Arc-shaped roller state detection method, system, device, medium and product

Abstract

The application discloses an arc-shaped roller state detection method, system, device, medium and product, relates to the technical field of battery production equipment, and discloses an arc-shaped roller state detection method, which obtains a first electric signal in the rotating process of an arc-shaped roller, the first electric signal is collected based on at least one first non-contact displacement sensor, the first non-contact displacement sensor is arranged away from two ends of the arc-shaped roller and is fixed in the relative position of the arc-shaped roller in a static state, and the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically in the rotating process of the arc-shaped roller, so that the first electric signal changes periodically; the rotating state of the arc-shaped roller is determined based on the first electric signal, and a method capable of realizing real-time detection of the rotating state of the arc-shaped roller is provided.

Description

Technical Field

[0001] This application relates to the field of battery production equipment technology, and in particular to methods, systems, equipment, media, and products for detecting the condition of curved rollers. Background Technology

[0002] The curved roller used in coating machines is a flexible roller whose body can be adjusted to different curvatures (usually with a central convexity). It is used in processes such as film alignment, leveling, and tension adjustment after the coating film exits the oven. Its stable rotation is crucial to ensuring that the substrate and film run straight, wrinkle-free, and with uniform tension. Currently, the rotation status of the curved roller is monitored by manual inspection, but manual inspection cannot achieve real-time detection. By the time a rotational failure of the curved roller is discovered, it has often already resulted in a large number of defective products or equipment damage. Summary of the Invention The main objective of this application is to provide a method, system, device, medium, and product for detecting the state of an arc-shaped roller, with the aim of providing a method that can realize real-time detection of the rotational state of an arc-shaped roller.

[0003] To achieve the above objectives, this application proposes a method for detecting the state of an arc-shaped roller. The method includes: acquiring a first electrical signal during the rotation of the arc-shaped roller, wherein the first electrical signal is acquired based on at least one first non-contact displacement sensor, the first non-contact displacement sensor is disposed at both ends away from the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed, and during the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, causing the first electrical signal to change periodically; and determining the rotation state of the arc-shaped roller based on the first electrical signal.

[0004] In one embodiment, determining the rotation state of the arc-shaped roller based on the first electrical signal includes: determining that the arc-shaped roller is stopped or jammed when the first electrical signal has no periodic changes and its duration is greater than or equal to a first preset duration; determining that the arc-shaped roller is intermittently jammed when the first electrical signal exhibits periodic changes and a first signal segment appears discontinuously in the periodic waveform, wherein the duration of the first signal segment is less than the first preset duration and the amplitude variation range of the first signal segment is less than a preset amplitude range.

[0005] In this embodiment, when the first electrical signal does not change periodically and its duration is greater than or equal to the first preset duration, the arc-shaped roller is determined to be in a stopped or jammed state, thus eliminating the possibility of short-term non-periodic situations such as normal start-stop or short-term speed fluctuations and preventing misjudgment; when the first electrical signal shows periodic changes, but there is a constant signal segment in the middle with a duration less than the first preset duration (i.e., the signal amplitude change range is extremely small), the arc-shaped roller is determined to be in an intermittent jammed state.

[0006] In one embodiment, the method further includes: acquiring a second electrical signal during the rotation of the arc-shaped roller, the second electrical signal being acquired based on a second non-contact displacement sensor, the second non-contact displacement sensor being disposed at both ends away from the arc-shaped roller and having a fixed relative position with the arc-shaped roller in a stationary state, the first non-contact displacement sensor and the second non-contact displacement sensor being located on the same first cross-section of the arc-shaped roller, and within the first cross-section, the two sensors forming a preset fixed angle with the center line of the first cross-section, the first cross-section being a cross-section in the radial direction of the arc-shaped roller; the first non-contact displacement sensor being a laser displacement sensor, the second non-contact displacement sensor being an eddy current sensor, the distance between the second non-contact displacement sensor and the mandrel of the arc-shaped roller changing periodically during the rotation of the arc-shaped roller, causing the second electrical signal to change periodically; and determining whether the arc-shaped roller has experienced internal slippage based on the first electrical signal and the second electrical signal.

[0007] In this embodiment, a second non-contact displacement sensor (eddy current sensor) is added to detect the rotation signal of the mandrel inside the arc-shaped roller, forming an internal-external comparison with the first non-contact displacement sensor (laser displacement sensor) detecting the roller body. Under normal circumstances, the roller body and mandrel of the arc-shaped roller rotate synchronously. There will be a fixed initial phase difference between the first electrical signal measured by the first non-contact displacement sensor and the second electrical signal measured by the second non-contact displacement sensor. This initial phase difference is exactly equal to the installation angle between the two sensors, i.e., a preset fixed angle. When internal slippage occurs in the arc-shaped roller, the roller body undergoes angular displacement relative to the mandrel, and this initial phase difference changes. Therefore, by monitoring the difference between the phase difference of the first and second electrical signals and the initial phase difference in real time, it is possible to determine whether internal slippage has occurred between the roller body and the mandrel of the arc-shaped roller.

[0008] In one embodiment, determining whether the arc-shaped roller has experienced internal slippage based on the first electrical signal and the second electrical signal includes: determining that the arc-shaped roller has experienced internal slippage when the first electrical signal and the second electrical signal exhibit periodic changes and the absolute value of the difference between the phase difference between the first electrical signal and the second electrical signal and the initial phase difference is greater than a first preset phase difference, wherein the initial phase difference is determined according to the preset fixed angle; or, determining that the arc-shaped roller has experienced internal slippage when the rate of change of the phase difference between the first electrical signal and the second electrical signal over time is greater than a preset rate of change and the duration is greater than a second preset duration.

[0009] This embodiment provides two feasible methods for judging internal slippage: (1) When both the first and second electrical signals change periodically, and the absolute value of the difference between the real-time phase difference and the initial phase difference is greater than the first preset phase difference, internal slippage is judged to have occurred. This method is sensitive to cumulative large slippage, and by using the initial phase difference as a reference, the fixed deviation caused by the installation position is eliminated. (2) When the rate of change of the phase difference with time is greater than the preset rate of change, and the duration is greater than the second preset duration, internal slippage is judged to have occurred. This method is more sensitive to continuous slow slippage response and can capture instantaneous angular velocity difference without relying on the initial phase difference. The two judgment methods complement each other, covering both the long-term accumulation of large slippage and ensuring rapid alarm of small slippage rates, significantly improving the reliability of internal slippage detection. In one embodiment, the method further includes: acquiring a third electrical signal during the rotation of the arc-shaped roller, the third electrical signal being acquired based on a third non-contact displacement sensor, the third non-contact displacement sensor being disposed at both ends away from the arc-shaped roller and having a fixed relative position to the arc-shaped roller in a stationary state, both the first non-contact displacement sensor and the third non-contact displacement sensor being laser displacement sensors, and the first non-contact displacement sensor and the third non-contact displacement sensor being symmetrically disposed on the left and right sides of the highest point of the protrusion of the arc-shaped roller, and the first non-contact displacement sensor and the third non-contact displacement sensor having the same distance from the arc-shaped roller in a stationary state; and determining whether the arc-shaped roller has experienced wear or deformation based on the first electrical signal and the third electrical signal.

[0010] In this embodiment, a third non-contact displacement sensor (laser displacement sensor) is added, symmetrically installed with the first non-contact displacement sensor (laser displacement sensor) relative to the highest point of the arc-shaped roller protrusion, with the same static distance. This symmetrical layout ensures that the electrical signal waveforms of the two sensors are identical during normal rotation (phase difference of 0°, amplitude ratio of 1). By acquiring the third electrical signal and analyzing it in conjunction with the first electrical signal, wear or deformation of the arc-shaped roller surface can be detected, because any asymmetrical wear or torsional deformation will disrupt the symmetry between the signals. In this embodiment, no additional calibration or complex model is required; online detection of the roller surface profile can be achieved solely using the relative relationship between the signals from the two sensors. The structure is simple and the cost is controllable. In one embodiment, determining whether the arc-shaped roller has worn or deformed based on the first electrical signal and the third electrical signal includes: determining that the arc-shaped roller has worn or deformed when the absolute value of the phase difference between the first electrical signal and the third electrical signal is greater than a second preset phase difference and the duration is greater than a third preset duration; or, determining that the arc-shaped roller has worn or deformed when the deviation of the amplitude ratio of the first electrical signal and the third electrical signal from 1 is greater than a preset amplitude deviation.

[0011] This embodiment provides two feasible methods for determining wear or deformation: (1) When the absolute value of the phase difference between the first electrical signal and the third electrical signal is greater than the second preset phase difference and the duration is greater than the third preset duration, wear or deformation is determined. This method is very sensitive to asymmetrical deformations such as the offset of the highest point and torsion, and prevents instantaneous interference through the duration condition. (2) When the deviation of the amplitude ratio of the two signals from 1 is greater than the preset amplitude deviation, wear or deformation is determined. This method has outstanding detection effect on unilateral wear (the height of the protrusion on one side is significantly reduced), and can alarm even if the phase difference is not obvious.

[0012] Furthermore, to achieve the above objectives, this application also proposes an arc-shaped roller state detection system, the system comprising: at least one first non-contact displacement sensor, the first non-contact displacement sensor being disposed at both ends away from the arc-shaped roller and having a fixed relative position with the arc-shaped roller in a stationary state; the at least one first non-contact displacement sensor being used to acquire a first electrical signal during the rotation of the arc-shaped roller, wherein the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically during the rotation of the arc-shaped roller, causing the first electrical signal to change periodically; and a processor being used to determine the rotation state of the arc-shaped roller based on the first electrical signal.

[0013] Furthermore, to achieve the above objectives, this application also proposes an arc-shaped roller state detection device, the device comprising: an acquisition module for acquiring a first electrical signal during the rotation of the arc-shaped roller, the first electrical signal being acquired based on at least one first non-contact displacement sensor, the first non-contact displacement sensor being disposed at both ends away from the arc-shaped roller and having a fixed relative position with the arc-shaped roller in a stationary state, the distance between the first non-contact displacement sensor and the arc-shaped roller changing periodically during the rotation of the arc-shaped roller, causing the first electrical signal to change periodically; and a processing module for determining the rotation state of the arc-shaped roller based on the first electrical signal.

[0014] In addition, to achieve the above objectives, this application also proposes an arc-shaped roller condition detection device, the device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the arc-shaped roller condition detection method as described above.

[0015] In addition, to achieve the above objectives, this application also proposes a storage medium, which is a computer-readable storage medium, on which a computer program is stored, and when the computer program is executed by a processor, it implements the steps of the arc roller state detection method described above.

[0016] In addition, to achieve the above objectives, this application also provides a computer program product, which includes a computer program that, when executed by a processor, implements the steps of the arc roller state detection method described above.

[0017] One or more technical solutions proposed in this application have at least the following technical effects: By setting a first non-contact displacement sensor, the relative position of the first non-contact displacement sensor and the arc-shaped roller in a stationary state is fixed. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, thereby generating a first electrical signal directly related to the distance between the first non-contact displacement sensor and the arc-shaped roller. The first electrical signal also changes periodically. Thus, the rotation state of the arc-shaped roller can be determined by detecting the change of the first electrical signal during the rotation of the arc-shaped roller, realizing real-time detection of the rotation state of the arc-shaped roller. Moreover, there is no physical contact between the first non-contact displacement sensor and the arc-shaped roller, preventing the problem of damage to the roller surface caused by contact detection. At the same time, the first non-contact displacement sensor is set away from both ends of the arc-shaped roller, located in the middle area of ​​the arc-shaped roller, to prevent the problem that the small change in the distance between the first non-contact displacement sensor and the ends of the arc-shaped roller during rotation will prevent the generation of an electrical signal with a significant and stable amplitude. This ensures that the obtained first electrical signal has a significant and stable amplitude, thereby improving the reliability of the arc-shaped roller state detection. Attached Figure Description

[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a flowchart illustrating an embodiment of the arc-shaped roller condition detection method of this application. Figure 2 This is a schematic diagram of the arc-shaped roller of this application; Figure 3 This is a schematic diagram of the sensor installation location in Embodiment 1 of this application; Figure 4 This is a flowchart illustrating Embodiment 2 of the arc-shaped roller condition detection method of this application; Figure 5 This is a schematic diagram of the sensor installation location in Embodiment 2 of this application; Figure 6 This is a schematic diagram of one installation position of the first cross section of the arc-shaped roller where the two sensors are located in Embodiment 2 of this application; Figure 7 This is a schematic diagram of another installation position of the first cross section of the arc-shaped roller where the two sensors are located in Embodiment 2 of this application; Figure 8 This is a flowchart illustrating Embodiment 3 of the arc-shaped roller condition detection method of this application; Figure 9 This is a schematic diagram of the sensor installation location in Embodiment 3 of this application; Figure 10 This is a flowchart illustrating Embodiment 4 of the arc-shaped roller condition detection method of this application; Figure 11 This is a schematic diagram of the sensor installation location in Embodiment 4 of this application; Figure 12 This is a structural schematic diagram of Embodiment 1 of the arc-shaped roller condition detection system of this application; Figure 13 This is a structural schematic diagram of Embodiment 2 of the arc-shaped roller condition detection system of this application; Figure 14 This is a structural schematic diagram of Embodiment 3 of the arc-shaped roller condition detection system of this application; Figure 15 This is a structural schematic diagram of Embodiment 4 of the arc-shaped roller condition detection system of this application; Figure 16 This is a schematic diagram of the module structure of the arc-shaped roller state detection device according to an embodiment of this application; Figure 17 This is a schematic diagram of the equipment structure of the hardware operating environment involved in the arc roller state detection method in this application embodiment.

[0021] The purpose, features, and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0022] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0024] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0025] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0026] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0027] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0028] The curved roller used in coating machines is a flexible roller whose body can be adjusted to different curvatures (usually with a central convexity). It is used in processes such as film alignment, leveling, and tension adjustment after the coating film exits the oven. Its stable rotation is crucial to ensuring that the substrate and film run straight, wrinkle-free, and with uniform tension. Currently, the rotation status of the curved roller is monitored by manual inspection, but manual inspection cannot achieve real-time detection. By the time a rotational failure of the curved roller is discovered, it has often already resulted in a large number of defective products or equipment damage. To address this, this application proposes a method for detecting the state of an arc-shaped roller. The method includes: acquiring a first electrical signal during the rotation of the arc-shaped roller, wherein the first electrical signal is acquired based on at least one first non-contact displacement sensor, the first non-contact displacement sensor is disposed at both ends away from the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed, and during the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, causing the first electrical signal to change periodically; and determining the rotation state of the arc-shaped roller based on the first electrical signal.

[0029] By setting a first non-contact displacement sensor, the relative position of the first non-contact displacement sensor and the arc-shaped roller in a stationary state is fixed. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, thereby generating a first electrical signal directly related to the distance between the first non-contact displacement sensor and the arc-shaped roller. The first electrical signal also changes periodically. Thus, the rotation state of the arc-shaped roller can be determined by detecting the change of the first electrical signal during the rotation of the arc-shaped roller, realizing real-time detection of the rotation state of the arc-shaped roller. Moreover, there is no physical contact between the first non-contact displacement sensor and the arc-shaped roller, preventing the problem of damage to the roller surface caused by contact detection. At the same time, the first non-contact displacement sensor is set away from both ends of the arc-shaped roller, located in the middle area of ​​the arc-shaped roller, to prevent the problem that the small change in the distance between the first non-contact displacement sensor and the ends of the arc-shaped roller during rotation will prevent the generation of an electrical signal with a significant and stable amplitude. This ensures that the obtained first electrical signal has a significant and stable amplitude, thereby improving the reliability of the arc-shaped roller state detection.

[0030] It should be noted that the executing entity in this embodiment can be a computing service device with data processing, network communication, and program execution functions, such as a computer, industrial control computer, or an electronic device capable of performing the above functions. The following description uses an electronic device as an example to illustrate this embodiment and the subsequent embodiments.

[0031] Based on the above, this application provides a method for detecting the state of an arc-shaped roller, referring to... Figure 1 , Figure 1 This is a flowchart illustrating the first embodiment of the arc-shaped roller state detection method of this application.

[0032] In this embodiment, the method for detecting the state of the arc-shaped roller includes steps S10 to S20: Step S10: Obtain the first electrical signal during the rotation of the arc-shaped roller. The first electrical signal is acquired based on at least one first non-contact displacement sensor.

[0033] Curved rollers, also known as bending rollers or bow rollers, have the following structure: Figure 2 As shown, the curved roller has a curved mandrel (usually made of metal) inside, and a roller body (usually made of rubber, polyurethane, etc.) on the outside. The mandrel is supported by bearings at both ends, and the mandrel drives the roller body to rotate together when it rotates. Because the mandrel is pre-bent into an arc shape, the roller body also presents an arc shape that is high in the middle and low at both ends.

[0034] The highest point is the point where the surface of the curved roller is most arched. The plane containing the lowest points at both ends of the curved roller is the reference plane. The vertical distance between the highest point and the reference plane is the arch height. The arch height is used to measure the degree of curvature of the curved roller. The higher the arch height, the greater the degree of curvature of the curved roller; conversely, the lower the arch height, the less the degree of curvature of the curved roller.

[0035] During the rotation of the curved roller, points on the roller body undergo displacement changes in space. The greater the vertical distance of a point on the roller body from the reference plane, the greater the displacement change in space; conversely, the smaller the vertical distance of a point on the roller body from the reference plane, the smaller the displacement change in space. Similarly, points on the mandrel of the curved roller also undergo displacement changes in space. The highest point of the mandrel is collinear with the highest point of the roller body, and the line connecting the highest points of the mandrel and the roller body is perpendicular to the reference plane. The highest point of the curved roller body experiences the greatest displacement change in space.

[0036] like Figure 3 As shown, this embodiment includes a first non-contact displacement sensor. This sensor detects the distance between itself and the curved roller and outputs a corresponding electrical signal (voltage or current signal) based on the distance. Based on this detection principle, the first non-contact displacement sensor should be positioned away from both ends of the curved roller. This is because during the rotation of the curved roller, the displacement changes in space at points on the roller body / spindle near both ends are small, resulting in insignificant changes in the electrical signal amplitude, which cannot accurately reflect the distance change between the sensor and the curved roller.

[0037] It is feasible to install the first non-contact displacement sensor on the roller body / mandrel within an arc-shaped roller region where the vertical distance from the reference plane is greater than a preset distance. The preset distance should be greater than 0. For example... Figure 3 As shown, three positions that can be set for the first non-contact displacement sensor are given. Among them, the first non-contact displacement sensor can be set directly opposite the highest point of the arc-shaped roller.

[0038] It is worth noting that, in order to prevent errors caused by changes in the relative position between the first non-contact displacement sensor and the stationary arc roller, the relative position between the first non-contact displacement sensor and the stationary arc roller is kept constant.

[0039] In this embodiment, the first non-contact displacement sensor can be a laser displacement sensor or an ultrasonic sensor. In this case, the first non-contact displacement sensor detects the distance between itself and the body of the arc-shaped roller.

[0040] The greater the distance between the first non-contact displacement sensor and the roller body, the smaller the detected reflected energy, and the weaker the strength of the output first electrical signal; conversely, the smaller the distance between the first non-contact displacement sensor and the roller body, the greater the detected reflected energy, and the stronger the output first electrical signal. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the roller body changes periodically with time, resulting in a periodically changing first electrical signal with varying signal strength.

[0041] In this embodiment, the first non-contact displacement sensor can also be an eddy current sensor. In this case, the first non-contact displacement sensor detects the distance between itself and the mandrel (metal material) of the arc-shaped roller.

[0042] The larger the distance between the first non-contact displacement sensor and the mandrel, the weaker the eddy current effect, the smaller the impedance change, and the weaker the signal strength of the output first electrical signal; conversely, the smaller the distance between the first non-contact displacement sensor and the mandrel, the stronger the eddy current effect, the greater the impedance change, and the stronger the output first electrical signal. During the rotation of the arc roller, the distance between the first non-contact displacement sensor and the mandrel of the arc roller changes periodically with time, resulting in a periodically changing first electrical signal with varying signal strength.

[0043] It is worth noting that other non-contact sensors can also be used as the first non-contact displacement sensor in this embodiment, but this will not be elaborated on in this embodiment.

[0044] Step S20: Determine the rotation state of the arc-shaped roller based on the first electrical signal.

[0045] The rotational state of the arc-shaped roller can be determined by observing the changing pattern of the first electrical signal. For example, if the first electrical signal exhibits the expected periodic change, it can be determined that the arc-shaped roller is rotating normally; conversely, it can be determined that the arc-shaped roller is rotating abnormally. If the abnormal rotation of the arc-shaped roller is determined, an early warning signal can be issued to alert the staff in real time, or the equipment can be paused to prevent the equipment from continuing to operate and generating more waste.

[0046] In this embodiment, a first non-contact displacement sensor is set up. The relative position of the first non-contact displacement sensor and the arc-shaped roller in a stationary state is fixed. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, thereby generating a first electrical signal that is directly related to the distance between the first non-contact displacement sensor and the arc-shaped roller. The first electrical signal also changes periodically. Thus, the rotation state of the arc-shaped roller can be determined by detecting the change of the first electrical signal during the rotation of the arc-shaped roller, realizing real-time detection of the rotation state of the arc-shaped roller. Moreover, there is no physical contact between the first non-contact displacement sensor and the arc-shaped roller, preventing the problem of damage to the roller surface caused by contact detection. At the same time, the first non-contact displacement sensor is set away from both ends of the arc-shaped roller and located in the middle area of ​​the arc-shaped roller. This prevents the problem that the distance between the first non-contact displacement sensor and the ends of the arc-shaped roller changes little during rotation, which would prevent the generation of an electrical signal with a significant and stable amplitude. This ensures that the obtained first electrical signal has a significant and stable amplitude, thereby improving the reliability of the arc-shaped roller state detection.

[0047] In one feasible implementation, step S20 includes: determining that the arc-shaped roller is in a stopped or jammed state when the first electrical signal does not change periodically and its duration is greater than or equal to a first preset duration; determining that the arc-shaped roller is in an intermittent jammed state when the first electrical signal shows periodic changes and a first signal segment appears intermittently in the periodic waveform, wherein the duration of the first signal segment is less than the first preset duration and the amplitude variation range of the first signal segment is less than the preset amplitude range.

[0048] In this embodiment, the rotation state of the arc-shaped roller is determined by analyzing the waveform characteristics of the first electrical signal obtained.

[0049] If the curved roller stops rotating (whether due to active shutdown or mechanical jamming), the distance between the first non-contact displacement sensor and the curved roller will remain fixed, and the first electrical signal will no longer exhibit periodic changes. That is, the amplitude of the first electrical signal will no longer change periodically with time, but will instead exhibit a basically constant value (possibly a non-zero value). If this "no periodic change" state lasts for a duration greater than or equal to a first preset duration, the curved roller is determined to be in a stopped or jammed state. The first preset duration can be 5 seconds, 10 seconds, etc., and can be set as needed.

[0050] By determining that the arc roller is stopped or jammed when the first electrical signal has no periodic change and the duration is greater than or equal to the first preset duration, the system eliminates the possibility of short-term non-periodic situations such as normal start-stop or short-term speed fluctuations, thus preventing misjudgment.

[0051] If the curved roller experiences brief, intermittent jamming during rotation (e.g., momentary stoppage due to foreign objects or poor lubrication), the first electrical signal, while generally exhibiting periodic changes, will show brief segments within certain time periods where the signal amplitude variation is less than a preset range—essentially a near-constant output segment. These segments last for less than a preset duration, and the signal returns to its normal periodic variation before and after each segment. Detecting this waveform characteristic confirms that the curved roller has intermittently jammed.

[0052] When the first electrical signal exhibits periodic changes, but a first signal segment appears in the middle of the periodic waveform with a duration shorter than a first preset duration and a signal amplitude variation range shorter than a preset amplitude range, the arc roller is determined to be in an intermittent jammed state.

[0053] It is achievable that, after determining the fault type of the arc roller through this embodiment, a warning signal can be issued and the specific fault type can be displayed on the display interface.

[0054] In this embodiment, the two judgment methods described above can accurately identify the complete stop / jamming state and the intermittent jamming state of the arc roller, providing a more precise fault type judgment for equipment maintenance and facilitating targeted repairs.

[0055] In one feasible implementation, refer to Figure 4 It also includes steps SA1 and SA2.

[0056] Step SA1: Acquire the second electrical signal during the rotation of the arc-shaped roller. The second electrical signal is obtained based on the second non-contact displacement sensor.

[0057] Internal slippage refers to relative rotation between the roller body and the internal spindle of the curved roller (e.g., keyway wear, rubber layer detachment from the spindle, etc.), in which case the roller body speed and the spindle speed are inconsistent. To detect this condition, such as... Figure 5 As shown, this embodiment also includes a second non-contact displacement sensor. The second non-contact displacement sensor is an eddy current sensor, while the first non-contact displacement sensor is a laser displacement sensor. Alternatively, the first non-contact displacement sensor can also be an ultrasonic displacement sensor, with the same detection effect.

[0058] The first non-contact displacement sensor detects the roller body. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the roller body changes periodically over time, thereby outputting a first electrical signal with periodically changing signal strength. Under normal rotation conditions, the frequency of the first electrical signal is proportional to the rotational speed of the roller body.

[0059] The second non-contact displacement sensor detects the mandrel inside the curved roller. The eddy current sensor is sensitive to metal and can directly detect mandrel characteristics through the roller body (if the roller body is made of rubber, polyurethane, or other materials). During the rotation of the curved roller, the distance between the second non-contact displacement sensor and the mandrel changes periodically, resulting in a periodically changing second electrical signal output. Under normal rotation conditions, the frequency of the second electrical signal is proportional to the mandrel rotation speed.

[0060] It is worth noting that, similar to the first non-contact displacement sensor, the second non-contact displacement sensor is located at both ends of the arc-shaped roller away from the roller and its relative position to the arc-shaped roller in a stationary state is fixed.

[0061] Furthermore, the first non-contact displacement sensor and the second non-contact displacement sensor are located on the same first cross-section of the arc-shaped roller, and within the first cross-section, the two sensors form a preset fixed angle with the line connecting the center of the first cross-section to the center of the first cross-section. The first cross-section is the cross-section in the radial direction of the arc-shaped roller. The radial direction of the arc-shaped roller is the direction that radiates outward from the center of the mandrel along the radius of the roller body. Figure 5 The direction of AA` shown is one of the radial directions of the arc-shaped roller.

[0062] In one example, a schematic diagram of the first cross-section obtained by cutting the curved roller with AA' is shown below. Figure 6 As shown, the two sensors form two lines with the center of the first cross-section, and the included angle B formed by the two lines is the preset fixed angle. Figure 6 The two sensors are positioned facing each other, forming a preset fixed angle of 180°.

[0063] In another example, such as Figure 7 The diagram shows another installation position of the first cross section of the arc-shaped roller where the two sensors are located. The two sensors and the center of the first cross section form two lines respectively. The included angle B formed by the two lines is the preset fixed angle, which is 90°.

[0064] The above Figure 6 and Figure 7 The positions of the two sensors are shown in the example only. In actual applications, the positions of the two sensors can be set as needed to form a preset fixed angle. The degree of the preset fixed angle can be 180°, 120°, 90°, 60°, etc., and there is no limitation in this embodiment.

[0065] The first non-contact displacement sensor and the second non-contact displacement sensor are located on the same first cross section of the arc-shaped roller, ensuring that the two sensors measure corresponding points on the same first cross section, eliminating axial torsion interference during the rotation of the arc-shaped roller, and making the phase difference between the measured first electrical signal and the second electrical signal directly reflect the angular displacement difference of the first cross section.

[0066] The preset fixed angle between the two sensors and the center of the first cross section is to establish a known, constant initial phase difference.

[0067] Under normal circumstances, the roller body and mandrel of the arc-shaped roller rotate synchronously. There will be a fixed initial phase difference between the first electrical signal measured by the first non-contact displacement sensor and the second electrical signal measured by the second non-contact displacement sensor. This initial phase difference is exactly equal to the installation angle between the two sensors, i.e., the preset fixed angle.

[0068] Step SA2: Determine whether the arc-shaped roller has experienced internal slippage based on the first and second electrical signals.

[0069] When internal slippage occurs in the curved roller, the roller body undergoes angular displacement relative to the mandrel, and this initial phase difference changes. Therefore, by monitoring the difference between the phase difference of the first and second electrical signals and the initial phase difference in real time, it is possible to determine whether internal slippage has occurred between the roller body and the mandrel of the curved roller.

[0070] In this embodiment, a second non-contact displacement sensor (eddy current sensor) is added to detect the rotation signal of the mandrel inside the arc-shaped roller, forming an internal-external comparison with the first non-contact displacement sensor (laser displacement sensor) detecting the roller body. Under normal circumstances, the roller body and mandrel of the arc-shaped roller rotate synchronously. There will be a fixed initial phase difference between the first electrical signal measured by the first non-contact displacement sensor and the second electrical signal measured by the second non-contact displacement sensor. This initial phase difference is exactly equal to the installation angle between the two sensors, i.e., a preset fixed angle. When internal slippage occurs in the arc-shaped roller, the roller body undergoes angular displacement relative to the mandrel, and this initial phase difference changes. Therefore, by monitoring the difference between the phase difference of the first and second electrical signals and the initial phase difference in real time, it is possible to determine whether internal slippage has occurred between the roller body and the mandrel of the arc-shaped roller.

[0071] This embodiment can not only analyze whether internal slippage occurs between the roller body and the mandrel of the arc-shaped roller based on the first electrical signal and the second electrical signal, but also analyze the complete stop / jamming state and intermittent jamming state of the arc-shaped roller based on the first electrical signal.

[0072] This embodiment overcomes the limitation that a sensor can only monitor the external rotation state, extending the detection range from the external state to the internal transmission, and filling the gap in the inability to detect slippage inside the arc roller online.

[0073] It is worth noting that, Figure 4The sequence of steps shown is for illustrative purposes only. In actual applications, steps SA1 and S10 can be executed sequentially or synchronously. This embodiment does not impose any restrictions on this. Similarly, steps SA2 and S20 can also be executed sequentially or synchronously.

[0074] The achievable step SA2 includes: determining that the arc-shaped roller has internal slippage when the first electrical signal and the second electrical signal change periodically and the absolute value of the difference between the phase difference of the first electrical signal and the second electrical signal and the initial phase difference is greater than the first preset phase difference, wherein the initial phase difference is determined according to a preset fixed angle; or, determining that the arc-shaped roller has internal slippage when the rate of change of the phase difference between the first electrical signal and the second electrical signal with time is greater than the preset rate of change of the second preset phase difference and the duration is greater than the second preset duration.

[0075] In this embodiment, after obtaining the first electrical signal and the second electrical signal, the internal slippage of the arc-shaped roller is determined by analyzing the signal characteristics of the two.

[0076] One method for determining this (cumulative angle difference method): When the curved roller is running normally without load, the initial phase difference between the first and second electrical signals is recorded (e.g., by aligning the rising edges of the two signals). The initial phase difference is determined based on a preset fixed angle between the lines connecting the two sensors and the center of the curved roller. When the curved roller is running, if both signals exhibit periodic changes, and the absolute value of the difference between the real-time phase difference and the initial phase difference is greater than the first preset phase difference (e.g., 10°), it can be determined that a significant relative angular displacement has occurred between the spindles of the curved roller, thus indicating internal slippage of the curved roller. This method is suitable for detecting significant cumulative slippage.

[0077] Another method (angular velocity difference method) involves calculating the rate of change of the phase difference between the first and second electrical signals over time (i.e., the change in phase difference per unit time, in units such as ° / s). If this rate of change is greater than a preset rate of change (e.g., 5° / s), and the duration of this state is greater than a second preset duration (e.g., 0.5 seconds), then it can be determined that there is continuous relative sliding between the mandrels of the arc-shaped roller, and thus, internal slippage of the arc-shaped roller is determined. This method is more sensitive to continuous, slow sliding and has a fast response speed.

[0078] This embodiment provides two feasible methods for judging internal slippage: (1) When both the first and second electrical signals change periodically, and the absolute value of the difference between the real-time phase difference and the initial phase difference is greater than the first preset phase difference, internal slippage is judged to have occurred. This method is sensitive to cumulative large slippage, and by using the initial phase difference as a reference, it eliminates the fixed deviation caused by the installation position. (2) When the rate of change of the phase difference with time is greater than the preset rate of change, and the duration is greater than the second preset duration, internal slippage is judged to have occurred. This method is more sensitive to continuous slow slippage response and can capture instantaneous angular velocity difference without relying on the initial phase difference. The two judgment methods complement each other, covering both the long-term accumulation of large slippage and ensuring rapid alarm of small slippage rates, significantly improving the reliability of internal slippage detection.

[0079] In another feasible implementation, refer to Figure 8 It also includes: step SB1 and step SB2.

[0080] Step SB1: Obtain the third electrical signal during the rotation of the arc-shaped roller. The third electrical signal is acquired based on the third non-contact displacement sensor.

[0081] The third non-contact displacement sensor is located at both ends of the arc-shaped roller away from the roller and its relative position to the arc-shaped roller in a stationary state is fixed. Both the first and third non-contact displacement sensors are laser displacement sensors. The first and third non-contact displacement sensors are symmetrically arranged on the left and right sides of the highest point of the arc-shaped roller with respect to the roller. The distance between the first and third non-contact displacement sensors and the arc-shaped roller in a stationary state is the same.

[0082] After prolonged use, the protrusions on the curved roller may wear down due to friction (symmetrically or asymmetrically), or deform due to stress, causing the roller profile to deviate from the original design. To detect wear or deformation of the curved roller, such as... Figure 7 As shown, two laser displacement sensors are installed, namely a first non-contact displacement sensor and a third non-contact displacement sensor, which are symmetrically arranged on the left and right sides of the highest point of the protrusion of the arc roller.

[0083] It is feasible to position the first and third non-contact displacement sensors away from both ends of the curved roller, specifically within the region of the curved roller where the vertical distance from the reference plane to a point on the roller body is greater than a preset distance. This prevents the problem that the distance between the first / third non-contact displacement sensor and the curved roller changes little during rotation due to insufficient curvature at the ends of the curved roller, thus failing to generate a significant and stable electrical signal. This ensures that the obtained first / third electrical signal amplitude is significant and stable, thereby improving the reliability of the curved roller status detection. The preset distance should be greater than 0.

[0084] It is worth noting that, in order to prevent errors caused by changes in the relative position between the first / third non-contact displacement sensor and the stationary arc roller, the relative position between the first / third non-contact displacement sensor and the stationary arc roller is kept constant.

[0085] Furthermore, when the arc-shaped roller is stationary, the distance between the two sensors and the roller surface is the same. Thus, when the arc-shaped roller rotates normally and the surface contour is intact, due to symmetry, the two sensors measure the same radial displacement of the roller surface at the same time. Therefore, the waveforms of the first and third electrical signals output are exactly the same, with a phase difference of 0° and equal amplitudes (amplitude ratio of 1).

[0086] Step SB2 determines whether the arc-shaped roller has been worn or deformed based on the first and third electrical signals.

[0087] By comparing the waveforms of the first and third electrical signals, it can be determined whether the arc-shaped roller has been worn or deformed. If the waveforms of the first and third electrical signals are the same, it can be determined that the arc-shaped roller has not been worn or deformed; conversely, if the waveforms of the first and third electrical signals are different, it can be determined that the arc-shaped roller has been worn or deformed.

[0088] In this embodiment, a third non-contact displacement sensor (laser displacement sensor) is added, symmetrically installed with the first non-contact displacement sensor (laser displacement sensor) relative to the highest point of the arc-shaped roller protrusion, with the same static distance. This symmetrical layout ensures that the electrical signal waveforms of the two sensors are identical during normal rotation (phase difference of 0°, amplitude ratio of 1). By acquiring the third electrical signal and analyzing it in conjunction with the first electrical signal, wear or deformation of the arc-shaped roller surface can be detected, because any asymmetrical wear or torsional deformation will disrupt the symmetry between the signals. This embodiment requires no additional calibration or complex models; online detection of the roller surface profile can be achieved solely using the relative relationship between the signals from the two sensors. The structure is simple and the cost is controllable.

[0089] It is worth noting that, Figure 8 The sequence of steps shown is for illustrative purposes only. In actual applications, steps SB1 and S10 can be executed sequentially or synchronously. This embodiment does not impose any restrictions. Similarly, steps SB2 and S20 can also be executed sequentially or synchronously.

[0090] The achievable step SB2 includes: determining that the arc-shaped roller is worn or deformed when the absolute value of the phase difference between the first electrical signal and the third electrical signal is greater than the second preset phase difference and the duration is greater than the third preset duration; or, determining that the arc-shaped roller is worn or deformed when the deviation of the amplitude ratio between the first electrical signal and the third electrical signal from 1 is greater than the preset amplitude deviation.

[0091] In this embodiment, after obtaining the first and third electrical signals, the arc-shaped roller is judged to have worn or deformed by analyzing the signal characteristics of the two signals.

[0092] One judgment method (phase difference method): Calculate the absolute value of the phase difference between the first electrical signal and the third electrical signal. If this absolute value is greater than a second preset phase difference (e.g., 5°) and the duration is greater than a third preset duration (e.g., 1 second), then it is determined that the arc roller has worn or deformed. This method mainly detects asymmetry problems caused by the offset of the highest point, torsion, or unilateral wear.

[0093] Another method of judgment (amplitude ratio method): Calculate the amplitude ratio of the first electrical signal to the third electrical signal (the ratio of the larger value to the smaller value or the absolute value). If the deviation of this amplitude ratio from 1 is greater than the preset amplitude deviation (e.g., 0.1, i.e., the amplitude ratio exceeds the range of 0.9 to 1.1), then it is determined that wear or deformation has occurred. This rule is more sensitive to unilateral wear (the height of the protrusion on one side is significantly lower than that on the other side).

[0094] This embodiment provides two feasible methods for determining wear or deformation: (1) When the absolute value of the phase difference between the first electrical signal and the third electrical signal is greater than the second preset phase difference and the duration is greater than the third preset duration, wear or deformation is determined. This method is very sensitive to asymmetrical deformations such as the offset of the highest point and torsion, and prevents instantaneous interference through the duration condition. (2) When the deviation of the amplitude ratio of the two signals from 1 is greater than the preset amplitude deviation, wear or deformation is determined. This method has outstanding detection effect on unilateral wear (the height of the protrusion on one side is significantly reduced), and can alarm even if the phase difference is not obvious.

[0095] The two judgment methods are related by "OR", complementing each other and covering different types of asymmetric damage, thus improving the comprehensiveness and reliability of wear / deformation detection.

[0096] It should be noted that although symmetrical overall wear (proportional reduction) cannot be detected by phase difference or amplitude ratio, it can be supplemented by setting an additional threshold for absolute amplitude, which does not affect the effectiveness of this embodiment for the vast majority of actual wear (most of which is asymmetrical).

[0097] In one embodiment, Figure 4 The illustrated embodiments and Figure 8 The embodiments shown can be combined to form new embodiments, and their method flowcharts are as follows. Figure 10 As shown. Step S10 can be executed synchronously with steps SA1 and SB1, and step S20 can be executed synchronously with steps SA2 and SB2. Figure 10 The order shown is for illustrative purposes only. Figure 10 The detection schematic diagram corresponding to the embodiment shown is as follows: Figure 11 As shown.

[0098] Figure 10 In the illustrated embodiment, the first electrical signal can be used to determine whether the arc-shaped roller is stopped or jammed, or intermittently jammed; the first and second electrical signals can be used to determine whether the arc-shaped roller is slipping internally; and the first and third electrical signals can be used to determine whether the arc-shaped roller is worn or deformed.

[0099] Figure 10 For specific implementation details of the embodiments, please refer to... Figure 1 , Figure 4 and Figure 8 The embodiments shown are not described in detail here.

[0100] This application also provides an arc-shaped roller condition detection system; please refer to [reference needed]. Figure 12 The system includes: At least one first non-contact displacement sensor 1 is provided at both ends of the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed. The first non-contact displacement sensor 1 is used to acquire a first electrical signal during the rotation of the arc-shaped roller. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, so that the first electrical signal changes periodically.

[0101] In this embodiment, a first non-contact displacement sensor 1 is provided. The first non-contact displacement sensor 1 is used to detect the distance between itself and the arc-shaped roller, and outputs a corresponding electrical signal (voltage signal or current signal) according to the distance. Based on this detection principle, the first non-contact displacement sensor 1 should be set away from both ends of the arc-shaped roller, because during the rotation of the arc-shaped roller, the displacement change of points on the roller body / mandrel near both ends of the arc-shaped roller in space is small, and the change in electrical signal amplitude is not obvious, which cannot accurately reflect the change in distance between the sensor and the arc-shaped roller.

[0102] It is feasible that the first non-contact displacement sensor 1 can be installed on the roller body / mandrel in an arc-shaped roller region where the vertical distance from the reference plane is greater than a preset distance. The preset distance should be greater than 0. For example... Figure 8 As shown, the first non-contact displacement sensor 1 can be positioned directly opposite the highest point of the curved roller body.

[0103] It is worth noting that, in order to prevent the change in the relative position between the first non-contact displacement sensor 1 and the arc-shaped roller in a stationary state from introducing errors, the relative position between the first non-contact displacement sensor 1 and the arc-shaped roller in a stationary state is kept fixed.

[0104] In this embodiment, the first non-contact displacement sensor 1 can be a laser displacement sensor or an ultrasonic sensor. In this case, the first non-contact displacement sensor 1 detects the distance between itself and the body of the arc-shaped roller.

[0105] The greater the distance between the first non-contact displacement sensor 1 and the roller body, the smaller the detected reflected energy and the weaker the strength of the output first electrical signal; conversely, the smaller the distance between the first non-contact displacement sensor 1 and the roller body, the greater the detected reflected energy and the stronger the output first electrical signal. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor 1 and the roller body changes periodically with time, resulting in a periodically changing first electrical signal with varying signal strength.

[0106] In this embodiment, the first non-contact displacement sensor 1 can also be an eddy current sensor. In this case, the first non-contact displacement sensor 1 detects the distance between itself and the mandrel (metal material) of the arc-shaped roller.

[0107] The larger the distance between the first non-contact displacement sensor 1 and the mandrel, the weaker the eddy current effect, the smaller the impedance change, and the weaker the signal strength of the output first electrical signal; conversely, the smaller the distance between the first non-contact displacement sensor 1 and the mandrel, the stronger the eddy current effect, the greater the impedance change, and the stronger the output first electrical signal. During the rotation of the arc roller, the distance between the first non-contact displacement sensor 1 and the mandrel of the arc roller changes periodically with time, thus the output signal strength of the first electrical signal changes periodically.

[0108] It is worth noting that other non-contact sensors can also be used as the first non-contact displacement sensor 1 in this embodiment, which will not be elaborated in this embodiment.

[0109] Processor 2 is used to determine the rotational state of the arc-shaped roller based on the first electrical signal.

[0110] The rotational state of the arc-shaped roller can be determined by observing the changing pattern of the first electrical signal. For example, if the first electrical signal exhibits the expected periodic change, it can be determined that the arc-shaped roller is rotating normally; conversely, it can be determined that the arc-shaped roller is rotating abnormally. If the abnormal rotation of the arc-shaped roller is determined, an early warning signal can be issued to alert the staff in real time, or the equipment can be paused to prevent the equipment from continuing to operate and generating more waste.

[0111] In this embodiment, a first non-contact displacement sensor is set up. The relative position of the first non-contact displacement sensor and the arc-shaped roller in a stationary state is fixed. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, thereby generating a first electrical signal that is directly related to the distance between the first non-contact displacement sensor and the arc-shaped roller. The first electrical signal also changes periodically. Thus, the rotation state of the arc-shaped roller can be determined by detecting the change of the first electrical signal during the rotation of the arc-shaped roller, realizing real-time detection of the rotation state of the arc-shaped roller. Moreover, there is no physical contact between the first non-contact displacement sensor and the arc-shaped roller, preventing the problem of damage to the roller surface caused by contact detection. At the same time, the first non-contact displacement sensor is set away from both ends of the arc-shaped roller and located in the middle area of ​​the arc-shaped roller. This prevents the problem that the distance between the first non-contact displacement sensor and the ends of the arc-shaped roller changes little during rotation, which would prevent the generation of an electrical signal with a significant and stable amplitude. This ensures that the obtained first electrical signal has a significant and stable amplitude, thereby improving the reliability of the arc-shaped roller state detection.

[0112] Specifically, the processor 2 is configured to determine that the arc-shaped roller is in a stopped or jammed state when the first electrical signal has no periodic changes and its duration is greater than or equal to a first preset duration; and to determine that the arc-shaped roller is in an intermittent jammed state when the first electrical signal exhibits periodic changes and a first signal segment appears intermittently in the periodic waveform, wherein the duration of the first signal segment is less than the first preset duration and the amplitude variation range of the first signal segment is less than a preset amplitude range.

[0113] In one feasible implementation, such as Figure 13 As shown, the system further includes: a second non-contact displacement sensor 3, which is disposed at both ends away from the arc-shaped roller and is fixed in relative position to the arc-shaped roller in a stationary state; the first non-contact displacement sensor 1 and the second non-contact displacement sensor 3 are located on the same first cross section of the arc-shaped roller, and within the first cross section, the two sensors form a preset fixed angle with the line connecting the center of the first cross section to the center of the first cross section; the first cross section is the cross section in the radial direction of the arc-shaped roller; the first non-contact displacement sensor 1 is a laser displacement sensor, and the second non-contact displacement sensor 3 is an eddy current sensor.

[0114] The second non-contact displacement sensor 3 is used to acquire a second electrical signal during the rotation of the arc-shaped roller. During the rotation of the arc-shaped roller, the distance between the second non-contact displacement sensor 3 and the spindle of the arc-shaped roller changes periodically, causing the second electrical signal to change periodically.

[0115] The processor 2 is also used to determine whether the arc-shaped roller has experienced internal slippage based on the first electrical signal and the second electrical signal.

[0116] Specifically, the processor 2 is configured to determine that the arc-shaped roller has experienced internal slippage when the first electrical signal and the second electrical signal exhibit periodic changes and the absolute value of the difference between the phase difference between the first electrical signal and the second electrical signal and the initial phase difference is greater than a first preset phase difference, wherein the initial phase difference is determined based on the preset fixed angle; or, when the rate of change of the phase difference between the first electrical signal and the second electrical signal over time is greater than a preset rate of change and the duration is greater than a second preset duration, the processor 2 is configured to determine that the arc-shaped roller has experienced internal slippage.

[0117] In one feasible implementation, such as Figure 14 As shown, the system further includes: a third non-contact displacement sensor 4, which is disposed at both ends away from the arc-shaped roller and is fixed in relative position to the arc-shaped roller in a stationary state. Both the first non-contact displacement sensor 1 and the third non-contact displacement sensor 4 are laser displacement sensors, and are symmetrically disposed on the left and right sides of the highest point of the protrusion of the arc-shaped roller with respect to the first non-contact displacement sensor 1 and the third non-contact displacement sensor 4, and have the same distance between them and the arc-shaped roller in a stationary state. The third non-contact displacement sensor 4 is used to acquire the third electrical signal during the rotation of the arc-shaped roller. The processor 2 is also used to determine whether the arc-shaped roller has been worn or deformed based on the first electrical signal and the third electrical signal.

[0118] It is achievable that the processor 2 is used to determine that the arc-shaped roller is worn or deformed when the absolute value of the phase difference between the first electrical signal and the third electrical signal is greater than a second preset phase difference and the duration is greater than a third preset duration; or, when the deviation of the amplitude ratio between the first electrical signal and the third electrical signal from 1 is greater than a preset amplitude deviation, the processor 2 is used to determine that the arc-shaped roller is worn or deformed.

[0119] In one feasible implementation, such as Figure 15As shown, the system includes a first non-contact displacement sensor 1, a second non-contact displacement sensor 3, and a third non-contact displacement sensor 4. This system can determine whether the arc-shaped roller is stopped, jammed, or intermittently jammed based on the first electrical signal output by the first non-contact displacement sensor 1; it can determine whether the arc-shaped roller is experiencing internal slippage based on the first electrical signal output by the first non-contact displacement sensor 1 and the second electrical signal output by the second non-contact displacement sensor 3; and it can determine whether the arc-shaped roller is worn or deformed based on the first electrical signal output by the first non-contact displacement sensor 1 and the third electrical signal output by the third non-contact displacement sensor 4. Specific implementation details of the system can be found above. Figure 12 , Figure 13 and Figure 14 The example shown.

[0120] It is feasible that the first non-contact displacement sensor 1, the second non-contact displacement sensor 3, and the third non-contact displacement sensor 4 in the above embodiments can be fixed to the equipment frame by an adjustable universal bracket. The bracket has a magnetic base or clamp, which facilitates quick installation and alignment in complex environments.

[0121] Processor 2 can be the signal processing unit of PLC. The sensor cable is connected to the explosion-proof junction box on site and finally connected to processor 2. After analysis, processor 2 displays the status information of the arc roller on the local display and uploads it to the factory MES system through the industrial switch.

[0122] It is feasible to have one or more of the first non-contact displacement sensor 1, the second non-contact displacement sensor 3, and the third non-contact displacement sensor 4 in the system. The processor 2 adopts voting logic or confidence fusion algorithm to integrate information from multiple sensors and further improve reliability.

[0123] It is feasible to add a rotary encoder installed at the end of the arc-shaped roller shaft to form redundant detection with the displacement sensor.

[0124] The beneficial effects of the arc-shaped roller condition detection system provided in this application are the same as those of the arc-shaped roller condition detection method provided in the above embodiments, and other technical features of the arc-shaped roller condition detection system are the same as those disclosed in the above embodiments, and will not be repeated here.

[0125] This application provides a device for detecting the condition of an arc-shaped roller, such as... Figure 16 As shown, the device includes: The acquisition module 10 is used to acquire a first electrical signal during the rotation of the arc-shaped roller. The first electrical signal is acquired based on at least one first non-contact displacement sensor. The first non-contact displacement sensor is set at both ends away from the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, so that the first electrical signal changes periodically.

[0126] The processing module 20 is used to determine the rotation state of the arc-shaped roller based on the first electrical signal.

[0127] The beneficial effects of the arc-shaped roller condition detection device provided in this application are the same as those of the arc-shaped roller condition detection method provided in the above embodiments, and other technical features in the arc-shaped roller condition detection device are the same as those disclosed in the above embodiments, and will not be repeated here.

[0128] This application provides an arc-shaped roller condition detection device, which includes: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor to enable the at least one processor to perform the arc-shaped roller condition detection method in the above embodiment 1.

[0129] The following is for reference. Figure 17 The diagram illustrates a structural schematic suitable for implementing the arc-shaped roller state detection device in the embodiments of this application. The arc-shaped roller state detection device in the embodiments of this application may include, but is not limited to, mobile terminals such as mobile phones, laptops, digital broadcast receivers, PDAs (Personal Digital Assistants), PADs (Portable Application Description), PMPs (Portable Media Players), in-vehicle terminals (e.g., in-vehicle navigation terminals), and fixed terminals such as digital TVs and desktop computers. Figure 15 The illustrated arc-shaped roller condition detection device is merely an example and should not impose any limitations on the functionality and scope of use of the embodiments of this application.

[0130] like Figure 17As shown, the arc roller condition detection device may include a processing unit 1001 (e.g., a central processing unit, a graphics processor, etc.), which can perform various appropriate actions and processes according to a program stored in a read-only memory (ROM) 1002 or a program loaded from a storage device 1003 into a random access memory (RAM) 1004. The RAM 1004 also stores various programs and data required for the operation of the arc roller condition detection device. The processing unit 1001, ROM 1002, and RAM 1004 are interconnected via a bus 1005. An input / output (I / O) interface 1006 is also connected to the bus. Typically, the following systems can be connected to the I / O interface 1006: input devices 1007 including, for example, a touchscreen, touchpad, keyboard, mouse, image sensor, microphone, accelerometer, gyroscope, etc.; output devices 1008 including, for example, a liquid crystal display (LCD), speaker, vibrator, etc.; storage devices 1003 including, for example, magnetic tape, hard disk, etc.; and communication devices 1009. Communication device 1009 allows the arc roll condition detection device to communicate wirelessly or wiredly with other devices to exchange data. Although the figure shows arc roll condition detection devices with various systems, it should be understood that implementation or possession of all the systems shown is not required. More or fewer systems may be implemented alternatively.

[0131] Specifically, according to the embodiments disclosed in this application, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments disclosed in this application include a computer program product comprising a computer program carried on a computer-readable medium, the computer program containing program code for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via a communication device, or installed from storage device 1003, or installed from ROM 1002. When the computer program is executed by processing device 1001, it performs the functions defined in the methods of the embodiments disclosed in this application.

[0132] The arc-shaped roller condition detection device provided in this application adopts the arc-shaped roller condition detection method in the above embodiments. The beneficial effects of the arc-shaped roller condition detection device provided in this application are the same as those of the arc-shaped roller condition detection method provided in the above embodiments. Furthermore, the other technical features of the arc-shaped roller condition detection device are the same as those disclosed in the above embodiments, and will not be repeated here.

[0133] It should be understood that the various parts disclosed in this application can be implemented using hardware, software, firmware, or a combination thereof. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments or examples.

[0134] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0135] This application provides a computer-readable storage medium having computer-readable program instructions (i.e., a computer program) stored thereon, the computer-readable program instructions being used to execute the arc roller state detection method in the above embodiments.

[0136] The computer-readable storage medium provided in this application may be, for example, a USB flash drive, but is not limited to, electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems, devices, or any combination thereof. More specific examples of computer-readable storage media may include, but are not limited to: electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this embodiment, the computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, system, or device. The program code contained on the computer-readable storage medium may be transmitted using any suitable medium, including but not limited to: wires, optical cables, RF (Radio Frequency), etc., or any suitable combination thereof.

[0137] The aforementioned computer-readable storage medium may be included in the arc roller condition detection device; or it may exist independently and not assembled into the arc roller condition detection device.

[0138] The aforementioned computer-readable storage medium carries one or more programs, which, when executed by the arc-shaped roller condition detection device, enable the arc-shaped roller condition detection device to implement the aforementioned arc-shaped roller condition detection method.

[0139] Computer program code for performing the operations of this application can be written in one or more programming languages ​​or a combination thereof, including object-oriented programming languages ​​such as Java, Smalltalk, and C++, and conventional procedural programming languages ​​such as the "C" language or similar programming languages. The program code can be executed entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving remote computers, the remote computer can be connected to the user's computer via any type of network—including a Local Area Network (LAN) or a Wide Area Network (WAN)—or can be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0140] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0141] The modules described in the embodiments of this application can be implemented in software or hardware. The names of the modules do not necessarily limit the functionality of the unit itself.

[0142] The readable storage medium provided in this application is a computer-readable storage medium, which stores computer-readable program instructions (i.e., a computer program) for executing the above-described arc-shaped roller state detection method. The beneficial effects of the computer-readable storage medium provided in this application are the same as those of the arc-shaped roller state detection method provided in the above embodiments, and will not be repeated here.

[0143] This application also provides a computer program product, including a computer program that, when executed by a processor, implements the steps of the arc-shaped roller state detection method as described above. The beneficial effects of the computer program product provided in this application are the same as those of the arc-shaped roller state detection method provided in the above embodiments, and will not be repeated here.

[0144] The above description is only a part of the embodiments of this application and does not limit the patent scope of this application. All equivalent structural transformations made under the technical concept of this application and using the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included in the patent protection scope of this application.

Claims

1. A method for detecting the condition of an arc-shaped roller, characterized in that, The method includes: A first electrical signal is acquired during the rotation of the arc-shaped roller. The first electrical signal is acquired based on at least one first non-contact displacement sensor. The first non-contact displacement sensor is disposed at both ends away from the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, causing the first electrical signal to change periodically. The rotation state of the arc-shaped roller is determined based on the first electrical signal; Determining the rotation state of the arc-shaped roller based on the first electrical signal includes: If the first electrical signal does not change periodically and its duration is greater than or equal to the first preset duration, the arc-shaped roller is determined to be in a stopped or jammed state. When the first electrical signal exhibits periodic changes and a first signal segment appears intermittently in the middle of the periodic waveform, it is determined that the arc-shaped roller is in an intermittent jammed state, wherein the duration of the first signal segment is less than the first preset duration, and the amplitude variation range of the first signal segment is less than the preset amplitude range.

2. The method as described in claim 1, characterized in that, The method further includes: A second electrical signal is acquired during the rotation of the arc-shaped roller. This second electrical signal is obtained based on a second non-contact displacement sensor. The second non-contact displacement sensor is positioned away from both ends of the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed. The first and second non-contact displacement sensors are located on the same plane of the arc-shaped roller's first cross-section. Within the first cross-section, the two sensors form a preset fixed angle with the line connecting the center of the first cross-section to the two sensors. The first cross-section is the cross-section in the radial direction of the arc-shaped roller. The first non-contact displacement sensor is a laser displacement sensor, and the second non-contact displacement sensor is an eddy current sensor. During the rotation of the arc-shaped roller, the distance between the second non-contact displacement sensor and the spindle of the arc-shaped roller changes periodically, causing the second electrical signal to change periodically. The determination of whether the arc-shaped roller has internal slippage is based on the first electrical signal and the second electrical signal.

3. The method as described in claim 2, characterized in that, The step of determining whether the arc-shaped roller has experienced internal slippage based on the first electrical signal and the second electrical signal includes: When the first electrical signal and the second electrical signal change periodically, and the absolute value of the difference between the phase difference of the first electrical signal and the second electrical signal and the initial phase difference is greater than the first preset phase difference, it is determined that the arc-shaped roller has internal slippage, wherein the initial phase difference is determined according to the preset fixed angle; Alternatively, if the rate of change of the phase difference between the first electrical signal and the second electrical signal over time is greater than a preset rate of change, and the duration is greater than a second preset duration, it is determined that the arc-shaped roller has experienced internal slippage.

4. The method according to any one of claims 1 to 3, characterized in that, The method further includes: A third electrical signal is acquired during the rotation of the arc-shaped roller. The third electrical signal is acquired based on a third non-contact displacement sensor. The third non-contact displacement sensor is located at both ends away from the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed. Both the first non-contact displacement sensor and the third non-contact displacement sensor are laser displacement sensors. The first non-contact displacement sensor and the third non-contact displacement sensor are symmetrically arranged on the left and right sides with respect to the highest point of the protrusion of the arc-shaped roller, and the distance between the first non-contact displacement sensor and the third non-contact displacement sensor and the arc-shaped roller in a stationary state is the same. The arc-shaped roller is determined to be worn or deformed based on the first electrical signal and the third electrical signal.

5. The method as described in claim 4, characterized in that, The step of determining whether the arc-shaped roller has experienced wear or deformation based on the first electrical signal and the third electrical signal includes: If the absolute value of the phase difference between the first electrical signal and the third electrical signal is greater than the second preset phase difference, and the duration is greater than the third preset duration, it is determined that the arc-shaped roller has been worn or deformed. Alternatively, if the deviation of the amplitude ratio of the first electrical signal to the third electrical signal from 1 is greater than a preset amplitude deviation, it is determined that the arc-shaped roller has been worn or deformed.

6. A state detection system for an arc-shaped roller, characterized in that, The system includes: At least one first non-contact displacement sensor is disposed away from both ends of the arc-shaped roller and its relative position to the arc-shaped roller in a stationary state is fixed. The at least one first non-contact displacement sensor is used to acquire a first electrical signal during the rotation of the arc-shaped roller. During the rotation of the arc-shaped roller, the distance between the first non-contact displacement sensor and the arc-shaped roller changes periodically, causing the first electrical signal to change periodically. The processor is configured to determine that the arc-shaped roller is in a stopped or jammed state when the first electrical signal does not change periodically and the duration is greater than or equal to a first preset duration. When the first electrical signal exhibits periodic changes and a first signal segment appears intermittently in the middle of the periodic waveform, it is determined that the arc-shaped roller is in an intermittent jammed state, wherein the duration of the first signal segment is less than the first preset duration, and the amplitude variation range of the first signal segment is less than the preset amplitude range.

7. A device for detecting the condition of an arc-shaped roller, characterized in that, The device includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the arc-shaped roller state detection method as described in any one of claims 1 to 5.

8. A storage medium, characterized in that, The storage medium is a computer-readable storage medium, and a computer program is stored on the storage medium. When the computer program is executed by a processor, it implements the steps of the arc-shaped roller state detection method as described in any one of claims 1 to 5.

9. A computer program product, characterized in that, The computer program product includes a computer program that, when executed by a processor, implements the steps of the arc-shaped roller state detection method as described in any one of claims 1 to 5.

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