Calender Roll Gap Sensing via Axle Box Displacement
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Solution Overview
Problem
Current rolling devices face challenges in accurately controlling the uniformity of the thickness of products manufactured by ensuring precise measurement of the gap between rolls, which affects the quality of the final product.
Innovation Solution
A rolling device equipped with a sensor unit that measures the movement of axle boxes by extending and contracting in alignment with their movement, allowing for high-accuracy detection of the gap between rolls, even when inclined, and includes features like cooling gas supply to maintain accuracy and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a noncontact-type distance sensor is used to measure the gap between rolls, then the measurement can be performed without contact, but the measurement precision is insufficient for high-accuracy thickness control
Solution Approach 1:
The patent replaces the noncontact-type distance sensor with a contact-type sensor unit that directly measures the position of axle boxes. This mechanical measurement approach provides higher precision (about 1 µm) compared to noncontact methods, while the sensor unit is designed to be interposed between axle boxes for straightforward installation and maintenance.
2Measurement precision
If the sensor unit is designed to directly measure axle box position for high precision, then measurement accuracy improves, but the device complexity and maintenance difficulty increase
Solution Approach 1:
The measurement system is segmented into independent sensor units, each capable of measuring the position of individual axle boxes. This modular design allows the sensor units to be independently installed, adjusted, and maintained without affecting other parts of the rolling device, thereby improving ease of repair while maintaining high measurement precision.
3Manufacturing precision
If the sensor unit measures gap between rolls directly, then the thickness uniformity control improves, but the device complexity increases
Solution Approach 1:
The patent introduces sensor units as intermediary devices that measure the position of axle boxes, which in turn determines the gap between rolls. This intermediary measurement approach enables precise control of product thickness uniformity while keeping the overall rolling device structure relatively simple, as the sensor units are integrated into the existing axle box configuration.
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A calender (1) includes: first and second rolls (12A, 12B) adjacent to each other; a first axle box (14A) rotatably supporting a shaft of the first roll; a second axle box (14B) rotatably supporting a shaft of the second roll and adjacent to the first axle box; an adjustment unit (18A) configured to adjust a position of the first axle box so as to move the first roll toward the second roll or to separate the first roll from the second roll; at least one sensor unit (24A) interposed between the first axle box and the second axle box and being in contact with both of the axle boxes; and a controller (26). The sensor unit includes a distance sensor including an extension/contraction portion configured to extend and contract in a direction in which the first and second axle boxes are aligned. The controller controls the adjustment unit on the basis of an extension/contraction amount of the extension/contraction portion.