Industrial Roll Position Detection Using Dual Gravity Vector Triggering
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Solution Overview
Problem
Existing methods for determining the rotative position of industrial rolls in papermaking machines are unreliable due to noise signals from accelerometer data, leading to incorrect matching of sensor data with roll positions.
Innovation Solution
A method and system utilizing an accelerometer to detect gravity vectors, with distinct pre-trigger and trigger levels to differentiate noise from actual position changes, ensuring accurate determination of the rotative position of the roll by comparing the magnitude and direction of the gravity vector to predetermined levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single trigger level is used for accelerometer-based position detection, then the system is simple to implement, but noise signals cause unreliable position determination
Solution Approach 1:
The trigger level is segmented into two distinct levels: a pre-trigger level and a trigger level. This segmentation allows the system to first detect when the accelerometer signal approaches the region of interest (pre-trigger), then confirm the actual trigger event (trigger). The two-level approach filters out noise by requiring the signal to cross both thresholds in sequence, significantly improving position detection reliability without adding complex hardware.
2Measurement precision
If noise filtering is applied to accelerometer data, then position determination accuracy improves, but response time increases
Solution Approach 1:
The pre-trigger level serves as a preliminary action that prepares the system for the actual trigger event. When the accelerometer signal first crosses the pre-trigger level, the system enters a ready state and begins monitoring for the confirmatory trigger level crossing. This preliminary detection reduces the effective response time because the system is already prepared to immediately recognize and process the actual trigger event, rather than waiting for full signal processing and noise filtering after the event occurs.
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 reliably triggers data gathering at specific points in each rotation, ensuring accurate matching of sensor data with roll positions, even in the presence of noise, thereby improving the precision of operational parameter monitoring.
Implementation Method 1
detecting a gravity vector generated in the accelerometer
Data Source
Figure 1~2
Figure 3~4A
Figure 4B
AI summary
A method of determining the rotative position of an industrial roll includes (a) providing a rotating industrial roll having a longitudinal axis, the industrial roll having mounted on one end thereof an accelerometer, the industrial roll further including a plurality of sensors; (b) determining a pre-trigger angular position of the roll based on a first gravity vector provided by the accelerometer; then (c) determining a trigger angular position of the roll based on a second gravity vector provided by the accelerometer, the magnitude of the second gravity vector differing from the magnitude of the first gravity vector by more than the magnitude of a typical noise signal; and (d) gathering data from the sensors after the roll has passed the trigger angular position; and (e) matching data gathered in step (d) with a respective sensor of the plurality of sensors based on the determination of the trigger angular position.