Measuring Roller Sensor Layout for Accurate Strip Flatness
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Solution Overview
Problem
Conventional measuring rollers for determining the flatness of metal strips face issues such as measurement errors due to vibrations, force shunts, and the weakening of the roller body due to recesses, which affect the accuracy and informative value of the measurements.
Innovation Solution
The solution involves arranging multiple force sensors in a concentrated row or a single recess on the measuring roller body with a closed peripheral surface, reducing the influence of vibrations and enhancing measurement resolution by ensuring all sensors see the strip in the same state of vibration, and using a solid roller design without a jacket tube to minimize disruptions and improve measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If force sensors are arranged in recesses with sealing (O-ring or plastic layer), then the measuring roller body is protected from dirt ingress, but force shunts occur and measurement accuracy deteriorates
Solution Approach 1:
The sealing elements (O-rings or plastic layers) are completely removed from the measuring roller design. Instead of protecting sensors with seals that cause force shunts, the patent exposes the force sensors directly on the measuring roller surface without any sealing, thereby eliminating the source of measurement error while the measuring roller continues to function in the rolling mill environment
Solution Approach 2:
The design transitions from a sealed configuration to an unsealed configuration by removing the sealing elements. This parameter change eliminates the force shunt effect caused by sealing forces, allowing accurate flatness measurements even though the sensors are directly exposed to the environment
2Area of stationary object
If multiple force sensors are distributed over the circumference of the measuring roller, then comprehensive flatness coverage is achieved, but vibration influence amplifies measurement errors
Solution Approach 1:
Multiple force sensors are merged into a concentrated linear arrangement rather than being distributed around the circumference. The sensors are positioned next to each other in a row, all facing the same direction to measure forces at different points along the strip width, thereby reducing vibration-induced measurement errors while maintaining comprehensive coverage
Solution Approach 2:
The sensor arrangement transitions from a circumferential distribution (one-dimensional circular pattern) to a linear arrangement (one-dimensional straight line). This dimensional reconfiguration allows all sensors to observe the strip in the same vibrational state while still providing comprehensive flatness measurement coverage
3Ease of operation
If deep-hole drilling tools are used to create recesses for force sensors, then axially accessible recesses are achieved, but misaligned drill channels occur and manufacturing precision deteriorates
Solution Approach 1:
The recesses are completely removed from the measuring roller body. Instead of creating cavities through deep-hole drilling, the force sensors are mounted directly on the surface of the measuring roller, eliminating the drilling process and its associated alignment problems entirely
Solution Approach 2:
The mechanical drilling process is replaced by a surface mounting approach. Force sensors are positioned and fixed directly on the measuring roller surface without requiring subsurface cavities, thereby substituting a complex drilling operation with a simpler surface attachment process
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 configuration increases the informative value of the tests by providing more precise flatness measurements with reduced vibration influence and eliminates force shunts, leading to higher resolution and accuracy in determining the properties of the strip-shaped material.
Implementation Method 1
at least one first force sensor (7a) and at least one second force sensor (7b) are arranged in the recess (3), with each force sensor having a sensor surface that generates a sensor signal when its position changes
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a measuring roller for determining a property of a strip-like product, more particularly a metal strip, guided over the measuring roller, having a measuring roller body with a circumferential surface, at least one recess in the measuring roller body, which is spaced apart from the circumferential surface or leads from the circumferential surface into the interior of the measuring roller body, and a first force sensor, which is arranged in the recess, and a second force sensor, which is arranged in the recess or in a further recess adjacent to the recess. The first force sensor has a sensor surface and the first force sensor can generate a sensor signal if the position of the sensor surface of the first force sensor changes, and the second force sensor has a sensor surface and the second force sensor can generate a sensor signal if the position of the sensor surface of the second force sensor changes.