accuracy during the adjustment process. After each adjustment, the controller calculates the pressure difference again based on the newly feedback pressure value to ensure that the pressure differences between all relevant pressure sensors are ultimately within the preset error range.

[0112] Based on the pressure of the pressure sensor reaching the first preset pressure range, the above-mentioned implementation manner of the embodiment of the present application continues to press down the above-mentioned straightening roll through the controller 102 so that the pressures received by the above-mentioned multiple pressure sensors are all within the second preset pressure range, and then adjusts the above-mentioned straightening roll based on the pressure values feedback by the pressure sensors so that the pressure difference between two pressure sensors among the above-mentioned multiple pressure sensors is within the preset error range. It can accurately calibrate the straightening machine.

[0113] As another implementation manner, in this embodiment, the corresponding electric down-pressing type parallel roll straightening machine roll box has a three-layer roll system, 9 working rolls with a roll diameter of 200 mm, and 7 bending rolls. Before starting the test, prepare three aluminum plates with a thickness of 10 mm, a width of 250 mm, and a length of 6000 mm, and 4 pressure sensors supporting the straightening machine. First, raise the roll gap to 60 mm, and then place the calibration blocks on the roll surfaces at the four corners of the straightening machine. The side with the boss of the calibration block faces upward. The specific positions are as follows: for the two calibration blocks at the entrance, they are placed at the intersection of the midline of the first working roll at the entrance of the upper platform and the first bending roll (the calibration block placed at the driving side entrance) and the seventh bending roll (the calibration block placed at the operating side entrance); for the two calibration blocks at the exit, they are placed at the intersection of the midline of the first working roll at the exit of the upper platform and the first bending roll (the calibration block placed at the driving side entrance) and the seventh bending roll (the calibration block placed at the operating side entrance). After the calibration blocks are placed, press the roll gap to 50 mm. Manually and slowly press down the roll gap to make all four calibration blocks show pressure, and the values are all within 1000 Kg, and the pressure difference between any two calibration blocks is not greater than 200 Kg. Manually continue to press down to make the pressures of all four calibration blocks between 2000 Kg and 3000 Kg, and the pressure difference between any two calibration blocks is not greater than 200 Kg. Continue to press down to make the pressures of all four calibration blocks within 8000 KG - 9000 KG, and the pressure difference between any two calibration blocks is within 200 Kg, thus completing the roll gap calibration.

[0114] After the roll gap is calibrated, the platform on the straightener can be considered to be in a horizontal plane. At this point, the next step can be performed: lower all bending rolls 1-7 of the straightener to the 0 position, ensuring the lower straightener roll box is horizontal. Then, begin the experiment. Select three aluminum plates (10mm thick, 250mm wide, 6000mm long) and place them parallel to the infeed direction, directly above the center of the guard plate on bending rolls 2, 4, and 6. The heads of the aluminum plates should extend 0.5m beyond the straightener, and the heads of the three aluminum plates should be horizontal. Then, simultaneously press down the inlet and outlet roll gaps of the straightener by 3mm, maintaining this pressure for 10 minutes. Afterward, raise the roll gaps to 50mm, remove the aluminum plates, and begin measuring the deformation. Figure 3 As shown, a straight steel ruler 301 and a standard gap gauge 302 are used for measurement. The steel ruler is placed horizontally between the two peaks, perpendicular to the surface of the aluminum plate. The gap gauge is used to measure the distance between the steel ruler and the position of maximum deformation of the aluminum plate. This value can be considered as the approximate value of the maximum wear at the corresponding position of the roller box. By measuring the deformation of the three aluminum plates respectively, the overall wear of the roller box can be obtained.

[0115] The standard measurement value for a wear-free roller box is 7mm. Based on the measurement value, roller box wear is roughly divided into three levels: 1. 80% of the measurements are ≥6.5mm, the roller box is in good condition, and the straightening effect is unaffected; 2. 6.5mm < 80% of the measurements are ≥5.5mm, the roller box has some wear, the straightening effect is affected, and it is recommended to disassemble the roller box and replace the worn roller system; 3. 80% of the measurements are <6.5mm, the straightening roller box has failed, and the straightening effect has been severely degraded.

[0116] It should be clarified that this application is not limited to the specific configurations and processes described above and shown in the figures. For the sake of brevity, detailed descriptions of known methods are omitted here. In the above embodiments, several specific steps are described and shown as examples. However, the method process of this application is not limited to the specific steps described and shown. Those skilled in the art can make various changes, modifications, and additions, or change the order of steps, after understanding the spirit of this application.

[0117] It should also be noted that the exemplary embodiments mentioned in this application describe methods or systems based on a series of steps or apparatus. However, this application is not limited to the order of the above steps; that is, the steps can be performed in the order mentioned in the embodiments, or in a different order, or several steps can be performed simultaneously.

[0118] The aspects of this disclosure have been described above with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this disclosure. It should be understood that each block in the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a controller of a general-purpose computer, a special-purpose computer, or other programmable data processing apparatus to create a machine such that these instructions, executable via the controller of the computer or other programmable data processing apparatus, enable the implementation of the functions / actions specified in one or more blocks of the flowchart illustrations and / or block diagrams. Such a controller can be, but is not limited to, a general-purpose controller, a special-purpose controller, an application-specific controller, or a field-programmable logic circuit. It is also understood that each block in the block diagrams and / or flowchart illustrations, and combinations of blocks in the block diagrams and / or flowchart illustrations, can also be implemented by special-purpose hardware performing the specified functions or actions, or can be implemented by a combination of special-purpose hardware and computer instructions.

[0119] The above description is merely a specific implementation of this application. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, modules, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. It should be understood that the protection scope of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the protection scope of this application.

Claims

1. A system for detecting the wear condition of a straightening roller, characterized in that, The straightening roll wear condition detection system includes: a conveying mechanism, a measuring device, and a controller; the controller is communicatively connected to the conveying mechanism and the measuring device. The conveying mechanism is used to transport the target sheet to a preset position in the target straightening machine; the ductility of the target sheet meets the preset ductility requirements; The controller is used to generate a first control command when it is determined that the target plate is located at a preset position in the target straightening machine, so that the straightening roller of the target straightening machine applies pressure to the target plate according to the first control command, and sends a second control command to the conveying mechanism after a preset time. The conveying mechanism is also used to remove the target sheet from the target straightening machine and transfer it to the measuring device according to the second control command; The measuring device is used to measure the distance between the maximum deformation point of the target plate and the reference position of the target plate; The controller is also used to determine the wear condition of the straightening roller based on the difference between the spacing and the standard value; The straightening roller wear condition detection system further includes: a pressure sensor; the measuring device includes a reference plate and a distance measuring instrument; The conveying mechanism is also used to place the pressure sensor on the straightening roller at the edge of the straightening machine; The controller is also configured to send a calibration command to the target straightener, so that the target straightener presses down the straightening roller according to the calibration command and applies pressure to the pressure sensor; The controller is also used to adjust the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure on the multiple pressure sensors is within a preset pressure range, and the pressure difference between any two pressure sensors is within a preset error range. The controller is also used to send a calibration end command issued by the controller to the target straightener, so that the target straightener raises the straightening roller; The measuring device is also used to place the reference plate perpendicular to the surface of the target plate at the point of maximum deformation of the target plate. The measuring device is also used to measure the distance between the reference straight plate placed at the target position and the position of maximum deformation of the target plate using the ranging instrument; The target position is the location perpendicular to the surface of the target plate, at the point of maximum deformation of the target plate.

2. The straightening roller wear condition detection system according to claim 1, characterized in that, The number of pressure sensors is four, and the four pressure sensors are respectively placed in the following positions: The point where the upper straightening roller at the entrance of the straightener intersects with the centerline of the first lower straightening roller; The point where the centerline of the upper straightening roller intersects with the centerline of the second lower straightening roller; The point where the centerline of the upper straightening roller intersects with the centerline of the first lower straightening roller; The point where the centerline of the upper straightening roller intersects with the centerline of the second lower straightening roller; Wherein, the first lower straightening roller is the straightening roller at the drive-side inlet below the straightener, and the second lower straightening roller is the straightening roller at the operation-side inlet below the straightener.

3. The straightening roll wear condition detection system according to any one of claims 1 to 2, characterized in that, The controller is also used to issue a replacement prompt message for the straightener roller box when the wear condition does not meet the preset conditions.

4. A method for detecting the wear condition of a straightening roller, characterized in that, The method is applied to the straightening roll wear condition detection system as described in any one of claims 1 to 2, and the method includes: The target sheet is conveyed to a preset position in the target straightening machine by a conveying mechanism; the ductility of the target sheet meets the preset ductility requirements; When the target plate is determined to be in a preset position in the target straightening machine, a first control command is generated by the controller so that the straightening roller of the target straightening machine applies pressure to the target plate according to the first control command, and after a preset time, a second control command is sent to the conveying mechanism. The transport mechanism removes the target sheet from the target straightening machine and transfers it to the measuring device according to the second control command. The distance between the maximum deformation point of the target plate and the reference position of the target plate is measured by a measuring device. The wear condition of the straightening roller is determined by the controller based on the difference between the spacing and the standard value; The method further includes, prior to conveying the target sheet to a preset position in the target straightening machine via the conveying mechanism: Multiple pressure sensors are placed on the straightening rollers at the edge of the straightening machine via a conveying mechanism; A calibration command is sent to the target straightener via a communication device, so that the target straightener presses down the straightening roller according to the calibration command and applies pressure to the pressure sensor; The controller adjusts the straightening roller based on the pressure values ​​fed back by the pressure sensors, so that the pressures on the multiple pressure sensors are all within a preset pressure range, and the pressure difference between any two pressure sensors is within a preset error range. The controller sends a calibration end command to the target straightener, causing the target straightener to raise the straightening roller. The step of measuring the distance between the maximum deformation point of the target plate and the reference position of the target plate using a measuring device includes: The reference straight plate is placed perpendicular to the surface of the target plate and positioned at the point of maximum deformation of the target plate. The distance between the reference plate placed at the target position and the position of maximum deformation of the target plate is measured by the distance measuring instrument; the target position is the position perpendicular to the surface of the target plate and at the point of maximum deformation of the target plate.

5. The method for detecting the wear condition of straightening rollers according to claim 4, characterized in that, The step of adjusting the straightening roller by the controller based on the pressure values ​​fed back by the pressure sensors, so that the pressures on the multiple pressure sensors are all within a preset pressure range and the pressure difference between any two pressure sensors is within a preset error range, includes: The controller presses down the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure received by the multiple pressure sensors is within a first preset pressure range; The controller adjusts the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure difference between two of the plurality of pressure sensors is within a preset error range.

6. The method for detecting the wear condition of straightening rollers according to claim 5, characterized in that, After adjusting the straightening roller by the controller based on the pressure value fed back by the pressure sensor, so that the pressure difference between two of the plurality of pressure sensors is within a preset error range, the method further includes: The controller continues to press down the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure received by the multiple pressure sensors is within the second preset pressure range; The controller adjusts the straightening roller based on the pressure value fed back by the pressure sensor, so that the pressure difference between two of the plurality of pressure sensors is within a preset error range.

7. The method for detecting the wear condition of straightening rollers according to any one of claims 4 to 6, characterized in that, After determining the wear condition of the straightening roller by the controller based on the difference between the spacing and the standard value, the method further includes: The controller determines the wear status of all straightening rollers in the straightening machine. If the wear status does not meet the preset conditions, a replacement prompt message for the straightening machine roller box is issued.

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