Rolling Mill Gap Measurement via Camera and Reference Scale
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Solution Overview
Problem
Existing methods for determining rolling gaps in multi-stand rolling mills are complex and prone to imaging inaccuracies, especially when measuring rolls or guides in the center or hard-to-reach areas, requiring cumbersome setup and potential interference from ambient conditions.
Innovation Solution
A system comprising a camera with a deep enough field of view to cover all roll stands, combined with background lighting and a comparison scale, allows for precise gap determination without additional optical adjustments, using image processing to recognize roll or guide contours and calculate positions based on a reference scale, which can be positioned easily and accessed from accessible regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a camera is disposed at one side of the roll stand with background lighting at the other side, then the measurement can be performed without components in the center of the rolling mill, but significant imaging inaccuracies occur due to the significant lengths of rolling mills
Solution Approach 1:
The patent applies preliminary action by pre-adjusting the camera optics to achieve a depth of field that spans the entire rolling mill length before measurements are taken. This preliminary optical configuration ensures that all roll stands remain in focus throughout the measurement process, eliminating the need for adjustments during operation and preventing imaging inaccuracies that would otherwise occur over the significant lengths of rolling mills.
2Measurement precision
If stencil bodies are clamped in place between the rolls of a roll stand and aligned by means of a laser system, then the rolling gap can be checked and optimized in accordance with the center line, but the procedure becomes complex particularly in the case of roll stands disposed in the center of the rolling mill
Solution Approach 1:
The patent extracts the measurement components from the center of the rolling mill by positioning the camera and background lighting at the input and output sides respectively. This eliminates the need to clamp stencil bodies between rolls at each roll stand and removes laser alignment systems from the center area, thereby simplifying the measurement procedure while maintaining the ability to check and optimize rolling gaps in accordance with the center line.
Solution Approach 2:
The patent uses optical copying by capturing images of roll surfaces and comparison scales with a camera. Instead of requiring physical stencil bodies and laser alignment at each stand, the system creates optical copies (images) that can be analyzed to determine rolling gap positions relative to the center line, significantly reducing device complexity.
3Measurement precision
If a camera with sufficient depth of field reaches over all roll stands, then imaging inaccuracies due to shift in focus can be avoided, but the camera optics must be precisely adjusted
Solution Approach 1:
The patent applies preliminary action by pre-adjusting the camera optics during installation or initial setup to achieve a depth of field that spans the entire rolling mill length. This preliminary configuration ensures that all roll stands remain in focus throughout the measurement process, eliminating the need for adjustments during operation and preventing imaging inaccuracies that would otherwise occur over the significant lengths of rolling mills.
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
Enables simple and precise measurement of rolling gaps without the need for complex adjustments or additional components, maintaining accuracy and reducing interference from ambient conditions, allowing for permanent camera installation and efficient gap optimization.
Implementation Method 1
a background light is disposed at the other of the input or output sides
Implementation Method 2
the camera has an optical device having a depth of field that reaches over all the roll stands and/or guide stands
Data Source
AI summary
A method for determining the rolling or guiding gap of the roll stands or guide stands in a multi-stand rolling mill positions a comparison scale at at least one stand, preferably at the first and the last stand, and subsequently the rolling or guiding gap of the respective stand is determined. In this method, a camera is arranged at one of the input or output sides and a transmitter for a reference device, a reference transducer and/or a reference scale is arranged at the other of the input or output sides before the comparison scale is positioned, such that adjustment operations at the camera can subsequently be avoided.