A size detection device for a polishing roller

Abstract

The application provides a size detection device for calendering roller processing, and relates to the technical field of calendering roller size detection, so as to solve the problems of complicated distance adjustment, inflexible base installation and low detection precision caused by the lack of matching software of the existing device. The device comprises a laser transmitter and a laser receiver arranged opposite to each other, a bottom plate with a guiding groove on the top surface, a sliding assembly comprising a driving motor, and a control software system, which comprises a pattern interference removal module, a data acquisition module, a distance self-adaptive adjustment module, a multi-dimensional parameter fusion calculation module, an error compensation module and a motor control module. The sliding assembly drives the laser transmitter to automatically adjust the distance, and the bottom surface of the bottom plate can accommodate a fixed plate to adapt to multiple scenes. The control software system removes the pattern interference, calculates the outer diameter, the cylindricity and the local concave-convex degree, and compensates for the environmental and mechanical errors. The device effectively solves the problems of the existing device, has strong software and hardware adaptability, significantly improves the detection efficiency and precision, is suitable for multiple specifications of calendering rollers, is convenient to operate and has high practicability.

Description

Technical Field

[0001] This invention relates to the field of heat-curing roller size detection technology, and in particular to a size detection device for heat-curing roller processing. Background Technology

[0002] During the production and processing of heat-pressing rollers, the accuracy of parameters such as outer diameter and cylindricity directly affects the heat-pressing effect of the fabric. Excessive dimensional deviation will lead to uneven heating of the fabric, resulting in local scorching or insufficient heat-pressing. Therefore, it is necessary to conduct precise dimensional inspection on the processed heat-pressing rollers to ensure that they meet the assembly and use requirements.

[0003] Existing laser inspection devices mostly mount the laser emitter and receiver directly on a straight base, and their positions are mainly fixed by bolts. This fixing method makes adjusting the distance between the laser emitter and receiver extremely cumbersome. When inspecting heat-pressing rollers of different diameters or lengths, multiple fixing bolts must be loosened first, the components must be manually moved to their approximate positions, and then the bolts must be tightened again for calibration. Not only is the adjustment process time-consuming and laborious, but it is also difficult to ensure the alignment of the two, which directly affects the inspection accuracy. At the same time, the mounting plate on the bottom surface of the base of such devices is mostly a fixed structure integrated with the base, which cannot be flexibly adjusted according to the inspection scenario.

[0004] Furthermore, existing devices rely solely on hardware to achieve basic detection functions, lacking a software system adapted to the hardware: detection data must be manually read and dimensional parameters calculated using external tools, resulting in low efficiency and susceptibility to human error; the detection results cannot be corrected in real time based on environmental interference (such as temperature and vibration), and the detection accuracy is significantly affected by external factors. Therefore, it is necessary to provide a dimensional detection device for heat-pressing roller processing to solve the above technical problems. Summary of the Invention

[0005] The present invention aims to solve the problems of cumbersome hardware spacing adjustment, inflexible base installation, and low data processing efficiency and insufficient detection accuracy in the existing heat-curing roller detection device, and provides a dimension detection device for heat-curing roller processing that is deeply compatible with hardware and software, has high detection convenience, excellent accuracy and intelligence.

[0006] To solve the above-mentioned technical problems, the present invention provides a dimension detection device for heat-curing roller processing, comprising a laser emitter and a laser receiver arranged opposite to each other;

[0007] The laser emitter has first bolt holes arranged in a triangular pattern on both sides. The laser emitter and the laser receiver are provided with a base plate at their bottom ends. The top surface of the base plate has a guide groove at the laser emitter. A sliding assembly is provided in the guide groove. The sliding assembly includes a drive motor. Multiple mounting holes are evenly provided on the top surface of the base plate between the guide groove and the laser receiver. The laser receiver is installed at one end of the top surface of the base plate.

[0008] The device also includes a control software system that is communicatively connected to the drive motors in the laser emitter, laser receiver, and sliding assembly;

[0009] The control software system includes a pattern interference removal module, a data acquisition module, a spacing adaptive adjustment module, a multi-dimensional parameter fusion calculation module, an error compensation module, and a motor control module.

[0010] The data acquisition module is used to receive the detection signal acquired by the laser receiver, and the pattern interference removal module removes false signals based on the pattern characteristics of the hot heat roller surface.

[0011] The spacing between the laser emitter and the laser receiver is dynamically optimized by combining the preset specifications of the heat-pressing roller to be tested with real-time detection data through the spacing adaptive adjustment module.

[0012] The multi-dimensional parameter fusion calculation module calculates the outer diameter, cylindricity, and local unevenness of the heat-pressing roller based on the pre-processed signal data and real-time spacing information.

[0013] The error compensation module corrects for environmental interference and pattern residue, and the motor control module outputs commands to adjust the operating state of the drive motor to control the movement trajectory and dwell position of the laser emitter. Preferably, the sliding assembly includes triangular plates symmetrically mounted on both sides of the laser emitter via bolts passing through first bolt holes. The bottom surfaces of the triangular plates have symmetrical slots on both sides. The bottom surfaces of the laser emitter have symmetrically arranged U-shaped frames at both ends. The top surfaces of the U-shaped frames have corresponding slot blocks at both ends. The bottom surfaces of the U-shaped frames have two symmetrically arranged protrusions. Mounting plates abut against both sides of the protrusions. Sliding sleeves are fixed to the bottom ends of the mounting plates. Lead screws and guide rods are respectively installed on both sides of the guide groove. Two sets of sliding sleeves are arranged corresponding to the lead screws and guide rods, with two sleeves in each set arranged in a rectangular pattern. A drive motor, partially embedded in the base plate, is coaxially fixed to one end of the lead screw.

[0014] Preferably, a first fixing bolt passes through the protrusion and the mounting plate, and a second fixing bolt, which is screwed to the locking block, passes through the slot on the outward side of the triangular plate.

[0015] Preferably, the bottom surface of the base plate has multiple storage slots equidistantly spaced on both sides, the bottom surface of each storage slot is provided with a magnetic block, a fixing rod is fixedly connected to the inner wall of the outward end of the storage slot, a fixing plate is rotatably installed in the storage slot through the fixing rod, and a threaded through hole is opened in the middle of the top surface of the fixing plate.

[0016] Preferably, the storage slot has an inwardly shaped finger groove at one end, and the top surface of the fixing plate has a rectangular groove at the end near the shaped finger groove to facilitate finger insertion.

[0017] Preferably, the pattern interference removal module pre-stores surface pattern feature templates for heat-pressing rollers of different specifications. The original detection signal transmitted by the laser receiver is compared frame by frame with the pattern feature template through a template matching algorithm. When the matching degree between the signal feature and the template is higher than the preset matching threshold, it is determined to be a false detection signal caused by pattern occlusion and is removed. At the same time, the effective size feature segment in the signal that reflects the actual size contour of the heat-pressing roller is marked and the effective size feature segment is synchronously transmitted to the data acquisition module.

[0018] Preferably, after receiving the effective size feature segment output by the pattern interference removal module, the data acquisition module performs noise reduction preprocessing on the effective size feature segment using a digital filtering algorithm. At the same time, it obtains the real-time rotation angle of the drive motor by communicating with the encoder of the drive motor, calculates the real-time position data of the laser emitter based on the lead parameter of the lead screw, and stores the preprocessed effective size feature segment and the real-time position data in association with the time axis to form a structured detection dataset, which is then transmitted to the multi-dimensional parameter fusion calculation module.

[0019] Preferably, the spacing adaptive adjustment module pre-stores the size parameter range of different specifications of heat-curing rollers. After receiving the preliminary size parameters output by the multi-dimensional parameter fusion calculation module, it compares the preliminary size parameters with the preset parameter range of the corresponding specifications. If the deviation exceeds the preset threshold, a spacing adjustment amount is generated based on the deviation value. The spacing adjustment amount is converted into a rotation angle command for the drive motor and transmitted to the motor control module. At the same time, the target position parameters of the laser emitter are updated. If the deviation is within the preset threshold, a spacing maintenance command is output to ensure that the laser beam always covers the effective detection area of ​​the heat-curing roller during the detection process.

[0020] Preferably, after receiving the structured detection dataset transmitted by the data acquisition module, the multi-dimensional parameter fusion calculation module calculates the basic outer diameter value of the heat-curing roller based on the real-time distance between the laser emitter and the laser receiver and the propagation path of the laser beam using a geometric relationship algorithm; combined with the movement trajectory data of the laser emitter along the guide groove, it analyzes the fluctuation of the basic outer diameter value at different detection positions and calculates the cylindricity deviation; by performing gradient analysis on the signal intensity change of the effective size feature segment, it identifies the signal intensity abrupt change point, determines it as a local unevenness defect on the surface of the heat-curing roller, calculates the depth and range of the local unevenness, and finally integrates the outer diameter, cylindricity, and local unevenness into a fused complete size parameter set.

[0021] Preferably, the error compensation module pre-establishes a multi-factor error compensation model. By communicating with external sensors, it acquires real-time temperature data of the detection environment and vibration frequency and amplitude data of the device. Combined with the pre-calibrated mechanical clearance parameters of the lead screw and sliding sleeve, it compensates and corrects the complete set of dimensional parameters output by the multi-dimensional parameter fusion calculation module.

[0022] To address temperature changes, the positional error caused by variations in the lead screw length is corrected based on the material's coefficient of thermal expansion.

[0023] To address vibration interference, the timing deviation of laser signal acquisition is corrected based on the vibration phase and amplitude;

[0024] To address mechanical gaps, the positional offset of the laser emitter is corrected based on the gap value to ensure the accuracy of the final output dimensional parameters.

[0025] Compared with related technologies, the dimension detection device for heat-pressing roller processing provided by the present invention has the following beneficial effects:

[0026] 1. This solution utilizes a storage groove and magnetic block on the bottom surface of the base plate, along with a rotatable fixing plate. The fixing plate can be unfolded or retracted around the fixing rod. When unfolded, it can be fixed to different worktable surfaces through threaded through holes. When retracted, it is positioned to prevent loosening with the help of magnetic blocks. At the same time, the arc-shaped finger groove of the storage groove and the rectangular groove design of the fixing plate facilitate quick operation by the operator without relying on a specific installation structure. This not only solves the problem of poor compatibility of the fixed installation plate, but also improves the convenience of device transfer and installation, adapting to various testing station scenarios.

[0027] 2. This solution utilizes the drive motor, lead screw, and sliding sleeve of the sliding assembly, combined with the spacing adaptive adjustment module of the control software system, to automatically drive the laser emitter to move smoothly along the guide groove. The module can dynamically optimize the spacing and correct deviations based on the preset specifications and real-time data of the heat-curing roller to be inspected, without the need to disassemble the bolts. This significantly improves the spacing adjustment efficiency and ensures that the laser emitter and receiver always remain aligned, adapting to the inspection needs of heat-curing rollers of different diameters and lengths, and avoiding the accuracy loss caused by manual adjustment.

[0028] 3. The control software system of this solution eliminates false signals through a pattern interference removal module, reduces noise and correlates position data through a data acquisition module, corrects temperature, vibration and mechanical clearance errors through an error compensation module, and automatically calculates outer diameter, cylindricity and local concavity / convexity through a multi-dimensional parameter fusion calculation module. The entire process requires no manual intervention, which avoids human error and offsets the influence of environmental interference, greatly improves detection accuracy and data processing efficiency, and solves the problems of inefficiency and insufficient accuracy of manual operation.

[0029] In summary, this solution addresses three core issues of existing devices—cumbersome spacing adjustment, inflexible base installation, and lack of supporting software—through deep integration of mechanical structure and control software systems. It achieves automatic and precise adjustment of laser emitter spacing, adaptability to diverse testing scenarios, and intelligent processing and error correction of testing data. This enhances the convenience and adaptability of heat-curing roller size testing while ensuring the accuracy of parameters such as outer diameter, cylindricity, and local unevenness, efficiently meeting the testing needs of various heat-curing roller specifications. Attached Figure Description

[0030] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0031] Figure 1 This is a first-view schematic diagram of the overall structure proposed in this invention;

[0032] Figure 2 This is a second-view schematic diagram of the overall structure proposed in this invention;

[0033] Figure 3 This is a schematic diagram of the overall structure for removing the fixing plate proposed in this invention;

[0034] Figure 4 This is a schematic diagram of the overall structure of the U-shaped frame proposed in this invention;

[0035] Figure 5 This is a schematic diagram of the control software system proposed in this invention.

[0036] The numbers in the diagram are: 1. Laser emitter; 2. Laser receiver; 3. Base plate; 4. Triangular plate; 5. Lead screw; 6. Drive motor; 7. Fixing plate; 8. Arc-shaped finger groove; 9. Guide rod; 10. Guide groove; 11. Sliding sleeve; 12. Mounting plate. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. The singular forms “group,” “class,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0039] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0040] Please refer to the following: Figures 1-5This invention discloses a dimensional detection device for heat-pressing roller processing, comprising a laser emitter 1 and a laser receiver 2 arranged opposite each other. The laser emitter 1 has first bolt holes arranged in a triangular pattern on both sides. A base plate 3 is provided at the bottom of the laser emitter 1 and the laser receiver 2. A guide groove 10 is formed on the top surface of the base plate 3 at the laser emitter 1, and a sliding component is provided within the guide groove 10. Multiple mounting holes are evenly distributed on the top surface of the base plate 3 between the guide groove 10 and the laser receiver 2. The laser receiver 2 is mounted on one end of the top surface of the base plate 3. The laser emitter 1 is a laser displacement sensor emitter of model LSM-6902H, and the laser receiver 2 is a matching connector of LSM-6902H. The receiver has high detection accuracy and can accurately capture the size data of the heat-pressing roller; the base plate 3 is made of Q235 carbon steel, with high structural strength and can stably bear the weight of each component; the mounting holes can help fix the heat-pressing roller support structure and facilitate the positioning of the heat-pressing roller to be tested; the above components together form the basic framework of the device, providing stable support for subsequent spacing adjustment, flexible installation and accurate detection; the sliding component includes triangular plates 4 symmetrically installed on both sides of the laser emitter 1 through the first bolt holes. The bottom surface of the triangular plates 4 has symmetrical slots on both sides, and the bottom surface of the laser emitter 1 has symmetrical U-shaped frames at both ends. The top surface of the U-shaped frames has corresponding slot blocks at both ends, and the bottom surface of the U-shaped frames has two symmetrical protrusions. Mounting plates 12 are abutting on both sides of the protrusion, and sliding sleeves 11 are fixed to the bottom of the mounting plates 12. Lead screws 5 and guide rods 9 are respectively installed on both sides of the guide groove 10. Two sets of sliding sleeves 11 are arranged corresponding to the lead screws 5 and guide rods 9, with two sleeves in each set arranged in a rectangular pattern. The triangular plate 4 is made of 6061 aluminum alloy, which is lightweight and high-strength, facilitating stable installation of the laser emitter 1. The U-shaped frame is made of stainless steel, which is corrosion-resistant and extends its service life. The sliding sleeves 11 are made of brass, which has good wear resistance and reduces frictional wear with the lead screws 5 and guide rods 9. The guide rods 9 are made of 45# steel, which has high straightness and ensures smooth movement of the sliding sleeves 11. Through the above, laser... The stable connection between the emitter 1 and the sliding assembly provides a structural foundation for the smooth movement of the laser emitter 1. A first fixing bolt passes between the protrusion and the mounting plate 12, and a second fixing bolt, screwed to the locking block, passes through the slot on the outward side of the triangular plate 4. Both the first and second fixing bolts are made of M8×20 stainless steel bolts, ensuring a firm connection and preventing rust. This ensures a stable connection between the protrusion and the mounting plate 12, and between the triangular plate 4 and the locking block, preventing the laser emitter 1 from loosening during movement or testing and guaranteeing testing accuracy. Through the above, the stability of the connection between the various components of the sliding assembly is improved, further ensuring the installation stability of the laser emitter 1.

[0041] In this invention, a drive motor 6, semi-embedded in the base plate 3, is coaxially fixed to one end of the lead screw 5. The lead screw 5 is a ball screw of model SFU1605, made of GCr15 bearing steel, which has high hardness and strong wear resistance, can withstand transmission loads for a long time, and extends its service life. It has high transmission efficiency and high precision, and can accurately drive the sliding sleeve 11 to move. The drive motor 6 is a stepper motor of model 57BYG250H, which has high control precision and can accurately adjust the rotation angle of the lead screw 5, thereby accurately controlling the moving distance of the laser emitter 1. Through the above, the automatic and precise adjustment of the spacing of the laser emitter 1 is realized, replacing manual adjustment and improving the efficiency and accuracy of spacing adjustment. Multiple storage slots are equidistantly opened on both sides of the bottom surface of the base plate 3. Magnetic blocks are provided on the bottom surface of the storage slots. A fixing rod is fixed to the inner wall of the outward end of the storage slot. A fixing plate 7 is rotatably installed in the storage slot through the fixing rod. A threaded through hole is opened in the middle of the top surface of the fixing plate 7. The magnetic blocks are neodymium iron boron magnets of model N35. The device is made of neodymium iron boron permanent magnet material, which has strong and stable magnetic properties, allowing for long-term stable adsorption of the fixing plate 7 and facilitating its storage and positioning. The fixing rod is made of No. 45 steel, which has high strength and can stably support the rotation of the fixing plate 7. The fixing plate 7 is made of Q235 carbon steel, which has high structural strength and can withstand the pressure during device installation and fixing. Through the above, the fixing plate 7 can be flexibly unfolded and stored, facilitating the installation and fixing of the device on different work surfaces and improving the device's installation adaptability. One end of the storage slot has an arc-shaped finger groove 8, and the top surface of the fixing plate 7 near the arc-shaped finger groove 8 has a rectangular groove for easy finger insertion. The design of the arc-shaped finger groove 8 and the rectangular groove is ergonomic, allowing operators to easily insert their fingers to operate the fixing plate 7, easily unfolding and storing it, reducing the difficulty of operation and improving the convenience of device installation and storage. Through the above, the ease of use of the device by operators is improved, further optimizing the user experience.

[0042] The device also includes a control software system that is communicatively connected to the laser emitter 1, the laser receiver 2, and the drive motor 6 in the sliding assembly;

[0043] The control software system includes a pattern interference removal module, a data acquisition module, a spacing adaptive adjustment module, a multi-dimensional parameter fusion calculation module, an error compensation module, and a motor control module;

[0044] The data acquisition module is used to receive the detection signal collected by the laser receiver 2, and the pattern interference removal module removes false signals based on the pattern characteristics of the hot heat roller surface;

[0045] The spacing between the laser emitter 1 and the laser receiver 2 is dynamically optimized by the spacing adaptive adjustment module, which combines the preset specifications of the heat-pressing roller to be tested with real-time detection data.

[0046] The multi-dimensional parameter fusion calculation module calculates the outer diameter, cylindricity, and local unevenness of the heat-pressing roller based on the pre-processed signal data and real-time spacing information.

[0047] The error compensation module corrects for environmental interference and pattern residue, and the motor control module outputs commands to adjust the operating state of the drive motor 6 to control the movement trajectory and dwell position of the laser emitter 1. Specifically, the pattern interference removal module pre-stores surface pattern feature templates of different specifications of heat-pressing rollers, and denotes the surface pattern feature template as T(j), where j is the template signal frame index, j=1,2,...,N, and N is the total number of signal frames of a single set of pattern templates;

[0048] The original detection signal transmitted by laser receiver 2 is denoted as S(i) by template matching algorithm, where i is the index of the original signal frame, i=1,2,...,M, and M is the total number of original signal frames in a single detection.

[0049] The normalized cross-correlation coefficient template matching algorithm is used to compare the original detection signal with the pattern feature template frame by frame. The frame-by-frame comparison includes the following steps:

[0050] S11, define the amplitude of the original detection signal S(i) in the i-th frame as... The signal amplitude of the pattern feature template T(j) in the j-th frame is Calculate the cross-correlation coefficient between the original detection signal S(i) and the pattern feature template T(j), using the following formula: ;in Let S(i) be the mean of the N frames of signals that match the template T(j) in the original detection signal S(i), and the formula is: ; Let T(j) be the mean value of the pattern feature template, and the formula is: ;

[0051] S12, set the matching threshold Th corresponding to the pattern type in advance, and if the cross-correlation coefficient of any frame of the original signal is... If the signal is false, it is determined that the frame is a false detection signal caused by pattern occlusion and is therefore discarded.

[0052] S13, Scan the original detection signal sequence after removing false signals, and mark the continuous signals that satisfy... The signal segment is the effective dimensional feature segment that reflects the actual size profile of the heat-pressing roller, denoted as... k is the index of the valid signal frame, k=1,2,...,P, where P is the total number of valid signal frames; and the valid size feature segment is... The data is transmitted synchronously to the data acquisition module.

[0053] Specifically, the data acquisition module receives the effective size feature segments output by the pattern interference removal module. After that, a digital filtering algorithm is used to perform noise reduction preprocessing on the effective size feature segment:

[0054] Set the filtering window size to , and is a positive integer, which is specifically pre-configured according to the detection accuracy requirements; calculate the filtered signal , and the formula is:

[0055] ;

[0056] where m is the signal frame index within the filtering window. When k < N_win, the window starts from the first frame and takes frames up to the k-th frame;

[0057] Then, connect to the encoder of the drive motor 6 through the communication interface to obtain the real-time rotation angle of the drive motor 6 output by the encoder, which corresponds one-to-one with the time stamp of the effective signal frame . Identify the pre-calibrated lead parameter of the lead screw 5 as , and identify the transmission ratio between the drive motor 6 and the lead screw 5 as , and calculate the real-time position data of the laser emitter 1. The formula is ;

[0058] According to the time stamp k = 1, 2,..., P, associate the filtered signal with the real-time position data L(k) to form a structured detection data set D = {( , , L(k))|k = 1, 2,..., P}, and transmit this data set D to the multi-dimensional parameter fusion calculation module.

[0059] Specifically, the spacing adaptive adjustment module pre-stores the size parameter ranges of different specifications of hot-rolling rollers. For any target specification of hot-rolling roller, its preset outer diameter range is denoted as , , where , respectively represent the minimum and maximum allowable outer diameters of this specification of hot-rolling roller, and the preset intermediate size value is denoted as ;

[0060] Receive the preliminary size parameters of the hot-rolling roller output by the multi-dimensional parameter fusion calculation module, where k is the detection frame index, k = 1, 2,..., P, represents the preliminary outer diameter value of the hot-rolling roller corresponding to the k-th frame; calculate the deviation ΔD(k) between the preliminary size parameter and the preset intermediate value. The formula is ;

[0061] Set preset deviation threshold Specifically, it should be pre-calibrated according to the required testing accuracy, with the unit consistent with the outer diameter; if It is determined that the distance between laser emitter 1 and laser receiver 2 needs to be adjusted, and the distance adjustment amount ΔL(k) is calculated using the formula: ,in This is the spacing adjustment coefficient, which is specifically calibrated in advance through experiments to reflect the linear correspondence between the outer diameter deviation and the spacing adjustment amount;

[0062] Based on the lead parameters of lead screw 5 and the transmission ratio between drive motor 6 and lead screw 5 The spacing adjustment ΔL(k) is converted into the rotation angle command Δθ(k) of the drive motor 6, using the following formula: Simultaneously update the target position parameters of laser emitter 1. The formula is ; and then the rotation angle command Δθ(k) and the target position parameters Transmitted to the motor control module;

[0063] like It determines whether the current spacing matches the detection requirements, outputs a spacing maintenance command, and ensures that the laser beam always covers the effective detection area of ​​the heat-curing roller, such as the radial section area where the roller body generatrix is ​​located.

[0064] Specifically, the multi-dimensional parameter fusion calculation module receives the structured detection dataset D={( , ,L(k))|k=1,2,...,P}, and calculate the fusion size parameter set according to the following steps:

[0065] S41, Calculate the basic value of the outer diameter of the heat-pressing roller:

[0066] Given that the laser beam propagation path is a straight line, let E(k) be the real-time distance between laser transmitter 1 and laser receiver 2, and define the filtered signal. The corresponding effective blocking chord length of the laser beam is l(k), where ,in The signal amplitude to physical length conversion factor is specifically calibrated in advance using standard-sized calibration parts; based on the chord length formula, the radius of the heat-pressing roller is denoted as... The effective blocking chord length l(k) of the laser beam is related to the radius of the heat-pressing roller. The real-time spacing E(k) satisfies the following relationship: After simplification, calculate the basic value of the outer diameter. The formula is ;

[0067] S42, Calculate the cylindricity deviation Cyl of the heat-pressing roller:

[0068] The maximum outer diameter is obtained by statistically analyzing the baseline outer diameter values ​​of all detected frames. Minimum outer diameter The cylindricity deviation Cyl is calculated based on twice the difference between the maximum and minimum radii within the same cross-section, according to the definition of cylindricity. The formula is as follows: ;

[0069] S43, Calculate the local unevenness of the heat-pressing roller:

[0070] Calculate the signal intensity gradient G(k) of the k-th frame, which reflects the rate of change of the signal amplitude. The formula is ;

[0071] Set gradient threshold ,like Then, the position corresponding to the k-th frame is determined to be a local concave-convex defect point, and marked as... ;

[0072] The amplitude of the normal frame signal adjacent to the defect point is , Near the defect point The frame index then determines the defect signal deviation. Calculate the depth of the concave and convex surfaces The formula is ;

[0073] If the continuous defect point frame index is If m is the number of consecutive defect frames, then the corresponding moving position of laser emitter 1 is... The range of concavity and convexity is: ;

[0074] S44, Integrating the outer diameter baseline value sequence Cylindricity deviation (Cyl) and local concavity / convexity parameters This forms a complete set of dimensional parameters after fusion.

[0075] Specifically, the error compensation module corrects the dimensional parameters through a multi-factor error compensation model, including:

[0076] Step 1: Correct for temperature errors based on real-time temperature data collected by the temperature sensor. Combined with the preset material thermal expansion coefficient of lead screw 5 Calibration temperature Effective length of lead screw and transmission ratio Calculate the position error of laser emitter 1 caused by temperature. The formula is ;

[0077] Step two: Correct the vibration error based on the vibration frequency collected by the vibration sensor. ,amplitude Vibration phase Combined with the real-time movement speed of laser emitter 1 Calculate the position error caused by vibration. The formula is ,in To calibrate the phase, Specifically, it depends on the lead screw. It is obtained by converting the motor speed;

[0078] Step 3: Correct the mechanical clearance error based on the preset calibrated mechanical clearance between the lead screw 5 and the sliding sleeve 11. 6. Rotation direction coefficient of drive motor Calculate the positional error caused by mechanical clearance. The formula is ;

[0079] Step four: Calculate the total compensation by summing the position errors from steps one through three to obtain the total position error. The formula is Correct the distance between laser emitter 1 and laser receiver 2. and based on The outer diameter, cylindricity, and local unevenness of the heat-pressing roller are recalculated to obtain a set of compensated dimensional parameters.

[0080] The motor control module performs the following operations to adjust the operating status of the drive motor 6 and control the movement trajectory and stopping position of the laser emitter 1, as follows:

[0081] Corrected spacing output by the receiver error compensation module The target position of laser emitter 1 output by the spacing adaptive adjustment module. Combined with the current position of laser emitter 1 The required rotation angle of the motor is calculated based on real-time feedback from the encoder of the drive motor. The formula is: ;

[0082] in, The lead screw has 5 leads. This refers to the transmission ratio between the drive motor 6 and the lead screw 5;

[0083] Based on the preset movement stability requirements, the target movement speed of laser emitter 1 is set. , combined Calculate the target speed of the motor The formula is: Used to ensure that the laser emitter 1 moves at a constant speed along the guide groove 10 and avoids trajectory deviation;

[0084] Output command to control drive motor 6 Rotation speed Angle, when the actual rotation angle fed back by the encoder is... The deviation is less than the preset angle deviation threshold When the time comes, output a stop command;

[0085] Dwelling location control: Arrival Then, the position deviation fed back by the encoder is monitored in real time. If the deviation is greater than the preset position threshold Then, the output fine-tuning command drives the motor to rotate 6 small angles until the deviation is within... Next, keep the laser emitter 1 stationary at the target position to complete the detection.

[0086] This invention provides a dimensional detection device for heat-pressing roller processing. Through flexible adjustment of the mechanical structure and coordination with laser detection logic, it achieves accurate dimensional detection of heat-pressing rollers. The specific working principle is as follows:

[0087] Depending on the condition of the workbench, the operator inserts their fingers into the arc-shaped finger groove 8 within the storage slot on the bottom of the base plate 3, and then engages the rectangular groove on the top surface of the fixing plate 7. This causes the fixing plate 7 to rotate and unfold around the fixing rod within the storage slot until it is perpendicular to or at an appropriate angle to the bottom of the base plate 3. Subsequently, bolts are passed through the threaded holes on the top surface of the fixing plate 7 to securely fix the device to the workbench. If no fixation is required or the device needs to be moved, the fixing plate 7 is rotated in the opposite direction into the storage slot, where it is held in place by the magnetic blocks on the bottom surface of the storage slot, preventing it from loosening and falling out.

[0088] Based on the diameter and length of the heat-pressing roller to be tested, the drive motor 6 of the semi-embedded base plate 3 is started. The drive motor 6 drives the lead screw 5 on one side of the guide groove 10 to rotate coaxially. Since one end of the sliding sleeve 11 is threadedly connected to the lead screw 5 and the other end is sleeved on the guide rod 9, the rotation of the lead screw 5 drives the two sets of sliding sleeves 11 to move smoothly along the guide groove 10. The top of the sliding sleeve 11 is connected to the U-shaped frame through the mounting plate 12 and the protrusion. The U-shaped frame is then engaged with the triangular plates 4 on both sides of the laser emitter 1 through the locking block. Therefore, the movement of the sliding sleeve 11 synchronously drives the laser emitter 1 to move along the guide groove 10. After the distance between the laser emitter 1 and the laser receiver 2 is adapted to the specifications of the heat-pressing roller, the drive motor 6 is turned off. The guide rod 9 can ensure that the laser emitter 1 and the laser receiver 2 remain aligned during the movement.

[0089] The heat-pressing roller to be tested is placed between the guide groove 10 on the top surface of the base plate 3 and the laser receiver 2. The mounting holes on the base plate 3 are used to help fix the heat-pressing roller support structure, so that the axis of the heat-pressing roller is perpendicular to the line connecting the laser emitter 1 and the laser receiver 2. The laser emitter 1 is activated to emit a detection laser. When the laser passes through the gap between the two, it is partially blocked by the heat-pressing roller, and the remaining laser is received by the laser receiver 2. The laser receiver 2 calculates the outer diameter, cylindricity, and other key parameters of the heat-pressing roller based on the laser blocking data and the preset spacing parameters. If it is necessary to test different positions of the heat-pressing roller, the heat-pressing roller can be moved directly, or the above spacing adjustment steps can be repeated to adapt it before testing.

[0090] The entire working process does not require disassembling cumbersome bolts, and the retractable fixing plate 7 can be adapted to different work surfaces. The spacing can be quickly adjusted by the cooperation of the drive motor 6 and the lead screw 5, and the size detection of the heat-pressing roller can be completed efficiently.

[0091] The formulas used in this device are all based on a large amount of measured data in the testing scenario of heat-curing rollers, and are obtained by software simulation and fitting, which can closely approximate the actual testing situation. Before the formula is calculated, the dimensions are removed by standardization and other means to obtain the numerical value. The specific dimension removal process is not described in detail. The preset parameters in the formula (such as matching threshold, deviation threshold, etc.) are set by those skilled in the art according to the actual situation such as the specifications of the heat-curing roller to be tested and the testing accuracy requirements.

[0092] This device embodiment can be implemented through software, hardware, firmware, or any combination thereof: the software part corresponds to the control software system (including modules such as pattern interference removal and data acquisition), and the hardware part corresponds to components such as laser transmitter 1, laser receiver 2, and drive motor 6; when implemented in software, it can form a computer program product, and after the computer instructions contained therein are loaded and executed, the device can realize detection processes such as signal acquisition, interference removal, size calculation, and error compensation.

[0093] The aforementioned computer instructions can be stored on computer-readable storage media such as USB flash drives, portable hard drives, ROM, RAM, magnetic disks, or optical disks. They can also be transmitted from one storage medium to another via wired or wireless means (such as infrared or microwave) to meet the storage and retrieval needs of device programs.

[0094] The sequence number of each detection process in the device does not represent the execution order; the specific order is determined by the functional logic. The units (such as software modules and hardware components) mentioned in the text are divided into logical functional divisions, which can be adjusted in actual implementation. The coupling or communication connection between components is achieved through the device's adapted interface (such as the communication interface between the control software and the drive motor), which can be in the form of electrical or mechanical connection.

[0095] The separate components in the device (such as laser emitter 1 and laser receiver 2) can be physically separated or integrated. The software functional units can be integrated into a processing unit or exist separately. Some or all units can be selected to achieve the purpose of the solution according to the detection requirements. If the software functions are sold as independent products, they can be stored in the above-mentioned computer-readable storage medium. The instructions are used to drive the computer equipment to execute the detection steps of the device.

[0096] Other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of the invention are indicated by the following claims.

[0097] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A dimensional detection device for heat-pressing roller processing, comprising a laser emitter (1) and a laser receiver (2) arranged opposite to each other, characterized in that: The laser emitter (1) has first bolt holes arranged in a triangular pattern on both sides. The laser emitter (1) and the laser receiver (2) are provided with a base plate (3). The top surface of the base plate (3) is provided with a guide groove (10) at the laser emitter (1). The guide groove (10) is provided with a sliding assembly, which includes a drive motor (6). The top surface of the base plate (3) is provided with multiple mounting holes evenly spaced between the guide groove (10) and the laser receiver (2). The laser receiver (2) is installed at one end of the top surface of the base plate (3). The device also includes a control software system that is communicatively connected to the laser emitter (1), the laser receiver (2), and the drive motor (6) in the sliding assembly; The control software system includes a pattern interference removal module, a data acquisition module, a spacing adaptive adjustment module, a multi-dimensional parameter fusion calculation module, an error compensation module, and a motor control module. The data acquisition module is used to receive the detection signal acquired by the laser receiver (2) and remove false signals based on the surface pattern characteristics of the heat-curing roller through the pattern interference removal module; The spacing between the laser emitter (1) and the laser receiver (2) is dynamically optimized by the spacing adaptive adjustment module in combination with the preset specifications of the heat-pressing roller to be tested and the real-time detection data. The multi-dimensional parameter fusion calculation module calculates the outer diameter, cylindricity, and local unevenness of the heat-pressing roller based on the pre-processed signal data and real-time spacing information. The error compensation module corrects the effects of environmental interference and pattern residue, and the motor control module outputs commands to adjust the operating status of the drive motor (6) to control the movement trajectory and dwell position of the laser emitter (1). The sliding assembly includes triangular plates (4) symmetrically installed on both sides of the laser emitter (1) through bolts passing through the first bolt holes. The triangular plates (4) have symmetrical slots on both sides of their bottom surface. The laser emitter (1) has U-shaped frames symmetrically arranged at both ends of its bottom surface. The top surfaces of the U-shaped frames have corresponding slot blocks at both ends. The bottom surface of the U-shaped frames has two symmetrical protrusions. The protrusions are abutted against by mounting plates (12) on both sides. The mounting plates (12) are fixedly connected to the bottom end of the mounting plates (12). The guide groove (10) has lead screws (5) and guide rods (9) installed on both sides respectively. The sliding sleeves (11) are arranged in two sets corresponding to the lead screws (5) and guide rods (9), with two in each set and arranged in a rectangular distribution. One end of the lead screw (5) is coaxially fixedly connected to a drive motor (6) that is partially embedded in the base plate (3). The pattern interference removal module pre-stores surface pattern feature templates for different specifications of heat-pressing rollers. The original detection signal transmitted by the laser receiver (2) is compared with the pattern feature template frame by frame through the template matching algorithm. When the matching degree between the signal feature and the template is higher than the preset matching threshold, it is determined to be a false detection signal caused by pattern occlusion and is removed. At the same time, the effective size feature segment in the signal that reflects the actual size contour of the heat-pressing roller is marked and the effective size feature segment is synchronously transmitted to the data acquisition module. After receiving the structured detection dataset transmitted by the data acquisition module, the multi-dimensional parameter fusion calculation module calculates the basic value of the outer diameter of the heat-pressing roller based on the real-time distance between the laser emitter (1) and the laser receiver (2) and the propagation path of the laser beam through a geometric relationship algorithm. Combined with the moving trajectory data of the laser emitter (1) along the guide groove (10), the fluctuation of the basic value of the outer diameter at different detection positions is analyzed, and the cylindricity deviation is calculated. By performing gradient analysis on the signal intensity change of the effective size feature segment, the signal intensity mutation point is identified and determined as a local concave-convex defect on the surface of the heat-pressing roller. The depth and range of the local concave-convexity are calculated, and finally the outer diameter, cylindricity, and local concave-convexity are integrated into a complete set of fused size parameters.

2. The dimensional detection device for heat-pressing roller processing according to claim 1, characterized in that, A first fixing bolt is inserted between the protrusion and the mounting plate (12), and a second fixing bolt is inserted on the outward side of the triangular plate (4) at the slot to be screwed to the block.

3. The dimensional detection device for heat-pressing roller processing according to claim 1, characterized in that... The bottom plate (3) has multiple storage slots equidistantly spaced on both sides of its bottom surface. A magnetic block is provided on the bottom surface of the storage slot. A fixing rod is fixedly connected to the inner wall of the outward end of the storage slot. A fixing plate (7) is rotatably installed in the storage slot through the fixing rod. A threaded through hole is opened in the middle of the top surface of the fixing plate (7).

4. The dimensional detection device for heat-pressing roller processing according to claim 3, characterized in that, The storage slot has an inward-facing arc-shaped finger groove (8), and the top surface of the fixing plate (7) near the arc-shaped finger groove (8) has a rectangular groove that facilitates finger insertion.

5. The dimensional detection device for heat-pressing roller processing according to claim 1, characterized in that, After receiving the effective size feature segment output by the pattern interference removal module, the data acquisition module uses a digital filtering algorithm to perform noise reduction preprocessing on the effective size feature segment. At the same time, it communicates with the encoder of the drive motor (6) to obtain the real-time rotation angle of the drive motor (6). Based on the lead parameter of the lead screw (5), it calculates the real-time position data of the laser emitter (1). The preprocessed effective size feature segment and the real-time position data are associated and stored according to the time axis to form a structured detection dataset, which is then transmitted to the multi-dimensional parameter fusion calculation module.

6. The dimensional detection device for heat-pressing roller processing according to claim 1, characterized in that, The spacing adaptive adjustment module pre-stores the size parameter range of different specifications of heat-curing rollers. After receiving the preliminary size parameters output by the multi-dimensional parameter fusion calculation module, it compares the preliminary size parameters with the preset parameter range of the corresponding specifications. If the deviation exceeds the preset threshold, it generates a spacing adjustment amount based on the deviation value, converts the spacing adjustment amount into the rotation angle command of the drive motor (6) and transmits it to the motor control module, and updates the target position parameters of the laser emitter (1) at the same time. If the deviation is within the preset threshold, it outputs a spacing maintenance command to ensure that the laser beam always covers the effective detection area of ​​the heat-curing roller during the detection process.

7. The dimensional detection device for heat-pressing roller processing according to claim 1, characterized in that, The error compensation module pre-establishes a multi-factor error compensation model. By communicating with external sensors, it obtains real-time temperature data of the detection environment and vibration frequency and amplitude data of the device. Combined with the pre-calibrated mechanical clearance parameters of the lead screw (5) and sliding sleeve (11), it compensates and corrects the complete set of size parameters output by the multi-dimensional parameter fusion calculation module. To address temperature changes, the positional error caused by the change in the length of the lead screw (5) is corrected based on the coefficient of thermal expansion of the material; To address vibration interference, the timing deviation of laser signal acquisition is corrected based on the vibration phase and amplitude; To address the mechanical gap, the position offset of the laser emitter (1) is corrected based on the gap value to ensure the accuracy of the final output dimensional parameters.

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