Surface roughness measuring device and surface roughness measuring method

Abstract

To provide a technique capable of evaluating the surface roughness of a pressure roll over the entire circumference and width of the pressure roll.SOLUTION: A surface roughness measuring device measures the surface roughness of a pressure roll, and comprises: a displacement sensor that has a detection part facing a surface of the pressure roll and measures the distance to a roll surface of the pressure roll; a stand that supports the displacement sensor; a rotation mechanism that allows the displacement sensor to relatively move in a circumferential direction along the surface of the pressure roll; a reciprocation mechanism that allows the stand to relatively translate along the surface of the pressure roll in a direction parallel to a direction along the axial direction of the pressure roll; a rotation sensor that can acquire the number of rotations and the position of rotations made by the rotation mechanism; and an operation unit that measures the surface roughness of the pressure roll from displacement data measured by the displacement sensor.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a surface roughness measuring device and a surface roughness measuring method for detecting the surface roughness of a roll surface of a rolling roll such as a hot rolling roll. [Background technology]

[0002] Conventional techniques for measuring the surface roughness of rolling rolls include a method for calculating a surface roughness index from the frequency and amplitude of the rolling load of a rolling mill, and a method for indirectly calculating surface roughness by calculating a wear coefficient from the forward advance and reduction of the rolling mill. The former technique is disclosed, for example, in Patent Document 1, and the latter technique is disclosed, for example, in Patent Document 2.

[0003] Furthermore, Patent Document 3 discloses a technology for detecting localized roughness and wear on the roll surface by placing a contact or non-contact surface roughness measuring instrument that scans the roll surface in the axial direction close to the roll and directly measuring the roughness.

[0004] Furthermore, Patent Document 4 discloses a technology for detecting surface defects on mill rolls with high measurement accuracy. This technology involves a device that includes a rotation mechanism that rotates the mill roll around its axis, a displacement sensor with a detector facing the surface of the mill roll and measuring the distance to the roll surface, and a reciprocating table that supports the displacement sensor and can move back and forth in a direction parallel to the axial direction of the roll. This device can measure the surface condition of the entire circumference and width of the roll, and can inspect the roll for localized, three-dimensional chipping of about a few millimeters. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 02-182310 [Patent Document 2] Japanese Patent Application Publication No. 02-255207 [Patent Document 3] Japanese Patent Application Publication No. 06-265335 [Patent Document 4] Japanese Patent Publication No. 2023-053825 Summary of the Invention [Problem to be solved by the invention]

[0006] The rolls to be inspected have been used in hot rolling for a long period of time and have a rough surface. For this reason, in conventional inspections, the above-mentioned conventional techniques have been developed to determine surface roughness that may have a harmful effect on the steel sheet. However, these conventional techniques have the following problems.

[0007] The methods described in Patent Documents 1 and 2 for calculating a surface roughness index from the frequency, amplitude, forward ratio, and reduction ratio of the rolling load of a rolling mill indirectly reveal the roll surface condition, but do not measure the roll surface itself, and therefore cannot directly measure or predict the roll surface condition.

[0008] Furthermore, the method described in Patent Document 3 has a problem in that although defects in the axial direction of the roll can be detected, defects distributed in the circumferential direction of the roll cannot be inspected.

[0009] With the technology described in Patent Document 4, it is possible to inspect and evaluate local chipping of the roll, but it is difficult to grasp the condition of the entire circumference and width of the roll.

[0010] For example, there is a method of taking a replica of a predetermined area of ​​the roll surface using silicone resin and evaluating the line roughness of the copied roll surface. When taking a replica, there is also the problem that the pressure applied by the worker varies, and when measuring line roughness, there is also the problem that the evaluation varies depending on the measurement position.

[0011] The present invention has been made in consideration of the above circumstances, and aims to provide a surface roughness measuring device and a surface roughness measuring method that can evaluate the surface roughness of a rolling roll over the entire circumference and width of the rolling roll. [Means for solving the problem]

[0012] The surface roughness measuring device of the present invention, which advantageously solves the above-mentioned problems, is a surface roughness measuring device for measuring the surface roughness of a rolling roll, and is characterized by comprising: a displacement sensor whose detection unit faces the surface of the rolling roll and measures the distance to the roll surface of the rolling roll; a base for supporting the displacement sensor; a rotation mechanism that allows the displacement sensor to move circumferentially along the surface of the rolling roll relative to the detection unit; a reciprocating movement mechanism that allows the base to move translationally along the surface of the rolling roll in a direction parallel to the axis of the rolling roll relative to the detection unit; a rotation sensor that can acquire the number of rotations and rotation position of the rotation mechanism; and a calculation unit that calculates the surface roughness of the rolling roll from the displacement data measured by the displacement sensor.

[0013] The surface roughness measuring device according to the present invention is (a) the calculation unit calculates the surface roughness of the entire circumference and width of the rolling roll; (b) the calculation unit has a first processing unit that linearly interpolates the displacement of the roll surface measured as unevenly spaced data to convert it into equally spaced data, a second processing unit that averages the data in two-dimensional directions, a third processing unit that removes noise from the data, a surface roughness calculation unit that calculates the surface roughness of the entire circumference and width of the rolling roll, and a visualization processing unit that visualizes and outputs the surface roughness calculation results, (c) the visualization processing unit creates a two-dimensional map of surface roughness over the entire periphery and width of the rolling roll based on the calculation result of the surface roughness and the position information of the rolling roll; (d) the surface roughness includes at least one piece of information among the ten-point average roughness Rz, the arithmetic average roughness Ra, the maximum depth Rv, and the skewness Rsk as line roughness, and the maximum height Sz and the arithmetic average roughness Sa as areal roughness; would be a more preferable solution.

[0014] The surface roughness measuring method of the present invention, which advantageously solves the above-mentioned problems, is a method for measuring the surface roughness of a rolling roll using any of the above-mentioned surface roughness measuring devices, and is characterized by comprising: a displacement measurement step of relatively moving a displacement sensor along the surface of the rolling roll in the circumferential direction and in a direction parallel to the direction along the axis of the rolling roll to measure the distance between the surface of the rolling roll and the displacement sensor; a data conversion step of performing linear interpolation on the distance data obtained in the displacement measurement step to convert unequally spaced data into equally spaced data; and a calculation step of averaging the equally spaced data obtained in the data conversion step to remove noise and then calculate the surface roughness of the entire circumference and width of the rolling roll.

[0015] In addition, a more preferable solution is that the surface roughness measurement method of the present invention includes a visualization processing step of visualizing and outputting the surface roughness calculation results, and a display step of displaying a two-dimensional map of the surface roughness within the range of the entire circumference and width of the rolling roll. [Effects of the Invention]

[0016] The surface roughness measuring device and method of the present invention can measure the surface roughness of a roll surface that has a rough surface after use in hot rolling, something that conventional optical surface inspection devices and ultrasonic flaw detection have difficulty with, over the entire circumference and width, and in a short time. Noise and waviness are removed from the surface displacement of the roll, and the surface roughness is calculated with high accuracy, optimizing the amount of roll grinding and improving the roll consumption rate. Furthermore, aspects of the present invention have the advantage that, for example, static visual inspection, which previously took a long time, can be replaced by the measurement and its results, thereby enabling faster inspections. [Brief explanation of the drawings]

[0017] [Figure 1] 1A and 1B are schematic diagrams showing an overview of a surface roughness measuring device according to one embodiment of the present invention, in which (a) is a schematic side view and (b) is a schematic front view. [Figure 2]FIG. 4 is a flow chart showing an example of a calculation unit of the surface roughness calculation device according to the embodiment. [Figure 3] FIG. 10 is a flow chart showing another example of the calculation unit of the surface roughness calculation device according to the embodiment. [Figure 4] FIG. 2 is an image diagram showing a surface roughness map of a rolling roll calculated by the surface roughness calculation device according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, embodiments of the present invention will be described in detail. Note that the drawings are schematic and may differ from the actual ones. Furthermore, the following embodiments exemplify equipment and methods for embodying the technical idea of ​​the present invention, and are not intended to limit the configuration to those described below. In other words, the technical idea of ​​the present invention can be modified in various ways within the technical scope described in the claims.

[0019] FIG. 1 is a schematic diagram showing an overview of a surface roughness measuring device according to one embodiment of the present invention. FIG. 1(a) is a schematic side view, and FIG. 1(b) is a schematic front view. The surface roughness measuring device of this embodiment includes a rotation mechanism, a reciprocating mechanism, a displacement sensor 2, a rotation sensor 15, and a calculation unit 5 that calculates surface roughness. It may further include laser distance meters 19A and 19B and a control unit 10. As shown in FIGS. 2 and 3 , the calculation unit 5 includes a one-rotation position recording unit 5A, a row / column averaging calculation unit 5B, a noise removal processing unit 5C, a data interpolation processing unit 5D, a counting unit 5E, a visualization processing unit 5F, and a display unit 5G.

[0020] <Rotation mechanism> The rotation mechanism can take any form as long as the displacement sensor can move circumferentially along the surface of the roll. In the example shown in FIG. 1(b), the mechanism rotates the roll 1 axially. The roll 1 is attached to a chock 12 (bearing) and installed in the surface roughness measuring device. One shaft of the roll 1 is connected to a tailstock 13, and the other shaft is connected to a headstock 14. A motor 14A, such as a single-axis servo motor, is mounted on the headstock 14 to drive the other shaft. Driving the motor 14A enables the roll 1 to rotate axially. The mechanism includes a rotation sensor 15 that detects the rotation speed and angle of the motor 14A. In the example shown in FIG. 1, the rotation mechanism is described as rotating the roll axially, but it may also be a mechanism in which the displacement sensor rotates around a stationary roll.

[0021] <Reciprocating mechanism> The reciprocating mechanism may take any form as long as the carriage is relatively movable in translation along the surface of the roll in a direction parallel to the axis of the roll. In the example of Figures 1(a) and (b), a carriage 4 is disposed to the side of the roll 1. The carriage 4 is movable in a reciprocating direction, which is a direction parallel to the axis of the roll 1. The direction parallel to the axis is defined to indicate that the carriage does not have to be completely parallel to the axis. In the example of Figure 1, the carriage moves, but the displacement sensor may be fixed and the roll 1 may reciprocate in the axial direction.

[0022] <Rotation sensor 15> The rotation sensor may be any sensor that can record the number of rotations of the rotation mechanism of the roll to be measured and the position information of one rotation along the roll surface. In the example of Figure 1(b), the rotation sensor 15 detects the number of rotations and rotation angle of the motor 4A. It may also be a sensor that can calculate the timing of one rotation from the rotation speed and period of the roll, or that can measure the number of rotations and rotation timing using a pulse signal or a contact or non-contact sensor.

[0023] <Displacement sensor 2> The displacement sensor 2 is supported by the carriage 4 and is positioned so that its detection part faces (opposes) the rolling roll 1. The displacement sensor 2 measures the distance to the roll surface of the rolling roll 1. Any known displacement sensor may be used for the displacement sensor 2. Since the displacement sensor 2 only needs to be able to measure the distance between the rolling roll 1 and the displacement sensor 2, it may be of either a non-contact or contact type as long as it can determine the distance. An advancing / retracting mechanism 3 is provided which moves the displacement sensor 2 toward and away from the carriage 4 towards the roll surface. The advancing / retracting mechanism 3 is made up of a linear guide device or other servo mechanism.

[0024] <Laser rangefinder 19A, 19B> Two-dimensional laser range finders 9A and 9B are preferably installed on the carriage 4 on both the left and right sides of the movement direction of the displacement sensor 2. Specifically, laser range finders 19A and 19B are installed upstream and downstream of the installation position of the displacement sensor 2 in the movement direction of the displacement sensor 2 in the reciprocating direction. At least the upstream laser range finder 19A is required. The laser range finders 19A and 19B constitute distance detection sensors and detect the distance to the roll surface. Here, the displacement sensor 2 and the laser range finders 19A and 19B are both installed on the carriage 4, and are configured to move together in the reciprocating direction. The measurement resolution of the displacement sensor 2 is preferably superior to that of the laser range finders 19A and 19B.

[0025] <Control unit 10> The control unit 10 includes an advance / retract control unit. The advance / retract control unit performs processing to advance / retract the displacement sensor 2 toward / from the roll surface via the advance / retract mechanism 3 according to the distance detected by the laser range finders 19A and 19B. For example, when the advance / retract control unit determines that the displacement sensor 2 is positioned facing the roll surface based on the detection values ​​of the laser range finders 19A and 19B, it moves the displacement sensor 2 closer to the roll surface while avoiding interference between the displacement sensor 2 and the roll surface. This approach improves the accuracy of the measurement value. Here, by inputting information such as the roll diameter and roll barrel length of the mill roll 1 into the control unit 10 in advance, the displacement sensor 2 approaches the roll surface to an appropriate distance standard.

[0026] At this time, the rolling roll 1 is attached with a chock 12, and depending on the combination of the roll diameter and the chock 12, there is a possibility that the displacement sensor 2 may interfere with the chock 12. For example, as shown in FIG. 1(b), there are cases in which the chock 12 protrudes further toward the shuttle 4 than the diameter of the rolling roll 1. In this case, if the displacement sensor 2 is brought close to the preset appropriate distance standard for the rolling roll 1, the displacement sensor 2 will interfere with the chock 12.

[0027] In response to this, the advance / retract control unit is able to detect the roll barrel end of the rolling roll 1 based on the distance detected by at least the laser range finder 19A located upstream of the displacement sensor 2, and moves the displacement sensor 2 backward until it reaches the roll barrel end position. Then, when it determines that the displacement sensor 2 has reached the roll barrel end, it performs approach / retract control to move the displacement sensor 2 closer to the roll surface. Here, during inspection, the carriage 4 moves in one of the advance / retract directions at a constant moving speed corresponding to the roll rotation speed (constant speed) based on detection by the rotation detector. Furthermore, even when the displacement sensor 2 is approaching the roll surface and measuring the distance to the roll surface, the detection information from the laser range finders 19A and 19B makes it possible to more reliably avoid interference of the displacement sensor 2 with the roll surface.

[0028] <Measurement of the distance between the displacement sensor and the rolling roll surface> In the above configuration, the roll surface of the roll 1 is measured spirally by performing continuous measurements with the displacement sensor 2 while the roll 1 rotates at a constant number of revolutions and the carriage 4 operates at a constant speed. In reality, scanning is performed in a direction slightly tilted relative to the roll rotation direction. The displacement data (distance data) measured by the displacement sensor 2 becomes the surface displacement data.

[0029] <Calculation section 5> When a two-dimensional displacement sensor is used, the measurement information from the displacement sensor is a sequence composed of rows and columns. In this embodiment, the rolls are rotated while being moved axially to continuously measure the inter-roll distance in a spiral pattern. Therefore, the number of columns in this sequence is the sensor measurement width and the total length of the continuously measured spiral. The surface roughness of the rolling roll is calculated using the flow shown in FIG. 2 for this sequence. After performing the processing from the row / column averaging calculation unit 5B to the data interpolation processing unit 5D illustrated in FIG. 2, the calculation unit 5E divides and reconstructs the sequence for each rotation of the rolling roll based on the one-rotation position information recorded by the one-rotation position recording unit 5A, converting it into a sequence in which the roll width direction length is the number of columns and the roll circumferential angle of 0 to 360° is the number of rows. As an example of another calculation unit, the processing from the calculation unit 5E may be performed first, as shown in the flow chart of FIG. 3, and then the processing from the row / column averaging calculation unit 5B to the data interpolation processing unit 5D may be performed.

[0030] The processing of the row and column averaging calculation unit 5B removes macroscopic fluctuations from the entire sequence by subtracting the average value in the row direction from the entire sequence data, and then subtracting the average value in the column direction from the sequence. Alternatively, the average value in the row direction may be subtracted after the average value in the column direction. The processing of the noise removal processing unit 5C removes abnormal values ​​contained in the data after processing by the row and column direction averaging calculation unit 5B.

[0031] The data interpolation processing unit 5D performs linear interpolation processing on the sequence data. Due to factors such as the play of the roll rotation and grinding carriage used for reciprocating movement, the displacement data may become an unevenly spaced sequence. For this reason, it is re-output as evenly spaced data through linear interpolation processing. For example, first a count is performed for each roll rotation. An array for the number of counted data is generated in 0.1° increments in the range of 0 to 360° around the roll circumference. Next, the distance data from the displacement sensor is read from the first rotation, and the unevenly spaced data is re-output as evenly spaced data through linear interpolation. If the data was originally evenly spaced, this processing is not necessary.

[0032] The visualization processing unit 5F and display unit 5G process the converted roughness map as an image. After completing one rotation in the circumferential direction and securing multiple points in the width direction, the difference between the maximum and minimum values ​​in the array is calculated for several points, and the average is calculated and displayed. The calculated image is output, for example, as shown in Figure 4. The vertical axis of the image is output as 0-360° in the circumferential direction, and the horizontal axis is the roll width direction. The vertical axis may represent the roll circumference, or the horizontal axis may represent the carriage travel distance, etc. The roughness level is displayed in length units using a concentration mapping for each point. It is preferable to display the roughness in color according to its level for easier viewing. This allows for a visualized and quantitative display of the roughness across the entire circumference and width of the roll. The surface roughness preferably includes at least one of the following information: the ten-point average roughness Rz, arithmetic mean roughness Ra, maximum depth Rv, and skewness Rsk as line roughness, and the maximum height Sz and arithmetic mean roughness Sa as areal roughness.

[0033] In this embodiment, the entire circumference and width of the roll to be measured and the roughness calculated does not necessarily have to be the entire width of the roll. As long as the central region of the roll width that actually comes into contact with the rolled material can be measured, the measurement of the roll width end portions may be omitted. Also, the roll width position where roughness is to be measured may be specified in advance as the measurement target, and then the roll roughness measurement and calculation of this embodiment may be performed. Furthermore, the method of this embodiment is most effective when applied to the entire circumference of the roll (0 to 360°). On the other hand, if the roll condition can be determined even by measuring and calculating roughness only within a half circumference (0 to 180°), this embodiment may be applied without measuring the entire circumference. [Example]

[0034] A roll to be inspected, 2050 mm wide and 1194 mm in diameter, was placed on the roll table shown in Figure 1(b) and rotated at a speed of 10 rpm. In this state, the grinding table on which the displacement sensor was installed was moved back and forth at a speed of 500 mm / min in a direction parallel to the axis of the roll, and the distance between the roll and the displacement sensor was measured.

[0035] Measurement was carried out while detecting the rotation position per rotation of the roll with a limit sensor installed on the roll table.

[0036] The measurement results of the distance between the roll and the displacement sensor were processed through the calculation flow shown in Figure 2, and the roll roughness (Rz, Ra) was recorded in 0.01 mm increments at each point across the entire circumference and width of the roll, from 0 to 360° in the circumferential direction of the vertical axis and from 0 to 2050 mm in the width direction of the horizontal axis, as shown in Figure 4. The magnitude relationship of these roughness values ​​was then calculated and displayed as a concentration map.

[0037] To verify the validity of the roughness mapping, the circumferential angle and width length were adjusted to match the calculated roughness information for the entire circumference and width, and then a replica measurement was performed using ShoeFlex to measure the height of the undulations on the replica.

[0038] We verified the correlation between the roughness information for the entire circumference and width and the roughness information measured from the replica at each point. The verification method was to compare the roughness of the roughness mapping at the same width and circumference positions as the shoeflex replica measurement positions. As a result, we found that the roughness mapping was able to measure and calculate roughly the same roughness as the shoeflex measurement results, and that there was a positive correlation between the two, and that the roughness displayed by the output roughness mapping was valid.

[0039] This measurement has the effect of being able to be carried out in a relatively short time compared to visual inspection of roll surface roughness. Also, while existing technologies and measurement methods could only measure and evaluate roughness at specific circumferential or widthwise positions on the roll, this method makes it possible to measure the roughness of the roll surface over the entire circumference and width. This makes it easier to determine defective parts of the roll and when grinding is complete during normal grinding, and it has been found to be effective in optimizing the amount of roll grinding that has been excessively done, thereby extending the roll's lifespan. [Explanation of symbols]

[0040] 1. Rolling mill 2. Displacement Sensor 3 Advancement / retraction mechanism 4 Reciprocating table (reciprocating mechanism) 5. Surface roughness calculation device 5A 1 rotation position recording unit 5B Row / column direction averaging calculation unit 5C Noise reduction processing section 5D data interpolation processing unit 5E Counting Unit 5F Visualization Processing Section 5G display 10 Control Unit 12 Chock 13 Tailstock 14 Headstock 14A motor (rotating mechanism) 15 Rotation Sensor 19A, 19B Laser rangefinder (distance detection sensor)

Claims

1. A surface roughness measuring device for measuring the surface roughness of a rolling roll, a displacement sensor having a detection portion facing the surface of the rolling roll and measuring the distance to the roll surface of the rolling roll; a base for supporting the displacement sensor; a rotation mechanism that allows the displacement sensor to move in a circumferential direction along the surface of the rolling roll; a reciprocating mechanism that allows the platform to translate along the surface of the roll in a direction parallel to the axis of the roll; a rotation sensor capable of acquiring the number of rotations and the rotation position of the rotation mechanism; a calculation unit that calculates the surface roughness of the rolling roll from the displacement data measured by the displacement sensor; A surface roughness measuring device comprising:

2. The surface roughness measuring device according to claim 1 , wherein the calculation unit calculates the surface roughness of the entire circumference and width of the rolling roll.

3. 2. The surface roughness measuring device according to claim 1, wherein the calculation unit comprises a first processing unit that linearly interpolates the displacement of the roll surface measured as unevenly spaced data to convert it into equally spaced data, a second processing unit that averages the data in two dimensions, a third processing unit that removes noise from the data, a surface roughness calculation unit that calculates the surface roughness of the entire circumference and width of the rolling roll, and a visualization processing unit that visualizes and outputs the surface roughness calculation results.

4. 4. The surface roughness measuring device according to claim 3, wherein the visualization processing unit creates a two-dimensional map of the surface roughness over the entire periphery and width of the rolling roll from the calculation result of the surface roughness and the position information of the rolling roll.

5. 2. The surface roughness measuring device according to claim 1, wherein the surface roughness includes at least one piece of information among ten-point average roughness Rz, arithmetic average roughness Ra, maximum depth Rv, and skewness Rsk as line roughness, and maximum height Sz and arithmetic average roughness Sa as areal roughness.

6. A method for measuring the surface roughness of a rolling roll using the surface roughness measuring device according to any one of claims 1 to 6, comprising: a displacement measuring step of relatively moving a displacement sensor along the surface of the rolling roll in a circumferential direction and in a direction parallel to the axis of the rolling roll to measure a distance between the surface of the rolling roll and the displacement sensor; a data conversion step of converting non-uniformly spaced data into uniformly spaced data by linearly interpolating the distance data obtained in the displacement measurement step; a calculation step of averaging the equally spaced data obtained in the data conversion step, removing noise, and then calculating the surface roughness of the entire circumference and width of the rolling roll.

7. a visualization processing step of visualizing and outputting the surface roughness calculation results; 7. The surface roughness measuring method according to claim 6, further comprising a display step of displaying a two-dimensional map of the surface roughness over the entire periphery and width of the roll.

Images