Laser-Guided Coil Winding Control for Uniform Rolled Products
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Solution Overview
Problem
Conventional winding systems for semi-finished metal products in the steel industry struggle to achieve precise control over coil formation due to non-uniform cross-sections, leading to imperfections such as gaps and overlaps, which affect production efficiency and coil density.
Innovation Solution
A winding system equipped with a laser triangulation profilometer that detects the surface profile of the coil in formation downstream of the instantaneous winding point, allowing for real-time adjustment of the distributor's translation speed to minimize deviations from theoretical parameters, ensuring even coil filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional winding systems are used with indirect measurement, then the system is simpler to implement, but the measurement precision and control accuracy are insufficient leading to coil imperfections
Solution Approach 1:
The patent replaces indirect mechanical measurement systems with direct optical measurement using a laser triangulation profilometer. This optical system directly measures the rod cross-section and coil geometry without mechanical contact, providing high precision measurements while maintaining system simplicity through non-contact sensing.
Solution Approach 2:
The patent creates a digital copy of the rod cross-section and coil geometry through laser scanning. The profilometer captures the physical shape of the rod and coil turns, converting them into digital data that can be processed and used for real-time control adjustments without physically altering the winding process.
2Adaptability or versatility
If the distributor moves as a shuttle between axial ends of the coiler, then the coil formation process is continuous, but the coordination between coiler and distributor cannot optimally adapt to rod cross-section variations
Solution Approach 1:
The patent implements a feedback control system where the laser profilometer continuously measures the actual rod cross-section and coil geometry during winding. This measurement data is fed back to the control system, which automatically adjusts the distributor position and coiler speed to compensate for rod variations, ensuring precise turn positioning while maintaining continuous operation.
Solution Approach 2:
The patent makes the winding system dynamic by enabling real-time adjustment of distributor position and coiler rotation speed based on measured rod characteristics. The system transitions from fixed predetermined parameters to dynamically adaptable parameters that respond to actual rod cross-section variations during the winding process.
3Reliability
If indirect measurement methods are used for rod parameters, then the measurement system is simpler, but the reliability and accuracy of parameter detection are insufficient
Solution Approach 1:
The patent replaces unreliable indirect mechanical measurement methods with direct optical measurement using laser triangulation. The profilometer directly scans the rod surface and coil geometry, providing reliable and accurate measurements without mechanical contact points that could fail or drift over time.
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 enables reliable and efficient winding by minimizing coil imperfections, improving coil density and overall production efficiency through precise control of the winding process.
Implementation Method 1
said detection means comprise at least one laser triangulation profilometer suitable for continuously detecting the surface profile of the coil of rolled product at every added turn
Data Source
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AI summary
The present invention relates to a system for winding a rolled product comprising a winder (10) comprising, in turn: a winding spool (11); spool rotation means (12); a distributor (13), which is suitable to guide the positioning of the rolled product towards the spool at an instantaneous winding point; distributor translation means (15). The system comprises a control and command unit (20), which is configured to control the rotation means (12) and the translation means (15) in a coordinated manner, in accordance with a predetermined winding programme which is a function of predetermined reference operating parameters storable by said control and command unit (20) and of operating parameters which can be acquired in real time during the winding by the control and command unit (20) by detection means (30) with which the winding system (1) is provided. Said detection means (30) comprise at least one laser triangulation profilometer (31), which is substantially arranged in a position diametrically opposite to the distributor (13) with respect to the spool (11) and is suitable to continuously detect the surface profile of the coil of rolled product at every added turn. The and in that it comprises a processing and calculation unit (200) which, on the basis of the surface profile of the coil of rolled product detected by the profilometer (32) at every added turn, is configured to feedback adjust the translation speed of the distributor so as to minimize the difference between an actual operating parameter calculated on the basis of the profile of the coil in formation detected by said profilometer (31) and the same operating parameter calculated on the basis of theoretical data related to a predetermined ideal winding of the coil.