Measuring Roller Sensor Segmentation for Strip Edge Detection
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Solution Overview
Problem
Existing measuring rollers struggle to accurately detect unevenness at the edge of strip-shaped materials, particularly in thin strips, due to limited sensor resolution and the restricted number of discrete sensors, which hinders precise determination of length and width distributions and limits the detection of defects like microripples and thickness variations.
Innovation Solution
The use of compact sensors, arranged in a segment of the measuring roller's circumferential surface, with a design that allows for a higher density of sensors by integrating them within a layer applied to the base body, rather than in recesses, enabling higher lateral resolution and detection of defects such as strip cracks, micro-ripples, and thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If piezoelectric force sensors with sensor areas larger than 600 mm² are used in recesses of the measuring roller body, then the structural stability of the measuring roller is maintained, but the lateral measurement resolution is insufficient and edge unevenness cannot be detected with required precision
Solution Approach 1:
The measuring roller surface is divided into multiple small sensor areas (each ≤600 mm²) arranged in a segmented pattern, allowing high lateral resolution while maintaining structural stability. The sensors are distributed across the roller circumference to capture detailed surface profile information.
Solution Approach 2:
The sensor arrangement transitions from a single recess location to a two-dimensional array distributed across the roller circumference. This dimensional expansion enables simultaneous measurement of multiple points, achieving high lateral resolution without requiring oversized individual sensors.
2Measurement precision
If the number of discrete sensors is limited, then the device complexity is reduced, but the detection of thin strip characteristics and length distribution becomes highly variable and imprecise
Solution Approach 1:
The roller circumference is segmented into multiple measurement zones with small sensors (≤600 mm² each), enabling precise detection of strip edge position and thin strip characteristics without requiring an excessive number of large sensors.
Solution Approach 2:
The sensor area parameter is reduced from traditional large sizes (>600 mm²) to small sizes (≤600 mm²), fundamentally changing the measurement capability to detect fine details while managing the total sensor quantity through optimized spatial distribution.
3Measurement precision
If sensors are arranged in recesses of the base body, then the structural stability is maintained, but the lateral resolution and detection capability for microripples and defects are limited
Solution Approach 1:
Multiple small sensor recesses (each accommodating sensors ≤600 mm²) are distributed around the roller circumference, enabling detection of microripples and surface defects while maintaining structural integrity through segmented rather than monolithic design.
Solution Approach 2:
Each local recess area is optimized for specific measurement functions with appropriately sized sensors, while the overall roller structure maintains global stability. The local sensor arrangements are tailored to detect specific defect types at different circumferential positions.
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 enhances the lateral measurement resolution, allowing for the detection of defects like strip cracks and micro-ripples, and provides detailed information on residual stresses and strip alignment, while maintaining the stability and longevity of the measuring roller.
Implementation Method 1
WO 2020/120329 A1 it is known to arrange a first piezoelectric force sensor next to a second piezoelectric force sensor in a recess of the measuring roller body
Data Source
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Figure 5~6
AI summary
A measuring roller for determining at least one property of a strip-type product guided over the circumferential surface of the measuring roller, in particular a metal strip (1), comprising – a measuring-roller body (3) which extends along a longitudinal axis A, has, at the ends, bearing journals (4) or bushes for rotatably mounting the measuring-roller body (3) and forms the circumferential surface, and - a plurality of sensors (5) which are arranged next to one another under the circumferential surface, and a segment (6) of the measuring-roller body (3) which is delimited • by a region (7) of the circumferential surface, • two radial planes (8, 9) which intersect in the longitudinal axis A of the measuring-roller body (3), each extend in a radial direction and intersect the circumferential surface, and • two planes which extend perpendicularly to the longitudinal axis A and intersect the circumferential surface, wherein the surface area of the region of the circumferential surface unrolled into a plane has a size of x mm2, wherein a number y of sensors (5) is arranged in the segment, where y is at least greater than or equal to 3 and y > 2x/100.