Material Web Data Conversion for Coiled Sheet Processing
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Solution Overview
Problem
Existing methods fail to efficiently utilize material web parameters measured during rolling processes in independent processing devices, leading to time-consuming and inefficient identification of missing material web segments, resulting in unnecessary material exclusion and suboptimal product quality.
Innovation Solution
The method involves using image processing to compare images of the winding mirrors on the rolling mill and processing coils, determining the missing material web segment's length and arrangement without physical handling, allowing for storage and access of corrected material web data independently of the rolling mill, enabling multi-user access and optimizing operating parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If material web segments are removed from the rolling mill coil after winding, then the material web quality is improved by excluding defective segments, but the time required to determine the length of removed segments increases significantly
Solution Approach 1:
The patent applies preliminary action by determining the length of missing material web segments before the coiling process. Image processing is used to capture the winding mirror surface of the rolling mill coil, and the missing segment length is calculated from this image data before any segments are removed. This allows the processing device to later identify and exclude defective segments efficiently without time-consuming measurements.
Solution Approach 2:
The patent uses image processing to create a digital copy or representation of the rolling mill coil's winding mirror surface. This image serves as a record that can be analyzed later to determine the length of missing segments, eliminating the need for physical measurements after segments are removed.
2Manufacturing precision
If material web parameters are measured during rolling mill production, then manufacturing precision is improved, but the complexity of data management and coordination between rolling mill and processing device increases
Solution Approach 1:
The patent introduces an intermediary approach by using image processing of the winding mirror surface as a mediator between the rolling mill and the processing device. Instead of directly transferring complex parameter data, the system uses the image data to determine missing segment lengths, which are then used to correct the material web parameter data. This simplifies the data management interface between the two devices.
Solution Approach 2:
The patent implements feedback by using the determined missing segment length information to correct the material web parameter data. The processing device receives the original parameter data from the rolling mill, applies corrections based on the missing segment length, and uses this corrected data to guide further processing operations, ensuring continuous improvement and coordination.
3Productivity
If corrected material web data is stored for access by processing devices independent of the rolling mill, then productivity is improved by enabling autonomous processing, but the loss of information about material web segments increases without proper correction
Solution Approach 1:
The patent replaces mechanical measurement systems with an optical/image processing system. Instead of using physical measurement devices to determine missing segment lengths, the system uses image processing of the winding mirror surface to calculate the lengths. This allows the information to be captured and stored digitally, enabling autonomous processing while preserving the necessary segment correlation data.
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
This approach enables accurate and efficient conversion of material web data records between rolling and processing coils, facilitating effective further processing and material utilization, while allowing for real-time optimization of rolling mill operations based on processing device feedback.
Implementation Method 1
a material web parameter Y is detected by means of a parameter detector device as a function of a web length coordinate X
Implementation Method 2
the further processing coil is compared with the rolling mill coil, with the comparison being carried out using an image processing method
Data Source
Figure 1
Figure 2
AI summary
Method for providing a web-length-related material web data set of a material web 12 produced in a rolling mill 10 for a processing facility 17 independent of the rolling mill, in which the material web produced in the rolling mill and wound into a rolling mill coil 16 is unwound and further processed starting from a processing coil 17, which is formed from a partial length of the material web produced in the rolling mill, wherein during the production of the material web in the rolling mill a material web parameter Y is recorded by means of a parameter detector device as a function of a web length coordinate X and a material web data set 24 formed from web length coordinates X and associated material web parameters Y is stored in a storage medium,in which a missing material web segment 26 on the processing coil is identified and a web length correction value corresponding to the length and relative arrangement of the material web segment in the rolling mill coil is determined, and the material web data set of the rolling mill coil is converted into a material web data set 35 of the processing coil taking into account the web length correction value, whereby a comparison of the processing coil with the rolling mill coil is carried out to determine the missing material web segment.