Laser Tracker Roller Alignment Device
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Solution Overview
Problem
Current methods for aligning rollers in continuous casting installations are time-consuming, inaccurate, and dependent on manual measurements, leading to high consequential costs and production downtime, with existing technologies failing to ensure precise alignment and reproducibility.
Innovation Solution
A device comprising a measuring body that reflects electromagnetic radiation, a measuring carriage with a sliding surface for physical contact, a holding unit for pivoting, and a restoring device to maintain contact, along with a laser tracker system for automated alignment determination, allowing for tactile measurement and reduced operator influence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods (micrometer screws, feeler gages, straightedges) are used for aligning rollers, then the alignment process can be performed with simple equipment, but the measurement accuracy is low and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical measurement methods (micrometer screws, feeler gages, straightedges) with an automated optical measurement system consisting of a laser tracker and reflective measuring bodies. The laser tracker automatically tracks the reflective bodies mounted on rollers, eliminating manual measurement operations while achieving high measurement accuracy and reducing alignment process time.
Solution Approach 2:
The measurement system enables self-measurement capability where the laser tracker automatically tracks multiple reflective bodies on rollers without requiring manual intervention for each measurement point. The system autonomously collects measurement data, calculates positions, and determines alignment, significantly reducing the time-consuming nature of manual measurements.
2Manufacturing precision
If re-truing is performed to eliminate incorrect positions of mold or roller segments, then alignment accuracy can be improved, but production downtime increases due to crane operations and re-fitting
Solution Approach 1:
The patent performs preliminary alignment measurement using the laser tracker system before final installation and commissioning. By measuring and determining the correct positions of rollers and roller segments in advance, the system enables precise positioning during assembly, eliminating the need for time-consuming re-truing operations with cranes and reducing production downtime.
Solution Approach 2:
The measurement system provides feedback on the actual positions and alignments of rollers and roller segments. This feedback information is used to guide adjustment operations and verify alignment accuracy, ensuring that roller segments are correctly positioned without requiring multiple re-truing cycles that would extend production downtime.
3Ease of manufacture
If indoor cranes are used for setting up and measuring mold and roller segments, then components can be positioned and measured, but the cranes are unavailable for production and setup time increases
Solution Approach 1:
The patent extracts the measurement function from the crane system by using a separate, dedicated laser tracker measurement system. This allows measurement operations to be performed independently without requiring crane involvement, freeing up cranes for production activities while maintaining the ability to position and measure components accurately.
Solution Approach 2:
The patent introduces reflective measuring bodies as intermediaries between the laser tracker and the rollers. These reflective bodies enable the laser tracker to accurately track and measure roller positions without requiring physical contact or crane operations during the measurement process, allowing setup and measurement to occur simultaneously or in optimized sequences.
4Reliability
If mechanical measuring means are used for alignment, then physical contact measurement can be performed, but the measuring means require annual checking and their state between inspections is unclear
Solution Approach 1:
The patent replaces mechanical measuring means (which require physical contact and annual calibration) with an optical laser tracker system. The laser tracker uses electromagnetic radiation to measure positions without physical contact, eliminating the need for mechanical components that wear out or drift, thereby improving reliability while reducing maintenance requirements.
Solution Approach 2:
The laser tracker system performs self-verification through its optical measurement process, continuously tracking reflective bodies to determine actual positions. The system autonomously monitors and records measurement data, providing ongoing verification of its own operational state without requiring external calibration or inspection, thereby maintaining reliable measurements between inspections.
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 solution simplifies and improves alignment processes, reducing setup time, increasing production efficiency, and enabling accurate, reproducible measurements without requiring indoor cranes, while allowing for quick repeat measurements and enhanced safety.
Implementation Method 1
at least one measuring body (7, 8), which reflects electromagnetic radiation
Data Source
AI summary
A device for determining orientation of an object, including a measurement body, which reflects electromagnetic radiation and can be brought into physical contact with a surface of the object to determine the orientation. The device includes: a measurement carriage movable along the object during the determination of the orientation and which has a sliding surface that can be brought into physical contact with the object; a retaining unit which retains the measurement body and is connected to the measurement carriage so as to be pivotable between a maximal position, in which the measurement body protrudes beyond the sliding surface on the object side, and a minimal position, in which the measurement body does not protrude beyond the sliding surface on the object side; and a restoring device that applies a force to the retaining unit toward the maximal position.