Roller Mill Surface Temperature Control via Non-Contact Thermography
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Solution Overview
Problem
Existing milling roll machines struggle to accurately monitor surface temperatures of rolls, leading to potential overlook of high temperature abnormalities and quality degradation in ground or split products.
Innovation Solution
A control apparatus with non-contact type thermography cameras and sensors that monitor both roll surface temperatures and product temperatures, enabling precise control of roll gap and flow rate to prevent temperature differences and ensure product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is attached to the bearing casing of the roller, then the temperature can be measured and correction control can be performed, but it is not possible to accurately detect surface temperatures of rolls
Solution Approach 1:
The patent replaces contact-type temperature sensors with non-contact-type temperature sensors (infrared thermography cameras) to measure roll surface temperatures. This substitution eliminates the fundamental limitation of contact sensors that can only measure bearing casing temperatures, enabling direct and accurate measurement of the actual roll surface temperatures without physical contact.
Solution Approach 2:
The patent introduces infrared radiation as an intermediary to transfer temperature information from the roll surface to the sensor. The non-contact temperature sensor detects infrared radiation emitted by the roll surface, converting thermal energy into electrical signals for temperature measurement, thereby enabling accurate remote temperature detection.
2Measurement precision
If a plurality of multi-point sensors are provided in the roll-axis direction, then roll surface temperatures can be monitored at multiple points, but if one sensor malfunctions, the roll surface temperature cannot any longer be monitored
Solution Approach 1:
The patent divides the roll surface into multiple measurement regions by positioning multiple non-contact temperature sensors at different locations along the roll axis. Each sensor independently monitors temperature in its specific region, providing comprehensive temperature distribution data while maintaining system reliability through redundant measurement capabilities.
Solution Approach 2:
The non-contact temperature sensor system is designed to perform multiple functions: it can monitor temperature at multiple points simultaneously, identify abnormal temperature rises, and continue operation even if individual sensors malfunction. The system provides universal temperature monitoring coverage across the entire roll surface.
3Temperature
If the gap between rolls is increased to keep roll temperature to a set value, then temperature control can be maintained, but milling efficiency and productivity are reduced
Solution Approach 1:
The patent implements a feedback control system where non-contact temperature sensors continuously monitor roll surface temperatures, and the measured temperature data is fed back to the control unit. Based on this real-time feedback, the control unit automatically adjusts operational parameters such as feed rate or cooling conditions to maintain optimal roll temperature without requiring increased roll gaps, thereby preserving milling efficiency.
Solution Approach 2:
Instead of changing the physical gap between rolls to control temperature, the patent changes operational parameters such as feed rate, rotation speed, or cooling conditions based on real-time temperature measurements. This parameter adjustment approach maintains optimal temperature control while avoiding the productivity loss associated with increased roll gaps.
Data Source
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AI summary
A method and an apparatus for controlling a milling roll machine capable of accurately monitoring a surface temperature of a roll and preventing a high temperature abnormality occurring on a roll surface from being overlooked are provided A temperature sensor S that monitors surface temperatures of a pair of rolls 4 and 5 and a temperature of a milled product after passing through the rolls is provided in the vicinity of the pair of rolls 4 and 5, and opening/closing control of the gap between the rolls 4 and 5 or flow rate control of the raw material stock is performed according to the surface temperatures of the rolls and the temperature of the milled product after passing through the rolls detected by the temperature sensor S.