Monitoring and control of the thermal image of the squeezing roll

Abstract

The metal processing system includes a roll and a control system. The roll includes a non-metallic surface for contacting a metal substrate, and the control system includes a sensor for detecting the temperature of the non-metallic surface of the roll. The control system also includes a controller, and the controller receives the detected temperature from the sensor and controls the roll based on the detected temperature. A method of controlling a roll with a non-metallic contact surface includes receiving the detected temperature from a sensor of at least a portion of the non-metallic contact surface of the roll and controlling the roll based on the received temperature.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 364,057, filed on May 3, 2022, entitled "IRONING ROLL THERMAL IMAGE MONITORING AND CONTROL", the content of which is hereby incorporated by reference in its entirety.

[0002] This application generally relates to metal processing, and more particularly to systems and methods for controlling ironing rolls in a metal processing system.

Background Art

[0003] Metal products can be rolled into strip - shaped metal during a rolling operation, and the strip - shaped metal can be wound into a coil. While winding the strip - shaped metal into a coil, an ironing roll can be used to press the strip - shaped metal against the coil to ensure that the coil is wound tightly and to minimize or prevent damage to the surface of the strip - shaped metal. Any of the cases where incorrect forces are used (e.g., due to misalignment of the ironing roll, unbalanced ironing roll, etc.) can cause scratches or scars on the surface of the strip - shaped metal. Furthermore, damage to the ironing roll itself is another major cause of scratches and gouging on the surface of the strip - shaped metal. In particular, the rubber coating of the ironing roll generally ruptures, is damaged in other ways, and sometimes fails unexpectedly during metal processing, and such damage often forms scratches or deep wounds on the surface of the strip - shaped metal. Such damage to the strip - shaped metal requires discarding the damaged part of the coil or even the entire coil.

Summary of the Invention

[0004] The embodiments to which this patent applies are defined not by this summary of the invention but by the following claims. This summary of the invention is a high-level overview of various embodiments and introduces some of the concepts further described in the section on forms for carrying out the following invention. This summary of the invention is not intended to identify the important or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. This subject matter should be understood by reference to the entire specification of this patent, any or all of the drawings, and the appropriate portions of each claim.

[0005] According to certain embodiments, a metalworking system includes a roll and a control system. The roll is rotatable about an axis and includes a non-metallic surface for contacting a metal substrate between a first end, a second end, and the first and second ends. The control system includes a sensor for detecting the temperature of the non-metallic surface of the roll. The control system also includes a controller communicatively coupled to the sensor. The controller can receive the detected temperature from the sensor and control the roll based on the detected temperature.

[0006] According to some embodiments, a control system for a metalworking system having a roll with a non-metallic contact surface includes a sensor for detecting the temperature of the non-metallic contact surface of the roll and a controller communicatively coupled to the sensor. The controller can receive the detected temperature from the sensor and generate an output signal for controlling the roll based on the received temperature.

[0007] According to various embodiments, a method of controlling a roll having a non-metallic contact surface for contacting a metal substrate includes receiving the detected temperature from a sensor of at least a portion of the non-metallic contact surface of the roll and controlling the roll based on the received temperature.

[0008] The various embodiments described herein may include additional systems, methods, features, and advantages, which may not necessarily be explicitly disclosed herein but will be apparent to those skilled in the art upon examination of the following detailed description and the accompanying drawings. All such systems, methods, features, and advantages are intended to be included within the present disclosure and protected by the appended claims.

[0009] This specification refers to the following accompanying drawings, and when the same reference numerals are used in different figures, it is intended to indicate the same or similar components.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

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Modes for Carrying Out the Invention

[0011] This specification describes a system and method for controlling a roll having a non-metallic surface in a metalworking system. The roll may be for contacting the surface of a metal substrate, and may include, but is not limited to, a squeeze roll for contacting the surface of a metal substrate within a coil. In certain embodiments, the system and method provided herein include a control system that measures and detects the temperature of the non-metallic surface of the roll and controls the operating parameters of the roll based on the detected temperature. In certain embodiments, the control system measures the temperature in a plurality of zones across the width of the roll, thereby enabling detection of a temperature difference across the roll that may differ on one side versus the other, and enabling correction as needed.

[0012] In some embodiments, the control system may amplify and / or otherwise control the size of the zones based on the distance between the sensor of the control system and the roll, thereby improving such measurements and / or control based on such temperature measurements by maintaining the proportion of the roll measured for a particular zone (i.e., the size of the measured area relative to the entire roll remains proportional regardless of the distance between the sensor and the roll). In certain embodiments, the system and method provided herein prevent and / or minimize damage to the squeeze roll during metalworking, thereby minimizing and / or preventing defects or damage (e.g., scratches, deep gouges) to the metal substrate due to failure of the squeeze roll. In some embodiments, the system and method provided herein can be used to predict damage or useful life of the squeeze roll, such that the squeeze roll can be replaced as needed prior to failure. In various embodiments, the system and method provided herein can provide improved flatness control using the squeeze roll. Various other benefits and advantages may be realized by the system and method provided herein, and the foregoing advantages should not be considered limiting.

[0013] Figures 1-6 depict a metalworking system 100 with a work station 102 that includes at least one roll 104. In the embodiments of Figures 1-6, the work station 102 is a winding station that includes a coiler 106 for selectively forming or unwinding a coil 108 of a metal substrate 110. In this embodiment, the roll 104 is a squeeze roll that contacts the coil 108 to facilitate good winding and construction of the coil 108 and / or unwinding from the coil 108 of the metal substrate 110. Although the work station 102 is shown as a winding station and the roll 104 is shown as a squeeze roll, in other embodiments, the work station 102 need not be a winding station and / or the roll 104 need not be a squeeze roll and may be provided at various other locations within the metalworking system as desired. As some non-limiting examples, the work station 102 with the roll 104 may be a cold rolling mill, a foil rolling mill, a slitter line, a continuous annealing solution heat treatment line, a coating line, and / or various other types of stations and / or metalworking systems as desired.

[0014] Referring to Figure 2, in various embodiments, the roll 104 includes a first end 112, a second end 114, and a contact surface 116 between the first end 112 and the second end 114. In certain embodiments, the contact surface 116 is a non-metallic surface suitable for contacting the metal substrate 110 during processing of the metal substrate 110 (e.g., winding or unwinding of Figures 1-6) when the roll 104 rotates about its axis 118. As a non-limiting example, the contact surface 116 is a rubber coating provided on the roll 104 between the ends 112 and 114. Optionally, the non-metallic surface may be deformable during metalworking. The contact surface 116 may be provided on the roll 104 using various techniques or processes as desired. The particular roll 104 having the contact surface 116 shown in Figures 1-6 should not be considered limiting.

[0015] Referring to FIGS. 1 and 3, during metal processing, the roll 104 can be supported on a support 121 such that at least the contact surface 116 contacts the coil 108. The particular support 121 shown should not be considered limiting, and various devices or structures can be utilized as the support 121 as desired. In some embodiments, at least one of the ends 112, 114 of the roll 104 is driven via various suitable actuators or drive mechanisms to maintain contact with the coil 108 as the roll 104 rotates about its axis 118 (see FIG. 2).

[0016] As shown by comparing FIG. 1 with FIG. 3, the roll 104 is radially movable as the size of the coil 108 changes from a smaller (or initial) size (FIG. 1) and a terminal (or larger) size (FIG. 3). The contact between the contact surface 116 and the coil 108 may expose the contact surface 116 to thermal vibrations and thermal fluctuations, which can in turn ultimately cause damage to the contact surface 116 and potential damage to the metal substrate 110. Additionally, during metal processing, the actuator of the roll 104 may cause flatness problems in the metal substrate 110 by means of a rocking motion, such that the metal substrate 110 becomes unsuitable for its intended purpose and / or correction may be required prior to further processing. For example, as shown in FIGS. 1 and 3, to minimize and / or prevent problems caused by the roll 104, the metal processing system 100 includes a control system 122 that measures at least the temperature of the contact surface 116 and generates an output response based on the measured temperature.

[0017] In a particular embodiment, the control system 122 includes a sensor 124 and a controller 126. Although a single sensor 124 and a single controller 126 are shown, in other embodiments, the control system 122 may have any number of sensors 124 and / or controllers 126 as desired.

[0018] The sensor 124 of the control system 122 can be various suitable devices or mechanisms for detecting at least the temperature of the contact surface 116 of the roll 104. In a particular embodiment, the sensor 124 is a thermal camera with a field of view 127. In various embodiments, the thermal camera may be a high frame rate thermal camera that acquires images at a rate higher than the operating frequency of the roll 104 to avoid or minimize the aliasing effect. As some non-limiting examples, the sensor 124 may acquire images at a frame rate higher than 20 Hz, such as higher than 30 Hz, higher than 40 Hz, higher than 50 Hz, higher than 60 Hz, etc. In some non-limiting examples, the thermal camera as the sensor 120 may have an acquisition rate higher than 60 Hz, such as about 70 Hz. In other embodiments, cameras with other acquisition rates may be utilized as desired.

[0019] In various embodiments, as shown in FIG. 4, sensor 124 can detect the temperature of at least the contact surface 116 of roll 104 using one or more detection zones 132 on roll 104 between ends 112 and 114. In the embodiment shown in FIG. 4, sensor 124 detects the temperature within six detection zones 132A - F, but the number of detection zones 132 should not be considered limiting. In some non - limiting examples, sensor 124 can use at least two detection zones, at least three detection zones, at least four detection zones, or at least five detection zones. In one non - limiting example, sensor 124 can include at least ten detection zones, such as at least fifteen detection zones, at least twenty detection zones, etc. In various embodiments, sensor 124 independently detects the temperature within each detection zone. As an example, sensor 124 detects the temperature of contact surface 116 within detection zone 132A independently of detecting the temperature of contact surface 116 within detection zone 132B. In certain embodiments, as will be discussed in detail below, multiple detection zones 132 can use control system 122 to improve the temperature measurement and control of roll 104. The specific size or area of each detection zone 132 with respect to roll 104 shown in FIG. 4 should not be considered limiting, and in other embodiments, detection zone 132 need not cover the entire width of roll 104. FIG. 6 is a non - limiting example where the detection region 134 (i.e., all detection zones 132) is smaller than the width of roll 104.

[0020] In various embodiments, the plurality of detection zones 132 may together form a detection area 136. The number of detection zones 132 within a particular detection area 136 need not be the same along the roll 104. In the embodiment shown in FIG. 4, the roll 104 includes three detection areas 136, which are a first detection area 136A formed by detection zones 132A - B, a second detection area 136B formed by detection zones 132C - D, and a third detection area 136C formed by detection zones 132E - F. The number of detection areas 136 should not be considered limiting. When detection areas 136 are included, the number thereof may be less than or equal to the number of detection zones 132.

[0021] In a particular embodiment, as shown in FIG. 5, the sensor 124 is provided at a position a predetermined distance 128 from an initial position of the roll 104 (e.g., the position of the roll 104 in FIG. 1 and the position represented by the dashed roll 104 in FIG. 5). At such a predetermined distance, at least the contact surface 116 can be within the field of view 127 at both the initial position and the end position (represented by the solid roll 104 in FIG. 5).

[0022] Referring to FIG. 6, the detection area 134 formed by the combined detection zones 132 can be controlled to maintain its size or area with respect to the roll 104. In FIG. 6, the individual detection zones 132 are omitted for clarity of the figure. In these embodiments, the sensor 124 can automatically adjust its focus such that the detection area 134 is adjusted based on the position of the roll 104 relative to the sensor 124. Such automatic adjustment of the focus and the detection area 134 can result in improving the temperature measurement and control of the roll 104 using the control system 122. As a non - limiting example, in FIG. 6, the detection area 134 (represented by the dashed line) on the roll 104 at the initial position is smaller than the detection area 134 of the roll at the end position (represented by the solid line and closer to the sensor 124), but the size of the detection area 134 with respect to the roll 104 is the same at both the initial position and the end position.

[0023] Referring back to FIG. 1, the sensor 124 may optionally be provided at an angle 130 with respect to the roll 104. In such an embodiment, the sensor 124 may be provided below the roll 104, and the angle 130 may optionally be an oblique angle as shown in FIG. 1. In such an embodiment, the angle 130 may further facilitate having at least the contact surface 116 within the field of view 127 when the roll 104 moves radially. In other embodiments, the angle 130 of the sensor 124 may be any other angle as desired, and the sensor 124 need not be positioned below the roll 104 and / or at an oblique angle 130.

[0024] The controller 126 of the control system 122 may include one or more processing units and / or one or more memory devices. The processing unit of the controller may be various suitable processing devices or combinations of devices including, but not limited to, one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, other electronic units, and / or combinations thereof. The one or more memory devices of the controller 126 may be any machine-readable medium that can be accessed by a processor, including, but not limited to, any type of long-term, short-term, volatile, non-volatile, or other storage medium, and is not limited to any particular type of memory or number of memories, or the type of medium on which the memory is stored. Further, as disclosed herein, the terms "storage medium", "storage device", or "memory" can represent one or more memories for storing data, including read-only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage media, optical storage media, flash memory devices, and / or other machine-readable media for storing information. The term "machine-readable medium" includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or other various storage media that can store or transmit instructions and / or data.

[0025] In certain embodiments, controller 126 optionally includes a related user interface, including but not limited to a graphical user interface, such that controller 126 can obtain information from and / or provide information to a user. In such embodiments, the user interface may be on controller 126 itself or, without limitation, at a location remote from controller 126, such as another location within metalworking system 100. Additionally or alternatively, controller 126 may optionally include various communication modules so that controller 126 can receive and / or transmit information as desired. Non-limiting examples of communication modules can include systems and mechanisms that enable wired and / or wireless communication (e.g., industrial Ethernet, Profibus®, short range, cellular, Wi-Fi, Bluetooth®, Bluetooth Low Energy (BLE), etc.).

[0026] Controller 126 of control system 122 is communicatively coupled to sensor 124 such that controller 126 receives thermal data from sensor 124 for one or more detection zones 132 and / or one or more detection regions 136. In various embodiments, controller 126 and / or sensor 124 can use various techniques as desired to determine the temperature for a particular detection zone 132 and / or detection region 136, including based on, for example, the maximum temperature detected within a particular detection zone 132 and / or detection region 136, the average of the temperatures detected within a particular detection zone 132 and / or detection region 136, the temperature at the center of detection zone 132 and / or detection region 136, and / or other desired things.

[0027] Based on the temperature data from the sensor 124, the controller 126 can generate various output responses. The output responses can include, but are not limited to, generating an alert or notification (e.g., audio or visual) on the user interface of the controller 126, sending an alert or notification to the operator, controlling the operating parameters of the roll 104 (e.g., by sending a control signal to the actuator or control device of the roll 104), and / or controlling the operating parameters of the metalworking system 100 (e.g., by sending a control signal to the actuator or control device of the metalworking system 100). The operating parameters of the roll 104 can include, but are not limited to, rolling force, the inclination of the roll 104, the pressure applied from the actuator to the roll 104, combinations thereof, and / or various other operating parameters as desired. The control of such operating parameters can include controlling the drive mechanism of the roll 104, the actuator of the roll 104 that applies the rolling force to the roll 104, combinations thereof, and / or other desired ones. The operating parameters of the metalworking system can include, but are not limited to, line speed, take-up speed, unwind speed, combinations thereof, and / or various other operating parameters as desired. The control of such operating parameters can include controlling the work stands upstream from the coiler 106, the drive mechanism that controls the rotational speed of the coiler 106, combinations thereof, and / or other desired ones.

[0028] The output response from the controller 126 may be based on various analyses of the measured temperature from the sensor 124 as desired.

[0029] As a non-limiting example, the output response from the controller 126 may be based on a comparison of the measured temperature for a particular detection zone 132 and / or detection region 136 with a threshold temperature for the particular detection zone 132 and / or detection region 136. In such embodiments, the threshold temperature can correspond to the temperature at which the contact surface 116 breaks, and can be predetermined, calculated, or otherwise generated or provided as desired. In other embodiments, the threshold temperature may be another temperature as desired and need not be the break temperature of the contact surface 116. In embodiments that perform this comparison, the controller 126 can generate an output response based on one of the detection zones 132 having a measured temperature that is within a predetermined range and / or exceeds the threshold temperature. As a non-limiting example, the controller 126 can generate an output response that reduces the rolling force on a portion of the roll 104 within the detection region 136A and reduces the temperature of the roll 104 within the detection region 136A based on the detection region 136A having a measured temperature that exceeds its threshold temperature, to control the actuator of the roll 104. Additionally or alternatively, the output response can include an alert or alarm provided to the operator based on whether the measured temperature exceeds or is within the range of the threshold temperature.

[0030] As another non-limiting example, the output response from the controller 126 may be based on a comparison of the measured temperatures of adjacent detection zones 132 and / or detection regions 136. In such embodiments, the output response may be generated if the change in temperature between adjacent detection zones 132 and / or detection regions 136 is within a predetermined range or exceeds a threshold. As a non-limiting example, the controller can generate an output response based on the difference between the measured temperature of the detection region 132C and the measured temperature of the detection region 132D exceeding a threshold. Additionally or alternatively, the output response can include an alert or alarm provided to the operator based on whether the difference in temperature exceeds or is within the range of the threshold.

[0031] As yet another non - limiting example, the output response from the controller 126 may be based on the measured temperature of each of the detection regions 136. In such an embodiment, the measured temperature from each detection zone 132 may be used to derive the temperature value of each of the detection regions 136. Optionally, the difference between the detection region 136A and the detection region 136C may be used to adjust the difference in the rolling forces applied to the first end 112 and the second end 114. For example, if the detection region 136A is hotter, the force may be adjusted such that the force is reduced at the first end 112 and increased at the second end 114. As yet another non - limiting example, the difference between the detection region 136B (e.g., at the center of the roll 104) and the average value of the temperatures of the detection regions 136A, 136C (or the edge - control temperature) may be used to increase or decrease the total rolling force. For example, if the temperature gradient from the center to the edge - control temperature exceeds a certain limit, the total rolling force may be increased.

[0032] As a further non - limiting example, the output response from the controller 126 may be based on the curvature or profile of the temperature signal along the roll 104, which may correspond to the pressure distribution from one or more actuators of the roll 104. In such an embodiment, the temperature signal may be a combination of the measured temperatures along the roll 104, and the controller 126 may compare the temperature signal to a target signal and / or determine the variation of the temperature signal exceeding a threshold. As a non - limiting example, the controller 126 may control the pressure applied to the roll 104 by an actuator (e.g., a pneumatic cylinder) to improve the flatness of the metal substrate 110 based on the identification of a plurality of variations in the temperature signal and / or based on the fact that the temperature signal has a "wavy" profile.

[0033] As another non-limiting example, the controller 126 can predict the future performance of the roll 104 based on the detected temperature, and the controller 126 can generate an alert based on the predicted performance meeting a predetermined condition. As a non-limiting example, the controller 126 can predict the remaining useful life of the roll 104 based on the historical temperature of the roll 104 and / or the measured current temperature of the roll 104, and the controller 126 can generate an alert or alarm for the operator based on the remaining useful life of the roll 104 being less than a predetermined minimum remaining life of the roll 104.

[0034] Optionally, various other analyses may be performed by the controller 126, and the examples described above should not be considered limiting.

[0035] The output response from the controller 126 based on the measured temperature of the contact surface 116 can lead to improved control of the roll 104, which can include, but is not limited to, minimizing or preventing damage to the contact surface 116 during metalworking and / or providing a metal substrate 110 with improved flatness, resulting in benefits.

[0036] Referring to FIG. 1, a method of controlling a roll 104 having a contact surface 116 can include receiving, by the controller 126, the detected temperature of at least a portion of the contact surface 116 of the roll 104 from the sensor 124. The method includes generating, by the controller 126, an output response based on the received temperature. In some embodiments, generating the output response includes controlling an operating parameter of the roll 104, controlling an operating parameter of the metalworking system, or generating an alert or alarm for the operator, including one or more of these.

[0037] In some embodiments, controlling the roll includes adjusting the operating parameters of the roll based on the received temperature that exceeds a threshold temperature. Optionally, controlling the roll may include controlling at least one actuator of the roll to control the rolling force from the roll.

[0038] In various embodiments, receiving the detected temperature from the sensor 124 includes independently receiving the detected temperature for each detection zone 132 of a plurality of detection zones 132 along the roll 104. Optionally, controlling the roll 104 is based on at least one of: the detected temperature for a particular detection zone 132 exceeding the threshold temperature for that particular detection zone 132; or the difference between the detected temperature of a first detection zone (e.g., detection zone 132A) of the plurality of detection zones 132 and the detected temperature of a second detection zone (e.g., detection zone 132B or 132F) of the plurality of detection zones 132 exceeding a threshold limit.

[0039] In some embodiments, the method includes determining a pressure distribution of at least one actuator on the roll based on a temperature signal formed by the detected temperature. In some embodiments, generating an output response may include controlling at least one actuator of the roll 104 based on the determined pressure distribution.

[0040] Optionally, the method may include predicting the performance of the roll based on the detected temperature and generating an alert based on the predicted performance meeting a predetermined condition. Optionally, generating an alert includes generating a visual or audible alert for an operator.

[0041] Various other processes may be implemented using the control system 122, and the control processes described above should not be considered limiting.

[0042] FIG. 7 is an example of a thermal image 701 of a roll 704 from a control system similar to control system 122. When compared with FIG. 4, the thermal image 701 includes 20 detection zones 132 and three detection regions 136.

[0043] FIG. 8 shows a plurality of temperature signals of a plurality of rolls similar to roll 104 obtained using a control system similar to control system 122. As shown in FIG. 9, each temperature signal has a “wavy” portion (see, e.g., region 803 of the temperature signal), which is caused by the rocking motion of the roll by the roll actuator. The controller 126 can adjust the roll actuator and / or generate various other outputs to minimize such vibrations.

[0044] FIG. 9 shows a plurality of temperature signals of a roll similar to roll 104 when measured, and the temperature signals of the same roll after the control system 122 has controlled the roll based on the measured temperature. As shown, prior to control by the control system 122, a portion of a particular roll had a temperature exceeding the threshold temperature 905. In these embodiments, in response to such detected temperatures, the control system 122 controlled the roll such that the temperature of the roll was below the threshold temperature 905 (e.g., by adjusting the actuator, controlling the line speed of the metal substrate, etc.).

[0045] A set of exemplary embodiments is provided below, including at least some that are explicitly listed as “exemplifications” providing further explanation of various exemplary embodiments according to the concepts described herein. These exemplifications are not intended to be mutually exclusive, exhaustive, or restrictive, and the present disclosure is not limited to these exemplary explanations, but rather includes all possible modifications and variations within the scope of the issued patent claims and their equivalents.

[0046] Example 1. A metal processing system, comprising: a roll configured to rotate about an axis, the roll including a first end, a second end, and a non-metallic surface for contacting a metal substrate between the first end and the second end; a control system, including: a sensor configured to detect a temperature of the non-metallic surface of the roll; and a controller communicatively coupled to the sensor, the controller configured to receive the detected temperature from the sensor and control the roll based on the detected temperature.

[0047] Example 2. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the roll is a squeezing roll for contacting a coil of the metal substrate, and the non-metallic surface includes a deformable material.

[0048] Example 3. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the deformable material includes a rubber material.

[0049] Example 4. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the sensor includes a thermal camera configured to detect the temperature at a frame rate of at least 60 Hz.

[0050] Example 5. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the frame rate is at least 70 Hz.

[0051] Example 6. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the sensor generates a plurality of independent detection zones along the roll between the first end and the second end for the temperature of the non-metallic surface of the roll, and detects the temperature of the non-metallic surface independently within each detection zone of the plurality of detection zones.

[0052] Example 7. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the plurality of independent detection zones includes at least three detection zones.

[0053] Example 8. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the controller receives the detected temperature of each detection zone of the plurality of detection zones, compares the detected temperature for each detection zone with a threshold temperature for the specific detection zone, and controls the roll based on the detected temperature of at least one detection zone of the plurality of detection zones exceeding the threshold temperature for that specific detection zone.

[0054] Example 9. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the controller receives the detected temperature of each detection zone of the plurality of detection zones, compares the detected temperature of a first detection zone of the plurality of detection zones with the detected temperature of a second detection zone of the plurality of detection zones, and controls the roll based on the difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone.

[0055] Example 10. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the first detection zone of the plurality of detection zones is at the first end or the second end of the roll, and the second detection zone of the plurality of detection zones is between the first end and the second end of the roll.

[0056] Example 11. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the controller is configured to control the roll based on the difference between the detected temperature in the first detection zone and the detected temperature in the second detection zone exceeding a threshold limit.

[0057] Example 12. The metal processing system according to any preceding or subsequent example or combination of examples including Example 6, wherein the sensor is configured to change the size of each detection zone based on a change in the distance between the roll and the sensor.

[0058] Example 13. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the sensor is configured to detect a maximum temperature for each detection zone or an average temperature for each detection zone.

[0059] Example 14. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the controller is configured to control the roll by controlling the rolling force applied by the roll, and controlling the rolling force includes controlling at least one actuator for the roll.

[0060] Example 15. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the controller is further configured to generate an alert based on the detected temperature exceeding a threshold temperature.

[0061] Example 16. The metal processing system according to any preceding or subsequent example or combination of examples, wherein the controller is further configured to determine a pressure distribution of at least one actuator on the roll based on the detected temperature and control at least one actuator based on the determined pressure distribution.

[0062] Example 17. The metalworking system according to any preceding or subsequent example or combination of examples, wherein the controller is further configured to predict the performance of the roll based on the detected temperature and generate an alert based on the predicted performance satisfying a predetermined condition.

[0063] Example 18. The metalworking system according to any preceding or subsequent example or combination of examples, wherein the predetermined condition includes damage to the non-metallic surface of the roll.

[0064] Example 19. A control system for a metalworking system including a roll, the roll including a non-metallic contact surface, the control system including a sensor for detecting the temperature of the non-metallic contact surface of the roll, and a controller communicatively coupled to the sensor, the controller configured to receive the detected temperature from the sensor and generate an output signal for controlling the roll based on the received temperature.

[0065] Example 20. The control system according to any preceding or subsequent example or combination of examples, wherein the sensor includes a thermal camera configured to detect the temperature at a frame rate of at least 60 Hz.

[0066] Example 21. The control system according to any preceding or subsequent example or combination of examples, wherein the frame rate is at least 70 Hz.

[0067] Example 22. The control system according to any preceding or subsequent example or combination of examples, wherein the sensor is configured to detect the temperature of the non-metallic surface of the roll by generating a plurality of independent detection zones along the roll and independently detecting the temperature of the non-metallic surface within each of the plurality of detection zones.

[0068] Example 23. The control system according to any preceding or subsequent example or combination of examples, wherein the plurality of independent detection zones includes at least three detection zones.

[0069] Example 24. The control system according to any preceding or subsequent example or combination of examples, wherein the controller receives the detected temperature of each detection zone of the plurality of detection zones, compares the detected temperature for each detection zone with a threshold temperature for a particular detection zone, and generates the output signal based on the detected temperature for at least one of the plurality of detection zones exceeding the threshold temperature for that particular detection zone.

[0070] Example 25. The control system according to any preceding or subsequent example or combination of examples, wherein the controller receives the detected temperature of each detection zone of the plurality of detection zones, compares the detected temperature of a first detection zone of the plurality of detection zones with the detected temperature of a second detection zone of the plurality of detection zones, and generates the output signal based on a difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone.

[0071] Example 26. The control system according to any preceding or subsequent example or combination of examples, wherein the controller is configured to generate the output signal based on the difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone exceeding a threshold limit.

[0072] Example 27. The control system according to any preceding or subsequent example or combination of examples, wherein the sensor is configured to detect a maximum temperature for each detection zone or an average temperature for each detection zone.

[0073] Example 28. The control system according to any preceding or subsequent example or combination of examples, wherein the controller is further configured to generate an alert based on the detected temperature exceeding a threshold temperature.

[0074] Example 29. The control system according to any preceding or subsequent example or combination of examples, wherein the controller is further configured to determine a pressure distribution of at least one actuator on the roll based on the detected temperature and to control the at least one actuator based on the determined pressure distribution.

[0075] Example 30. The control system according to any preceding or subsequent example or combination of examples, wherein the controller is further configured to predict the performance of the roll based on the detected temperature and to generate an alert based on the predicted performance meeting a predetermined condition.

[0076] Example 31. A method of controlling a roll including a non-metallic contact surface for contacting a metal substrate, the method including receiving a detected temperature from a sensor of at least a portion of the non-metallic contact surface of the roll and controlling the roll based on the received temperature for at least the portion of the non-metallic contact surface.

[0077] Example 32. The method according to any preceding or subsequent example or combination of examples, wherein controlling the roll includes adjusting an operating parameter of the roll based on the received temperature exceeding a threshold temperature.

[0078] Example 33. Receiving the detected temperature includes independently receiving the detected temperature for each of a plurality of detection zones along the roll, and controlling the roll is based on at least one of whether the detected temperature for a particular detection zone exceeds a threshold temperature for that particular detection zone, or whether a difference between the detected temperature of a first detection zone of the plurality of detection zones and the detected temperature of a second detection zone of the plurality of detection zones exceeds a threshold limit, according to any preceding or subsequent example or combination of examples described herein.

[0079] Example 34. Controlling the roll includes controlling at least one actuator of the roll to control the rolling force from the roll, according to any preceding or subsequent example or combination of examples described herein.

[0080] Example 35. Further including determining a pressure distribution of at least one actuator on the roll based on the detected temperature, and controlling the at least one actuator based on the determined pressure distribution, according to any preceding or subsequent example or combination of examples described herein.

[0081] Example 36. Further including predicting the performance of the roll based on the detected temperature, and generating an alert based on the predicted performance meeting a predetermined condition, according to any preceding or subsequent example or combination of examples described herein.

[0082] Example 37. Generating the alert includes generating a visual alert or an auditory alert, according to any preceding or subsequent example or combination of examples described herein.

[0083] The subject matter of the embodiments is described herein using specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be construed as implying a particular order or arrangement between various steps or elements, except when the order of individual steps or the arrangement of elements is explicitly described. References to directions such as "above," "below," "top," "bottom," "left," "right," "front," and "rear" are intended to refer to the orientation illustrated and described in one (or more) of the figures to which the components and directions are being referred. Throughout this disclosure, reference numerals with letters refer to specific examples of elements, and reference numerals without letters refer to elements generally or collectively. Thus, by way of example (not shown), a device "12A" refers to an example of a device class that may collectively be referred to as device "12," any one of which may be generically referred to as device "12." In the drawings and description, like numerals are intended to represent like elements. As used herein, the meanings of "a," "an," and "the" include references to both singular and plural forms unless the context clearly dictates otherwise.

[0084] The above aspects are merely possible examples of embodiments and are described only to clearly understand the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments (s) without substantially departing from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of the disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the disclosure. Further, specific terms are used in this specification and the following claims, but they are used only in a general and descriptive sense and not for the purpose of limiting the described embodiments or the following claims.

Claims

1. A metal processing system comprising: a roll configured to rotate about an axis, the roll including a first end, a second end, and a non-metallic surface for contacting a metal substrate between the first end and the second end; and a control system, a sensor configured to detect the temperature of the non-metallic surface of the roll, a controller communicatively coupled to the sensor, the controller receiving the detected temperature from the sensor and configured to control the roll based on the detected temperature, the control system including.

2. The metal processing system according to claim 1, wherein the roll is a squeezing roll for contacting a coil of the metal substrate, and the non-metallic surface includes a deformable material.

3. The metal processing system according to claim 1, wherein the sensor includes a thermal camera, and the thermal camera is configured to detect the temperature at a frame rate of at least 60 Hz.

4. The sensor is configured to detect the temperature of the non-metallic surface of the roll by generating a plurality of independent detection zones along the roll between the first end and the second end, and independently detecting the temperature of the non-metallic surface within each detection zone of the plurality of detection zones. The metal processing system according to claim 1.

5. The controller is configured to receive the detected temperature of each detection zone of the plurality of detection zones, for each detection zone, compare the detected temperature with a threshold temperature for the specific detection zone, and control the roll based on the detected temperature of at least one detection zone of the plurality of detection zones exceeding the threshold temperature for that specific detection zone. The metal processing system according to claim 4.

6. The controller is configured to receive the detected temperature of each detection zone of the plurality of detection zones, compare the detected temperature of a first detection zone of the plurality of detection zones with the detected temperature of a second detection zone of the plurality of detection zones, and control the roll based on the difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone. The metal processing system according to claim 4. Claim 7 The metalworking system according to claim 4, wherein the sensor is configured to change the size of each detection zone based on a change in the distance between the roll and the sensor. Claim 8 A control system for a metalworking system including a roll, the roll including a non-metallic contact surface, the control system comprising: a sensor for detecting the temperature of the non-metallic contact surface of the roll; and a controller communicatively coupled to the sensor, the controller configured to receive the detected temperature from the sensor and generate an output signal for controlling the roll based on the received temperature. Claim 9 The control system according to claim 8, wherein the sensor includes a thermal camera, and the thermal camera is configured to detect the temperature at a frame rate of at least 60 Hz. Claim 10 The sensor is configured to detect the temperature of the non-metallic surface of the roll by generating a plurality of independent detection zones along the roll, and independently detecting the temperature of the non-metallic surface within each detection zone of the plurality of detection zones. The control system according to claim 9. Claim 11 The controller is configured to receive the detected temperature of each detection zone of the plurality of detection zones, for each detection zone, compare the detected temperature with a threshold temperature for the specific detection zone, and generate the output signal based on the detected temperature of at least one detection zone of the plurality of detection zones exceeding the threshold temperature for that specific detection zone. Claim 12 The controller is configured to receive the detected temperature of each detection zone of the plurality of detection zones, compare the detected temperature of a first detection zone of the plurality of detection zones with the detected temperature of a second detection zone of the plurality of detection zones, and generate the output signal based on a difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone. Claim 13 The control system according to claim 12, wherein the controller is configured to generate the output signal based on that the difference between the detected temperature of the first detection zone and the detected temperature of the second detection zone exceeds a threshold limit.

14. The control system according to claim 9, wherein the controller is further configured to determine a pressure distribution of at least one actuator on the roll based on the detected temperature and to control the at least one actuator based on the determined pressure distribution.

15. The control system according to claim 9, wherein the controller is further configured to predict the performance of the roll based on the detected temperature and to generate an alert based on that the predicted performance meets a predetermined condition.

16. A method for controlling a roll including a non-metallic contact surface for contacting a metal substrate, the method comprising: receiving a detected temperature from a sensor of at least a portion of the non-metallic contact surface of the roll; controlling the roll based on the received temperature. The method as described above.

17. Receiving the detected temperature includes independently receiving the detected temperature for each detection zone of a plurality of detection zones along the roll, and Controlling the roll is based on at least one of the following, the method according to claim 16: that the detected temperature for a particular detection zone exceeds a threshold temperature for that particular detection zone, or that the difference between the detected temperature of a first detection zone of the plurality of detection zones and the detected temperature of a second detection zone of the plurality of detection zones exceeds a threshold limit.

18. The method according to claim 16, wherein controlling the roll includes controlling at least one actuator of the roll to control the rolling force from the roll.

19. The method according to claim 16, further comprising determining a pressure distribution of at least one actuator on the roll based on the detected temperature and controlling the at least one actuator based on the determined pressure distribution.

20. The method according to claim 16, further comprising predicting the performance of the roll based on the detected temperature and generating an alert based on the predicted performance satisfying a predetermined condition.

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