Rolled Product Winding Control Using Laser Coil Profiling
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Solution Overview
Problem
Existing winding systems in the steel industry struggle to achieve precise control over the winding of semi-finished metal products, leading to imperfections such as gaps and overlaps in the coils, which affect coil density and production efficiency.
Innovation Solution
A winding system and method that utilize a laser triangulation profilometer to continuously detect the surface profile of the coil, allowing for real-time feedback adjustment of the distributor's translation speed to minimize deviations from ideal winding parameters, thereby ensuring correct and efficient coil formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional winding systems are used with indirect parameter measurement, then the system structure is simpler, but the manufacturing precision of coil formation deteriorates due to gaps and overlaps
Solution Approach 1:
The patent replaces indirect mechanical measurement systems with direct optical measurement using a laser triangulation profilometer. The profilometer uses a laser beam and camera to non-contactively measure the coil surface profile, substituting complex mechanical measurement devices with a simpler optical system that provides direct and accurate measurements of coil formation parameters.
Solution Approach 2:
The patent creates an optical copy (image) of the coil surface using the laser profilometer's camera system. This optical copy is then processed to extract precise geometric information about the coil turns, allowing accurate measurement without physical contact or complex mechanical sensors on the moving rod.
2Reliability
If indirect measurement methods are used to control winding parameters, then the device complexity is reduced, but the reliability of parameter detection deteriorates
Solution Approach 1:
The patent replaces unreliable indirect mechanical measurement with direct optical measurement. The laser triangulation profilometer provides reliable direct measurement of coil geometry by capturing light reflected from the coil surface, eliminating the need for complex mechanical sensors that require constant coordination with the distributor and rod characteristics.
3Productivity
If conventional winding control is used without real-time feedback, then the control system is simpler, but the productivity deteriorates due to low coil density and production defects
Solution Approach 1:
The patent implements a feedback control system where the laser profilometer continuously measures the coil surface profile during winding, and the control unit processes this data to detect deviations from ideal winding. The system automatically adjusts winding parameters in real-time based on this feedback, ensuring optimal coil density and eliminating defects that would reduce productivity.
Solution Approach 2:
The patent performs preliminary detection of potential winding defects using the laser profilometer before they become serious problems. By continuously monitoring coil formation and detecting deviations early, the system can make corrective adjustments to maintain optimal winding parameters throughout the entire coil production process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves reliable and precise winding of coils, improving coil density and reducing production defects by accurately adjusting the winding parameters based on real-time coil formation data.
Implementation Method 1
a laser triangulation profilometer suitable for continuously detecting the surface profile of the coil
Data Source
AI summary
A system for winding a rolled product includes a winder having a winding spool, a spool rotator, a distributor guiding positioning of the rolled product towards the spool at an instantaneous winding point, and a distributor translator. A control and command unit coordinates the rotator and the translator according to a predetermined winding program which is a function of predetermined reference operating parameters and of real time operating parameters. The detector includes a laser triangulation profilometer diametrically opposite to the distributor, and continuously detects the surface profile of the coil of rolled product at every added turn. A processing and calculation unit feedback adjusts translation speed of the distributor to minimize a difference between an actual operating parameter calculated based on the profile of the coil in formation detected by the profilometer and the same operating parameter calculated based on theoretical data related to a predetermined ideal coil winding.