Laser Roll Alignment Measurement for Real-Time Parallelism Checks
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Solution Overview
Problem
Existing roll alignment measurement technologies are limited by the need for high-resolution sensors and complex setups, making it difficult for non-professionals to accurately measure and correct roll alignment, especially at varying distances and roll lengths, leading to inefficiencies and product defects.
Innovation Solution
An apparatus with a subject position fix unit and a relative position measurement unit that uses laser signals to measure roll alignment, allowing for real-time output of alignment data, enabling quick and accurate alignment of measurement rolls with respect to subject rolls, regardless of distance or sensor resolution, and simplifying the measurement process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-resolution sensors are used to measure roll alignment accurately, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical laser-based measurement system. The laser transmitting unit emits laser beams that are reflected by the measurement roll's surface, and the laser receiving unit captures the reflected beams to calculate alignment parameters. This optical substitution eliminates the need for high-resolution mechanical sensors while achieving accurate measurement through light reflection geometry analysis.
Solution Approach 2:
The patent introduces a laser beam as an intermediary carrier to transfer alignment information from the measurement roll to the receiving unit. The laser beam reflects off the roll surface and carries geometric information about the roll's position and orientation, which is then decoded by the control unit to determine alignment status without requiring direct contact or complex sensing mechanisms.
2Measurement precision
If complex measurement setups are used to achieve accurate alignment measurement, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The measurement system is mounted directly on the measurement roll itself, making the roll self-measuring. The laser transmitting unit is positioned on the measurement roll and emits beams that reflect off its own surface, automatically capturing its alignment state without requiring external measurement equipment or complex setup procedures by operators.
Solution Approach 2:
The laser-based measurement system serves multiple functions: it measures both the position and orientation (parallelism and horizontality) of the measurement roll simultaneously, provides real-time alignment data, and can be applied to various roll sizes and configurations without requiring different measurement equipment, simplifying operation across different scenarios.
3Productivity
If traditional measurement methods are used, then device complexity is reduced, but productivity decreases due to measurement and correction time
Solution Approach 1:
The laser measurement system operates continuously during the roll operation, providing real-time alignment monitoring. The laser beams continuously reflect off the measurement roll surface, and the control unit continuously calculates alignment parameters, enabling ongoing measurement without interrupting the production process and allowing for immediate correction when misalignment is detected.
Solution Approach 2:
The system provides real-time feedback on the measurement roll's alignment status by continuously monitoring the reflected laser beam positions and calculating parallelism and horizontality parameters. This feedback is immediately available to operators, enabling quick identification and correction of alignment issues, thereby reducing downtime and improving overall productivity.
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 apparatus allows for easy and accurate alignment of rolls in roll process lines, improving productivity and reducing defects by providing intuitive alignment feedback and standardizing data collection, even with standard sensor resolution, and enabling alignment checks without disassembling the roll process line.
Implementation Method 1
a subject position fix unit (100) mounted on a subject roll (SR), that is the reference of measurement, and discharging a laser signal (L) to a measurement roll (MR) to be measured
Implementation Method 2
a received-laser signal reflection module (231) that passes and reflects the first laser signal (L1) discharged from the subject position fix unit (100)
Data Source
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Figure 3~4
Figure 5(a)~5(b)
AI summary
The present invention relates to an apparatus for detecting relative positioning information between rolls, and a method for measuring a roll alignment state by using same, and to an apparatus for detecting relative positioning information between rolls, and a method for measuring a roll alignment state by using same, the apparatus outputting a measurement result in real time so that a measurer can easily recognize the degree of parallelism and the degree of horizontality of a roll when a roll process line is formed, and thus an inter-roll alignment state can be checked or a measurement roll can be corrected according to the alignment state.