Auto-calibration and real-time communication of data, problems, damage, maneuvers, and errors from a network of battery-powered smart guide nodes within the rolling mill

Abstract

A system for use in a rolling mill is disclosed that includes (a) a roll holder housing a plurality of rollers, and (b) a smart module coupled to the roll holder that includes (1) a power source for powering the smart module, (2) a microcontroller, (3) a motor for moving the roll holder and thereby controlling the position of the plurality of rollers based on instructions from the microcontroller, (4) one or more position sensors for detecting the position of the roll holder, and (5) a communications module that communicates with a central control computer to (i) communicate the position of the roll holder and other sensor data to the central control computer and (ii) receive instructions from the central control computer for controlling the position of the roll holder.

Description

[Technical Field]

[0001] The present invention relates generally to the field of rolling mills, and more particularly to automatic calibration and real-time communication of data, problems, damage, steering, and errors in roller guides of rolling mills utilizing a battery-powered Smart Guide node network. [Background technology]

[0002] A roller guide may be mistakenly calibrated to the wrong side (or to the incorrect side, left or right) or installed on the wrong stand (in the case of a two-strand rolling mill with opposing stands on each strand on each side). This condition cannot be detected by visual inspection, and the guide may be operated without the operator's knowledge. Operating the mill in this fault condition may result in premature guide failure, unplanned mill downtime, and / or reduced final product quality. The disclosed method provides real-time feedback and alerts the operator if the guide is mispositioned.

[0003] Roller guides can be manually steered after calibration while idle and before installation on the rolling mill. This situation is not good practice, but it is not readily apparent to other operators. This steered adjustment can result in premature guide failure, unplanned mill downtime, and / or reduced end product quality. The disclosed method provides real-time feedback and alerts the operator if the guide has been steered or manually adjusted after calibration.

[0004] Roller guides or other equipment within a rolling mill sometimes have problems that first manifest as a change in sound. Some of these problems may be detected by an operator experienced in distinguishing these sound changes, but others may be missed or simply unclear. The method of the present disclosure provides a solution for real-time sound discrimination of problems that subsequently alerts the operator.

[0005] Roller guides may be inadvertently set to the wrong finished product size. This condition is not always readily apparent to the operator and requires very careful inspection to identify. Operating the rolling mill under these conditions may result in premature guide failure, unplanned mill downtime, and / or reduced final product quality. The disclosed method provides real-time feedback to the operator prior to rolling mill operation if a guide set to the wrong product is selected or used.

[0006] Adjusting and calibrating roller guides requires significant physical effort to physically adjust the guide to the correct orientation. This process is time-consuming and subject to carelessness, mistakes, and variability from person to person and from guide to guide. The disclosed method provides for automatic calibration and adjustment of roller guides.

[0007] Each of these problems is currently performed manually and can only be identified through careful attention and individual inspection by an operator.

[0008] Bradshaw's U.S. Patent No. 5,999,623 discloses a roller guide assembly for guiding a workpiece into the roll pass of a rolling mill. Figure 5 shows a roller guide assembly 18 by Bradshaw. The guide assembly includes a rigid housing structure, a pair of roller holders 26 extending the length of the housing structure on either side of the intended direction of movement of the workpiece, with compression springs 32 disposed within bores in the roller holders 26 (the springs are captured within each bore via cover plates 34, and the housing structure further includes a vertical pivot 30), and guide rollers 28 rotatably supported on the roller holders 26, defining a gap between the guide rollers 28 and configured to engage and guide the workpiece into the roll pass of the rolling mill. The system includes guide rollers 28, pivots for mounting the roller holders on the housing structure for movement about axes extending generally parallel to the axes of rotation of the guide rollers, springs for applying a force to the roller holders to rotate the roller holders about their respective axes in a direction that urges the guide rollers apart, and stops on the housing structure for resisting rotation of the roller holders, at least one of which operates via a force sensor to provide an indication of the force applied to each roller holder. The spring-induced rotation of the roll holders 26 is resisted by the stops with adjustment screws 36 positioned for contact by load-sensing sensors 38. Drive point 48a is for manual adjustment, typically utilized for offline setting of the guide. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] U.S. Patent No. 6,209,378 Summary of the Invention [Problem to be solved by the invention]

[0010] Embodiments of the present invention are improvements over prior art systems and methods. [Means for solving the problem]

[0011] In one embodiment, the present invention provides a system for use in a rolling mill, the system comprising: (a) a roll holder containing a plurality of rollers; and (b) a smart module coupled to the roll holder, the smart module comprising: (1) a power supply for powering the smart module, (2) a microcontroller, (3) a motor for moving the roll holder and thereby controlling the position of the plurality of rollers based on instructions from the microcontroller, (4) one or more position sensors for detecting the position of the roll holder, and (5) a communications module for communicating with a central control computer to (i) communicate the position of the roll holder and other sensor data to the central control computer and (ii) receive instructions from the central control computer for controlling the position of the roll holder.

[0012] In another embodiment, the present invention provides a system for use in a rolling mill, the system comprising: (a) a roll holder containing a plurality of rollers; and (b) a smart module coupled to the roll holder, the smart module comprising: (1) a power supply for powering the smart module, (2) a microcontroller, (3) a motor for controlling the position of the plurality of rollers by moving the roll holder based on instructions from the microcontroller, (4) one or more position sensors for detecting the position of the roll holder, (5) a microphone for collecting acoustic data, the microphone performing an acoustic spectrum analysis on the collected acoustic data and identifying one or more problems with the rolling mill based on the acoustic analysis, and (6) a communications module for communicating with a central control computer to (i) communicate the roll holder position and other sensor data to the central control computer, (ii) receive instructions from the central control computer for controlling the position of the roll holder, and (iii) communicate the one or more problems identified based on the acoustic analysis to the central control computer.

[0013] The present disclosure will now be described in detail with reference to the accompanying drawings, by way of one or more various examples. These drawings are provided solely for illustrative purposes and merely illustrate examples of the present disclosure. These drawings are provided to facilitate the reader's understanding of the present disclosure and should not be considered as limiting the scope, scope, or applicability of the present disclosure. It should be noted that the drawings are not necessarily drawn to scale for purposes of clarity and simplicity of illustration. [Brief explanation of the drawings]

[0014] [Figure 1] 13A-13C show the addition of a "smart module" to the roller guide. [Figure 2] FIG. 1 is an overall block diagram showing how the system of the present invention is set up in a rolling mill. [Figure 3] FIG. 10 illustrates a calibration process associated with a roller guide. [Figure 4] FIG. 2 is a diagram showing a pair of roller holders. [Figure 5] FIG. 1 illustrates a prior art roller guide assembly. DETAILED DESCRIPTION OF THE INVENTION

[0015] While the present invention has been shown and described in a preferred embodiment, it can be made in many different configurations. While a preferred embodiment of the present invention is shown in the drawings and described in detail herein, this is done with the understanding that the present disclosure should be considered as an illustration of the principles of the invention and relevant functional details for construction, and is not intended to limit the invention to the illustrated embodiment. Many other possible variations within the scope of the present invention will be anticipated by those skilled in the art.

[0016] In this description, the term "one embodiment" refers to a feature that is referenced and is included in at least one embodiment of the present invention. Furthermore, in this description, each distinct reference to the term "one embodiment" does not necessarily refer to the same embodiment, and none of them are mutually exclusive unless expressly stated and unless readily apparent to one skilled in the art. Thus, the present invention may include any of the various combinations and / or integrations of the embodiments described herein.

[0017] Each of these problems is solved by adding a "smart module" to the roller guide. FIG. 1 shows a smart controller for a roller guide according to the teachings of the present invention. This smart module includes a microcontroller 102, a wireless communication module 104, a motor 106 (e.g., a stepper motor) for controlling the position of a roller 108 by moving a roller holder 110, an accelerometer 120 for detecting acceleration and orientation, a position sensor 112 for sensing the position of the roller holder, a temperature sensor for measuring temperature at one or more locations within the roller guide, and a microphone 114. The accelerometer is used to determine the orientation of the roller guide in space by measuring acceleration due to gravity in three axes. If the z-axis is set horizontally, the z-axis will show the full gravity effect when the guide tilts to one side. One of the other axes will begin to show partial gravity effect. This data is used to calculate the angular position of the guide. The accelerometer also measures acceleration amplitude generally about the x-, y-, and z-axes, which can determine whether a problem is occurring that manifests as increased vibration.

[0018] It is also noted that in one embodiment, the accelerometer data is also used to detect loosening of the roller guide mounting during rolling. In this scenario, the rolling mill cover is closed during operation, so the operator is unaware of the loose mounting condition. If the accelerometer indicates a change in orientation during operation, the central control computer will alert the operator that the guide may be loosening from its mounting.

[0019] The temperature sensor may measure the overall ambient temperature inside the smart module or the bulk temperature of the guide itself, depending on its mounting location. If the guide has some kind of problem and the bulk temperature of the guide or ambient air begins to rise, the temperature sensor will detect this change and alert an operator if necessary. This is used in combination with other sensor data, such as microphones and accelerometers, to help determine what the problem is and whether it is severe enough to shut down the mill for investigation.

[0020] The smart module is powered by a rechargeable battery 116, which allows for fully wireless operation within the rolling mill, and is fitted with a multi-coloured LED 118 to indicate various warnings or status.

[0021] Figure 4 shows a pair of roller holders. Typically, a pair of rollers is standard, with one roller held in each roll holder. In some cases, two rollers may be used for each roll holder.

[0022] The accelerometer is used to detect the orientation of the guide in space, specifically whether the guide is mounted on the correct side (LH or RH) stand. These stands are oriented at a 90-degree angle to each other and typically at a 45-degree angle to the ground. Therefore, the signal from the accelerometer is used to detect whether the guide is mounted on the LH stand or the RH stand. The accelerometer is also used to detect vibrations in the guide, specifically vibrations from the rollers / bearings to determine if there is an error in the rollers / bearings.

[0023] Figure 2 shows the overall setup of how such a system is installed on a rolling mill. Multiple guides with attached smart modules 202A-202C are mounted in place on the rolling mill 200. These smart modules simultaneously communicate with a nearby central control computer 204. The central computer can set the operating mode of each smart module, send commands to move the guide rollers, and receive data from the smart modules, including sensor data, warnings, and general information.

[0024] Before installation on the rolling mill, the roller guides are calibrated on an offline alignment station 206. This offline alignment station 206 is also a computer-controlled system and may also communicate with the smart module.

[0025] 3 shows the calibration process. The offline alignment station 302 sends position information to the smart module 304, which then automatically adjusts the guide roller positions to the correct positions. Once calibration is complete, the offline alignment station communicates various configuration information, including roller position, product size, mounting side, number of stands, etc., to the smart module, which stores this data in its memory.

[0026] In one embodiment, the present invention provides a system for use in a rolling mill, the system comprising: (a) a roller holder housing a plurality of rollers; and (b) a smart module coupled to the roller holder, the smart module comprising: (1) a power supply for powering the smart module, (2) a microcontroller, (3) a motor for controlling the position of the plurality of rollers by moving the roller holder based on instructions from the microcontroller, (4) one or more position sensors for detecting the position of the roll holder, and (5) a communications module for communicating with a central control computer to (i) communicate the position of the roll holder and other sensor data to the central control computer and (ii) receive instructions from the central control computer for controlling the position of the roll holder.

[0027] In another embodiment, the present invention provides a system for use in a rolling mill, the system comprising: (a) a roll holder containing a plurality of rollers; and (b) a smart module coupled to the roll holder, the smart module comprising: (1) a power supply for powering the smart module, (2) a microcontroller, (3) a motor for controlling the position of the plurality of rollers by moving the roll holder based on instructions from the microcontroller, (4) one or more position sensors for detecting the position of the roll holder, (5) a microphone for collecting acoustic data, wherein the microcontroller performs an acoustic spectrum analysis on the collected acoustic data and identifies one or more problems associated with the rolling mill based on the acoustic analysis, and (6) a communications module for communicating with a central control computer to (i) communicate the roll holder position and other sensor data to the central control computer, (ii) receive instructions from the central control computer for controlling the position of the roll holder, and (iii) communicate the one or more problems identified based on the acoustic analysis to the central control computer.

[0028] The roller position is stored in the smart module memory via the position sensor, allowing the smart module to notify the operator if any changes occur after calibration. When the smart module is switched on, the microcomputer continuously compares the current output value of the position sensor against the stored value. If a change (above a specified threshold) is detected, the smart module will give an indication, such as flashing an internal LED red.

[0029] The product size configured for each guide is stored in the smart module memory based on a calibration process. Before a guide can be used in the rolling mill, it must be synchronized via a handshake with the central control computer. This handshake transfers the data stored in the smart module memory to the central computer and sets the guide to "enabled" mode. The operator must select the product to be rolled on the central computer before synchronizing any guide for rolling. If the operator attempts to add a guide configured for a different product, the operator is warned of this issue.

[0030] The calibrated side must match the side on which the guide is mounted on the rolling mill, so the mounting side is memorized. When the roller guide is ready to be installed on the rolling mill, power to the smart module is switched on. When the microcontroller is powered, it continuously reads orientation data from the accelerometer and compares this data to the calibrated side. If the orientation matches the calibrated side, the smart module will provide an indication, such as turning on an internal LED green. If the orientation is opposite the calibrated side, the smart module will provide an indication, such as flashing an internal LED red.

[0031] When a roller guide is installed on a rolling mill, an operator can send a command via a central computer to initiate acoustic problem detection. The smart module collects acoustic data from a microphone and performs acoustic spectrum analysis using a fast Fourier transform. The smart module transmits spectral content data to the central computer, which analyzes this data for potential problems. If a problem is identified, the operator is notified.

[0032] 1, position sensor 112 is shown, but other sensors in addition to position sensor 112 are also contemplated. For example, in one embodiment, accelerometer block 120 or position sensor block 112 may further include a temperature sensor that may be used to identify problems in the rolling mill. Alternatively, this temperature sensor may be an independent sensor mounted anywhere on the structure shown in FIG. 1.

[0033] Advantages of the present invention include reduced guiding errors, higher finished product quality, reduced rolling mill downtime, longer useful life of guiding equipment, and reduced manpower required to maintain and monitor roller guides when compared to prior art solutions.

[0034] In particular, the feature of adding a smart module to the guide with built-in sensors and wireless communication with a central computer allows the above-mentioned advantages to be realized.

[0035] Another advantage of the present invention is that it allows for the retrofit or upgrade of existing rolling mills.

[0036] Different configurations of sensors and actuators can potentially solve these problems. Furthermore, communications can be entirely wired rather than wireless, and smart modules can be mains powered rather than individual batteries.

[0037] In one embodiment, the smart modules communicate with each other and with a central control computer, which in some circumstances allows the guides to instruct each other to take action in the event of an error, or allows for certain applications without the central control computer, or simply improves overall system efficiency.

[0038] In other embodiments, a central control computer is not required because the smart modules can make their own adjustments and decisions, operate autonomously, and optionally still communicate with other smart modules. This configuration can still have a central display screen that displays information from the smart modules. The smart modules can communicate with each other via wireless communication in the same way that they communicate with the central control computer. This can also be done via a wired connection. There are several situations in which communication between smart modules can be advantageous. One such situation is when the distance between smart modules is relatively great (in a rolling mill with multiple mill positions where a smart guide is used) and direct communication between the guide and the central control computer may not be possible. In this example, command cascading can be achieved by communicating with one smart module, which then instructs the other smart modules to take action. Another example in which direct communication is advantageous is when it simplifies the communication required between the central control computer and the guide. For example, if all five guides of a rolling mill are to be activated, a command can be sent to each guide to activate it to begin sending sensor data to the central control computer. In a scenario where one of the guides is defined as the "master," an activation command can be sent to that one guide, which in turn sends activation commands to the other four guides ("slaves") of the rolling mill. Ideally, the system would have a combination of both central computer-to-guide and guide-to-guide communication. Communication between smart modules can be done by the same equipment.

[0039] The features and applications described above can be implemented as a software process specified as a set of instructions recorded on a computer-readable storage medium (also referred to as a computer-readable medium). When these instructions are executed by one or more processing units (e.g., one or more processors, processor cores, or other processing units), the instructions cause the processing units to perform the operations suggested in the instructions. Embodiments within the scope of the present disclosure can also comprise tangible and / or non-transitory computer-readable storage media for carrying or having computer-executable instructions or data structures stored thereon. Such non-transitory computer-readable storage media can be any available medium that can be accessed by a general-purpose computer or a special-purpose computer having the functional design of any specific application processor. For example, and without limitation, such non-transitory computer-readable storage media can include flash memory, RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code means in the form of computer-executable instructions, data structures, or processor chip designs. Computer-readable media does not include carrier waves and electronic signals transmitted over wireless or wired connections.

[0040] Computer-executable instructions include, for example, instructions and data that cause a general-purpose computer, special-purpose computer, or special-purpose processing device to perform a particular function or group of functions. Computer-executable instructions also include program modules that are executed by computers in stand-alone or network environments. Generally, program modules include routines, programs, components, data structures, objects, and functions that perform particular tasks or implement particular abstract data types, and that are specific to a particular processor design. Computer-executable instructions, associated data structures, and program modules represent examples of the program code means for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described in such steps.

[0041] Processors suitable for executing a computer program include, by way of example, both general-purpose and special-purpose microprocessors, and any one or more processors of any kind of digital computer. Typically, a processor receives instructions and data from a read-only memory or a random-access memory, or both. The essential elements of a computer are a processor for performing or executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include one or more mass storage devices for storing data, such as, for example, magnetic disks, magneto-optical disks, or optical disks, or will be operatively coupled to transmit data to, receive data from, or both, such mass storage devices. However, a computer need not necessarily have such devices. Furthermore, a computer can be embodied in another device.

[0042] As used herein, the term "software" is meant to include firmware residing in read-only memory or applications stored on magnetic or flash storage, such as a solid-state device that can be loaded into memory for processing by a processor. Also, in some implementations, multiple software technologies may be implemented as subparts of a larger program while still being separate software technologies. In some implementations, multiple software technologies may be implemented as separate programs. Finally, any combination of separate programs that together implement the software technologies described herein is included within the scope of the subject technology. In some implementations, these software programs, when installed to operate on one or more electronic systems, constitute one or more dedicated machine implementations that execute and carry out the operations of the software programs.

[0043] A computer program (also known as a program, software, software application, script, or code) can be written in any type of programming language, including compiled or interpreted, declarative or procedural, and can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, object, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a file in a file system. A program can be stored as part of a file that holds other programs or data (e.g., one or more scripts stored in a marked-up language document), in a single file dedicated to the program, or in multiple cooperating files (e.g., a file storing one or more modules, subprograms, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers located at one site or distributed across multiple sites and interconnected by a communications network.

[0044] The functions described above can be implemented in digital electronic circuitry, computer software, firmware, or hardware. These techniques can be implemented using one or more computer program products. Programmable processors and programmable computers can be contained within or packaged as mobile devices. These processes and logic flows can be implemented by one or more programmable processors and one or more programmable logic circuits. General-purpose and special-purpose computing devices and storage devices can be interconnected via a communications network.

[0045] Some implementations comprise electronic components, such as a microprocessor, storage, and memory, that store computer program instructions on a machine-readable or computer-readable medium (alternatively referred to as a computer-readable storage medium, machine-readable medium, or machine-readable storage medium). Some examples of such computer-readable media include RAM, ROM, read-only compact discs (CD-ROMs), recordable compact discs (CD-Rs), rewritable compact discs (CD-RWs), read-only digital versatile discs (e.g., DVD-ROMs, dual-layer DVD-ROMs, etc.), various recordable / rewritable DVDs (e.g., DVD-RAMs, DVD-RWs, DVD+RWs, etc.), flash memory (e.g., SD cards, mini-SD cards, micro-SD cards, etc.), magnetic or solid-state hard drives, read-only and recordable Blu-Ray® discs, ultra-high density optical discs, any other optical or magnetic medium, and floppy disks. The computer-readable medium may store a computer program executable by at least one processing unit, the computer program including a set of instructions for performing various operations. Examples of computer programs or computer code include machine code, such as produced by a compiler, and files containing higher-level code that are executed by a computer, electronic component, or microprocessor using an interpreter.

[0046] Although the discussion above primarily refers to microprocessors or multi-core processors executing software, some implementations are performed by one or more integrated circuits, such as, for example, application specific integrated circuits (ASICs) or field programmable gate arrays (FPGAs). In some implementations, such integrated circuits execute instructions stored on the circuit itself.

[0047] In this specification and any claims herein, the terms "computer," "server," "processor," and "memory" all refer to electronic or other technological devices. These terms do not include a person or group of people. For purposes of this specification, the terms display or display mean a display on an electronic device. As used herein and in any claims herein, the term "computer-readable medium" is limited only to tangible physical objects that store information in a form readable by a computer. These terms do not include any wireless signals, wired download signals, or any other ephemeral signals.

[0048] It is understood that any specific order or hierarchy of steps in the processes of the present disclosure is an example approach. Based on design preferences, it is understood that the specific order or hierarchy of steps in these processes may be changed, or that all of the illustrated steps may be performed. Some of the steps may be performed simultaneously. For example, multitasking and parallel processing may be advantageous in some environments. Furthermore, the separation of various system components illustrated above should not be understood as requiring such separation, and it should be understood that the described program components and systems may be packaged into more software products than may generally be integrated together in a single software product.

[0049] Various modifications to these embodiments are readily apparent, and the general principles set forth herein may be applied to other embodiments. Accordingly, the claims are not intended to be limited to the embodiments set forth herein, but are to be accorded the full scope consistent with the language of the claims. In this context, reference to an element in the singular is not intended to mean "one and only one" unless expressly stated, but rather "one or more." Unless specifically indicated otherwise, the term "some" refers to one or more. Masculine pronouns (e.g., his) include feminine and neuter pronouns (e.g., her and its), and vice versa. Headings and subheadings, if any, are used for convenience only and do not limit the subject technology.

[0050] For example, the use of a phrase such as "an aspect" does not imply that the aspect is essential to the subject technology or that the aspect applies to every configuration of the subject technology. Disclosure relating to one aspect may apply to every configuration, or to one or more configurations. For example, the use of a phrase such as "an aspect" may refer to one or more aspects, and vice versa. For example, the use of a phrase such as "a configuration" does not imply that the configuration is essential to the subject technology or that the configuration applies to every configuration of the subject technology. Disclosure relating to one configuration may apply to every configuration, or to one or more configurations. For example, the use of a phrase such as "a configuration" may refer to one or more configurations, and vice versa.

[0051] The various embodiments described above are presented solely by way of example and should not be construed to limit the scope of the present disclosure. Those skilled in the art will readily recognize various modifications and changes that can be made to the principles described herein without going beyond the example embodiments and applications shown and described herein and without departing from the spirit and scope of the present disclosure.

[0052] While the specification contains numerous specific implementation details, these should not be construed as limiting the scope of the invention or what may be claimed, but rather as descriptions of features that may be specific to particular embodiments of a particular invention. Some features that are described herein in the context of each separate embodiment may also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, while features may be described above as operating in certain combinations and may even initially be claimed as such, one or more features of a claimed combination may, in some instances, be deleted from the combination, and the claimed combination may be directed to a subcombination or variations of the subcombination.

[0053] Similarly, although operations are illustrated in a particular order in the figures, this should not be understood as requiring that such operations be performed in the particular order or sequential order shown, or that all of the operations shown be performed, to achieve desired results. In some situations, multitasking and parallel processing may be advantageous. Furthermore, the separation of various system components in the above-described embodiments should not be understood as requiring such separation in all embodiments, and it should be understood that the program components and systems described may be packaged into more than one software product, and may generally be integrated together in a single software product.

[0054] Although specific embodiments of the subject matter have been described above, other embodiments are also within the scope of the appended claims. For example, the actions recited in the claims may be performed in a different order and still achieve the desired results. As one example, the processes depicted in the accompanying figures do not necessarily require the particular order or sequential order depicted to achieve the desired results. In some implementations, multitasking and parallel processing may be advantageous.

[0055] Conclusion The above embodiments have shown a system and method for effectively implementing automatic calibration and real-time communication of data, problems, damage, maneuvers, and errors utilizing a network of battery-powered SmartGuide nodes within a rolling mill. While various preferred embodiments have been shown and described, it should be understood that no limitation of the invention is intended by such disclosure, but rather that the invention is intended to cover all modifications within the spirit and scope of the invention as defined in the appended claims. [Explanation of symbols]

[0056] 102 Microcontrollers 104 Wireless communication module 106 Motor 108 Laura 110 Roller holder 112 Position sensor, position sensor block 114 Microphone 116 Rechargeable Battery 118 Multicolor LED 120 Accelerometer, Accelerometer Block 200 Rolling Mill 202A Smart Module 202B Smart Module 202C Smart Module 204 Central Control Computer 206 Offline Alignment Station 302 Offline Alignment Station 304 Smart Module

Claims

1. 1. A system for use in a roller guide of a rolling mill, comprising: (a) a roll holder that houses a plurality of rollers; (b) a smart module coupled to the roll holder, (1) a power source that powers the smart module; (2) a microcontroller; (3) a motor that controls the positions of the rollers by moving the roll holder based on commands from the microcontroller; (4) one or more position sensors for detecting the position of the roll holder; and (5) a communications module communicating with a central control computer to (i) communicate the position of the roll holder to the central control computer and (ii) receive commands from the central control computer to control the position of the roll holder; a smart module comprising: A system comprising:

2. The system of claim 1 , wherein the smart module further comprises an indicator for signaling one or more warnings regarding a condition of the rolling mill.

3. The system of claim 2 , wherein the indicator is a multi-color light emitting diode (LED).

4. 3. The system of claim 2, wherein the one or more warnings are any of the following: a first warning issued when a sensed position of the roll holder differs from a calibrated position of the roll holder by a predetermined threshold; a second warning issued when a product size being rolled differs from a calibrated size; a third warning issued when a sensed orientation of the roll holder differs from a calibrated orientation of the roll holder; and a fourth warning issued when an acoustic spectrum analysis of acoustic data collected via a microphone indicates a problem with the rolling mill.

5. The system of claim 1 , wherein the communication module is capable of wireless communication with the central control computer.

6. The system of claim 1 , wherein the smart module further comprises an accelerometer.

7. The system of claim 1 , wherein the smart module further comprises a temperature sensor.

8. The system of claim 1 , wherein the power source is a rechargeable battery.

9. the smart module further comprises a microphone; collecting acoustic data from the microphone; performing an acoustic spectrum analysis on the collected acoustic data; identifying one or more problems with the rolling mill based on the acoustic spectrum analysis; The system of claim 1 , further comprising: communicating the one or more problems to the central control computer via the communication module.

10. The system of claim 9 , wherein the acoustic spectrum analysis is performed by a Fast Fourier Transform (FFT).

11. The system is calibrated before use, such calibration being receiving position data for the plurality of rollers from an offline alignment station; adjusting the positions of the plurality of rollers according to the received position data; receiving and storing, as part of said calibration, one or more or a combination of the following data: roller position data, product size data, attachment side data, stand count data, user data, and date and time data; The system of claim 1 , comprising:

12. 1. A system for use in a roller guide of a rolling mill, comprising: (a) a roll holder that houses a plurality of rollers; (b) a smart module coupled to the roll holder, (1) a power source that powers the smart module; (2) a microcontroller; (3) a motor that controls the positions of the rollers by moving the roll holder based on commands from the microcontroller; (4) one or more position sensors for detecting the position of the roll holder; (5) a microphone for collecting acoustic data, the microphone performing an acoustic spectrum analysis on the collected acoustic data, and identifying one or more problems with the rolling mill based on the acoustic spectrum analysis; and (6) a communications module that communicates with a central control computer to (i) communicate the position of the roll holder and other sensor data to the central control computer, (ii) receive instructions from the central control computer for controlling the position of the roll holder, and (iii) communicate one or more problems identified based on the acoustic spectrum analysis to the central control computer; a smart module comprising: A system comprising:

13. The system of claim 12 , wherein the acoustic spectrum analysis utilizes a Fast Fourier Transform (FFT).

14. The system of claim 12 , wherein the smart module further comprises an indicator for signaling one or more warnings regarding a condition of the rolling mill.

15. The system of claim 14 , wherein the indicator is a multi-color light emitting diode (LED).

16. 15. The system of claim 14, wherein the one or more warnings are any of the following: a first warning issued when a sensed roll holder position differs from a calibrated roll holder position by a predetermined threshold; a second warning issued when a product size being rolled differs from a calibrated size; a third warning issued when a sensed roll holder orientation differs from a calibrated roll holder orientation; and a fourth warning issued when an acoustic spectrum analysis of acoustic data collected via a microphone indicates a problem with the rolling mill.

17. The system of claim 12 , wherein the communication module is capable of wireless communication with the central control computer.

18. The system of claim 12 , wherein the smart module further comprises an accelerometer.

19. The system of claim 12 , wherein the smart module further comprises a temperature sensor.

20. The system of claim 12 , wherein the power source is a rechargeable battery.

21. The system is calibrated before use, such calibration being receiving position data for the plurality of rollers from an offline alignment station; adjusting the positions of the plurality of rollers according to the received position data; receiving and storing one or more or a combination of the following data as part of said calibration: roller position data, product size data, attachment side data, and stand count data; The system of claim 12 , comprising:

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