Metal Plate Edge Crack Detection with Adaptive Sensor Region Selection

Solution Overview

Problem

Existing edge crack detection methods for metal plates conveyed on rolling lines face inefficiencies in processing large numbers of detection signals from multiple sensors, making it challenging to accurately detect small edge cracks at high speeds.

Innovation Solution

An edge crack detection apparatus with a detection part comprising multiple elements along the plate width, a plate edge position determination part, and an edge crack detection part that selects a narrower region of elements based on the edge position to efficiently detect cracks, using a smaller number of elements and reducing calculation load.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a plurality of sensors are arranged in the plate-width direction to detect edge cracks, then the detection coverage is improved, but the calculation load and processing complexity increase

Engineering Contradiction:

Improveedge crack detection accuracyVSAvoidsensor arrangement complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent segments the sensor arrangement into two distinct functional regions: a first region with a larger number of sensors for detecting plate edge position, and a second region with a smaller number of sensors for detecting edge cracks. This segmentation allows each region to be optimized for its specific detection task, reducing overall system complexity while maintaining detection accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sensor array are assigned different densities and functions: the first region has higher sensor density for precise edge position detection, while the second region has lower density sufficient for crack detection. This local quality differentiation optimizes the detection system for its specific tasks in different spatial zones.

Inventive Principle:

Principle #3Local quality

2Measurement precision

If a plurality of sensors are arranged in the plate-width direction to detect edge cracks, then the detection coverage is improved, but the processing time increases

Engineering Contradiction:

Improveedge crack detection accuracyVSAvoiddetection cycle time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent segments the sensor arrangement into two distinct functional regions: a first region with a larger number of sensors for detecting plate edge position, and a second region with a smaller number of sensors for detecting edge cracks. This segmentation allows each region to be optimized for its specific detection task, reducing overall system complexity while maintaining detection accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using all sensors for both edge position and crack detection, the patent applies partial action by using only the necessary number of sensors in the second region for crack detection. This reduces the processing load and detection cycle time while maintaining sufficient detection capability.

Inventive Principle:

Principle #16Partial or excessive action

3Measurement precision

If a large number of sensors are used to detect small edge cracks at high speed, then the detection accuracy is improved, but the calculation load increases

Engineering Contradiction:

Improvesmall edge crack detection accuracyVSAvoidcalculation processing load

Core Design Contradiction:

Measurement precisionVSPower

Solution Approach 1:

The patent segments the sensor arrangement into two distinct functional regions: a first region with a larger number of sensors for detecting plate edge position, and a second region with a smaller number of sensors for detecting edge cracks. This segmentation allows each region to be optimized for its specific detection task, reducing overall system complexity while maintaining detection accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent extracts the crack detection function from the general sensor array and assigns it to a specific second region with a reduced number of sensors. This extraction allows the system to use only the necessary computational resources for crack detection, reducing the overall calculation load while maintaining detection accuracy.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11808720B2Edge crack detection device, rolling mill facility and edge crack detection method

Publication Date: 2023.11.07 PRIMETALS TECHNOLOGIES JAPAN LTD

AI summary

An apparatus for detecting an edge crack of a metal plate being conveyed includes: a detection part including a plurality of elements configured to detect a presence or absence of the metal plate at a position of the element in the plate width direction; a plate edge position determination part configured to determine a plate edge position of the metal plate in the plate width direction on the basis of a detection result of each of a plurality of first elements positioned within a first region in the plate width direction; and an edge crack detection part configured to detect an edge crack of the metal plate on the basis of a detection result of each of a plurality of second elements selected on the basis of the plate edge position and positioned within a second region which is narrower than the first region in the plate width direction.