Laser Triangulation Sensor Layout for Driver Roller Surface Defect Detection
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Solution Overview
Problem
Current methods for detecting defects on driver rollers in rolling mills are inefficient, unsafe, and prone to human error, leading to reduced production quality and safety risks due to manual inspections and ineffective cleaning.
Innovation Solution
A sensor unit with laser line triangulation sensors arranged along a sensor axis, emitting divergent laser beams that overlap in a plane, allowing for contactless detection of the driver roller's surface structure, integrated with a housing, cooling system, and control unit to analyze surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual visual inspection is used to detect surface defects on driver rollers, then inspection cost is reduced, but detection precision and reliability deteriorate due to human error and safety risks
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical measurement system consisting of laser line triangulation sensors. These sensors emit laser lines that reflect off the driver roller surface, and the reflected light is captured by receivers to detect surface deviations. This substitution eliminates human error and safety risks while maintaining cost-effectiveness through automated operation.
Solution Approach 2:
The patent introduces laser line triangulation sensors as an intermediary between the driver roller surface and the inspection process. The sensors use laser light as a mediator to probe surface topography, converting physical surface features into measurable optical signals that can be analyzed automatically without direct human contact or exposure to hazardous environments.
2Productivity
If driver roller surface inspection is performed during production downtimes, then production interruption is minimized, but detection precision deteriorates because defects are only discovered after they affect the rolled stock
Solution Approach 1:
The patent implements continuous or frequent inspection of driver roller surfaces during operation or between production runs, rather than waiting for scheduled downtimes. The automated optical system can quickly scan surfaces and identify defects early, allowing preventive maintenance to be scheduled before defects impact rolled stock quality, thus maintaining both productivity and detection precision.
3Device complexity
If manual cleaning with grindstones is used to remove deposits, then equipment complexity is reduced, but manufacturing precision deteriorates due to ineffective cleaning and safety hazards
Solution Approach 1:
The patent replaces manual mechanical cleaning with automated optical detection that can identify the precise location and extent of surface deposits. The laser line triangulation system creates detailed 3D maps of surface topography, enabling targeted removal methods that preserve surface precision while eliminating the need for operators to manually grind hazardous deposits.
4Productivity
If driver rolls are operated for long periods between inspections, then productivity is improved, but reliability deteriorates as surface defects accumulate and impair rolled stock quality
Solution Approach 1:
The patent implements a feedback-based inspection system where laser line triangulation sensors continuously monitor driver roller surface conditions. When surface deviations exceeding predetermined thresholds are detected, the system automatically alerts operators to inspect or replace the driver roller. This feedback mechanism allows extended operational periods while maintaining reliability by preventing defective rollers from producing impaired stock.
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
Enables precise, automated detection of surface defects on driver rollers, improving production quality and safety by reducing downtime and human intervention, while ensuring accurate and continuous monitoring.
Implementation Method 1
each laser sensor is designed as a laser line triangulation sensor which is configured to output a laser light beam
Implementation Method 2
to receive laser light, wherein the main output directions of all laser sensors coincide and the laser light beams of all laser sensors are concentrated in one plane
Data Source
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AI summary
The invention relates to a sensor unit (1) for detecting a surface structure of a surface (3, 54, 56) of a measurement object (5, 53, 55). The sensor unit (1) comprises a sensor carrier (9) and a plurality of laser sensors (7) arranged next to one another along a sensor axis (21) and each fixedly connected to the sensor carrier (9). Each laser sensor (7) is designed as a laser line triangulation sensor configured to output a divergent laser light beam (23) that expands fan-shaped from the laser sensor (7) around a main output direction (25) of the laser sensor (7), and to receive laser light (29). The main output directions (25) of all laser sensors (7) coincide, and the laser light beams (23) of all laser sensors (7) are concentrated in one plane.