Ring Rolling Profile Control Using a Light Section Sensor
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Solution Overview
Problem
Existing ring rolling machines lack precision in monitoring and controlling the forming process, especially for tall rings or sleeves, due to complex and less effective measurement methods such as mechanical feeler rollers and laser triangulation, which do not allow for real-time adjustments during the forming process.
Innovation Solution
The implementation of a light section sensor that uses a constant laser line to monitor the workpiece profile, enabling precise measurement and evaluation of over 500 or more measuring points, allowing for real-time adjustments and control of the forming tools during the rolling process, thereby improving the accuracy and quality of the rolled rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical feeler rollers or laser triangulation with multiple points are used to monitor the forming process, then measurement capability is provided, but device complexity increases and real-time control during forming is not achieved
Solution Approach 1:
The patent replaces mechanical feeler rollers with a light section sensor that uses optical methods (laser line projection and camera imaging) to measure the workpiece profile. This substitution eliminates mechanical contact during measurement, reducing device complexity and enabling non-contact real-time monitoring during the forming process.
Solution Approach 2:
The light section sensor creates an optical copy (laser line image) of the workpiece profile and captures it via camera. This optical copying method provides precise measurement information without requiring complex mechanical measurement systems, resolving the contradiction between measurement precision and device complexity.
2Measurement precision
If measurements are carried out before or after forming, then profile information is obtained, but real-time intervention during forming cannot be performed
Solution Approach 1:
The light section sensor continuously measures the workpiece profile during the entire forming process, not just before or after. This continuous measurement enables real-time detection of profile deviations and allows immediate control interventions to correct deviations, eliminating the time loss associated with post-forming inspection and correction.
Solution Approach 2:
The patent implements a feedback control loop where the light section sensor continuously monitors the workpiece profile during forming, compares it with the target profile, and feeds this information back to the control system for real-time adjustment of forming parameters, enabling timely correction of deviations.
3Productivity
If a constant laser line is used for measurement, then over 500 measuring points can be simultaneously evaluated, but measurement system complexity increases
Solution Approach 1:
The laser line is segmented into multiple discrete measuring points along the workpiece profile. Each point on the laser line provides independent measurement data, allowing simultaneous evaluation of over 500 measuring points. This segmentation approach increases measurement productivity while keeping the optical system relatively simple by using a single line laser and camera combination.
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 solution allows for precise monitoring and control of the forming process, enabling the detection of curvatures and profile changes in real-time, leading to improved quality and reduced errors in the rolled products, even in high-temperature forming processes, and simplifies the mechanical design of the ring rolling machine.
Implementation Method 1
a light section sensor (13) which is directed towards the workpiece (22) arranged in the working area (23) of the ring rolling machine (4) and represents an input variable for a forming control device (27)
Implementation Method 2
the constant laser line of a light section sensor with a corresponding camera enables the simultaneous measurement and evaluation of over 500 or over 1000 or even over 3000 measuring points
Data Source
Figure 1
AI summary
A forming machine (1), in particular a ring rolling machine, which includes a light section sensor (13) directed at a workpiece arranged in a working area of the forming machine, can operate precisely with a simple machine design.