Roller surface state monitoring device and method of use thereof

Abstract

The present application relates to the technical field of metallurgical rolling equipment detection, and particularly relates to a roller surface state monitoring device and a use method thereof. The device is directly installed on the inner wall of a roller rotating machine seat supporting roller rotation, without the need to transform the rolling mill structure and disassemble the roller, and is composed of a fixed support assembly, a pose adjustment assembly, a moving execution assembly, a detection sensor assembly and a data transmission and control assembly. The fixed support assembly takes a horizontal connecting rod as a carrier, the pose adjustment assembly can drive the horizontal connecting rod to complete independent adjustment in the horizontal and vertical diameters, and eliminate the parallelism error with the roller axis; the moving execution assembly can drive the detection sensor assembly to realize full-length scanning along the roller axis, and the detection sensor assembly completes non-contact real-time surface scanning through a laser profiler; and the data transmission and control assembly realizes roller 3D appearance reconstruction and detection result visualization based on scanning data. The device can calibrate and eliminate installation errors, realize online non-contact high-precision monitoring, and solve the problems of detection downtime inefficiency and production influence.

Description

Technical Field

[0001] This invention relates to the field of metallurgical rolling equipment testing technology, specifically a roll surface condition monitoring device and its usage method. Background Technology

[0002] Rolls are the core working components in rolling mills that enable continuous plastic deformation of metals. Their bodies directly participate in the metal rolling process, and the surface morphology and condition of the rolls directly determine the forming quality of the rolled product and the service life of the rolls. In actual rolling production, rolls are subjected to a combination of loads, including rolling force, cyclic friction, temperature fluctuations, and impact from metal oxide scale. This makes them highly susceptible to surface wear, pitting, and cracking. Therefore, routine inspection of the roll surface condition is necessary to ensure the continuous and stable operation of the rolling production line.

[0003] Currently, the industry commonly uses offline shutdown testing, which requires stopping rolling production and manually disassembling and reassembling the rolls before testing can begin. This is a typical post-fault maintenance mode. This method not only has a long testing cycle and high labor costs, but also causes long-term production line shutdowns, severely disrupting production continuity and causing significant economic losses. It is difficult to meet the efficient, continuous, and intelligent operation and maintenance requirements of modern rolling production lines.

[0004] To address the technical pain points of low efficiency and disruption to normal production caused by traditional offline downtime inspections, there is an urgent need to develop a new type of monitoring equipment that can be directly installed on existing roller rotators without modifying the mill structure, enabling real-time online monitoring of the roll surface, automatically eliminating installation parallelism errors, and completing accurate surface condition detection and data presentation. Summary of the Invention

[0005] To address the technical problems of low efficiency and disruption to normal production caused by traditional offline downtime inspections, this invention provides a roll surface condition monitoring device and a roll surface condition monitoring method using the device.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A roll surface condition monitoring device, characterized in that the device is integrally installed on the inner wall of the base of a roller rotary machine that supports and drives the roll rotation, comprising: The fixed support assembly includes a transverse link, on which a moving actuator is slidably mounted and at the end a posture adjustment assembly is mounted; The position adjustment component is used to drive the transverse link to complete independent horizontal radial and vertical diameter displacement adjustment, eliminating the error of the transverse link not being parallel to the roll axis; The moving execution component is equipped with a detection sensor component that performs real-time detection of the surface condition of the roll, which is used to drive the detection sensor component to complete a full-length scan along the axial direction of the roll. Detection sensing components, including a laser profilometer for real-time scanning of the roll surface; The data transmission and control component is used to reconstruct the 3D morphology of the roll based on the scanning data of the laser profilometer and to visualize the roll surface condition detection results in real time.

[0007] As a further embodiment of the present invention: the fixed support assembly further includes a flange, a first ball hinge, and a second ball hinge; the flange is fixedly installed on the inner wall of the base, the first end of the transverse link is hinged to the flange through the first ball hinge, and the second end of the transverse link is hinged to the posture adjustment assembly through the second ball hinge, providing multi-directional rotational freedom for the posture adjustment of the transverse link.

[0008] As a further embodiment of the present invention: the pose adjustment component is a YZ displacement platform, which adopts a stacked dual-axis orthogonal structure, including a fixed base, a Y-axis displacement unit, a Z-axis displacement unit, a displacement feedback component and an electromagnetic locking mechanism. The fixed base is fixed to the inner wall of the machine base, and the movable end of the YZ displacement platform is connected to the second ball hinge. After adjustment, the electromagnetic locking mechanism automatically locks the position.

[0009] As a further embodiment of the present invention: the moving execution component includes a transverse guide rail, a rack, a slider trolley and a stepper motor; the transverse guide rail and the rack are fixed parallel to each other on the upper surface of the transverse connecting rod, and the slider trolley is slidably engaged with the transverse guide rail; the stepper motor is fixed to the slider trolley, and its output shaft is driven by the rack through a transmission gear to drive the slider trolley to move at a constant speed along the roller axis.

[0010] As a further embodiment of the present invention: the detection sensing component also includes a magnetic base and a vibration sensor; the laser profilometer is fixed on the slider carriage by magnetic adsorption, the emitting end is perpendicular to the roll axis and projects a linear narrow light band; the vibration sensor is magnetically fixed on the outside of the roll bearing seat and is used to collect the radial vibration signal of the roll rotation.

[0011] As a further embodiment of the present invention: the data transmission and control component includes a signal synchronization module, a host computer, and a monitoring room display terminal; the signal synchronization module provides a unified system clock for the laser profilometer and vibration sensor, the host computer is used for data processing, vibration error compensation, busbar fitting and 3D morphology reconstruction, and the monitoring room display terminal is used to visualize the roll surface condition detection results.

[0012] A method for monitoring the surface condition of a rolling mill roll, based on a rolling mill roll surface condition monitoring device, includes the following steps: The roll is controlled to rotate at a constant speed. The laser profilometer is driven by the moving execution component to complete the pre-scan of the entire roll body. The radial distance is calculated based on the collected pre-scan data and the roll generatrix is ​​fitted to obtain the tilt and offset of the transverse link relative to the roll axis. The position adjustment component is used to complete the position adjustment of the transverse link and realize the parallelism calibration between the transverse link and the roll axis. After the parallelism calibration is completed, real-time scanning data from the laser profilometer and real-time radial vibration signals from the rolls are collected simultaneously. The real-time radial vibration signal is de-DC, filtered and integrated to obtain the real-time vibration displacement compensation amount. Based on this real-time vibration displacement compensation amount, the real-time vibration error of the laser profilometer is corrected to obtain the true radial distance. Based on the true radial distance, least squares circle fitting is performed on a single cross section of the roll to obtain the coordinates of the center of each cross section. Then, spatial straight line fitting is performed on the center of all cross sections to obtain the true axis of the roll. Using the actual axis of the roll as a reference, the actual radial distance of all cross sections is mapped to the global detection coordinate system, and a three-dimensional morphological model of the roll surface is generated by splicing them together, and surface defect identification and marking are completed.

[0013] As a further aspect of the present invention: in parallelism calibration, the specific steps for obtaining the busbar fitting and the tilt and offset are as follows: The roll is controlled to rotate at a uniform speed, and the moving actuator drives the laser profilometer to complete a full-length pre-scan of the roll body along the roll axis, collecting the position, circumferential angle, and profile data of each sampling point; the sampling points are then converted into spatial points P(X) in the roll body coordinate system. i ,Y i Z i ), where X i Y i Z i These represent the X, Y, and Z coordinates of the sampling point in the roll body coordinate system; using the formula r i =(Y i 2 +Z i 2 ) 0.5 Calculate radial distance r i The spatial points corresponding to the same circumferential angle are selected to form a set of generatrix points. The least squares method is used to fit the generatrix points to a straight line in space, and the Y-direction inclination a and Z-direction inclination c of the transverse connecting rod relative to the roll axis are obtained. The total offset ΔY=a×L and ΔZ=c×L are calculated in combination with the effective length L of the roll.

[0014] As a further aspect of the present invention, the specific steps of vibration signal processing and error correction are as follows: The acquired real-time radial vibration acceleration signal of the roll is sequentially subjected to DC-free processing and bandpass digital filtering to remove zero-point drift, electromagnetic noise, and environmental vibration interference. The preprocessed real-time radial vibration acceleration signal is then integrated twice over time to obtain the real-time vibration displacement compensation s(t). Based on a unified system clock, the real-time vibration displacement compensation s(t) is compared with the real-time radial distance d measured by the laser profilometer. meas Perform point-to-point synchronous matching using formula d true =d meas -s(t) performs real-time vibration error correction on the real-time scanning data to obtain the true radial distance d on the roll surface. true .

[0015] As a further aspect of the present invention, the specific steps for single-section profile fitting and obtaining the true axis of the roll are as follows: the real radial distance after real-time vibration error correction is mapped to the roll body coordinate system O-XYZ, and the point cloud of the single-section profile is fitted with a circle using the least squares method to obtain the center coordinates of the circle of the section; data acquisition, error correction and circle fitting are completed section by section along the roll axis, the center coordinates of all detected sections are extracted, and the spatial straight line is fitted with all center coordinates using the least squares method. The fitted spatial straight line is the true axis of the roll in the roll body coordinate system.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. The roll surface condition monitoring device is directly installed on the inner wall of the roller rotator base, which supports and drives the roll rotation. This eliminates the need for structural modifications to the mill or roll disassembly, fundamentally removing the traditional operation of stopping the machine and manually disassembling the rolls, ensuring continuous rolling production. Using the transverse connecting rod of the fixed support assembly as the mounting base, the moving actuator drives the detection sensor assembly equipped with a laser profilometer to complete a full-length scan along the roll axis. Combined with the laser profilometer, it performs real-time non-contact scanning of the roll surface, achieving online real-time detection of the roll surface condition. Routine monitoring can be completed without interrupting the production process. Simultaneously, the device monitors the roll surface condition through position and posture... The adjustment component allows for independent and precise adjustment of the transverse connecting rod in both the horizontal radial and vertical diameter directions, quickly eliminating detection errors caused by the non-parallelism between the transverse connecting rod and the roll axis, ensuring the accuracy and reliability of online detection. Furthermore, the data transmission and control component reconstructs the 3D morphology of the roll in real time based on laser scanning data and visualizes the detection results. This allows for rapid assessment of the roll surface condition and preventative maintenance, avoiding downtime caused by roll damage. It truly achieves continuous, non-disassembly-free, high-efficiency, and continuous roll surface condition monitoring, completely solving the technical problems of long traditional offline inspection cycles, high labor costs, serious disruption to normal production, and economic losses.

[0017] 2. By using uniform rotation of the roll in conjunction with full-length pre-scanning of the roll body by a laser profilometer, online automatic detection of the parallelism between the transverse connecting rod and the roll axis is achieved, eliminating the need for manual debugging, machine shutdown calibration, or equipment disassembly and assembly. Through roll body coordinate system transformation and radial distance formula calculation, the radial dimension parameters of each sampling point can be accurately quantified. By selecting spatial points with the same circumferential angle to construct a generatrix point set, the true generatrix characteristics of the roll can be accurately extracted, avoiding fitting deviations caused by data mixing. Using the least squares method to perform spatial linear fitting on the generatrix point set, the tilt of the transverse connecting rod in the Y and Z directions can be scientifically and stably solved. Combined with the effective length of the roll, the total offset is calculated, realizing the digital quantitative acquisition of parallelism error. This provides accurate data basis for posture adjustment, fundamentally eliminating the detection distance drift error caused by the non-parallelism between the transverse connecting rod and the roll axis, and laying a high-precision detection benchmark for subsequent full-process online detection.

[0018] 3. By sequentially performing DC-free processing and bandpass digital filtering on the radial vibration acceleration signal, zero-point drift, electromagnetic noise, and environmental vibration interference in the signal can be effectively eliminated, preserving the true radial vibration characteristics during roll rotation. Performing two time integrations on the pre-processed vibration acceleration signal accurately converts the acceleration signal into a vibration displacement compensation amount that can be directly used for correction, enabling quantitative calculation of vibration errors. Relying on a unified system clock, point-to-point synchronous matching of the vibration displacement compensation amount and the laser-measured radial distance is achieved, and real-time error correction is completed through formulas. This completely eliminates the interference of roll radial vibration on laser scanning data, avoiding misjudging vibration displacement as roll surface wear, pits, or other defects, significantly improving the authenticity and accuracy of the detection data. This provides reliable raw data for subsequent cross-section fitting, roll axis reconstruction, and surface defect identification, ensuring the accuracy and reliability of the final detection results. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a roll surface condition monitoring device.

[0020] Figure 2 This is a schematic diagram of the assembly structure of the roll surface condition monitoring device and the roller rotating machine.

[0021] Figure 3 This is a flowchart of a method for monitoring the surface condition of rolling mill rolls.

[0022] In the diagram: 1. Roll; 2. Machine base; 3. Flange; 4. First ball hinge; 5. Transverse connecting rod; 6. YZ displacement platform; 7. Sliding trolley; 8. Vibration sensor; 9. Stepper motor; 10. Laser profilometer; 11. Magnetic base; 12. Rack; 13. Transverse guide rail; 14. Second ball hinge. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] I. Roll Surface Condition Monitoring Device

[0025] like Figure 1 and Figure 2 As shown, this roll surface condition monitoring device is installed entirely on the inner wall of the base 2 of the roller rotator that supports and drives the roll 1 to rotate. It allows for online real-time detection of the roll surface without disassembling the roll 1 or altering the original mill structure. The device consists of five parts: a fixed support assembly, a position adjustment assembly, a movement execution assembly, a detection sensing assembly, and a data transmission and control assembly. The connection relationships and installation methods of each component are as follows: (a) Fixed support components The fixed support assembly is the installation base of the device, used to securely connect the overall structure to the mill base 2, and includes a flange 3, a first ball hinge 4, a second ball hinge 14, and a transverse connecting rod 5.

[0026] 1. Flange

[0027] Flange 3 is fastened to a preset mounting position on the inner wall of the base 2 by bolts, providing a rigid connection base for the ball hinge.

[0028] 2. First ball joint

[0029] One end of the first ball hinge 4 is fixedly connected to the flange 3, and the other end is fixedly connected to the first end of the transverse link 5, which can realize multi-directional small-angle rotation, providing flexible motion freedom for the fine-tuning of the position and posture of the transverse link 5.

[0030] 3. Second ball hinge

[0031] One end of the second ball hinge 14 is fixedly connected to the second end of the transverse link 5, and the other end is fixedly connected to the movable end of the posture adjustment component, so as to achieve precise adjustment of the overall posture of the transverse link 5 in conjunction with the first ball hinge 4.

[0032] 4. Lateral connecting rod

[0033] The transverse connecting rod 5 is a long, rigid rod that is approximately parallel to the roll axis in its initial installation state. It serves as the mounting carrier for the transverse guide rail 13 and the rack 12, and its position can be adjusted in coordination with the position adjustment component via a ball joint.

[0034] (ii) Pose adjustment component

[0035] This device uses the existing YZ displacement platform 6 (YZ two-dimensional precision electric displacement platform) as the posture adjustment execution component. It belongs to the conventional and general precision displacement structure in this field and does not require redesign and development. It is used to realize independent high-precision micro-displacement adjustment of the horizontal radial (Y direction) and vertical diameter (Z direction) of the transverse connecting rod 5, and eliminate the measurement system error caused by the non-parallelism between the transverse guide rail 13 and the roll axis.

[0036] 1. Overall Structure

[0037] The YZ two-dimensional precision electric displacement platform adopts a stacked dual-axis orthogonal structure, consisting of a fixed base, Y-axis displacement unit, Z-axis displacement unit, drive assembly, displacement feedback assembly, electromagnetic locking mechanism, and ball hinge connector. The entire platform is made of high-strength aluminum alloy, which is vibration resistant, has low creep, and is suitable for the harsh working conditions of the rolling mill site.

[0038] 2. Installation Relationship

[0039] Fixed base: It is fastened to the inner wall of the base 2 with high-strength bolts, and the bottom surface is completely in contact with the inner wall of the base 2 to ensure that the installation reference is stable and free from deformation.

[0040] Ball joint connector: It is fixedly installed on the top surface of the sliding table of the Z-axis displacement unit and rigidly connected to the second ball joint 14 to realize the hinged engagement between the displacement platform and the transverse connecting rod 5.

[0041] 3. Motor function

[0042] The YZ displacement platform 6 can independently drive Y-axis and Z-axis movements, with the two axes moving in strictly perpendicular directions. It has built-in closed-loop displacement feedback and electromagnetic locking functions, receives instructions from the host computer to complete precise compensation and adjustment, and automatically locks the sliding stage after adjustment to ensure constant posture during the detection process.

[0043] (iii) Mobile Execution Component

[0044] The moving execution component is used to drive the laser profilometer 10 to move along the entire length of the roll axis to achieve full-length surface scanning of the roll 1. It includes a transverse guide rail 13, a rack 12, a slider carriage 7, and a stepper motor 9.

[0045] 1. Horizontal guide rail

[0046] The transverse guide rail 13 is fastened to the upper surface of the transverse connecting rod 5 by screws, and its extension direction is consistent with that of the transverse connecting rod 5. It provides linear motion guidance for the slider trolley 7 and ensures that the motion trajectory is straight.

[0047] 2. Gear rack

[0048] The rack 12 is mounted parallel to one side of the transverse guide rail 13 by screws, and is completely aligned with the extension direction of the transverse guide rail 13, providing a meshing basis for the gear rack transmission.

[0049] 3. Sliding Cart

[0050] The slider trolley 7 is movably mounted on the transverse guide rail 13 and can slide freely in a straight line along the transverse guide rail 13, providing a mounting carrier for the laser profilometer 10.

[0051] 4. Stepper motor

[0052] Stepper motor 9 is fixedly mounted on slider trolley 7. The motor output shaft is equipped with transmission gear, which meshes with rack 12. Stepper motor 9 receives control commands from host computer and drives slider trolley 7 to move uniformly and precisely along transverse guide rail 13 through gear and rack 12 mechanism. Displacement data can be fed back to host computer in real time.

[0053] (iv) Detection of sensor components

[0054] The detection sensing component is the core detection unit, responsible for collecting the contour, vibration, and rotation speed signals of the roll 1, including the laser profiler 10, the magnetic base 11, and the vibration sensor 8.

[0055] 1. Magnet base

[0056] The magnetic base 11 is fixedly attached to the upper side of the slider carriage 7, providing a detachable mounting base for the laser profilometer 10, which is convenient to install and does not damage the slider carriage 7.

[0057] 2. Laser profilometer

[0058] The laser profilometer 10 is fixedly mounted on the magnetic base 11. The emitting end is perpendicular to the surface of the roll body 1 and emits a linear narrow light band laser. Based on the laser triangulation measurement principle, it acquires the full circumference profile point cloud data of a single section of the roll 1 in one go. The data is transmitted to the host computer in real time.

[0059] 3. Vibration sensor

[0060] Vibration sensor 8 is fixed to the outside of the bearing seat of roll 1 by magnetic attraction. It is used to collect radial vibration acceleration signals during the rotation of roll 1 in real time. The sampling frequency is preferably 10KHz. The signal is synchronously transmitted to the host computer.

[0061] (v) Data transmission and control components

[0062] The data transmission and control components enable signal synchronization, command issuance, and data processing, including a signal synchronization module, a host computer, and a monitoring room display terminal.

[0063] 1. Signal synchronization module

[0064] The signal synchronization module provides a unified system clock for the laser profilometer 10, vibration sensor 8, and rolling mill encoder, ensuring that the timestamps of all acquired data are consistent.

[0065] 2. Host computer

[0066] The host computer is deployed in the monitoring room and has built-in signal processing, data fitting, and 3D modeling software. It is responsible for receiving all sensor data, issuing control commands, and completing data calculation and compensation.

[0067] 3. Monitoring room display terminal

[0068] The monitoring room display terminal is connected to the host computer to display the roll surface profile, vibration data, 3D morphology and defect detection results in real time.

[0069] II. Detection Coordinate System

[0070] To ensure the uniqueness and accuracy of line laser data processing, guide rail parallelism calibration, geometric fitting, and 3D modeling, three core coordinate systems are defined: the roll body coordinate system, the guide rail motion coordinate system, and the global detection coordinate system. All detection data are transformed, calculated, and mapped based on the above coordinate systems.

[0071] 1. Roll body coordinate system O-XYZ

[0072] The roll body coordinate system is the inherent reference coordinate system of roll 1, which is used to characterize the real spatial position of the physical axis, cross-sectional profile, generatrix and surface defects of roll 1.

[0073] Origin of coordinates: Select the geometric center point of the left end face of roll 1.

[0074] X-axis: Completely coincides with the physical axis of roll 1, and the positive direction is the right end face of roll 1. It is defined as the roll axis.

[0075] Y-axis: Located in the plane of the left end face circle of roll 1, the positive direction is horizontal inward, and it is defined as the horizontal radial direction of roll 1.

[0076] Z-axis: Located in the plane of the left end face circle of roll 1, with the vertical upward direction as the positive direction, defined as the vertical diameter direction of roll 1.

[0077] Application: Characterizes the spatial position of the generatrix of roll 1, the single-section profile circle, and the true axis of roll 1, and maps the true morphology of the roll surface.

[0078] 2. Guide rail motion coordinate system O'-X'Y'Z'

[0079] The guide rail motion coordinate system is a dedicated motion coordinate system for the transverse guide rail 13, used to position the axial position of the slider trolley 7 and the laser profiler 10, and to calculate the parallelism deviation between the transverse guide rail 13 and the roll axis.

[0080] Origin O': Select the geometric center of the left end point of the horizontal guide rail 13.

[0081] X' axis: It coincides completely with the center line of the transverse guide rail 13, and the positive direction is the right end of the transverse guide rail 13. It is defined as the axis of movement of the guide rail.

[0082] Y' axis: Located in the vertical plane of the left end face of the transverse guide rail 13, with the positive direction being horizontal inward, and defined as the horizontal radial direction of the guide rail.

[0083] Z' axis: Located in the vertical plane of the left end face of the transverse guide rail 13, with the vertical upward direction as the positive direction, defined as the vertical diameter direction of the guide rail.

[0084] Application: To calculate the offset of the guide rail relative to the roll axis in the Y and Z directions, providing data for fine-tuning of the YZ two-dimensional precision displacement platform.

[0085] 3. Global detection coordinate system O all -X all Y all Z all

[0086] The global detection coordinate system serves as the unified data processing reference coordinate system for the host computer, integrating the data from the roll body coordinate system and the guide rail motion coordinate system to achieve normalized processing of multi-source detection data.

[0087] Origin of coordinates all It completely coincides with the origin O of the roll body coordinate system, ensuring the consistency of the reference of the entire system.

[0088] X all Axis: It is completely coincident with the X-axis of the roll body coordinate system and serves as the global axial reference.

[0089] Y all Axis: It is completely coincident with the Y-axis of the roll body coordinate system and serves as the global horizontal radial reference.

[0090] Z all Axis: It is completely coincident with the Z-axis of the roll body coordinate system and serves as the global vertical diameter reference.

[0091] Application: To unify the mapping of line laser contour data, vibration compensation data, and roll rotation angle data to complete the reconstruction of the complete 3D morphology of the roll surface.

[0092] 4. Parallel correspondence between the 6 motion axes of the YZ displacement platform and the system coordinate system

[0093] To ensure the accuracy and uniqueness of the guide rail parallelism calibration, the motion axis system of the YZ two-dimensional precision displacement platform is strictly parallel to the three coordinate systems of this system, with the specific correspondence as follows: YZ 2D Precision Displacement Platform Y-axis: Aligned with the Y-axis of the roll body coordinate system, the Y' axis of the guide rail motion coordinate system, and the global detection coordinate system. all The three axes are parallel to each other and all correspond to the horizontal radial direction of the system.

[0094] The Z-axis of the YZ two-dimensional precision displacement platform is aligned with the Z-axis of the roll body coordinate system, the Z' axis of the guide rail motion coordinate system, and the global detection coordinate system. all The three axes are parallel to each other and all correspond to the vertical diameter of the system.

[0095] Axis orthogonality: The Y-axis and Z-axis of the YZ two-dimensional precision displacement platform are strictly orthogonal, and their orthogonality is completely consistent with the orthogonality of the Y and Z axes of the three coordinate systems of the system, ensuring that the displacement adjustment can be directly used for guide rail parallelism error compensation.

[0096] III. Methods for Monitoring the Surface Condition of Rolls

[0097] This method, based on the aforementioned roll surface condition monitoring device and defined coordinate system, uses a laser profilometer 10 as the core detection unit. Through seven steps—guide rail parallelism calibration, linear laser synchronous data acquisition, vibration error compensation, geometric fitting, and 3D topography reconstruction—it achieves high-precision online detection of the roll surface. Figure 3 As shown, the specific process is as follows: (a) Parallelism calibration of transverse guide rail and roll axis This step is a core pre-process of line laser inspection, eliminating the systematic error caused by the tilt of the transverse guide rail 13 leading to the drift of the distance between the laser profiler 10 and the roll surface.

[0098] Since the transverse guide rail 13 and the transverse connecting rod 5 are parallel to each other and fixed together, the assembly connection between the transverse guide rail 13 and the laser profilometer 10 is more direct and closer. Therefore, the transverse guide rail 13 is used as the calibration object during parallelism calibration. The calibration result can directly and equivalently reflect the parallelism state between the transverse connecting rod 5 and the roll axis, ensuring the consistency between the calibration accuracy and the detection benchmark.

[0099] 1. Set the roll running status

[0100] The roller 1 is controlled to rotate at a low and uniform speed to ensure that the laser profilometer 10 can completely scan the circumferential cross section of the roller 1, thereby improving the accuracy of the busbar extraction.

[0101] 2. Line laser full-length pre-scan

[0102] The host computer issues a command, and the stepper motor 9 drives the slider carriage 7 to drive the laser profilometer 10 to complete the full length pre-scan of the roll body 1 along the transverse guide rail 13; the laser profilometer 10 continuously projects a linear narrow light band onto the surface of the roll to collect data on axial position, circumferential angle and radial distance.

[0103] 3. Spatial coordinate transformation and radial distance calculation

[0104] The host computer converts the sampling point data collected by the laser profilometer 10 into spatial point coordinates P(X) in the roll body coordinate system O-XYZ.i ,Y i ,Zi), where X i Y represents the axial position of the measured spatial point. i Z represents the horizontal radial coordinate of the measured spatial point. i Let be the vertical diameter coordinate of the measured spatial point. Based on the formula for the distance from the midpoint to a straight line in spatial analytic geometry, calculate the perpendicular straight-line distance from this spatial point to the roll axis (X-axis), i.e., the radial distance r. i The calculation formula is: r i =(Y i 2 +Z i 2 ) 0.5 The radial distance is the core geometric parameter for generatrix fitting and parallelism determination.

[0105] 4. Extract roll busbar data

[0106] The host computer pre-selects a fixed reference angle θ0 as a reference, and selects the circumferential angle θ from all sampling points. i The set of spatial points that coincide with the reference angle θ0 is the discrete point set of a single busbar of roll 1.

[0107] 5. Busbar Fitting and Offset Calculation

[0108] In the guide rail motion coordinate system O'-X'Y'Z', the host computer uses the least squares method to fit a spatial straight line to the set of points on the generatrix. Through iterative calculation, the sum of the squares of the perpendicular distances from all discrete points to the fitted line is minimized, thus obtaining the optimal spatial straight line equation for the generatrix. Then, the tilt a and tilt c of the transverse guide rail 13 in the Y' direction and Z' direction in the guide rail motion coordinate system are obtained, as well as the corresponding intercepts b and d. Combined with the effective detection length L of the roll 1, the total offset ΔY=a×L and the total offset ΔZ=c×L of the transverse guide rail 13 that need to be compensated in the Y direction are calculated respectively.

[0109] 6. YZ displacement platform with automatic fine-tuning

[0110] Based on the parallel correspondence between the YZ displacement platform 6 and the system coordinate system, the host computer drives the YZ displacement platform 6 to complete precise displacement compensation along the horizontal radial direction (Y-direction) and the vertical diameter direction (Z-direction). The Y-direction offset ΔY is used to adjust the horizontal radial position, and the Z-direction offset ΔZ is used to adjust the vertical diameter position. If ΔY is positive, the host computer controls the YZ displacement platform 6 to move the compensation amount ΔY along the positive Y-direction (horizontal radial direction); if ΔY is negative, it moves the compensation amount |ΔY| along the negative Y-direction. If ΔZ is positive, the host computer controls the YZ displacement platform 6 to move the compensation amount ΔZ along the positive Z-direction (vertical diameter direction); if ΔZ is negative, it moves the compensation amount |ΔZ| along the negative Z-direction.

[0111] During the adjustment process, the built-in feedback component of the displacement platform transmits displacement data in real time to ensure that the compensation amount accurately matches ΔY and ΔZ. After the adjustment is in place, the electromagnetic locking mechanism automatically locks the sliding table of the displacement platform to prevent the position deviation caused by the vibration of the rolling mill.

[0112] 7. Parallelism qualification judgment

[0113] The host computer controls the laser profilometer 10 to re-execute the full-length pre-scan of the roll body, radial distance calculation, and linear fitting of the generatrix space. If the tilt a in the Y' direction and the tilt c in the Z' direction of the guide rail obtained by the second fitting are both approximately 0 (|a| and |c| are both less than 0.0005), it is determined that the transverse guide rail 13 and the roll axis have reached a parallel state, and the guide rail parallelism calibration process is completed.

[0114] (ii) Linear laser synchronous data acquisition

[0115] After the parallelism calibration of the transverse guide rail 13 is completed, the system starts a unified clock and enters the formal data acquisition stage. The laser profilometer 10, vibration sensor 8, rolling mill encoder, and stepper motor 9 achieve time-synchronized acquisition to ensure that all data timestamps are completely consistent. 1. Acquire line laser profile data The laser profilometer 10 projects a linear narrow light band along the vertical line of the roll 1 busbar, acquiring the full circumference profile point cloud data of a single section of the roll 1 in one go, and uploading it to the host computer in real time.

[0116] 2. Acquire roll rotation angle signal

[0117] The mill encoder provides real-time feedback on the rotation angle θ of roll 1. i This provides a basis for circumferential positioning of cross-sectional point clouds.

[0118] 3. Collect vibration signals

[0119] Vibration sensor 8 collects the radial vibration acceleration signal a(t) of the bearing housing of roll 1 in real time at a sampling frequency of 10KHz.

[0120] 4. Acquire axial displacement signals

[0121] The stepper motor 9 provides real-time feedback on the current axial position X of the slider carriage 7 and the laser profilometer 10. i This completes the axial positioning of the roll in all dimensions.

[0122] (III) Vibration signal preprocessing and feature extraction

[0123] The host computer standardizes the raw acceleration signal collected by vibration sensor 8, removes interference, and extracts the core parameters for vibration compensation. 1. DC removal processing Eliminate zero-point drift of acceleration signals and unify the signal reference plane.

[0124] 2. Digital Filtering

[0125] A bandpass filtering algorithm is used to filter out electromagnetic noise and environmental vibration interference, while retaining the true mechanical vibration signal of roll 1.

[0126] 3. Spectrum Analysis

[0127] Extract vibration characteristic parameters such as principal vibration frequency, vibration phase, and root mean square value.

[0128] 4. Vibration displacement conversion

[0129] The preprocessed acceleration signal is integrated twice over time to obtain the vibration displacement signal s(t), which is the vibration error compensation amount of the line laser profile measurement.

[0130] (iv) Real-time compensation for vibration error of line laser profile data

[0131] Eliminate the interference of mechanical vibration of roll 1 on radial distance measurement, avoid misjudging vibration displacement as roll surface defects, and complete accurate radial distance correction: 1. Compensation model calculation Laser profilometer 10 measured radial distance d meas =True radial distance d true +Vibration error e v , where e v =s(t), therefore the formula for calculating the true radial distance is: d true =d meas -s(t).

[0132] 2. Point-to-point synchronous compensation

[0133] Based on a unified system clock, the host computer will record the measured radial distance d corresponding to each sampling time t. meas It accurately matches the vibration displacement s(t) to complete real-time correction of a single sampling point.

[0134] 3. Determination of the effectiveness of compensation

[0135] Calculate the standard deviation σ1 of the radial distance of the single cross section before compensation and the standard deviation σ2 after compensation. If σ2 < 0.5σ1, the vibration compensation is deemed effective and can proceed to the subsequent fitting stage.

[0136] (v) Least square fitting of single-section profile circle

[0137] Based on the actual radial distance after vibration compensation, the geometric parameters of a single cross-section are fitted to obtain the core features of the cross-section. 1. Coordinate Mapping The host computer maps the corrected single-section profile point cloud data to the roll body coordinate system O-XYZ.

[0138] 2. Least squares circle fitting

[0139] The least squares method is used to fit a circle to the point cloud of a single cross section, and the coordinates of the center of the circle (Y) are obtained by solving the problem. i Z i ) and cross-sectional radius R i .

[0140] 3. Continuous cross-section scanning

[0141] The host computer controls the stepper motor 9 to drive the laser profilometer 10 to move along the roll axis (X-axis) to the next detection position, repeating the data acquisition, vibration compensation, and single-section circle fitting steps until the detection of all sections of the roll body 1 is completed.

[0142] (vi) Spatial linear fitting of the roll axis

[0143] Based on the centers of all detected cross sections, the true axis of the roll is fitted to provide a benchmark for 3D topography reconstruction. 1. Summary of center coordinates Extract the spatial coordinates (X) of the center of all detection sections along the entire length of roll 1. i ,Y i Z i ), where X i Y represents the axial position of the cross section. i Z i The radial coordinates of the center of the cross section; 2. Spatial linear fitting The host computer uses the least squares method to fit a straight line to all the center points in space. The fitted straight line is the true axis of the roll in the O-XYZ coordinate system of the roll body.

[0144] (vii) Reconstruction of the three-dimensional morphology of the roll surface

[0145] Using the actual axis of roll 1 as a reference, and integrating the full-section inspection data, a complete 3D model reconstruction and defect identification of the roll surface of roll 1 was completed. 1. Coordinate system normalization After compensation, the radial distance and circumferential angle θ of all cross sections i Axial position X i Unified mapping to the global detection coordinate system O all -X all Y all Z all .

[0146] 2.3D topography stitching

[0147] By sequentially stitching together the contour data of all cross sections in axial order, a complete three-dimensional topographic model of roll body 1 is generated.

[0148] 3. Defect Identification and Output

[0149] The host computer automatically identifies surface wear, pits, cracks and other defects based on the 3D topography model, marks the location, size and depth of the defects, and transmits the detection results to the display terminal in the monitoring room, providing data support for the preventive maintenance of roll 1.

[0150] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A device for monitoring the surface condition of a rolling mill roll, characterized in that, The device is installed on the inner wall of the base (2) of the roller rotary machine that supports and drives the rotation of the rolls, and includes: The fixed support assembly includes a transverse link (5), on which a moving execution component is slidably mounted and at the end is a posture adjustment component; The position adjustment component is used to drive the transverse link (5) to complete the independent displacement adjustment in the horizontal radial and vertical diameter directions, and eliminate the error of the transverse link (5) not being parallel to the roll axis; The moving execution component is equipped with a detection sensor component that performs real-time detection of the surface condition of the roll, which is used to drive the detection sensor component to complete a full-length scan along the axial direction of the roll. The detection sensing components include a laser profilometer (10) for real-time scanning of the roll surface. The data transmission and control component is used to reconstruct the 3D morphology of the roll (1) based on the scanning data of the laser profilometer (10) and visualize the roll surface condition detection results in real time.

2. The roll surface condition monitoring device according to claim 1, characterized in that, The fixed support assembly also includes a flange (3), a first ball hinge (4), and a second ball hinge (14); the flange (3) is fixedly installed on the inner wall of the base (2), the first end of the transverse link (5) is hinged to the flange (3) through the first ball hinge (4), and the second end of the transverse link (5) is hinged to the position adjustment assembly through the second ball hinge (14), providing multi-directional rotational freedom for the position adjustment of the transverse link (5).

3. The roll surface condition monitoring device according to claim 2, characterized in that, The pose adjustment component is a YZ displacement platform (6), which adopts a stacked dual-axis orthogonal structure, including a fixed base, a Y-axis displacement unit, a Z-axis displacement unit, a displacement feedback component and an electromagnetic locking mechanism. The fixed base is fixed to the inner wall of the machine base (2), and the movable end of the YZ displacement platform (6) is connected to the second ball hinge (14). After adjustment, the electromagnetic locking mechanism automatically locks the position.

4. The roll surface condition monitoring device according to claim 1, characterized in that, The moving execution component includes a transverse guide rail (13), a rack (12), a slider carriage (7), and a stepper motor (9); the transverse guide rail (13) and the rack (12) are fixed parallel to each other on the upper surface of the transverse connecting rod (5), and the slider carriage (7) is slidably engaged with the transverse guide rail (13); the stepper motor (9) is fixed to the slider carriage (7), and its output shaft is driven by meshing with the rack (12) through a transmission gear, driving the slider carriage (7) to move at a constant speed along the roller axis.

5. The roll surface condition monitoring device according to claim 1, characterized in that, The detection sensing component also includes a magnetic base (11) and a vibration sensor (8); the laser profilometer (10) is attached to the slider carriage (7) by magnetic base (11), and the emitting end is perpendicular to the roll axis and projects a linear narrow light band; the vibration sensor (8) is magnetically attached to the outside of the roll bearing seat and is used to collect the radial vibration signal of the roll (1) rotation.

6. The roll surface condition monitoring device according to claim 1, characterized in that, The data transmission and control components include a signal synchronization module, a host computer, and a monitoring room display terminal. The signal synchronization module provides a unified system clock for the laser profiler (10) and vibration sensor (8). The host computer is used for data processing, vibration error compensation, bus fitting, and 3D morphology reconstruction. The monitoring room display terminal is used to visualize the results of the roll surface condition detection.

7. A method for monitoring the surface condition of a rolling mill roll, characterized in that, The roll surface condition monitoring device based on any one of claims 1-6 is implemented by comprising the following steps: Control the roll to rotate at a constant speed, drive the laser profiler (10) through the moving execution component to complete the full-length pre-scan of the roll body, calculate the radial distance based on the collected pre-scan data and fit the roll generatrix, obtain the tilt and offset of the transverse link (5) relative to the roll axis, complete the pose adjustment of the transverse link (5) through the pose adjustment component, and realize the parallelism calibration of the transverse link (5) and the roll axis. After the parallelism calibration is completed, the real-time scanning data of the laser profiler (10) and the real-time radial vibration signal of the roll (1) are collected simultaneously. The real-time radial vibration signal is de-DC, filtered and integrated to obtain the real-time vibration displacement compensation amount. Based on the real-time vibration displacement compensation amount, the real-time vibration error of the laser profilometer (10) is corrected to obtain the real radial distance. Based on the true radial distance, least squares circle fitting is performed on a single cross section of the roll to obtain the coordinates of the center of each cross section. Then, spatial straight line fitting is performed on the center of all cross sections to obtain the true axis of the roll. Using the actual axis of the roll as a reference, the actual radial distance of all cross sections is mapped to the global detection coordinate system, and a three-dimensional morphological model of the roll surface is generated by splicing them together, and surface defect identification and marking are completed.

8. The method for monitoring the surface condition of a roll according to claim 7, characterized in that, In parallelism calibration, the specific steps for busbar fitting and obtaining tilt and offset are as follows: The roll is controlled to rotate at a uniform speed, and the moving actuator drives the laser profilometer to complete a full-length pre-scan of the roll body along the roll axis, collecting the position, circumferential angle, and profile data of each sampling point; the sampling points are then converted into spatial points P(X) in the roll body coordinate system. i ,Y i Z i ), where X i Y i Z i These represent the X, Y, and Z coordinates of the sampling point in the roll body coordinate system; using the formula r i =(Y i 2 +Z i 2 ) 0.5 Calculate radial distance r i Select spatial points corresponding to the same circumferential angle to form a set of generatrix points. Use the least squares method to fit the generatrix points to a straight line in space. Obtain the Y-direction inclination a and Z-direction inclination c of the transverse connecting rod (5) relative to the roll axis. Combine with the effective length L of the roll, calculate the total offset ΔY=a×L and ΔZ=c×L.

9. The method for monitoring the surface condition of a roll according to claim 7, characterized in that, The specific steps for vibration signal processing and error correction are as follows: The acquired real-time radial vibration acceleration signal of the roll is sequentially subjected to DC-free processing and bandpass digital filtering to remove zero-point drift, electromagnetic noise, and environmental vibration interference. The preprocessed real-time radial vibration acceleration signal is then integrated twice over time to obtain the real-time vibration displacement compensation s(t). Based on a unified system clock, the real-time vibration displacement compensation s(t) is compared with the real-time radial distance d measured by the laser profilometer. meas Perform point-to-point synchronous matching using formula d true =d meas -s(t) performs real-time vibration error correction on the real-time scanning data to obtain the true radial distance d on the roll surface. true .

10. A method for monitoring the surface condition of a rolling mill roll according to claim 7, characterized in that, The specific steps for single-section profile fitting and obtaining the true axis of the roll are as follows: map the real radial distance after real-time vibration error correction to the roll body coordinate system O-XYZ, use the least squares method to perform circle fitting on the single-section profile point cloud to obtain the center coordinates of the section; complete data acquisition, error correction and circle fitting for each section along the roll axis, extract the center coordinates of all detected sections, and use the least squares method to perform spatial line fitting on all center coordinates. The spatial line obtained by fitting is the true axis of the roll in the roll body coordinate system.

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