Roll Surface Inspection Using Refracted Light and Line Scan Imaging
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Solution Overview
Problem
Traditional methods for inspecting and grinding roll surfaces in metal rolling processes are inefficient, as they fail to effectively detect and remove defects in real-time, leading to suboptimal product quality and increased maintenance costs.
Innovation Solution
A system comprising a prism, camera, light source, and plate is used to refract light and capture high-resolution images of the roll surface during grinding, allowing for real-time defect detection and concurrent grinding adjustments, utilizing a line scan camera and programmed computer system to generate two-dimensional images and evaluate defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used for roll surfaces, then the inspection process is simpler, but the defect detection capability and real-time monitoring are insufficient
Solution Approach 1:
The inspection system divides the roll surface into multiple scanning zones using a line scan camera that captures sequential line images as the roll rotates. Each line of pixel sensors captures a specific circumferential section, and multiple lines are combined to form a complete two-dimensional surface map, enabling high-resolution defect detection without requiring a single complex wide-area sensor
Solution Approach 2:
The system transitions from traditional point-by-point or area camera inspection to a line-based scanning approach that adds the temporal dimension of sequential capture. The line scan camera rotates with the roll, capturing images in the circumferential direction while simultaneously progressing in the axial direction, creating a two-dimensional surface map through multi-dimensional data integration
2Manufacturing precision
If real-time defect detection is implemented during grinding, then product quality improves, but the system complexity and processing requirements increase
Solution Approach 1:
The inspection system is integrated directly into the grinding machine tool, combining the defect detection camera system with the grinding spindle and control unit. This merging allows real-time surface inspection to occur during the grinding operation itself, enabling immediate feedback and correction without requiring separate inspection equipment or stopping the manufacturing process
Solution Approach 2:
The system implements closed-loop feedback by continuously monitoring the roll surface during grinding, detecting defects in real-time, and providing immediate feedback to the control system. This enables dynamic adjustment of grinding parameters or alert operators to correct defects before they affect product quality, creating a self-correcting manufacturing process
3Measurement precision
If high-resolution imaging is used for defect detection, then measurement precision improves, but the data processing time and system resource requirements increase
Solution Approach 1:
The system performs preliminary organization of image data during the scanning process by sequentially capturing line images and pre-assembling them into two-dimensional surface maps as the roll rotates. This preliminary action prepares the data in advance for defect analysis, reducing the processing burden during critical inspection phases and enabling faster real-time evaluation of surface defects
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 continuous in-process imaging and defect evaluation, improving the quality of rolled products by allowing for immediate correction of surface defects during the grinding process, thus enhancing productivity and reducing maintenance needs.
Implementation Method 1
the prism is configured to refract light from the light source
Data Source
AI summary
A system and method that includes, in an embodiment, a prism, a camera, a light source, and a plate. The system, in an embodiment, is configured for scanning a roll and generating an image of the roll surface. The prism, in an embodiment, is positioned below the camera and above the plate. In an embodiment, the plate is positioned below the prism and above the roll surface. In an embodiment, the light source is positioned above the prism. In an embodiment, the light source and the prism are positioned to provide light to the roll surface at an angle of at least 75 degrees measured from a line normal to the roll surface. In an embodiment, the prism is configured to refract light from the light source, the camera is a line scan camera that includes a row of pixel sensors, and the light source includes light emitting diodes.