Roller Alignment in Continuous Casting Segments
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Solution Overview
Problem
The existing methods for aligning rollers in continuous casting segments are time-consuming, complex, and require manual labor, leading to inefficiencies and potential inaccuracies in maintaining the alignment of rollers, which affects the quality of the cast product.
Innovation Solution
A system utilizing a robot with a laser tracker and an automatic recognition device to measure and align the rollers, eliminating the need for manual intervention and significantly reducing alignment time, while ensuring high accuracy through automated processing and mechanical adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods using templates and shims are used, then measurement precision can be achieved, but measurement time becomes very long (3.5-5 hours)
Solution Approach 1:
The patent replaces the manual mechanical measurement system (templates and shims) with an automated optical measurement system using a laser tracker and robot. The laser tracker uses laser beams to measure roller positions automatically, eliminating the need for manual template placement and shim measurements, thereby reducing measurement time from 3.5-5 hours to a much shorter duration while maintaining precision through automated data processing.
Solution Approach 2:
The measurement system performs self-measurement by automatically positioning itself using the robot and laser tracker to measure all rollers without requiring operator intervention for each measurement point. The system autonomously collects data, processes measurements, and generates alignment results, eliminating the need for two operators working manually for hours.
2Manufacturing precision
If manual measurement and adjustment procedures are used, then roller alignment can be achieved, but device complexity and operational difficulty increase
Solution Approach 1:
The complex manual procedure involving multiple operators, templates, shims, and repeated measurements is replaced by an automated system where a robot controls the laser tracker to automatically measure all rollers. The processing unit automatically processes the collected data and generates adjustment instructions, eliminating the complexity of manual procedures while ensuring consistent alignment precision.
Solution Approach 2:
The patent introduces a processing unit as an intermediary between the laser tracker and the rollers. This processing unit automatically processes the raw measurement data from the laser tracker, calculates alignment deviations, and generates adjustment instructions, thereby simplifying the overall system operation and eliminating the need for complex manual calculation and decision-making procedures.
3Productivity
If automated robot and laser tracker system is used, then measurement time is significantly reduced, but device complexity increases
Solution Approach 1:
The automated system is divided into distinct functional modules: the robot for positioning, the laser tracker for measurement, and the processing unit for data analysis. This segmentation allows each component to perform its specific function efficiently, achieving high productivity while managing complexity through modular design. The robot handles movement, the laser tracker handles measurement, and the processing unit handles computation, allowing parallel operation and reduced measurement time.
Solution Approach 2:
The processing unit serves as an intelligent intermediary that manages the complexity of coordinating the robot and laser tracker. It receives raw data from the laser tracker, processes the information, and generates control signals for adjustments, thereby simplifying the overall system operation and enabling high-speed automated alignment without requiring complex manual coordination.
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
The system achieves rapid and accurate alignment of rollers, reducing measurement time to about 10 minutes and eliminating the need for manual templates, resulting in improved product quality and increased efficiency with reduced operator involvement.
Implementation Method 1
a laser tracker adapted to track said reflector by means of a laser beam and to calculate the position in space of each of said points
Implementation Method 2
a robot having an arm provided at one end thereof with a reflector, said robot being adapted to move the reflector in order to successively put it in contact with a plurality of predetermined points
Data Source
Figure 1
Figure 2a~2d
Figure 3
AI summary
A measurement system (1) for measuring the position of the axes of the rollers of a containment and guide segment, adapted to contain and guide a cast product exiting from a crystallizer in a continuous casting process, the system comprising a robot (2) having an arm (4) provided at one end thereof with a reflector (5), said robot being adapted to move the reflector (5) in order to successively put it in contact with a plurality of points of each roller of the containment and guide segment; and comprising a laser tracker (3) adapted to track the reflector (5) by means of a laser beam and to calculate the position in space of each of said points of the containment and guide segment so as to determine the position of the axis of each roller.